Spray Coating
Spray Coating for Metal-Sheeted Industrial Roofs
Industrial facilities rely heavily on the integrity of their roofing systems to protect assets, maintain energy efficiency, and ensure safe operations. Spray coating can protect your roof further.
Metal-sheeted roofs are a popular choice for industrial buildings due to their durability and strength. However, over time, they can suffer from corrosion, leaks, thermal movement, and UV degradation.
One highly effective solution to extend the lifespan and performance of these roofs is spray coating.
What Is Spray Coating?
Spray coating is the process of applying a protective layer (typically a liquid polymer or polyurethane based coating) directly onto the surface of a metal roof using high-pressure spray equipment. Once applied, the coating cures into a seamless, flexible protective layer that adheres to the contours and seams of the roof, providing enhanced weatherproofing and insulation.
Why Spray Coat Metal Roofs?
Leak Prevention and lap Sealing
Over time, the sheet overlaps, cut edges, fixings and flashings on metal roofs can deteriorate and allow water to penetrate.
Spray coatings form a continuous layer and part of the process can involve sealing all overlap joints, fixings and penetrations, preventing further corrosion to the roof or in many cases roof leaks without the need for full roof replacement.
Rust and Corrosion Resistance
Metal roofs exposed to moisture and industrial environments are vulnerable to rust. Many spray coatings contain corrosion-inhibiting properties that block moisture and oxygen from reaching the metal surface, preventing rust from progressing and therefore increasing the
life expectancy of that surface.
UV and Heat Reflection
Reflective spray coatings, such as a goosewing polymer-based coating, can deflect a large portion of the sun’s heat and UV radiation. This can keep the building cooler, reduce energy costs, and protects the metal roof from thermal expansion and contraction.
Cost-Effective Maintenance
In some cases in comparison to a full roof replacement, spray coating may be more economical. It extends the roof’s lifespan by 10–25 years (depending on which system you require) and more importantly have minimal disruption to site operations.
Quick and Non-Invasive Application
Application is relatively fast and does not require dismantling of the existing roof structure. This minimises downtime and ensures a safer environment for all during on going works.
The Spray Coating Process
Inspection and Preparation
The roof is thoroughly inspected for existing damage, rust, or structural issues.
Undertake a thorough wet clean of all roof surfaces, including, but without limitation; perimeter capping trims, parapets, gutters etc., soiling dirt, dust, moss and lichen growth, and any other debris. To facilitate preparation and cleaning a pressure washer fitted with a rotating spinning head capable of delivering a minimum of 3000 psi is required. An adhesion test would be carried to ensure proper adhesion.
Cut Edge and Overlaps
All laps are treated for corrosion using our cut edge process. This protects the sheet edge from further corrosion and creates a seal to stop water penetration via capillary reaction. In many cases corrosion starts at the cut edges and overlaps. If left untreated then the corrosion can exceed the fixings lines and a full roof replacement becomes necessary
Fixings are encapsulated for protection and to create a watertight seal as part of the process.
Application of Coating
The spray coating is applied in layers using specialised equipment. Multiple passes ensure complete coverage and WFT – Wet film depth readings are taken during the course of application to ensure that the correct depth is achieved.
Curing and Final Inspection
The coating is allowed to cure fully, forming a rubber-like protective membrane (Polymer based coating).
A final inspection using a DFT – Digital film thickness reader to ensures thickness. We then check for adhesion, and uniformity meet specification.
Let’s Talk
If you’re looking for a dependable commercial roofing partner with national reach and local expertise, get in touch with us today. We’re here to help — no matter the size or complexity of your project.