Mixed Material Flat Roof Replacement and Roof Coating | Alliance Group

Every commercial flat roof replacement or restoration project is unique with its own priorities, challenges, and positive aspects. That’s why it takes a team of skilled professionals to give a thorough assessment of a building’s roof damage and determine a plan of action that works for the customer.

For this roof replacement project in Daytona Beach, Alliance Group worked alongside Maxwell Urethane Roofing Inc. We replaced and coated the 53,000+ square foot commercial flat roof at Seaside Healthcare. View the video below to get an overview of the project.


The Roof Damage

Along with the Daytona Beach area in general, the Seaside Healthcare building, built in 1961, received a great deal of damage from Hurricane Matthew in October of 2016. The building owners began to notice roof leaks and contacted Maxwell Urethane Roofing Inc. to check the damage.

Past attempts were made to repair and seal leak-prone areas with acrylic coatings and tar. After cutting into the roofing layers in several different spots, the roof inspector found waterlogged insulation. This means that a roof replacement was the best choice for the building owners.


Water damaged roofing insulation.

Insulation samples before the roof replacement.


Tear off debris from a commercial flat roof.


Flat Roof Replacement

Our roofing crews have experience working with all types of flat commercial roofing systems. The existing roof was a mix of different roofing materials. Among them were, styrofoam, lightweight concrete, modified roof, and tar and gravel. With the right equipment preparation and job site planning, our crews systematically removed the old damaged roofing layers while the next crew prepped and installed the new roof right behind them. Once people are on the roof working, it’s always important to move the job forward in the most efficient and safest way possible. It is a top priority to maintain a safe job site for all team members and building occupants during all roofing projects.

As the team worked in sections, removing and hauling away the old roofing debris, others prepped the new deck. A portion of the roof had a wood deck, so we replaced and re-nailed it to the current building code requirements. Because the water damage on this roof was extensive, several trusses also required replacement.


Commercial flat roof deck replacement due to water damage.


Commercial Flat Roof Coating

With a strong new deck and insulation board in place, we begin the roof coating process. With this project, a layer of spray polyurethane foam roof coating is applied first. This additional layer of insulation not only increases the R-value but also provides a seamless, waterproof surface for applying silicone onto. The irregular shapes found on this roof are a great candidate for SPF coating. The foam will securely fit into odd roof shapes and crevices for maximum coverage.


Spray polyurethane foam roof coating for a commercial flat roof by Alliance Group.


Areas surrounding A/C units, vents, and other roof projections are common places for leaks. Silicone roof coating ensures a tight bond to all roof projections. Gaco Western’s silicone roof coating is guaranteed to withstand ponding. Silicone is also tough against UV rays and severe weather, so you can count on this protective layer to last for decades.

Lastly, to increase traction on the roof we mixed in roofing granules into the top layer of silicone while it was wet. Gaco carries a specialized product for this type of application, GacoFlex WalkPad. Gaco’s WalkPad is highly visible, durable, and resistant to traffic wear and tears.


The Completed Roof

Before and after a commercial flat roof replacement and roof coating project by Alliance Group.



Completed roof replacement, SPF application, and silicone roof coating.