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Case Studies

Ballasted EPDM Saved by GacoRoofFoam and GacoFlex Silicone Coating

Location: Upper Marlboro, MD
Specification: Master Spec - 07 57 00 / SI-38-GF20 / GacoFlex S20 Over Polyurethane Foam 38 Mil
Contractor: Remtek Services

A leaking roof is a problem that needs to be addressed immediately, but the high cost of a traditional re-roof can be alarming. Not every leaky roof requires a total replacement, though. Learn how a Prince George’s County building saved thousands of dollars by restoring its roof with a Gaco roofing system


What Problem Did Gaco Help the Building Owner Address? 

The building was facing water intrusion, which was causing leaks. The ballast was large and hard to move, so during a rain or a snow event, it was challenging to find the source of the leak. With the pitched deck, water would run once it entered the system, making it very difficult to chase the leak.


How Did Gaco and the Contractor Help Solve the Problem?

Gaco’s licensed applicator, Remtek, developed a system to solve all the problems the building was encountering. This goal was achieved by utilizing a local hydrovac company to come in and suck all the river stones off the roof. The wet vacuum process was also used to clean the roof of dirt and debris. 

Once the rock was removed, a wood fiber recovery board was installed with plates and screws over the entire roof surface to secure the ISO and EPDM. Remtek then applied GacoRoofFoam F2733 at an average thickness of 1.5” to encapsulate the system. GacoFlex S2048 (tan) Silicone Coating was then applied as a topcoat to waterproof the whole system. The GacoFlex S20 coating was also used in conjunction with Sesco Rainbow Roofing Granules to provide a more durable top coat that would provide a non-slip surface for foot traffic and to help dissipate water and ice.


What Made GacoRoofFoam and GacoFlex Silicone Especially Suitable for Prince George’s County?

Prince George’s County is located near the Chesapeake Bay southeast of Washington DC. In the winter, they can experience winter storms that dump a couple of feet of snow on the roof, while 100-degree temperatures are not out of the ordinary in the summer. Being on the East Coast, this area also experiences hurricanes in the fall.

The combination of the recovery board and spray polyurethane foam increases the energy efficiency in winter and summer to regulate building temperatures, ultimately lowering energy expenses. The assembly is Miami Dade County and FM/UL approved, and the silicone top coat will provide UV protection and waterproofing for the next 20 years.


What Made GacoRoofFoam and GacoFlex Silicone Roof Coating Especially Suitable for This Building?

The building is very active and has people staffing it 24/7/365. Avoiding disruptions to operations was essential. Plus, the diversity of weather in the area can go from 100 °F (37 °C) during the day to temperatures that drop into 40 – 50 °F (5 – 10 °C) at night. This system will help maintain consistency in the building creating a more enjoyable work environment.


How Did Gaco Help the Building Owner Drive Out Costs and Reduce Risks?

By utilizing the GacoRoofFoam and GacoFlex Silicone System, we added an additional R-value of approximately R-10* to the building. This insulation factor will assist in lowering energy costs by making the building more energy-efficient. 

This system is monolithic, so there are no seams for water and wind to make their way into the building. On our first visit to the building, we encountered multiple roof tiles that were falling in due to water saturation. These were a safety concern and an eye sore because of the brown water stains. Not to mention the cost of replacing the tiles every time it rained. When the tiles become saturated, they also can promote mold growth, which is detrimental to clean breathing air. The ballast river stone is also hazardous to walk across, and the Gaco System provides a much smoother, slip-resistant surface to traverse safely.


What About This Project Can Help Gaco and Our Contractors Earn More Business?

This project shows how a full roofing system using GacoRoofFoam and GacoFlex Silicone can be installed to fully restore a leaky roof on buildings beginning to show their age. Ballasted roofs were prevalent in 1980s construction as a way to lower costs and keep the roof in place during harsh, windy weather. The GacoRoofFoam and Silicone System is a highly cost-effective way to retrofit a building with a new roof system that will last for years to come, even in the unpredictable Northeast climates 


What About This Project Highlights the Hands-On Approach of Gaco’s Team of Experts? 

This project had many moving parts. The Area Manager was the information hub between the engineer, architect, maintenance staff, contractor, and building owner. It was a 4-month process that required focused coordination between parties to keep the project moving forward. The building owner needed to develop a system that was energy efficient as well as cost-effective. The system we created met all those criteria. The original plan was to rip off the entire system and install a new roof. Gaco, partnering with the contractor, was able to create a solution to address all the customer’s needs, while saving the customer over 40% when compared to the original re-roof plan.


Click here to see the full list of products used in accordance with this specification.

*R-value has been validated at 1” thickness to provide R-6.5, and validated at 3.5” thickness to provide R-25. Please reference the Product Data Sheet for full details.

Learn How Gaco Can Help Your Business

Ballasted EPDM. Metal Panels. Granulated surfaces. Gaco solutions have been used on a wide range of roofing projects. To learn more about our products and find the right fit for your leaky or aging roof, contact your local Gaco Area Manager today.

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