EPDM Roof Restoration with Liquid Rubber Coatings, September 2015, Edmonton

GRS first carried out an inspection and some light repairs on this commercial building's EPDM roof in April of 2012. There are two roofs in this system, one EPDM and one metal. We began working on the roof in September of 2015, proceeding with an engineered liquid rubber coating, on top of repairing any new fault areas that have developed since then. Check out this page for the original inspection information, though it may be referenced in some sections below.
Table of Contents:
Inspection
Scope of Work
Roof Reports [all 2015]
  Inspection: April 17, 2012 The original inspection is very thorough and worth reviewing. In summary, the EPDM and metal roof was suffering from some puncture holes, leaks, and membrane degradation. The structure itself is sound, but could use some maintenance to address then-current and future problems. Spot repairs could be carried out, or the roof could be recovered with a new watertight system (ie: liquid rubber).   Scope of Work: September 7, 2015 The crew made a list of things to present to the client, covering all of the pertinent safety information and everything needed to demonstrate that the scope of the project has been thoroughly considered. Below is a copy of everything they were prepared to cover.
Required on site to show HSE Manager:
  • GRS tool box documents
  • MSDS (attached)
  • WHIMIS tickets.
  • First aider with ticket
  • Fall arrest tickets
  • First aid kit
  • Pylons and caution tape for 6' control zone
  • Harnesses and ropes
  • Proper safety glasses
  • Steel toe boats (with green triangle symbol)
  • Long sleeve shirts
  • Gloves
 
Other:
  • Liquid rubber - 15 - 17 pails
  • Rollers, sleeves, brushes
  • Seam tape
  • Flashing mesh
  • Pressure washer, hose, electrical - be sure to advise office staff that roof may leak while washing.
  • Rags (materials to dry roof)
  • EPDM repair materials and tools
 
Notes:
  • Access to roof is with roof door - walk out on roof. Do not use ladders to access roof.
  Scope of Work:   Roof 1. EPDM ballast roof restoration. Approximately 36' x 50'
  • Remove rock ballast from half of EPDM roof
  • Wash EPDM roof membrane to white-glove clean
  • Repair EPDM as required
  • Coat half roof with liquid rubber (about 900 sq feet or 3 - 5 pails)
  • Return ballast to EPDM roof
  • Remove rock ballast from other half of EPDM roof
  • Wash EPDM roof membrane to white-glove clean
  • Repair EPDM as required
  • Coat half roof with liquid rubber (about 900 sq feet or 3 - 5 pails)
  • Return ballast to EPDM roof
  Roof 2. Metal Roof Coating. Approximately 56' x 50' Details first. Wash roof and/or internal gutters as required. Dry. Reinforce all your details with liquid rubber and/or seam tape or mesh as required before rolling out or spraying liquid rubber. Check all fasteners and replace as required or coat with liquid rubber. Check all rooftop penetrations, flashing, roof-to-wall connections, roof eave to gutter area, internal gutters and sheet metal connections, internal gutter to wall connections, and seams (especially horizontal) that may be separating. Clear old caulking etc. Add seam tape or mesh with liquid rubber. Coat complete metal roof, in gutters, and up parapet walls 30" in liquid rubber. Be sure to tape off a clean line at wall at a height of 30" or so - the line needs to be clean and straight. Pay close attention to internal gutters especially where sheet metal connects and where the internal gutter is at a vertical meeting the metal roof edge (that's where most leaks on these systems occur).  
Metal roof coating repair video and explanation of scope of work at this link:
  Roof Report: September 8, 2015 The team met in the morning for a brief safety meeting with the entire crew present. They then went up to the roof to begin moving the ballast from the west side onto the east side, preparing the area for cleaning. Using pressure washers to clean off the surface, the team found some difficulty with the amount of clay mixed in with the dirt. They sent one of the technicians out to pick up more scrub pads that could handle the tougher soil. Heavy rain began rolling in, so the team had to depart a little bit early. Half of the roof is cleaned off and prepared for the following day's application of liquid rubber. Plan for September 9: Arrive for 7:00am, and put down the first layer of liquid rubber on the now-complete half of the roof. While it cures, the second half of the roof will be prepared for the same.  
