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.  
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Puncture hole around the detailing of a ventilation unit.
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Pressure washers were used to clean the surface, which was covered in a mixture of clay and dirt.
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Scrub pads were used to remove the remaining soil. After the roof was dirt-free, we gave it a final wash.
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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.
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Completed liquid rubber coatings on one of the metal roofs.
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Clearing away residual moisture and ballast rocks from the other half of the EPDM roof.
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Detailing around the rooftop units also required new coatings, with cracks forming around the corners.
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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.
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Various rooftop appliances also required coatings around their bases.
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Once the EPDM had cured, we applied liquid rubber to half of the roof which had previously been covered in residual moisture.
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The parapet walls were inspected for various deficiencies, such as punctures and pockets formed at the wall connections.
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Initial patch applied to the detailing around a rooftop unit on the metal roof.
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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.
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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.
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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.
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Concurrently, another technician applied coatings to the remaining metal roof's ribs.
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Completed liquid rubber recovery to an EPDM roof.
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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.  

EPDM Roofing Replacement, July and August 2015, Edmonton

Below you will find a series of ongoing reports for a client in Edmonton looking to re-roof their building with an EPDM system. The building is a low slope duplex, where the entire roof would receive treatment with the new surface. Continue reading EPDM Roofing Replacement, July and August 2015, Edmonton

Fort Saskatchewan Leak Repair Service, April 2015

This client in Fort Saskatchewan required a leak repair service as they were experiencing several water leaks on their roof. A crew was dispatched to locate and repair the leaks. Roof Report, April 7, 2015: Today we fixed three leaks. Leak number one was along the north wall, I pin pointed the leak to a curb or a make up air unit (both beside each other). I found numerous cracks in the EPDM which I repaired with form flash.
Leak two was above the pharmacy on the west wall. I found a corner that had a puncture in it so we cleaned it well and installed a corner patch. Leak three was on the center of the roof. After measuring it out we pin pointed it to an air unit. I shoveled back the gravel and cleaned and inspected the area, then I found a lap that had a nice size fish mouth in it which I repaired with cover strip. Approximately 20 man hours were required for this repair.
Material Used:
  • 1 can of quick prime (1 gallon).
  • 1 roll of EPDM form flash (8 inch).
  • 1 box of rags.
  • Splice wash (2 gallons).
20150407_100404_resized 20150407_100405_resized 20150407_100419_resized 20150407_101320_resized 20150407_101327_resized 20150407_101342_resized 20150407_104326_resized 20150407_104331_resized 20150407_104333_resized 20150407_110258_resized 20150407_110301_resized 20150407_110312_resized 20150407_110655_resized 20150407_110951_resized 20150407_112447_resized 20150407_112453_resized 20150407_113705_resized 20150407_114246_resized < End Report > CODE: 9360 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.

Edmonton EPDM Roof Restoration Liquid Rubber Coating, April 2012

Below is the collection of field reports for an industrial roofing system repaired by GRS in April 2012.
Table of Contents:
Inspection
Roof Reports
  Initial Inspection: April 17, 2012: Sealants The sealants on all 9 roof levels are deteriorated and require attention. Drainage One drain was found to have a great deal of debris blocking the way for water. It was cleared as best as possible, but is still draining slowly. Parapet Walls The EPDM roofs (of which there are 2 from the total 9) seem to be in good condition. The metal lining the parapets are also in good condition. Building Structure Building Structure Interior - Very good condition Building Structure Exterior - Very good condition Tie-Ins See 'Sealants' (above). Several of the EPDM plumbing boots, wire boots etc. are damaged. This can be seen in cases where the caulking has been worn away or when there are holes in the rubber itself. Air Conditioning Units We found that much of the flashing sealants have cuts and abrasions. There is moisture is getting through that needs to be addressed. 100_1204 Splitting N/A Blistering N/A Ridging N/A Fish-mouthing N/A Punctures We found punctures in the metal roofing, but did not observe any in the EPDM as it is covered with large ballast (approximately 1 to 1.5 inch gravel). The client, however, has reported many leaks in that part of the building, so openings of some sort must be present. We will need investigate further. 100_1214 Ballast For the most part, the ballast is adequate and well-distributed. Summary It is very difficult to pinpoint where the moisture is entering on the EPDM portions of the roof, however it appears to coming in in several areas. Several offices within the building have experienced substantial leaking. This is a very large structure and would benefit from regularly scheduled maintenance. Many of the current issues could have been mitigated before becoming a problem. Roof dimensions are:
  • 55' X 112' EPDM.
  • 38' X 51' EPDM.
  • 60' X 51' METAL.
  • 128' X 97' METAL.
  • 125' X 97' METAL.
  • 158' X 80' METAL.
  • 77' X 25' METAL.
  • 77' X 57' METAL.
  • 38' X 47' METAL.
Additional Photos: 100_1200 100_1201 100_1206 100_1207 100_1209 100_1210 100_1212 100_1213 100_1217 100_1218 100_1219 100_1221 100_1222 Roof Report, May 28 2012: Two of our crew arrived to the job site for 9am and began conducting some of the smaller repairs necessary. Materials:
  • 2 tubes ms detail.
  • 1 tube of barr.
  • 2 tubes lap sealant.
  • 4 ft. of cover tape.
  • Primer.
  • Splice adhesive.
They left the site for 5:00 pm, scheduled to return the following day (May 29). Roof Report, May 29 2012: Crew members investigated the leaks on the upper and lower EPDM roofs. They found improper rubber detail on the walls, and a corner termination. The installation of the EPDM near the roof access doorway was in a poorly state as well. They re-glued and secured the EPDM along the wall and patched several holes from staples, nails, or other rooftop debris. The flashing atop one of the offices was removed where there were signs of recent water ingress. They brought EPDM up and over the wall properly and replaced the metal that sits on top of it. After this, they moved to the upper roof had a 'popped' corner in the EPDM, as well as a pipe boot's flashing was left uncaulked (large, open gap). There were other holes located in the metal portion of the roof, which have now been sealed up properly. A pipe boot, however, appears to have been cut at some time which left an open hole and some semi-exposed wiring. We put a temporary seal on it for the night, and plan to cover it with plate or suitable flashing the next day. Roof Report, May 30 2012: Today, we finished the repairs to the roofing system. Virtually all of the penetrations (roof vents, jacks, boots, etc.) were missing sealant, so we reapplied some and ensured that they would be watertight. There was also caulk sealant around many curbs in poor shape that needed removal and reapplication. We used MS detail to reseal them (as well as some roof jack edges), using mesh to bridge the cracking or exposed edges. One of the metal walls along the roof needed the entire base resealed due to badly failing sealant. MS detail and mesh was used again to address this spot. There is a gutter on the roof in bad shape that will need to be repaired or replaced. This may have been caused by a heavy snow pack sliding down towards the gutter; a snow brake may be useful in this location. The last point of note is that the sign on the roof may need to be looked at in the future. There are holes in the metal from nails or screws tearing through in a couple of locations. It's difficult to get a proper view without getting more invasive, but this may be a concern in the future to be mindful of. 132 133 134 135 136 137 138 139 140 141 142 143 144 145 146 147 148 149 150 151 152 153 154 155 156 157 158 159 160 161 162 163 164 165 166 167 168 169 170 171 172 173     This report is ongoing and will be updated as more information comes in. 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.