Metal roof refurbishment involves the restoration and repair of an existing metal roof to extend its lifespan and improve its performance. This process typically includes cleaning the roof, addressing any corrosion or damage, and applying protective coatings to prevent future deterioration. Refurbishment helps maintain the structural integrity of the roof while avoiding the higher costs associated with a full roof replacement.
What Is Metal Roof Refurbishment?
Metal roof refurbishment is a process focused on restoring and revitalising an existing metal roof, ensuring it continues to perform well and remains durable for years to come. The refurbishment process usually begins with a comprehensive cleaning to eliminate dirt, debris, and any rust that has accumulated over time. Following this, any areas affected by corrosion or damage are carefully repaired, with particular emphasis on treating cut edge corrosion, a common issue where exposed metal edges start to deteriorate. To protect the roof from future wear and tear, a protective coating is then applied, shielding it from further corrosion, UV exposure, and water penetration.
This refurbishment not only refreshes the appearance of the roof but also adds an extra layer of defence against the elements, making future maintenance less frequent and less costly. By choosing refurbishment over replacement, property owners can save significantly, as this approach is generally more affordable and less disruptive than installing a new roof. Moreover, it helps preserve the building’s structural integrity, ensuring the roof remains functional and efficient for many years. According to the National Federation of Roofing Contractors (NFRC), a well-executed refurbishment can extend the lifespan of a metal roof by up to 15 years, offering a practical and cost-effective solution for both industrial and commercial properties.
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How Do You Refurbish A Metal Roof?
To refurbish a metal roof, you restore its condition by cleaning, repairing any damage, and applying protective coatings. This process begins with a thorough cleaning to remove debris, dirt, and rust, followed by repairing areas affected by corrosion or physical damage. Finally, a protective coating is applied to the entire roof to prevent further deterioration and extend its lifespan.
- Inspection of the Metal Roof
- Cleaning the Metal Roof Surface
- Repairing Damaged Areas of the Metal Roof
- Surface Preparation for Metal Roof Refurbishment
- Application of Protective Coating to the Metal Roof
- Final Inspection of the Refurbished Metal Roof
1. Inspection of the Metal Roof
The first step in metal roof refurbishment is a detailed inspection to assess the roof's current condition. This involves checking for signs of deterioration, such as rust, corrosion, loose fasteners, and damaged panels. Inspecting the roof allows you to identify areas needing attention, including the presence of cut edge corrosion, which is common in metal roofs where exposed edges are vulnerable to degradation. A thorough inspection ensures all potential issues are addressed during refurbishment, preventing further damage and extending the roof's lifespan.
2. Cleaning the Metal Roof Surface
After inspection, the next step is to thoroughly clean the metal roof. This process involves removing dirt, debris, rust, and any old paint from the roof surface, typically using power washing or specialised cleaning agents. Cleaning is essential because it prepares the roof for subsequent repairs and coatings, ensuring these treatments adhere properly. A clean surface also helps reveal any hidden damage or corrosion that might have been missed during the initial inspection, allowing for a more comprehensive refurbishment.
3. Repairing Damaged Areas of the Metal Roof
Once the roof is clean, the focus shifts to repairing any damaged sections. Metal roof repair work includes addressing cut edge corrosion, where the edges of metal sheets have deteriorated, as well as fixing loose fasteners, replacing damaged panels, and sealing leaks. Properly repairing these issues is vital to restoring the roof’s structural integrity and preventing further deterioration. Ensuring all damaged areas are repaired before applying the protective coating guarantees that the roof will perform optimally and remain durable for years to come.
4. Surface Preparation for Metal Roof Refurbishment
Before applying the protective coating, the roof surface must be prepared to ensure the coating adheres effectively. This preparation might involve sanding down rough areas, applying a primer, or treating the surface with rust inhibitors. Surface preparation is a crucial step because it enhances the bonding between the metal and the coating, ensuring the refurbishment is long-lasting. Proper preparation also helps prevent the coating from peeling or blistering over time, which would undermine the effectiveness of the refurbishment.
5. Application of Protective Coating to the Metal Roof
Applying the protective coating is the most critical step in the metal roof refurbishment process. This coating serves as a barrier against environmental elements such as UV rays, moisture, and pollutants, which can cause further damage to the roof. The type of coating chosen depends on the specific needs of the roof, but it is typically a high-quality, durable product designed to withstand the demands of industrial or commercial environments. Applying the coating evenly and thoroughly is essential to ensure the entire roof is protected, thereby extending its service life and improving its performance.