20150908_092006
Puncture hole around the detailing of a ventilation unit.
20150908_103000
Pressure washers were used to clean the surface, which was covered in a mixture of clay and dirt.
20150908_150347
Scrub pads were used to remove the remaining soil. After the roof was dirt-free, we gave it a final wash.
20150908_150404
We had to shut the site down when heavy rain began to roll in. Half of the roof was cleared and now prepared for liquid rubber applications.
    Roof Report: September 9, 2015 The GRS crew arrived on site for 6:45am, and had their toolbox meeting for fifteen minutes until the client arrived to grant access to the roof. They began by clearing off the residual moisture and prepared to apply the liquid rubber to half of the EPDM roof. In the meanwhile, the other part of the team was at the shop picking up another six buckets of the liquid rubber solution. By the time they'd returned, the first team kept cleaning the metal roof. Half of the metal roof had liquid rubber applied to it, and the technicians kept preparing the gutter and sidewalls for recovery. Once the west side of the EPDM roof had cured, the crew moved the ballast back from the east side. They kept preparing and cleaning the east side for tomorrow's application of liquid rubber, as some rainfall prevented them from more liquid rubber application. Both the EPDM and metal roofs have been half-completed with liquid rubber, with the other half prepared for the following day's work. The customer also reported a heavy leak, which was traced and temporarily patched until it can be addressed at-length.
20150909_071304
Completed liquid rubber coatings on one of the metal roofs.
20150909_071310
Clearing away residual moisture and ballast rocks from the other half of the EPDM roof.
20150909_071744
Detailing around the rooftop units also required new coatings, with cracks forming around the corners.
20150909_071842
After cleaning the remaining portion of the metal roof, a second team of technicians completed the coatings after preparing the gutter and sidewalls for recovery.
20150909_071809
Various rooftop appliances also required coatings around their bases.
20150909_090516
Once the EPDM had cured, we applied liquid rubber to half of the roof which had previously been covered in residual moisture.
20150909_114826
The parapet walls were inspected for various deficiencies, such as punctures and pockets formed at the wall connections.
20150909_114922
Initial patch applied to the detailing around a rooftop unit on the metal roof.
20150909_115001
Remaining half of the metal roof to be recovered.
  Roof Report: September 10, 2015 Work began on the roof around 6:45am, where the team got to cleaning the EPDM roof in preparation for more liquid rubber. Everything was cleaned and prepared for 10:00am, and after a brief coffee break one technician got to applying the rubber solution to the ribs of the metal roof while another applied it to the EPDM. The two remaining crew mates finished up the mesh and detail work on the metal roof, working through 12:30pm until lunch. Resuming at 1:00, they all continued with their assigned tasks until the metal roof was done around 3:00pm. The EPDM roof has a 5' x 36' section still requiring ballast removal, cleaning, and liquid rubber application. It's expected that the work will be finished tomorrow.
20150910_081808
After clearing the ballast rocks from the other half of the EPDM roof, we again had to wash off the clay/dirt mixtures from the surface.
20150910_101401
After washing the detritus, the surface was nearly ready for liquid rubber coatings. Scrub pads were used to remove any remaining buildups. One 5' x 36' section of ballast was still remaining, as well.
20150910_101450
Concurrently, another technician applied coatings to the remaining metal roof's ribs.
20150910_144303
Completed liquid rubber recovery to an EPDM roof.
20150910_152349
Completed metal roof.
