Location: Archbold, OH
Facility Type: Manufacturing Plant
Size: 220,000+ sq. ft.
System: Roof Coating-838 Coatings Silicone Roof Restoration
Warranty: 10-Year Material & Labor Warranty
Project Overview
This large-scale silicone roof coating project for a Northwest Ohio manufacturing facility spanned over 220,000 square feet, making it one of our more time-sensitive and logistically demanding jobs of the season. The existing roof had suffered hail damage, and with Northern Ohio’s short window for coating season, weather was a critical factor.
Thanks to a tightly coordinated team, fast mobilization, and deep experience with silicone systems, we were able to restore the roof in under two months, wrapping up just before the October weather deadline. The result: a seamless, watertight roof surface protected by a high-performance 838 Coatings system—and a satisfied client entering winter with confidence.
Scope of Work
Surface Preparation
- Performed extensive pressure washing to clean the full roof surface
- Sealed all visible fractures in the existing membrane
Flashing & Penetration Detailing
- Applied 838 MS sealant to all curb edges, stacks, penetrations, and vulnerable seams to reinforce critical areas before coating
Silicone Coating Application
- Applied 1 coat of 838 Fast One silicone at 2 gallons per square
- Ensured consistent coverage and adhesion across all roof sections
- Conducted pull tests post-application with adhesion results ranging from 7 to 11 lbs, exceeding standard expectations
Challenges & Solutions
Challenge
- Late-season weather window (September–October)
- Large roof with multiple penetrations and hail damage
- Tight schedule and coating deadline
Solution
- Mobilized quickly, secured materials in advance, and started pressure washing during weekends to maximize dry days
- Used a systematic team approach to seal all penetrations, reinforce weak points, and ensure thorough prep before applying silicone
- Executed with precision thanks to an experienced crew, clear communication, and full-team buy-in on the urgency and quality expectations
Results & Client Feedback
Despite the pressure of weather and scale, the coating adhered extremely well, with exceptional pull test results confirming strong adhesion and performance. The client was impressed not just with the finished product, but with our ability to work efficiently, safely, and without disruption to daily operations.
This project served as a reminder that “how you practice is how you play”—our preparation, experience, and internal coordination made all the difference.
The project was a success, the roof is protected, and as the coating season came to a close, the facility entered winter with peace of mind and a 10-year NDL material and labor warranty.