When it comes to an existing metal roof that is worn-out and in need of replacement or recover, industrial facilities look for safe and smart approaches. The video below walks through the options considered for this particular roof at a Cargill corn processing plant in Iowa.
Ultimately, a full liquid-applied recover with the flexible, durable, and thick TritoFlex 2K synthetic rubber was chosen and installed by a local Certified Contractor. This was not only used to recover the metal roof, but the adjacent block wall and crazed TPO roof. After the roof was completed, the city experienced a rare natural disaster that brought sustained 90 mph winds with gusts up to 140 mph. These roofs recovered with Triton were the only at the plant to not leak during the storm and had zero damage from flying debris or wind uplift. Watch a detailed overview of the entire project below to see the explanation and results.
Metal Roof Recover Options
Before replacing, recovering, or restoring an existing metal roof, we walk through common options and why a liquid-applied recover may be your best choice.
In Saskatchewan and Alberta, Canada, Triton representatives have worked alongside Richardson Pioneer to provide long-term, seamless, and eco-friendly solutions for their western Canada grain elevators.
Whether it’s restoring the roofs of grain elevators, or protecting steel structures from corrosion at potash mines, NAU Group has used TRITOflex as an indispensable tool with their agricultural and industrial clients.
The Pioneer grain elevators shown here were restored by NAU Group to watertight condition with TRITOflex and TRITOtherm throughout Western Canada in 2016. Their clients selected TRITOflex to protect their agricultural assets because of its:
• 1900% elongation
• Class A fire rating
• Hail and impact resistance
• UV stability and ceramic technology
• Seamless and self-terminating
• No harmful VOC’s or toxic fumes
• Highest adhesion ratings to concrete in the world
• Impermeable resistance to acids and much more
Seamless Installation
Pioneer’s grain elevators were spread out across these two provinces, but the user-friendly Triton instant-set spray system made for easy transportation, cleaning, and quick application. TRITOflex was spray-applied in one coat, instantly stopping all leaks on each structure and protecting value agricultural resources stored inside.
This giant petrochemical complex in Texas is one of the largest and most advanced refineries in the world, where they have pioneered some of the most innovative petrochemical technologies from the 1920’s to today. This particular laboratory facility within the engineering complex contains highly sensitive and confidential operations, making a full roof replacement disruptive and costly.
Rather than tear-off the existing roof systems or overlay the old roof with another seamed single-ply membrane, the client elected for a stronger, safer alternative that would utilize the seam-free TritoFlex 2K industrial-grade, non-toxic synthetic rubber membrane. They had attempted roof restorations with acrylic and silicone coatings in the past with poor results. First, concentrated areas of wet insulation were removed and replaced before the Certified Contractor applied TritoFlex 2K directly over the existing EPDM, PVC, and BUR roofs on the building to create a new, seamless, and impermeable waterproofing membrane. With high durability and puncture-resistance, resistance to chemicals, and resistance to severe hail and hurricane-force winds, Triton products were engineered to last in this type of industrial environments.
After the roofs were recovered with the TritoFlex 2K synthetic rubber membrane and watertight, the highly reflective, sacrificial TritoCryl 2K white topcoat was installed for energy efficiency and sustainability. Both the TritoFlex 2K and TritoCryl 2K products are inherently slip-resistant, providing a safer roof surface during and after installation that reduces the likelihood of slips and falls. The new liquid-applied roof system came with a 15-Year NDL Material and Labor Renewable Warranty that provides peace of mind to the client and building management group, even in the harshest weather events. The liquid-applied Triton roof recover system was a stronger, safer, sensible alternative that saved the company hundreds of thousands of dollars.
While wastewater is waiting to be processed and treated at the plant, it must be safely stored and contained. This wastewater treatment plant’s storage reservoir had been leaking, resulting in contaminants leaching into the local groundwater. After multiple attempts to stop the leaks with other products, they chose to have the entire concrete reservoir lined with TritoFlex 2K liquid rubber.
The water treatment company had first tried sealing only the joints with an expensive epoxy sealant. These fixes were only temporary and they ended up back where they started. The client made a decision to go with the TritoFlex 2K system for its:
• 1900% elongation
• Class A fire rating
• Hail and impact resistance
• UV stability and ceramic technology
• Seamless and self-terminating
• No harmful VOC’s or toxic fumes
• No harmful VOC’s or toxic fumes
• Highest adhesion ratings to concrete in the world
• Impermeable resistance to acids and much more
The entire concrete reservoir was drained, cleaned, and sprayed with 80 mils of water-based TritoFlex 2K rubber. After application, TritoFlex 1K Brush-Grade was used as an extra reinforcement in sensitive areas and to seal any spray imperfections. After the products were fully dry, the reservoir was able to be re-filled and has been operating leak-free. The client was able to choose an environmentally-safe product to solve an environmental problem. With great chemical resistance and UV resistance, TritoFlex has proven itself up to the task of holding harsh wastewater in a hot and humid climate.