    Roof Report: September 11, 2015 The crew arrived on site for 7:30am, and got to cleaning the remaining section of the EPDM roof. By the time they took a break around 10:10am the roof was clean and ready for the liquid rubber. They performed a leak test on the second roof, and made sure that there was no water ingress to the offices below. Once confirmed, they prepared the breather holes on the metal roof's ribbing with mesh and rubber. Lunch break went from 11:30 - 12:00pm, and the EPDM roof was finished shortly after. The rubber has to cure before the ballast can be replaced, so the team moved on to the metal roof to continue adhering the mesh and rubber to the ribbing. Come 2:40pm, they had the site cleaned up and marked the job complete. < End Report >   CODE: 6621 Contact Us Call our 24 hour emergency roof repair at 1.780.424.7663. Mail to: 3428 99 Street NW Edmonton, Alberta T6E-5X5. We service all of Alberta including Edmonton, Stony Plain, Spruce Grove, Fort Saskatchewan, St Albert, Sherwood Park, Leduc, Nisku, Beaumont, Lac La Biche, Grande Prairie, High Level, Westlock, Slave Lake, Edson, Drayton Valley, Devon, Camrose, Wetaskiwin, Tofield, Lamont, Morinville, Vegreville, Tofield, Millet, Calmar, Evansburg, Redwater, Onaway, Viking, Athabasca, High Prairie, Valleyview, Fairview, Peace River, Whitecourt, Mayerthorpe and many more rural areas and towns.  

Nisku Liquid Rubber Roof Recovery, August 2011

The report below follows services carried out on a metal roof for one of our industrial clients. They sought GRS' assistance in recovering their roof with engineered liquid rubber, with some other spot repairs to complete as needed. Inspection: June 2, 2011 The GRS crew went on location to inspect the existing roof system and take photos that will help the project management group form a better idea of what service will be needed at this location. The photos appear below.
100_0006
Our client had an industrial-grade metal roof. A crew was dispatched to perform an initial inspection with regard to the scope and requirements of performing a roof recovery using engineered liquid rubber.
100_0008
Many of the screws were exposed or missing, with parts of the metal beginning to rust.
100_0009
Rusting at the seams, with exposed screws running the length of this section of the roof.
100_0010
There were signs of previous spot repairs. In this case, caulking had been applied to the screws.
100_0011
More spot repairs, with caulking applied at the seams and over the edges. This solution had expired, with cracks forming along the length of the roof where the caulking had been applied over the seams.
100_0012
Closeup of some old sealant applied over seams and around raised screws. Note the hole in the fastener that had previously been closed off. As well, there are slight buckles in the metal. Each of these deficiencies contribute to common leak entry points and a loss of a metal roof's water shedding properties.
100_0013
We inspected the wall connection, noting whether any components on the wall itself needed to be replaced, and whether we had to order any new flashing as part of the recovery.
100_0016
Sealant had previously been applied to the window sills, flashing, along the wall seams, as well as on the intersection between the flashing and the standing seams on the roof. Besides showing signs of cracking, there was also more rusting along the walls.
100_0017
Significant rusting on the flashing, with an unsealed base for the rooftop appliance. As well, the edging over the window sills is not flush with each segment. Further down, it can be seen to be curling up from the window.
  Quotation Delivered: June 6, 2011 After seeing the roofers' investigation photos and measurements, GRS' project management could deliver an accurate quotation for services to be carried out of the roof. Included in the quotation were two separate services; the engineered liquid rubber application and an EPDM installation for the area around two eaves. Also attached to the quotation were the documents and web links surrounding GRS' workmanship guarantee, system methods, schedule availability for the season, and more. There was another note mentioned that regarding schedule availability, it's best to book liquid rubber jobs earlier in the season for when it's warmer. Even though the solution will bond, it performs best when applied in warmer weather.   Roof Report: July 20, 2011 The crew went out to the client's building and got to administering trowel-grade liquid rubber to all penetrations, joints, and problematic areas that has been previously discovered. They also did a lap around the perimeter, ensuring watertightness on the high-risk parts of the roof. They then set up the pump to apply the spray-on liquid rubber and managed to cover roughly one-quarter of the roof itself. Their plan was to finish the entirety of the roof the following day, so they packed up the equipment, cleaned the site, and closed the site for the evening.  
DSC00882
Trowel-grade liquid rubber curing at the base of two plumbing appliances.
DSC00883
Liquid rubber coatings applied and curing at the base of a chimney stack.
DSC00885
We began the roof recovery by applying coatings at the wall connections, paying attention to the penetrations.
