Case Studies



With all of our coatings and roofing systems, you get the best of both worlds. Combining state-of-the-art technology with the most durable and advanced roof coating materials, we provide the most efficient installation systems on the market. We offer the best value for you and your clients. And we guaranty everything we do.


Fluid-Applied Case Studies

Custom Color Tint Roof Coatings Over Metal

Solutions By Roof Type - American WeatherSTar

In 2007, the Oklahoma State University Tulsa campus invited several coatings contractors in the Tulsa OK area to submit their chosen coating for a test on OSU’s main campus building to determine what product they would use to restore the roof back to its original new condition. OSU has a beautiful campus and building, but the roof was aging, it had some leaks, and simply wasn’t quite up to OSU standards.

David Paine with Sooner Roof Restoration, Inc., an AWS approved Contractor, submitted and tested the American WeatherStar Acrylic 211 HT, our best coating for color retention against UV degradation on a roof. We were competing with several other roofing products also tested, and all products were reviewed over a period of several months. After approximately six months, OSU chose our roofing material to restore the main campus building.

The project consisted of power-washing the entire roof with 3,500 psi of pressure, then priming the existing metal with AWS Rust Prime 912 to ensure adhesion and surface rust would not be an issue.

To waterproof the metal roof, all seams, penetrations and transitions were properly treated with AWS waterproofing materials.

The final step was to apply two coats of the AWS Acrylic 211 HT custom tinted to the green color that OSU has always used on their roofs at the Tulsa campus. The final product was an outstanding looking roof that OSU, Sooner Roof, and American WeatherStar are all very proud of today.


Leaking Metal Roof Restoration


This rusty metal roof that leaked every time it rained is like many of the metal roofs that our Contractors are faced with with every day. Stopping a metal roof leak is as easy as applying one of roof coatings.

To being with, every square inch of this roof was power-washed using over 3,000 pounds of pressure to ensure that the WeatherStar roof coating system would adhere to the metal. After power washing, AWS Rust Prime 910 was applied to the entire roof area. The Rust Prime 910 is only necessary where visible rust is apparent and as you can see, this metal roof definitely needed rust proofing.

After priming the roof, we begin the waterproofing stage. Every penetration, fastener, and seam is addressed to make sure they do not allow water to pass through the panels into the building. On this roof, a polyester fabric was used with the Acrylic 211 on every seam and penetration. After each fastener was tightened or replaced, AWS Brush-Grade 220 was applied to every one to ensure all are water-tight.

The final stage is to apply two coats of Acrylic 211 over the entire roof to form a seamless rubber-like membrane that will keep this building cool and dry for years to come. Other AWS top coats that work well on metal roofs include: Butyl 310, Urethane 520, or either one of the fast set roof coatings we offer.

Single-Ply EPDM Roof Restoration

This EPDM membrane roof was approximately ten years old and at the time of the job, roof leaks were random throughout the system. The building owner wanted a roof coatings system to waterproof the roof, to cut down on the heat within the building, and to prevent future degradation of the roofing membrane.

The WeatherStar Coatings Contractor cleaned the membrane roofing using our Etching Primer 920, which is specifically designed to clean carbon and dirt off an EPDM roof. The contractor applied AWS Etching Primer 920 with a garden sprayer then power-washed the roof using 3,000 psi of pressure. He then began waterproofing the roof by applying our Miami-Dade County approved Silicone 410, and polyester fabric on all seams and penetrations that were causing the building owner problems. 

After he completed waterproofing the system, the Contractor applied two coats of WeatherStar Coatings bright white Silicone 410, to the entire roof area to form a seamless elastomeric membrane that will last for at least ten years.

Other American WeatherStar top coats suitable for EPDM restoration include Urethane 520 for low sloped roofs that don’t drain well or our Acrylic 211, which is Miami-Dade County approved, for roofs that do drain well. American WeatherStar recommends a moisture survey before installing any of our coating systems to an EPDM rubber roof. If moisture is found, the wet insulation should be replaced before the AWS coating system is applied.

Smooth Built-Up Roof Restoration

This Smooth Built Up Roof was in the beginning stages of breaking down. And here at American WeatherStar, we don’t understand why roofs were ever designed black. A black roof has limited ability to fight the harmful Ultraviolet Rays the sun puts out every day and, in most cases, causes the black roof to degrade prematurely. To make matters worse, the heat from the black roof ends up in the building, causing either increased energy costs or just an extremely hot interior. This building owner contracted our Contractor to apply our bright white, energy-efficient roof coatings system on his roof to make it last longer and cool it down.

Before installing our roof coating system, the contractor had a moisture survey done on this roof to ensure there wasn’t wet insulation. If wet insulation is found, it must be replaced before installing our roof coatings.

