General Thoughts on Roof Restoration

ERSystems

Systems Training

Who is ERSystems?

Manufacturing Facility

• 50,000 ft2

– 45,000 ft2 is manufacturing & warehouse

• State of the art• Indoor tank farm• Capacity of 150,000 #

per day

System Costs and Modules ERSystems

Restoration

• Trends & Economics• Increasing material prices of installed

roofs• Increasing competition• Diminishing labor market-higher labor

costs• Increasing Insurance-workers comp costs• Decreasing return- lower margins to the

contractor

Restoration

• Why Not?– Decrease overhead– Decrease crew size– Save on insurance– Save landfill expense– INCREASE Profits and ROI

Metal Restoration

• Millions of square feet restored annually through ERSystems Contractors

• Most cost effective and labor saving system for metal in the industry

• HER is still the only product that consistently performs without Fabric

• Since 1977!!

Metal Restoration

• Benefits to the contractor and building owner:– Installation labor is easier, faster, saves $– White finish is reflective and great emitter of

heat saving energy– Manufacturer guarantee that is renewable

every 5-10 years

Metal Restoration

• Installation in just a few easy steps– Remove foreign material– Tighten loose fasteners– Pressure wash– Prime (if needed)– HER seams, screws, and penetrations– Finish coating

Metal Restoration

Common seam issue

Metal Restoration

HER 2000 Extruded

Metal Restoration

Brushing HER 2000

Metal Restoration

Brushing HER 2000

Metal Restoration

Seam Sealed

With HER

Metal Restoration

HER 2000

Complete

Metal Restoration

1st Finish

Metal Restoration

Restored

Penetration

Metal Restoration

Metal

Restoration

Before

Metal Restoration

Metal

Restoration

After

Metal Restoration

Before

Metal Restoration

After

Metal Restoration

• PowerWash $.05-$.20 per sq ft=$.12 per sq ft• Primer $.10-$.15 per sq ft=$.12 per sq ft• HER $.08-$.20 per sq ft=$.14 per sq ft• Basecoat field $.10-$.25=$.17 per sq ft• Finish Coat $.10-$.25=$.17 per sq ft

Labor cost $.43- $1.05 per sq ft

Metal Restoration

• Acrylic/Polyurethane System– Eraguard 2000 Primer $.13 per sq ft– HER seam and fasteners $.23 per sq ft– Eraguard 1000 Finish coat $.45 per sq ft

Total $.81 per sq ft

Metal Restoration

System Summary• Material Cost $.81 per sq ft• Labor Cost $.43-$1.05 per sq ft• $1.24-$1.86 per sq ft plus your

Margin/Markup/Profit

Jobs are sold at $1.60-$3.75

Thermoset Restoration

• ERSystems was the first to warrant a system to restore Thermoset material

• First to warrant Hybrid systems utilizing spray foam as flashing material

• EPDM, Hypalon, other?


• Understand the system you are restoring

• EPDM vs. Hypalon– Weak/failure points

• System must be in watertight condition before coating application


• Assess system condition-– Moisture level of insulation-remove wet

areas.• Address problem areas

– Transitions– Flashings– Seams– Penetrations

• Power wash• Prime-as necessary• Coat


Priming seams


Taped Seams

First layer of

Finish Coat


Eraguard 1000

Finish Coat applied in center;

Perimeter to be rolled.

Finished

Section


Before

ThermoSet Restoration

• Material Cost

• Primer 1=$.10 / square ft• Seam Tape=$.62 / lin. ft.

– Basecoat over seams=$.40 / lin ft• Basecoat field=$.32 / sq ft• Finish Coat =$.21 / sq ft

ThermoSet Continue

• 20,000 sq ft project 20x100 rolls– Primer 1=$2,000– Seam Tape/coating=$1,428– Base Coat=$6400– Finish coat=$4200

Total material cost=14,028=$.70 / sq ft


Labor Cost• Power wash $.05-$.15 per sq ft=$.10 / sq ft• Primer $.08-$.20 per sq ft=$.14 / sq ft• Seam Tape$.08-$.20=$.14 / sq ft• Basecoat field $.10-$.25=$.17 / sq ft• Finish Coat $.10-$.25=$.17 / sq ft

Labor cost $.41- $.1.05 per sq ft


Job Summary• Material Cost $.70 / sq ft• Labor Cost $.41-1.05 / sq ft• $1.11-1.75 / sq ft plus your Margin

/Markup/Profit


Thermoplastic Restoration

• Understand the membrane being restored– What are the failure points of the

system

• PVC-Tends to become brittle with time, surface crazing (varies widely with formulation). Heat-welded seams.

• TPO-early formulations stiff, crack, chalk, seam issues.


