Metal roof restoration
Rust at the fasteners and open side laps do not mean a new roof. Stop the corrosion, seal every seam and screw head, and coat the whole panel.
- Pr335Rust-inhibiting primer
- Every fastenerSealed, not replaced
What happens to metal
Exposed-fastener metal fails at the details before the panel does. Washers dry out, screws back out with thermal movement, side and end laps open, and rust starts at every scratch and cut edge. Standing seam holds up longer but leaks at the clips and end laps.
Restoration is a details job first — fasteners, laps, penetrations — and a coating job second. Primer choice follows the rust: Pr335 across the field where corrosion is general, spot-primed where it is not.
A coating job when
- Panels sound; rust is surface or at fasteners
- Fastener heads and laps accessible
- Deck and purlins dry
- Owner wants to keep the profile and the insulation
Not a coating job when
- Rust-through or perforated panels across the field
- Loose panels moving under foot
- Soaked insulation below the deck
Not sure? Send photos and a core cut. A rep will call it.
The build-up, in order.
For low-slope metal that holds water at the end laps, and anywhere a single topcoat over the primer is the goal.For pitched metal that sheds water. Reflectivity for the interior, at a lower cost per square than silicone.
Clean & rust prep
Wash, then remove loose rust and scale with a wire wheel. Tighten or replace backed-out fasteners. Replace washers that have failed.
Prime rusted panels
Optional · onRust-inhibiting primer across the field where corrosion is general. Spot-prime where the panel finish is intact.
Pr335 Rust-Inhibiting Primer1 gal / 200 ft²Seams & fasteners
A dab on every fastener head, a bead along every side and end lap, fabric at the end laps and penetrations.
Si790 Silicone Mastic1 gal / 60 lin ftTopcoat
Spray the field, back-roll the ribs. Ribbed and corrugated profiles take more per square than a flat panel.
Si710 Silicone Roof Coating11 dry mils per gal / 100 ft²Walkways
Around units and along service paths, set into wet topcoat and clipped at the corners.
GripTite Walkway Pad Walkway ProtectionSized to layout
Clean & rust prep
Wash, then remove loose rust and scale with a wire wheel. Tighten or replace backed-out fasteners. Replace washers that have failed.
Prime
Rust-inhibiting primer across the whole field. Required under acrylic on metal.
Pr335 Rust-Inhibiting Primer1 gal / 200 ft²Seams & fasteners
Fibered mastic on every fastener head and lap, fabric at end laps and penetrations.
Ac595 Acrylic Mastic1 gal / 40 lin ftWalkways
Around units and along service paths, set into wet topcoat and clipped at the corners.
GripTite Walkway Pad Walkway ProtectionSized to layout
- 04 · TopcoatSi710
- 03 · Seams & fastenersSi790
- 02 · Prime rusted panelsPr335
- Substrate · Metal panel
Thickness not to scale. Optional steps appear here when switched on in the estimator below.
Rough quantities for this roof.
Enter the roof and get gallons and containers for the route above. It is a planning number, not a bill of materials — your rep confirms coverage before anything ships.
Estimate
25,000 ft² · 30 dry mils · silicone- 02Pr335 Rust-Inhibiting PrimerPrime rusted panels · 1 gal / 200 ft²138 gal28 × 5-gal pails
- 03Si790 Silicone MasticSeams & fasteners · 5,000 lin ft · 10 penetrations · 12,500 fasteners149 gal75 × 2-gal pails
- 04Si710 Silicone Roof CoatingTopcoat · 30 dry mils750 gal13 × 55-gal drums + 7 × 5-gal pails
- 05GripTite Walkway Pad Walkway ProtectionWalkways · Rolls and clipsSized to the layout — your rep quotes it
Liquid product, all steps1,037 gal
- Smooth surface: no texture allowance
- 10% overage on every liquid product
- Quantities rounded up to whole gallons, then to full containers
- Pr335 at 1 gal / 200 ft² — TDS
- Si790 at 1 gal / 60 lin ft of seam, 0.2 gal per penetration, 0.512 fl oz per fastener head — rule of thumb
- Si710: 11 dry mils per gal / 100 ft² — TDS; 30 mils this coat
Rough estimate for planning. Actual coverage depends on surface porosity, texture, application method and verified mil thickness. Confirm with the TDS and your rep before ordering.
Estimate
25,000 ft² · 32 dry mils · acrylic- 02Pr335 Rust-Inhibiting PrimerPrime · 1 gal / 200 ft²138 gal28 × 5-gal pails
- 03Ac595 Acrylic MasticSeams & fasteners · 5,000 lin ft · 10 penetrations · 12,500 fasteners196 gal40 × 5-gal pails
- 04Ac510 Acrylic Roof CoatingBase coat · 16 dry mils500 gal9 × 55-gal drums + 1 × 5-gal pail
- 05Ac550 Acrylic Roof CoatingTopcoat · 16 dry mils518 gal9 × 55-gal drums + 5 × 5-gal pails
- 06GripTite Walkway Pad Walkway ProtectionWalkways · Rolls and clipsSized to the layout — your rep quotes it
Liquid product, all steps1,352 gal
- Smooth surface: no texture allowance
- 10% overage on every liquid product
- Quantities rounded up to whole gallons, then to full containers
- Pr335 at 1 gal / 200 ft² — TDS
- Ac595 at 1 gal / 40 lin ft of seam, 0.3 gal per penetration, 0.512 fl oz per fastener head — rule of thumb
- Ac510: 8.8 dry mils per gal / 100 ft² — SESCO build-up rate (the TDS states 9); 16 mils this coat
- Ac550: 8.5 dry mils per gal / 100 ft² — from 53% volume solids (the TDS states no dry-mil yield); 16 mils this coat
Rough estimate for planning. Actual coverage depends on surface porosity, texture, application method and verified mil thickness. Confirm with the TDS and your rep before ordering.
Case studies.
Case studies are on the way.
The data sheets for this route.
Published TDS and SDS for the silicone route. Ask your rep for any sheet not listed; the spec letter comes from your rep.Published TDS and SDS for the acrylic route. Ask your rep for any sheet not listed; the spec letter comes from your rep.
Order through your rep.
Reps confirm coverage and write the spec letter. Send the estimate, or call 1-812-776-6727.