After determining the substrate was dry, the installer power-washed the roof with more than 3,000 psi to make sure the roof was extremely clean. He then applied one coat of AWS Fabric Bond 930 to make sure our top coats adhered to the roofing material. Other appropriate primers for a smooth BUR roof include AWS Acrylic Bonding Pimer 905 and SBS Primer 950.

Often times at this point our Contractor would begin the waterproofing stage of our system, but this roof was caught before the roof leaks began. In this case the building owner was only using the WeatherStar roof coatings system for preventive maintenance. So the installer then sprayed two coats of AWS Acrylic 211 to form a bright white seamless membrane to make sure his customer’s roof lasted for years to come. To coat a smooth Built Up Roof that does drain well, use our Miami-Dade County approved Acrylic 211, but for roofs that do not drain well, use our Butyl 310 or Urethane 520.

Full Fabric System Over Built-Up Roof

This office building had an aged asphalt coated Built Up Roof that was causing the tenants problems with persistent roof leaks, not to mention the black roof was straining the air condition system in the building. The owner asked us to come up with a solution that would not only solve the roof leaking issues, but would also help cool the building down.

After a survey of the roof, the American WeatherStar independent Contractor determined that our Full Fabric System was the best solution for this situation. Due to the small cracks in the asphalt coating throughout the roof, the Contractor felt the roof needed to be completely reinforced with AWS polyester membrane along with the roof coating system to ensure all roof leak issues would be resolved.

After core cutting the roof in several areas, the AWS Contractor determined the system under the top surface was dry and a coatings candidate. At this point, if the Contractor finds wet insulation, he would need to cut those areas out, and install like roofing materials to bring the current system up to a coat-able standard.

The project began with power-washing at 3,500 psi to clean the system thoroughly, then the 3′ polyester sheets are laid out, overlapping several inches on the ends and side laps. American WeatherStar Fabric Bond 930 is rolled out onto the fabric using enough coating so that it saturates the fabric and adheres to the roof substrate. The entire roof was covered with AWS Polyester Fabric and Fabric Bond 930. If the roof would have had penetrations and/or curbs, the same system would have been used at the transition points, and several inches up the penetration, to ensure a water-tight roofing system.

After all fabric was installed, the AWS Contractor installed two coats of our Butyl 310 for a total coverage rate of 3 gallons per 100 sq ft. The system gives the building owner a dry and cooler building to work in. AWS Butyl 310 offers close to 90% reflectivity, which will also protect the existing roof substrate from degradation for many years to come. This same fabric system can be used on many types of substrates including Modified Bitumen, Smooth or Granulated BUR, and Single-Ply roofing systems. On roofs that drain well, our Full Fabric System can be top-coated with any of several of our coatings, including the Miami-Dade County approved Acrylic 211, Ceramic Acrylic 212, or the Butyl 310, as used on this roof. For roofs that don’t drain as well, we recommend using our Silicone 410 which is also Miami-Dade County approved, and Urethane 520.

Polyurea & Urethane System Over Concrete Deck


Northwestern University in Natchitoches, LA was looking for a durable deck coating system that could withstand hundreds of students walking across the system daily, plus it needed to be flexible enough to waterproof sections of the deck that were causing leaks in the adjacent Student Union. Steve Loga with Roofing Solutions in Prairieville, LA worked closely with the engineering firm to design the best system for the project. The 23,000 sq. ft. walk path and deck had over 15 years of service life and was well past its prime.

Steve manages Roofing Solutions’ coating division and worked closely with their owner, Tupcac De La Cruz, in order to design the best approach to getting the job completed within 30 days, a contract requirement. Roofing Solutions’ Commercial Roofing Division handled the tear-off of the gravel surface to bring the substrate to a point suitable for coating. After tearing off the first layer they found several areas where a 24 hour curing structural concrete was needed to repair the existing deck.

The American WeatherStar deck coating system includes a polyurea base coat manufactured by Versa Flex, Inc. based in Kansas City, KS, plus a base and top coat of a single component deck coating manufactured by Neogard of Dallas, TX.

After the complete tear-off and repairs of the existing system, aggressive power-washing and shot blasting was done to make sure the surface was clean. A water-block was then used in several areas to ensure ground moisture would not affect the new coating system.

After caulking joints with Versa Flex Polyurea Joint Filler, 80 mils of polyurea were applied to all seams, cracks, and transition areas. To complete the polyurea application, 50 mils of the two component coating were applied to the entire surface with a sand aggregate, broadcast over the polyurea within seconds before the coating dried.

