Real Results for Commercial and Industrial Buildings
Our commercial roofing projects and case studies highlight the work we perform for warehouses, industrial facilities, manufacturing plants, retail centers, agricultural buildings, and commercial properties across Illinois and Iowa. Each project includes inspection, planning, documentation, and installation using systems such as metal restoration, membrane roofs, spray foam systems, or commercial roof coatings.
To learn more about the systems used in these case studies, visit Services or explore specific pages like Metal Roofs, Membrane Systems, Spray Foam Systems, Roof Coatings, and Full Replacements.
For national roofing best practices, see the NRCA.
Case Study 1: Metal Roof Restoration – Galesburg, Illinois
Building Type: Manufacturing facility
Roof Size: 80,000 sq ft
System Installed: Metal roof restoration with coating reinforcement
Challenge: Rusting panels, seam movement, failing fasteners
Outcome: Leak elimination, extended roof life 10 to 12 years
The Situation
This Galesburg manufacturing plant had ongoing leaks along fasteners and seams. High humidity and temperature swings accelerated rusting near panel laps. A full replacement was not budget friendly, and the building could not close operations.
The Challenges
- Metal panels expanding and contracting
- Rust spreading across panel edges
- Numerous penetrations needing reinforcement
- Interior operations required zero interruption
The Solution
We applied a metal restoration system with seam reinforcement and a reflective topcoat. Rust inhibitor was used across the deck, fasteners were tightened or replaced, and penetrations were sealed. Work was completed without disrupting production.
Learn more about this type of system on our Metal Roofs and Roof Coatings pages.
Results
- All leaks eliminated
- Roof lifespan extended 10 to 12 years
- Lower interior heat load due to reflectivity
- No operational downtime during installation
Case Study 2: Spray Foam Roofing – Muscatine, Iowa
Building Type: Distribution warehouse
Roof Size: 100,000 sq ft
System Installed: Spray polyurethane foam (SPF)
Challenge: Poor insulation, standing water, uneven deck
Outcome: Improved insulation, leveled surface, waterproof seal
The Situation
This Muscatine warehouse struggled with rising energy costs and leaks caused by uneven roof sections. Spray foam was chosen to solve both insulation and waterproofing concerns at once.
The Challenges
- Roof deck had dips and birdbaths
- Membrane had absorbed water
- Needed improved insulation value
- Facility required access throughout installation
The Solution
We installed a spray foam system with a protective coating. Foam expanded to level the deck and eliminate low areas where water collected. The reflective topcoat reduced heat load and protected the foam from UV exposure.
Learn more about this system on our Spray Foam Systems page.
Results
- Energy efficiency improved significantly
- Standing water eliminated
- Seamless waterproofing installed
- Renewable system with long term maintenance path
Case Study 3: Commercial Roof Coating – Quincy, Illinois
Building Type: Manufacturing plant
Roof Size: 60,000 sq ft
System Installed: Fabric reinforced coating system
Challenge: Seam failures, aging membrane, energy loss
Outcome: Extended roof life 12 to 15 years
The Situation
The membrane roof on this Quincy plant was aging but structurally sound. The building experienced seam failures and high energy costs during summer.
The Challenges
- Membrane shrinkage at edges
- Seam separation letting in water
- Heat transfer through the roof
- Budget did not support a full tear off
The Solution
We installed a fabric reinforced roof coating system. Seams were embedded into fabric, penetrations were detailed, and a reflective topcoat was applied to improve energy efficiency.
See similar systems on our Roof Coatings and Membrane Systems pages.
Results
- Roof lifespan extended 12 to 15 years
- Reflective surface reduced heat absorption
- Leaks eliminated
- No tear off required
What These Case Studies Show
These commercial roofing projects demonstrate:
- How we evaluate metal, membrane, spray foam, and coating systems
- How we minimize disruption to operations
- How we extend roof life through restoration systems
- When replacement is the correct choice
- Our documentation, planning, and installation process
- Our long term commitment to commercial and industrial clients
If you want to compare systems directly, review Services.
FAQS
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Smithshire, IL