A 15,000 sq ft commercial flat roof restoration using silicone roof coating that extended the roof's life by 15+ years while reducing energy costs — at a fraction of full replacement cost.
The building owner faced a difficult decision: the 18-year-old modified bitumen roof had multiple seam failures and ponding water areas, but a full flat roof replacement would cost $120,000+ and require 2-3 weeks of disruption. The substrate was still structurally sound — only the waterproof surface had degraded. The warehouse operated 6 days a week with sensitive inventory that could not be exposed to construction debris or moisture.
After a thorough commercial roof inspection including core cuts to verify substrate integrity, we recommended silicone roof coating restoration. Silicone was chosen over acrylic because it performs in ponding water conditions — critical for Houston flat roofs where drainage is rarely perfect. The reflective white finish also reduces cooling loads significantly, qualifying for Energy Star compliance.
Completed in 4 days with zero disruption to warehouse operations. Total cost was approximately 40% of full replacement — saving the owner roughly $70,000. The owner reported a 22% reduction in summer cooling costs within the first year. The silicone coating can be recoated at the end of its warranty period, potentially extending the roof's total service life to 40+ years without ever requiring a full tear-off and replacement.
The entire 15,000 sq ft roof surface was pressure washed at 3,000 PSI to remove 18 years of dirt, algae, and debris. All loose modified bitumen granules were removed. Six ponding areas were repaired with reinforced membrane patches and leveling compound to improve drainage before coating application.
All seams and flashing transitions were reinforced with 6-inch polyester fabric embedded in silicone — the most common failure points on aging modified bitumen roofs. Two coats of high-solids silicone were then spray-applied to achieve a total dry film thickness of 30 mils, exceeding the manufacturer's minimum for the 15-year warranty.
All 8 roof drains and 4 scuppers were cleared of debris buildup and reinforced with additional silicone and polyester fabric collars extending 12 inches from each penetration. New galvanized drain strainers were installed on all interior drains. The reflective white finish was confirmed at 85% solar reflectance using a portable reflectometer.
This commercial coating project was completed in four working days — Day 1 for pressure washing and surface preparation, Day 2 for ponding repairs and seam reinforcement, Day 3 for the first coat of silicone, and Day 4 for the second coat, drain detailing, and final inspection. No warehouse operations were interrupted during any phase. The owner received a 15-year manufacturer material warranty on the silicone coating system, with the option to recoat at year 15 for another 10-15 years of protection — effectively eliminating the need for a full roof replacement indefinitely as long as the substrate remains structurally sound.
"Our warehouse roof was leaking in multiple spots and we were quoted $180,000 for full replacement. Tell Project applied the silicone coating for a fraction of that cost. Two years later — zero leaks, and our AC bills are down 22%."
Richard T., Property Manager — East Downtown, Houston TX | Commercial Roof Coating
Roof coating restored this 18-year-old commercial roof at roughly 40% of full replacement cost, while adding 15+ years of service life. For budget-conscious property owners, roof coatings often make more financial sense than tear-off.
The reflective white silicone coating reduced rooftop surface temperatures by up to 50°F on peak summer days, directly lowering HVAC loads and energy costs by an estimated 20-25%.
Unlike full replacement, coating application requires no tear-off debris, no loud equipment during business hours, and no building closure. This warehouse stayed fully operational during the entire 4-day project.
Roof coatings extend your roof's life 15+ years at a fraction of replacement cost.
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