America’s large food manufacturers and processors feed billions of people throughout the world. With massive manufacturing plants spread across the country, protecting these facilities with high-performing roof systems is of vital importance.
The TritoFlex 2K Rubber roof recover system helped this multinational food-manufacturing corporation avert a disruptive, costly, and wasteful tear-off on one of their production facilities.
Triton’s liquid membrane used the existing roof to its advantage by upgrading the roof with increased thickness, durability, flexibility, and resistance to acids, chemicals, and Mother Nature herself. TritoFlex is the ideal solution for industrial facilities with countless penetrations, protrusions, high foot traffic, and frequent changes to roof-top equipment. It is self-terminating and does not require reinforcement due to extremely high elongation combined with high tensile strength.
With a Class A fire rating, hail-resistant warranty, and anti-slip finish, TritoFlex 2K Rubber was applied to form a seamless membrane on large sections of the plant. Multiple types of roofs were tied together into one monolithic roof system.
Beyond providing a watertight roof, the TritoTherm reflective top coat with ceramic nanotechnology has drastically reduced heat transfer into the plant during warm months and has proven to remain cooler after becoming dirty. This results in long-term protection of the underlying roof components. On average, the Triton roof system has reduced heat transfer to the roof deck by 25 degrees F at this plant.
As a versatile material, TritoFlex rubber was also used to solve previously unsolvable moisture intrusion problems on the exterior tilt-up concrete walls of the plant. This moisture intrusion had been affecting the sensitive food production area. After applying the impermeable TritoFlex Rubber membrane to the exterior walls, the moisture intrusion was finally stopped.
Triton is headquartered in Cedar Rapids, Iowa, a state some consider to be the heart of America. One of Cedar Rapids’ iconic landmarks is the Quaker Oats (PepsiCo) cereal mill built in the 1940’s. It still holds top spot as the largest cereal mill in the world. Right in the middle of downtown, its various smells are famous to Iowans.
The industrial-grade, non-toxic TritoFlex 2K Rubber restoration system has been chosen over the years by PepsiCo to restore worn-out, leaking roofs of various types. From Built-Up (BUR) Asphalt roofs to metal roofs, PepsiCo was able to upgrade the existing roof substrates by adding a thick, durable, and seamless rubber membrane. The TritoFlex system stronger and safer than conventional options and avoids costly, disruptive tear-offs. The bright white TritoTherm ceramic coating was then applied as a sacrificial topcoat and radiant barrier over the rubber waterproofing.
All of the work was completed with absolutely no disruption to the daily operations of the plant. There were no harmful odors, solvents, or VOC’s from the liquid materials. These cold-applied coatings avoid traditional use of torches (open flames), hot asphalt, smelly adhesives, or using thousands of screws to hold down a new rolled membrane. To a food production plant, this was pivotal. In addition, the finished surfaces are slip-resistant and safe.
In addition to extensive roof work, one of the head houses was completely sealed and encapsulated with TritoFlex 2K Rubber and then painted with our TritoCryl 1K white acrylic coating. Triton materials solve issues for the entire building envelope.
We are proud to have our materials used at a company that represent our city’s rich history and makes up part of its economic backbone. Triton focuses on manufacturing technologies that are stronger, safer, and innovative, and the Quaker Oats cereal mill is now protected each day from these technologies.
Fighting hundreds of leaks, an industrial spring manufacturer in North Carolina sought a smart roof restoration solution that would stop their leaks and fit their budget. Triton was the perfect match.
In addition to hundreds of leaks across multiple types of metal roof systems, heavy rust and corrosion was occurring in this humid Carolina climate. Due to the cost and disruption, a complete replacement of metal wasn’t an option. A single-ply overlay would also be expensive and potentially lead to structural concerns with a change in water weight distribution. Liquid-applied restoration made the most sense. But out of all the roof coatings on the market, which one would work best?
The client quickly realized that the TritoFlex Rubber products were the best liquid products for metal roofs in the industry. With a combination of high elongation, high recovery, and high tensile strength, it made the most sense to seal the roof with these products. While a brand new waterproofing membrane on the entire roof would come with a warranty that covered large hail, ponding water, and foot traffic, it didn’t quite fit in the budget. And the leaks needed to be stopped to prevent further disruption to company operations.
The roof was first pressure washed and primed with Triton’s Metal Prime, a rust-inhibiting coating. Loose and missing fasteners were replaced and then TritoFlex 2K was spray-applied to 80 mils dry on all seams, butt joints, penetrations, transitions, and flashings. TritoFlex 1K was quickly applied at 80 mils dry on all fasteners.
The contractor then applied two coats of TritoTherm acrylic ceramic coating over the entire roof surface to provide UV protection, extend the life of the existing metal, and drastically reduce heat transfer with its unique nanotechnology. The client was provided a 10-year material and labor leak-free warranty and the peace of mind they made the right choice choosing a Triton restoration system.