• Assess system condition-– Moisture level of insulation-remove wet

areas.• Address problem areas

– Transitions– Flashings– Seams– Penetrations

• Power wash• Prime-as necessary• Coat


Cleaning


Basecoat


Finish-

Coat


Polyurethane

Or Acrylic

Coating systems


Completed Acrylic system


Material Cost• Barrier Coat = $.21 / sq ft• Primer 1=$.10 / sq ft• Basecoat field=$.32 / sq ft• Finish Coat =$.21 / sq ft

Total $.63-.73 per sq ft in material based on Primer I


Labor Cost• PowerWash $.05-$.15 per sq ft=$.10 / sq ft• Primer $.08-$.20 per sq ft=$.14 / sq ft• Basecoat field $.10-$.25=$.17 / sq ft• Finish Coat $.10-$.25=$.17 / sq ft

Labor cost $.33- $.85 / sq ft


Job Summary• Material Cost $.63 / sq ft• Labor Cost $.33-$.85 / sq ft• $.96-1.48 per sq ft plus your

Margin/Markup/Profit


Asphalt Restoration

• What asphalt systems can be restored?

• SMOOTH BUR• SMOOTH MODIFIED BITUMEN• GRANULATED MODIFIED BITUMEN

Asphalt Roof Performance

• UV deterioration-alligatoring, splits, cracks, hard, brittle.

• Hot, low reflectivity.• Flashings, transitions tend to fail,

no elongation, high tensile strength.

• Long performance history.

Asphalt Restoration

• Inspect for general condition of system

• Be certain the roof is restorable, – CAUTION: Asphalt BUR, Modified

Bitumens and asphalt adhesives are highly VARIABLE in composition, adhesion tests recommended

• Repair deficiencies, – Key to repair of asphalt systems is to

use ‘Like’ materials if possible• Be sure roof is clean, dry,

structurally sound• Wash-with Enviro-Wash

Asphalt Repair Materials

• Common repair materials, use “like” materials where possible–Modified bit single-ply–Plastic Cement, fabric–Emulsion, fabric–Spray Polyurethane Foam

(flashings)

Asphalt Restoration

Modified

Repair

Asphalt Restoration

Emulsion

and

Fabric

Asphalt Restoration

Erathane 300 Base

/ Polysoft II

Asphalt Restoration

Mod Bit

T-Patch / 300

Basecoat

Asphalt Restoration

Valley w/

Erathane 300

Basecoat &

Polysoft II

Asphalt Restoration

Valley Complete

300 Base &

300 Finish AL

Asphalt Restoration

Erlastic Basecoat

Eraguard 1000 Finish

Asphalt Restoration

Acrylic system

Erlastic /Eraguard 1000

Asphalt Restoration

Acrylic System

Asphalt Restoration

Before

Asphalt Restoration

After

Asphalt Restoration

Material Cost

• Basecoat =$.20 / sq ft• Finish Coat =$.45 / sq ft

Total $.65 cents per sq ft in material

Asphalt Restoration

• Labor Cost

• PowerWash $.05-$.15 per sq ft=$.10 / sq ft• Basecoat field $.10-$.25=$.17 / sq ft• Finish Coat $.10-$.25=$.17 / sq ft

Labor cost $.25- $.65 per sq ft

Asphalt Restoration

Job Summary• Material Cost $.64 / sq ft• Labor Cost $.25-$.65 / sq ft• $.89-$1.29 / sq ft plus your Margin/Markup/Profit


Replace vs. Restore

40,000 sq ft EPDMYR. Old Way New Way

1 $160,000 New roof $160,000 New roof

5 $2,000 repair/maintain $2,000 repair/maintain


15 $240,000 replace $80,000 restore


$409,000 cost $249,000 cost25-30 year Cost Analysis—OWNER

Value to the Contractor

• REPLACE• 40,000 square feet

– $160,000 job revenue– $80,000 material cost– 2 week project 6 man

• 480 hrs*50/hr=$24,000• Overhead = $5000

– $160,000 Revenue-$80,000 Material

-$29,000 Labor/Overhead

$51,000 Net Profit

• RESTORE• 40,000 square feet

– $80,000 job revenue– $25,000 material cost– 5 day project 3 man

• 120 hrs*50/hr=$6,000• Overhead = $2,500

– $80,000 revenue-$25,000 material

-$8,500 Labor/Overhead

$46,500 Net Profit

Restoration with Foam

• Asphalt roof in restorable condition and ADDITIONAL INSULATION DESIRED.

• SPRAY POLYURETHANE FOAM is an excellent option.– Insulates, waterproofs, reflective- all in one

operation.– Proven history– Effective option to adding insulation board

and second asphalt roof.

Restoration With Foam

• Important Features–Best R-Value / Inch of insulation–Flashing curbs, walls, difficult

areas–Eliminates tear off in some

situations–Great over metal where more

insulation is needed

Spray Foam

Spray foam

direct to metal

Spray Foam

Foam to metal

Spray Foam Over BUR

Flashing skylight

Spray Foam Over BUR

Restoration Summary

• Benefits of Restoration– Decrease overhead– Decrease crew size– Save on insurance– Save landfill expense

–INCREASE Profits and ROI

Restoration Summary

• Does Restoration fit in your business?• Is restoration in your 2009 plans?

– Great option during tough economic times!– Great option during solid economic times!

Documents

General Thoughts on Roof Restoration