Within 12-24 hours, a base coat of the Neogard Urethane Coating was applied over the polyurea with another layer of aggregate broadcast into the wet urethane. To complete the project, a top coat of the polyurethane was sprayed over the entire deck. In all, the deck has approximately 80-90 dry mils of combined polyurea and single component polyurethane that gives Northwestern University a uniform, seamless, water-tight deck coating system.

Modified Bitumen Roof Restoration

This twenty year old Modified Bitumen Roof is over a wood processing plant so, as you might imagine, a leaking roof is not only inconvenient, it’s also costly due to down time and ruined product. The first thing our Contractor did was power-wash the entire roof surface with over 3,000 psi to ensure our roof coatings system would adhere to the aged and worn out roofing material.

Before applying any of the AWS Coating System, a moisture survey was completed to ensure the roofing substrate and insulation were dry. If wet insulation is found, it must be replaced before the AWS roof coatings system is installed

After a thorough cleaning, the contractor applied one coat of Acrylic Bonding Primer 905 in order to ensure adhesion of the butyl coating system to the roof substrate. Other suitable AWS primers include Fabric Bond 930 and SBS Primer 950. 

At that point, the waterproofing stage began. The WeatherStar Contractor addressed every seam and penetration with a polyester fabric and the Butyl 310. He sprayed an initial layer of Butyl 310 on to each seam, then laid the fabric into the coating and finally sprayed another layer of Butyl 310. The same process was done around each penetration on the roof. The next step was to apply the fabric and Butyl 310 to larger areas in the field of the roof since this particular roof had aged to the point where leaks were throughout the field of the roof. In many circumstances the contractor may install a full fabric system over entire roof area.

After the fabric was installed in all the areas of concern the entire roof was sprayed with two more coats of Butyl 310 to form a seamless elastomeric membrane over the entire roof area. Other appropriate top coats for this type of application include Urethane 520 in low slope applications that don’t drain well or Miami-Dade County approved Acrylic 211 in situations where the roof does drain well.


Spray Polyurethane Foam Case Studies

SPF Over Gravel Built-Up Roof


This roof coatings case study shows what a typical gravel built up roof looks like when it is twelve to fifteen years old and then after a Spray Polyurethane Foam and the WeatherStar Roof Coating System have been installed.

The Contractor first takes off all the loose gravel on the roof and thoroughly cleans the roofing substrate. In this case he accomplishes both by wet-vacuuming the roof. This ensures the spray polyurethane foam will adhere to the exiting roof substrate. We always recommend a moisture survey before installing spray foam to ensure a successful roofing job. If moisture is found in existing roofing system, the contractor will remove wet areas before installing the Spray Polyurethane Foam.

The foam is sprayed on the roof at a minimum of 1 1/2 inches to seal the entire roof area. Special care is taken around parapet walls and roof penetrations to make sure there is a weather-tight seal.

After the spray foam is installed, in order to protect the foam from the sun’s destructive ultraviolet rays, the Contractor applies two coats of a WeatherStar top coat. Options include Acrylic 211 on roofs with a positive draining slope and on flat roofs that don’t drain water well, we recommend either the Urethane 520 or Silicone 410. Without the coating, the foam would quickly break down under UV rays.

The spray foam and WeatherStar Roof Coatings not only give the building owner an outstanding waterproof roofing solution, they also add an R-10 insulation value to the building. (Foam sprayed at 1.5”)

SPF & Silicone System Over Modified Bitumen


This tired Modified Bitumen (Mod Bit) roof was applied directly to the roof deck with no insulation. This roof was not made for hot summers with the black Mod Bit top nor for cold winters since it had no insulation. There were leaks over very expensive pieces of equipment that had plagued this barrel on a box roof design.

First, the entire roof was power washed with 3000 psi of water. This ensured that foam insulation would adhere to the clean Mod Bit substrate.

After power washing, Spray Polyurethane Foam (SPF) roofing insulation was applied to the Mod Bit substrate one section at a time. (SPF must be coated or primed within hours as it has little to no UV Stability.)

As each section was foamed in, AWS Silicone 410 was applied to give the new SPF roof the UV stability and “Bright White” Energy Star finish it needed to last for years to come. This application consisted of a base coat and a top coat of AWS Silicone 410.

This system is one of many choices you can make when coating a new SPF roofing system. Other AWS top coat options are: Acrylic 211, Urethane 520 or even our new Ure-A-Sil System (Urethane 520 base coat & Silicone 410 top coat).

Polyurethane Foam Recoat

This spray polyurethane foam roof was installed over five years ago. On average, most of these type roofs have 1 to 2 inches of foam sprayed onto an existing roof substrate such as a built up, modified bitumen, or metal roof. They are then coated with an acrylic, silicone, or urethane roof coating. Spray polyurethane foam is a great roof system, but must be coated every ten years to protect it from the sun’s harmful UV rays.