DSC00886
A lap around the perimeter was completed to ensure that high risk parts of the roof were protected.
DSC00887
Mid-application over a significantly rusted section of the roof.
DSC00888
By the end of the day, our technicians managed to coat one-quarter of the entire roof.
    Site Inspection: August 1, 2011   One of the senior members of GRS' crew went on-site to inspect the liquid rubber application and found it to be forming a good seal. There was some water that had formed a small bubble in the rubber, but once popped it was deemed fit for continued use as the rubber still formed a solid barrier to the metal.   Roof Report: November 25, 2011 Several months after the initial liquid rubber coating, the client call in to report some other leaks in separate areas of the roof. GRS sent a team out to the site to investigate and carry out the necessary repairs. They administered sealant to the flashing where the wall meets the north-facing roof edge, and again on the south-west corner of the building. They also sealed in the wall-to-roof spots on the west-facing wall and inspected the existing wall spray. After carrying out the spot repairs, they had a better idea of what else needed to be done to the roofing system, and returned the following report:
  • The west-facing wall where the windows are is 3' x 78'. Will need 100' x 6" skrim sheet, and roughly 16 man-hours to install it.
  • The north-facing wall is 3' x 40'. Need 50' x 6" skrim sheet for another 12 man-hours to install.
  • The west-facing wall's upper roof is 3' x 24'. Need 25'x6" skrim sheet and 10 man-hours to finish.
The site was cleaned up, and the crew departed, leaving the repair options in the hands of the client.   This report will be updated as more reports come in, should the client elect to move forward with repairs. CODE: 1409 Contact Us Call our 24 hour emergency roof repair at 1.780.424.7663. Mail to: 3428 99 Street NW Edmonton, Alberta T6E-5X5. We service all of Alberta including Edmonton, Stony Plain, Spruce Grove, Fort Saskatchewan, St Albert, Sherwood Park, Leduc, Nisku, Beaumont, Lac La Biche, Grande Prairie, High Level, Westlock, Slave Lake, Edson, Drayton Valley, Devon, Camrose, Wetaskiwin, Tofield, Lamont, Morinville, Vegreville, Millet, Calmar, Evansburg, Redwater, Onaway, Viking, Athabasca, High Prairie, Valleyview, Fairview, Peace River, Whitecourt, Mayerthorpe and many more rural areas and towns.  

Edmonton Commercial Metal Roof Leak Repair, August 2011

This report begins with a quotation outlining various options for a metal roof repair. There is moisture entering the building and leaking which is occurring after rain and snow falls. There also appears to be a number of maintenance issues with the existing sheet metal. Roof Observation Report: Very difficult to pinpoint where the moisture is entering, however it appears to be coming in at a number of areas. The metal roofing has a number of maintenance/sheet metal issues but the inherent expansion and contraction also likely causes issue. This roof leaks after the snow melts and heavy rainfalls. The roof is approximately 25 years old and could use a metal roof replacement but the Engineered Liquid Rubber coating will stop the roof from leaking for many years. Project Manager Recommendations (emailed to client):
This roof structure is a candidate for either a repair-maintenance program or an engineered coating and does not have to be replaced. I would not recommend an elastomeric coating or the SPF Spray Foam as the acrylic and EPDM covering options do not last well in Edmonton climate, but liquid rubber performs well in our climate. Generally speaking, metal roof systems are constant aggravating roof structures. Industrial metal roof systems have a deficient design - they are water-shedding and not water-proofing coverings. Metal expands and contracts more than any other roofing material. Metal roofs tend to leak from expansion and contraction and ice / snow loads. Leaks are intermittent at seams, penetrations (stacks, etc.), fasteners (fastener holes get larger with expansion and contraction), around the perimeter as ice back-ups at gutters and then under eave, and at joints between roof and wall connections. Metal rust / corrosion may start at places, the seams and fasteners are vulnerable from expansion / contraction and snow loads, and any traditional caulking or coating won’t last more than a few seasons at best. Remedies are either spot repairs-maintenance with caulking or more extensive maintenance which involves engineered coatings. Our recommendation is a high end engineered liquid rubber polymer coating that carries a 10 Year Manufacturer Warranty and has option for maintenance contracts for extended warranty. General Roofing is considered a pioneer and leader in engineered roof coatings; (www.liquidrubber.ca, https://www.grscanadainc.com/Roof_Coatings.html, https://www.grscanadainc.com/Liquid_Rubber.html). We have significant liquid rubber operations specifically serving industrial facilities with low slope metal roofs. Our clients include companies such as Imperial Oil, Shell Oil, Telus, Fortis, Toran Power, National Oil Well Varco (NOV), Teck Resources, and many more.(https://www.grscanadainc.com/Project_Portfolio.html). In this instance, we recommend a 2 Ply System engineered liquid rubber coat to complete metal roofing, fastener replacement as required, sheet metal repair as required to-achieve a water-tight state. Typically this is even more successful than a full metal roof replacement. A recent project with photos can be found at; http://generalroofingsystemscanadainc.blogspot.ca/2012/05/roof-repair-liquid-rubber-metal-roof.html Thank you.
