METAL RESTORATION

Potomac Millwork

Full coating restoration over a previously restored metal roof

Project Overview

Potomac Millwork operates from a large metal-roofed building in Woodbridge, in Prince William County. The roof had already been restored with a coating at some point in the past, and that coating had weathered.

The owner needed the roof brought back to a sound, protected condition, and the old skylights across the roof needed to be dealt with as part of the job.

Job Photos

Weathered earlier coating on the metal roof, with rows of skylight panels in view (Potomac Millwork, Woodbridge, VA) — Weathered earlier coating on the metal roof, with rows of skylight panels in view

Crew preparing a section of the roof next to an area that is already white (Potomac Millwork, Woodbridge, VA) — Crew preparing a section of the roof next to an area that is already white

White top coat going on over the tan base coat across the metal panels (Potomac Millwork, Woodbridge, VA) — White top coat going on over the tan base coat across the metal panels

Crew member applying coating on the roof with spray equipment and hoses (Potomac Millwork, Woodbridge, VA) — Crew member applying coating on the roof with spray equipment and hoses

Finished white coating around pipe vents on the restored metal roof (Potomac Millwork, Woodbridge, VA) — Finished white coating around pipe vents on the restored metal roof

Aerial view of the Potomac Millwork building with the full white roof restoration (Potomac Millwork, Woodbridge, VA) — Aerial view of the Potomac Millwork building with the full white roof restoration

The Challenge

A coating restoration does not last forever. Over time the surface chalks, thins and gets dirty. This roof had faded and streaked, with the old coating worn down along the panel ribs.

The roof also had rows of skylight panels. Plastic skylight panels on metal roofs age faster than the metal around them, and the laps and fasteners where they meet the metal are common leak points. Coating over a weathered skylight panel does not make it a reliable part of the roof.

Our Solution

We covered the skylights with metal panels so those openings became part of the metal roof. Then we cleaned the roof and applied a full coating restoration over it. A tan base coat went down first, followed by the white top coat.

1We covered the existing skylights with metal panels.
2We cleaned and prepared the previously coated metal roof.
3We applied a tan base coat across the roof.
4We applied the white top coat over the base coat to finish the restoration.

Why This Approach

Recoating a roof that has already been coated is often the most economical way to keep it protected, as long as the old coating is still well bonded and the surface is properly cleaned and prepared. It avoids tearing off metal panels on an occupied building. Covering old skylights with metal removes one of the weakest details on the roof, so the new coating goes over a consistent metal surface instead of aging plastic panels. A two-coat system with contrasting base and top coat colors also makes it easier to see that every area got full coverage.

Results

Old skylights covered with metal panels
Full coating restoration over the previously coated metal roof
Base coat and white top coat applied across the building
Bright white finished roof surface

Common Questions

Can a metal roof be recoated if it was coated before?

Yes, in many cases. The existing coating needs to be checked for adhesion, cleaned thoroughly, and repaired where it has failed. If it is still bonded to the metal, a new coating can be applied over it to renew the roof's protection.

Should old skylights be removed or covered during a roof restoration?

If the building does not need the daylight, covering old plastic skylights with metal panels is a common choice, because the panels and their laps tend to crack and leak as they age. If the daylight is important, the skylights can be cleaned and resealed or replaced instead.