The WeatherStar Roof Coatings system requires the Contractor to clean the top surface of the roof with 1,500 to 2,000 psi of pressure. We do not recommend heavy power-washing as this may damage the current coating system installed on the roof. We do recommend a detergent such as TSP to clean any heavy residue off the roof surface.

The next step is to cut out any damaged foam and spray additional foam in the damaged areas to match the current foam system. It is especially important to cut out any areas where water has saturated the roofing system. If there are only small blisters, these may be cut out and patched using a polyester fabric and one of our top coats to seal the area. American WeatherStar always recommends a moisture survey on these re-coats to ensure a successful job.

After all areas of concern are addressed, the WeatherStar Roof Coatings Fabric Bond 930 was applied to the entire roof area to ensure that our top coating will adhere to the current system. A bonding primer is not always necessary, but we had adhesion concerns on this roof. AWS Bonding Primer 905 and SBS Primer 950 are also suitable adhesion primers.

Finally, two coats of Miami-Dade County approved Silicone 410 were sprayed on the roof surface to form a seamless, bright white membrane to protect the foam from UV rays for many years to come. Other options on a flat roof include our Urethane 520. If the roof has enough slope and drains water, any one of the American WeatherStar acrylic coatings will work as well.

** If your previous foam and coatings project used silicone as the top coat, Silicone 410 must be used to restore your roof as nothing will stick to silicone except for silicone.

Spray Polyurethane Foam Install


An old-time New Orleans building is back in business after being vacant for four years. This circa 1940’s building in New Orleans, Louisiana, just a block away from the Mississippi River, had been vacant since Hurricane Katrina damaged it in 2005. The roof was in such bad shape the building was not functional for any business.

The owner/property manager in New Orleans received a mailer from the American WeatherStar Co-Op marketing program about the same time they signed a lease with a movie production company out of California needing a place to store equipment as they filmed a movie in the Big Easy.

American WeatherStar immediately turned the building over to their Contractor and Contractor in NOLA, Duralite Insulators of Houma LA. Bill Marmande of Duralite met with the building owner and designed the system that would best fit the situation. A complete tear-off including the metal deck was necessary for much of the building. After new metal decking was installed, 4′ x 8′ sheets of Secure Rock was fastened to the deck, then 1″ to 1.5″ of 2.8 lb polyurethane foam was sprayed over the new decking to offer a water-tight system and needed insulation.

Finally, Duralite sprayed two coats of American WeatherStar urethane coating systems to give the foam UV protection and help keep the system and building cool and comfortable. This system by Duralite Insulators, supplied by American WeatherStar, offers the building owner a ten-year watertight roofing system with outstanding SPF insulation.


Single-Ply Case Studies

60 Mil TPO Single Ply System over BUR Gravel


This 33,000 square foot Built Up Roof on a shopping center in Montgomery, Alabama had definitely served its purpose and was ready for resurfacing. According to the developer, several of the stores had evident leaks. The American WeatherStar approved Contractor offered an initial survey and analysis which determined that our 60 mil TPO membrane was best suited for this type of roof.

The Contractor first installed the Nova Rollout, which is a 5/8″ thick inorganic rock mat underlayment. This allows for the TPO membrane to be successfully installed without any concerns of the original roof surface harming the TPO membrane. It also allows for roof and equipment maintenance after the single-ply system is installed.

After installation of the Nova Rollout, the approved Contractor fastened the TPO membrane around the perimeter of the building, then throughout the field of the roof. The seams of the membrane are heat welded to completely waterproof the system. There are no tapes or glues used to seal this system.

This particular building had a 10′ parapet wall around the front of the building, so the Contractor also fastened the TPO up the parapet wall and under the existing metal coping to encapsulate the entire roof and walls with a heat welded, durable white membrane.

This building now has a bright white roof top helping each tenant with their energy bills and a water-tight roof that will last for over ten years.

TPO Recover Over Metal


As the AWS Contractor in Birmingham, AL surveyed this shopping center in the suburbs, he realized that this metal roof had been ignored for too long for a coating system to be successful. It was decided that a TPO single-ply roof system was necessary to successfully waterproof this building for the long term.

The AWS Contractor/Contractor installed a custom cut insulation foam board (ESP) in between each rib of each metal panel. Then an ESP fan fold was fastened over the entire system to ensure a smooth flush finish. To water-proof the system, an AWS 60 mil TPO membrane was fastened to the metal to give the building owner and his tenants a water-tight building for at least ten years.

This TPO single-ply roofing system can be used to waterproof just about any metal roof that is structurally sound. The insulation system also offers the occupants an extra R-Value on top of the bright white reflective membrane.