6. Final Inspection of the Refurbished Metal Roof
After the protective coating has been applied, a final inspection is conducted to ensure the refurbishment has been completed successfully. This step involves checking that all repairs are secure, the coating has been applied uniformly, and no areas are left vulnerable to future damage. The final inspection is crucial for verifying the quality of the work and ensuring the refurbished metal roof will provide long-lasting protection and durability. Addressing any issues found during this inspection ensures the refurbishment meets the highest standards, offering peace of mind to property owners.
What Is The Best Roof Coating System For Metal Roof Refurbishment?
The best roof coating system for metal roof refurbishment depends on the specific needs of the roof, but elastomeric coatings, such as silicone or polyurethane, are often highly recommended. These coatings provide excellent durability, flexibility, and resistance to UV radiation, which are crucial for protecting against cut edge corrosion and extending the roof's lifespan. Additionally, their ability to form a seamless, waterproof barrier makes them ideal for safeguarding metal roofing systems in various environmental conditions.
When choosing the best roof coating system for metal roof refurbishment, particularly for addressing cut edge corrosion, several advanced liquid and elastomeric coatings stand out due to their specialised properties and effectiveness in varying environmental conditions.
- Desmoflex Fiberfix
- Desmoflex Thix
- MPM Starflex Monotix
- Desmoflex Polyurethane
1. Desmoflex Fiberfix
Desmoflex Fiberfix is widely recognised as an optimal solution for treating cut edge corrosion, particularly in areas needing additional reinforcement. The inclusion of glass fibre particles in its formulation enhances the coating’s durability and longevity, making it particularly effective in strengthening vulnerable sections where traditional coatings might underperform. Its flexibility allows it to adapt to the roof's movements, preventing cracks and maintaining a secure seal even during temperature fluctuations. This makes Desmoflex Fiberfix an excellent choice for roofs subjected to regular foot traffic or requiring additional mechanical resilience to endure environmental pressures.
2. Desmoflex Thix
Desmoflex Thix is particularly well-suited for metal roofs with contoured or profiled surfaces, often found in industrial settings. Its thixotropic properties enable the coating to maintain a thick, consistent layer that does not slump or run, even on vertical surfaces or intricate profiles. This ensures the coating adheres effectively to complex surfaces, providing dependable protection across the entire roof. Desmoflex Thix is highly effective in the UK's unpredictable weather conditions, including heavy rain, strong winds, and temperature variations, making it ideal for roofs requiring a robust coating able to withstand harsh elements while conforming to irregular surfaces.
3. MPM Starflex Monotix
MPM Starflex Monotix is another excellent option for industrial roofs with complex contours, offering strong protection with its thixotropic and anti-slump properties. Like Desmoflex Tix, MPM Starflex Monotix is designed to adhere well to intricate surfaces, ensuring a durable and uniform finish on metal roofs with challenging profiles. The coating forms a resilient barrier against moisture, oxygen, and other corrosive elements, preventing rust and significantly extending the roof’s lifespan. Its reliability in demanding environments makes it a reliable choice for industrial applications where maintaining the roof's integrity is essential for safeguarding the underlying structure.
4. Desmoflex Polyurethane
Desmoflex Polyurethane, part of the Desmoflex Pu system, is exceptional for large areas and can be spray applied, making it highly efficient for extensive metal roofs. This system produces a highly hydrophobic membrane that seals and protects the roof while providing excellent UV resistance. The Desmoflex Pu system's advanced technology offers high whiteness, water vapour permeability, and exceptional thermal resistance. Desmoflex Polyurethane is particularly effective in situations where other methods fail, such as surfaces with stagnant water or ice. Based on pure elastomeric hydrophobic polyurethane resins, this coating provides outstanding mechanical, chemical, thermal, UV, and environmental resistance, ensuring long-lasting protection for metal roofs.
What Are The Signs An Industrial Or Commercial Metal Roof Needs Refurbishment?
The primary signs an industrial or commercial metal roof needs refurbishment include; visible rust, leaks, and cut edge corrosion. These issues indicate the roof's protective layers are failing, leading to potential structural damage if not addressed. Additionally, increased maintenance frequency and rising energy costs due to poor insulation or reflective properties may also signal the need for refurbishment.
1. Visible Rust and Corrosion
Visible rust and corrosion are clear indicators a commercial or industrial metal roof is deteriorating. According to the Metal Construction Association, rust can reduce the structural integrity of a metal roof by up to 75% if not treated promptly. These signs suggest the protective coating on the roof sheets has worn away, exposing the metal to moisture and other corrosive elements. Left untreated, rust can lead to serious structural issues, weakening the roof’s integrity and potentially causing leaks or even collapse in severe cases. Regular inspections of commercial roofing systems can help identify rust early, allowing for timely refurbishment before the damage becomes extensive.
