Commercial Roof Coating Systems

What Are Commercial Roof Coatings?

Commercial roof coatings are fluid-applied membrane systems that are rolled, sprayed, or brushed directly onto an existing roof surface to create a seamless, protective barrier against water, ultraviolet radiation, and thermal stress. Unlike traditional roofing systems that require tear-off and full replacement, coatings restore and extend the functional life of a roof that is still structurally sound, delivering significant cost savings while improving energy performance.

Windward Roofing & Construction has been applying commercial roof coatings across Illinois, Wisconsin, Michigan, Indiana, and Florida for over 40 years. Our team evaluates each roof individually, recommending the specific coating chemistry that best addresses the building's exposure conditions, existing roof type, and performance goals.

Types of Roof Coatings

Silicone Roof Coatings

Silicone coatings are moisture-cured systems that offer exceptional resistance to ponding water, making them the preferred choice for flat and low-slope commercial roofs where drainage is slow or incomplete. Silicone remains flexible throughout its service life without becoming brittle or cracking, even under extreme temperature swings experienced in the Chicago area. These coatings provide outstanding UV resistance and maintain their reflective properties over time with minimal chalking or dirt pickup. Windward Roofing works with silicone coating systems from manufacturers including Carlisle, GAF, and Tremco to ensure proven, warrantied performance.

Acrylic Roof Coatings

Acrylic coatings are water-based elastomeric systems known for their high reflectivity, excellent color retention, and environmental friendliness. They are among the most cost-effective coating options and are available in a range of colors, though white and light tints are most common for maximum solar reflectance. Acrylic coatings perform best on roofs with positive drainage, as prolonged exposure to standing water can cause the coating to soften and degrade. They are an excellent choice for metal roofs, modified bitumen, and single-ply systems in good condition where ponding is not an issue.

Polyurethane Roof Coatings

Polyurethane coatings provide the highest abrasion and impact resistance of any coating type, making them ideal for roofs with heavy foot traffic, rooftop equipment access paths, or exposure to falling debris. Aromatic polyurethane is typically used as a base coat for its toughness, while aliphatic polyurethane serves as a top coat with superior UV stability and color retention. This two-coat system delivers both durability and long-term weather resistance and is commonly specified for warehouse and industrial roofs that experience regular maintenance foot traffic.

Benefits of Roof Coatings

Applying a roof coating system offers multiple advantages that make it one of the most practical investments a building owner or facility manager can make:

• Extends roof life: A quality coating application can add 10 to 20 years of service life to an existing roof, postponing or eliminating the need for a full replacement.
• Reduces costs: Coatings cost 50 to 70 percent less than a full tear-off and replacement, and the absence of demolition work minimizes labor, disposal, and disruption expenses.
• Improves energy efficiency: Reflective white coatings can reduce rooftop surface temperatures by up to 60 degrees Fahrenheit compared to dark roofing surfaces, significantly lowering cooling costs and qualifying for cool-roof incentives.
• Eliminates seams: Fluid-applied coatings cure into a seamless membrane, removing the joints, laps, and fastener penetrations where most roof leaks originate.
• Sustainable solution: Because no tear-off is required, coatings keep existing roofing material out of landfills and reduce the environmental impact of re-roofing projects.
• Minimal business disruption: Coating application is quiet compared to mechanical roofing installation, produces no construction debris falling from the roof edge, and can often be completed while the building remains fully operational.

The Coating Application Process

Windward Roofing follows a systematic process to ensure every coating application delivers maximum performance and longevity.

Roof Assessment: Our team begins with a thorough inspection of the existing roof, including infrared moisture scanning to identify areas of trapped moisture within the insulation. Any saturated insulation sections must be removed and replaced before the coating is applied, as moisture trapped beneath a coating will continue to cause deterioration.

Surface Preparation: This is the most critical step in any coating project. The existing roof surface is power washed to remove dirt, debris, biological growth, and any contaminants that would prevent proper adhesion. Seams, flashings, and penetrations are repaired and reinforced with fabric-embedded base coat to ensure these critical transitions are fully waterproofed before the field coating is applied.

Primer Application: Depending on the existing roof substrate, a primer may be required to promote adhesion between the coating and the membrane. Our team selects the appropriate primer chemistry based on the specific substrate type.

Coating Application: The coating is applied in multiple passes using airless spray equipment or roller application to achieve uniform thickness across the entire roof surface. Minimum dry film thickness is verified using wet film gauges during application to ensure full coverage. Most coating systems require a minimum of 20 to 30 mils dry film thickness for warranted performance.

Inspection and Warranty: After curing, our quality control team inspects the completed application for uniform coverage, proper thickness, and clean detail work at all flashings and penetrations. Manufacturer warranty documentation is processed and delivered to the building owner.

When Coatings Are Appropriate vs. Replacement

Roof coatings are a powerful tool, but they are not the right solution for every situation. Windward Roofing recommends coatings when the existing roof structure and insulation are fundamentally sound and the primary issues are surface-level deterioration, aging membranes, or the desire for improved energy performance. Coatings are appropriate when:

• The existing membrane is well-adhered with no widespread blistering or delamination
• Moisture scans indicate less than 25 percent of the insulation is saturated
• The building owner wants to extend roof life without the cost and disruption of replacement
• Energy efficiency improvements and cool-roof certification are desired

A full roof replacement is the better investment when moisture has saturated large portions of the insulation, the existing deck has structural damage, or the roof has already been coated multiple times and has reached its maximum feasible thickness. Windward Roofing provides honest assessments, always recommending coatings only when they represent genuine long-term value for the building owner.

Why Choose Windward Roofing for Roof Coatings

Our 40-plus years of experience in commercial roofing means we have applied coatings over virtually every roof system type in service today. We are certified applicators for leading coating manufacturers including Carlisle, GAF, Tremco, and Sika, allowing us to provide manufacturer-backed warranties that protect your investment. From the initial assessment through final inspection, our project management approach ensures quality control, on-time completion, and clear communication throughout every coating project.

Frequently Asked Questions