August 16th, 2011: The crew arrived on site and found two pipe boots and two patches that were leaking. Also discovered were two large holes in the membrane of the north corner (also causing leaking). It appears that something heavy had dropped on the roof at some point causing the holes. The insulation around the two holes was totally saturated and this was clearly allowing quite a bit of water into the system. The insulation is acting like a sponge and is releasing water into the Q deck and lunch room of the building. The crew performed a drip count within the three areas where dripping was occurring. The first drip count was done before the flood test and the results are as follows: Area 1:  every 10 seconds. Area 2:  every 6 seconds. Area 3:  every 19 seconds. After the repair and during the flood test the results were as follows: Area 1:  every 16 seconds. Area 2:  every 20 seconds. Area 3:  none.
The test indicates that the repairs were successful and that there is a slow drip only because of the still saturated insulation. The crew also searched the rooftop for any other possible leak spots. One area was found and patched. It was further reported to the client that the A/C unit in front of the roof hatch was dripping water from inside the unit.
The client was highly satisfied with the execution of the repairs.
DSC01206
Two large holes in the membrane were found, and the insulation was completely saturated with water. Water had been entering the building through these holes and leaking into the lunch room.
DSC01207
We moved the ballast rocks around the piping systems and other roof appliances, checking for deficiencies. The coatings around the base of this drain were past their life cycle.
DSC01209
Second tear location. Although this section of the roof had previously been patched over, some heavy object had fallen and caused the hole.
DSC01210
The torn off EPDM was tucked back into place, with new liquid rubber coatings applied over top.
DSC01211
Coatings completed on both tears.
DSC01212
After the coatings had cured, they were patched over with new EPDM.
DSC01213
Finally, caulking was applied over the seams to make the new patches watertight.
DSC01216
We found some other old patchwork that had been provided in past spot repairs. Some of them had been coming apart, although no water had been entering the building through these sections.
DSC01217
There were a few other patches along the perimeter of the roof that we also identified as requiring touch-ups.
DSC01218
Liquid rubber coatings and spud at the seams were applied over these patches to mitigate leaking in the future.
DSC01219
Water had been dripping from inside of the A/C unit into the roof structure.
< End Report >
CODE: 12250
Contact Us Call our 24 hour emergency roof repair at 1.780.424.7663. Mail to: 3428 99 Street NW Edmonton, Alberta T6E-5X5. We service all of Alberta including Edmonton, Stony Plain, Spruce Grove, Fort Saskatchewan, St Albert, Sherwood Park, Leduc, Nisku, Beaumont, Lac La Biche, Grande Prairie, High Level, Westlock, Slave Lake, Edson, Drayton Valley, Devon, Camrose, Wetaskiwin, Tofield, Lamont, Morinville, Vegreville, Tofield, Millet, Calmar, Evansburg, Redwater, Onaway, Viking, Athabasca, High Prairie, Valleyview, Fairview, Peace River, Whitecourt, Mayerthorpe and many more rural areas and towns.