This nuclear plant is the largest carbon-free energy producer in the state of Minnesota. Built in the early 1970’s, roofs throughout the plant were heavily aged and causing disruptive leaks in sensitive facilities. After receiving bids to re-roof, Xcel found Triton’s alternative, industrial-grade, and non-toxic liquid roof systems would avoid disruption and high costs.
TritoFlex 2K is an industrial-grade, non-toxic rubber membrane that was spray-applied directly over 250,000 sf of roofs at this nuclear power station. Multiple types of roofs were restored, including Gravel Built-Up, EPDM, and Metal. The Certified Contractor first prepared the roofs to clear them of dirt and debris and then applied TritoFlex 2K to create a seamless, impermeable waterproofing membrane over the existing substrates. With high elongation, high tensile strength, resistance to chemicals, and resistance to Minnesota’s harsh winters, Triton products were specially engineered to last in these types of industrial environments.
Roofs protecting the nuclear turbine plant, offices, warehouses, and a critical training facility were completely recovered with the TritoFlex 2K membrane and then finished with the renewable, reflective TritoCryl 2K topcoat. Plant operators had been frustrated with costly, disruptive leaks for years. For the first time, they are happily leak-free after investing in protection with Triton’s industrial-grade roofing products.
Dow Chemical’s facilities in Texas produce billions of pounds of products each year that enhance the quality of life for people around the globe. Their Freeport site is the largest integrated chemical manufacturing complex in the Western Hemisphere. Two of their high-level flexible packaging plants had been suffering from expensive, disruptive roof leaks. Triton delivered a stronger, safer alternative to a conventional roof tear-off that led to multi-million dollar savings.
Rather than tear-off the existing roof system, requiring all mechanical equipment to be lifted to accommodate new insulation, Dow chose to use Triton’s non-toxic, industrial-grade liquid membrane to recover the existing roof membranes and increase overall durability and strength. Concentrated areas of wet insulation were first removed and replaced before the Certified Contractor applied TritoFlex 2K directly over the existing Modified Bitumen, single-ply, and metal roofs on the plants to create a new seamless, durable, flexible, and impermeable 80 mil waterproofing membrane. With high durability and puncture-resistance, resistance to chemicals, foot-traffic durability, and resistance to severe hail and hurricane-force winds, Triton products were engineered to last in these types of industrial environments. Industrial plants typically have a high number of roof-top penetrations, curbs, and equipment, making conventional rolled roofing more expensive and more prone to leakage. A seamless, liquid-applied, self-terminating membrane makes the most sense for complicated, busy roof-tops.
The TritoFlex products are VOC-free, water-based, and non-flammable, meaning no disruption or safety risks posed to anyone on or inside the building during installation. After the roofs were sprayed with the TritoFlex 2K synthetic rubber membrane and proven to be watertight, the highly reflective, sacrificial TritoCryl 2K white topcoat was installed for reflectivity and renewability. Both the TritoFlex 2K and TritoCryl 2K products are slip-resistant, providing a safer roof surface during and after installation that dramatically reduces the risk of slips and falls. The new liquid-applied roof system came with a 20-Year NDL Material and Labor Warranty that can be renewed indefinitely for the life of the building. The liquid-applied Triton roof recover system was a stronger, safer, sensible alternative that saved this client millions of dollars.
Algorta Norte is a large mining company in the Antofagasta region of northern Chile, specializing in the extraction and production of Iodine. Mining and refinery facilities face the harshest environments, with raw minerals and chemicals that cause corrosion on concrete and steel/metal surfaces. Protection of these surfaces is critical. Beyond that, chemicals and liquid waste need to be properly contained to avoid leaching into the ground and affected water ways.
Traditionally, mining companies use rolled rubber goods as a containment lining. While they hold up very well, the seams and termination points become the problem with time. A liquid membrane makes the most sense, but the client struggled with numerous liquid products over the years. Until they were presented with an innovative rubber product, applied in liquid form. TritoFlex is a synthetic rubber product that is water-based, contains no solvent or VOC’s, and is applied to form a seamless rubber lining.
TritoFlex 2K and 1K Rubber was applied to various facilities and surfaces at Algorta Norte’s mines in the region. It was used to line canals that carry chemical waste from the Iodine refining process and to line ocean water storage tanks. The rubber was also used to protect concrete and steel surfaces that don’t even come into contact with liquid chemicals from corrosion. Often at mines like this, just the presence of raw mineral residue in the air causes quick corrosion to steel and to concrete. TritoFlex is extremely resistant to these residues and works as an excellent protective layer to avoid damage to these structures.
TritoFlex Rubber products have been used at mines, refineries, and chemicals plants all over the world for its superior physical properties, combined with its excellent chemical resistance and impermeability.