2. Leaks and Water Ingress
Leaks and water ingress are critical signs a metal roof in industrial buildings requires refurbishment. According to a report by the Building Research Establishment (BRE), 70% of building leaks are attributed to roofing issues. These problems typically arise when the roof sheets or seals have been compromised, allowing water to penetrate the structure. Water ingress can lead to internal damage, such as mould growth and deterioration of insulation, which increases maintenance costs and disrupts operations. Addressing leaks promptly through refurbishment can prevent more severe water damage and extend the roof's lifespan.
3. Cut Edge Corrosion
Cut edge corrosion occurs at the exposed edges of roof sheets, where the protective coating has worn away, leaving the metal vulnerable to rust. This is a common problem in both industrial and commercial roofing, especially where metal sheets overlap or have been cut during installation. According to the Steel Construction Institute, cut edge corrosion can reduce the lifespan of a metal roof by 20-30% if not treated. Refurbishing the roof with appropriate coatings is essential to halt this type of corrosion from spreading and to maintain the roof's integrity.
4. Increased Maintenance Frequency
If maintenance on a metal roof becomes more frequent, it may be a sign refurbishment is needed. Industrial buildings often require regular upkeep, but when the frequency of repairs or the cost of maintenance begins to rise, it suggests the roof sheets are no longer performing as they should. According to a study by the National Federation of Roofing Contractors (NFRC), frequent repairs can increase the overall maintenance cost by up to 40%. Increased maintenance could indicate underlying issues such as rust, leaks, or coating failure, all of which can be addressed through a comprehensive refurbishment process.
5. Rising Energy Costs
Rising energy costs can indicate a commercial roofing system is not functioning efficiently, possibly due to worn or damaged roof sheets. Poor insulation or reflective properties of an aging metal roof can cause the building to lose heat in winter and gain excessive heat in summer, leading to higher energy bills. The Carbon Trust reports that improving roof insulation and reflectivity can reduce energy consumption by up to 25%. Refurbishing the roof with modern coatings designed to improve energy efficiency can help reduce these costs while also enhancing the overall performance of the roof.
6. Deterioration of Coatings or Paint
When the coatings or paint on a metal roof begin to deteriorate, it is a clear sign refurbishment is necessary. Peeling, flaking, or faded paint on roof sheets indicates the protective barrier is breaking down, leaving the metal exposed to the elements. This can accelerate rust and corrosion, leading to more significant damage over time. According to a study by the British Coatings Federation (BCF), proper maintenance and recoating can extend the life of a metal roof by up to 15 years. Refurbishing the roof with new, high-quality coatings will restore its protective properties and improve the appearance of the building.
7. Loose or Missing Fasteners
Loose or missing fasteners are a significant sign a metal roof in industrial buildings may need refurbishment. Fasteners play a crucial role in securing the roof sheets to the structure, and when they become loose or fall out, it can lead to leaks, panel movement, and wind damage. According to the BRE, improperly secured fasteners are responsible for 60% of metal roof failures during storms. Addressing this issue during refurbishment ensures the roof is securely fastened, preventing further damage and maintaining the safety and stability of the roofing system.
8. Warped or Damaged Panels
Warped or damaged panels are a clear indication a metal roof requires attention. Roof sheets that have become warped due to heat, impact, or age can compromise the roof's ability to protect the building from the elements. Damaged panels can lead to water ingress, reduced energy efficiency, and overall structural weakness. The Metal Building Manufacturers Association (MBMA) notes that replacing or repairing damaged panels can restore a roof’s efficiency and extend its lifespan by up to 20 years. Refurbishment involves repairing or replacing these panels, restoring the roof’s integrity and ensuring it continues to perform effectively in protecting the building.
How Much Does Metal Roof Refurbishment Cost?
Metal roof refurbishment generally costs from £45 to £130 per square metre (sqm). This cost variation depends on the specific refurbishment activities required, such as inspections, cleaning, repairs, and recoating. Refurbishment is vital for prolonging the lifespan and performance of the metal roofing system, helping to avoid more expensive problems in the future.
| Service | Cost Range |
|---|---|
| Metal Roof Refurbishment | £45 to £130 per sqm |
*These estimates are general, and actual costs can vary based on specific project requirements, location, and market conditions.
