Stopping 50+ Leaks: Silicone Restoration at Vermillion Flooring, Springfield MO

Vermillion Flooring, a hardwood flooring manufacturer in Springfield, Missouri, was fighting a losing battle with its aging metal panel roof. Water was entering the plant at more than 50 separate locations, a serious threat in a facility where moisture and wood products cannot coexist. Working with Gaco licensed applicator Alliance Roof Solutions & Coatings, the company restored the roof with a silicone coating system instead of replacing it.

The Challenge

With leaks scattered across the entire roof area, spot repairs were no longer a realistic strategy. A tear-off and replacement would have exposed the production floor and inventory below to the weather and almost certainly forced interruptions to manufacturing. The owner needed a whole-roof solution that could be installed over the existing metal panels while the plant kept running.

The Coating Solution

The applicator built a layered system tailored to weathered metal. Rusted areas were treated with a direct-to-metal rust-inhibiting primer, and GacoFlex E5320, a two-part epoxy primer, was used to prepare the substrate for coating. Problem details and penetrations were sealed with GacoPatch silicone sealant. The finished membrane came from GacoFlex S42, a high-adhesion silicone coating applied across the roof to form a seamless, waterproof, and UV-stable surface in reflective white.

The Results

The restoration eliminated the leaks across the facility, and the work was completed without interrupting manufacturing operations or forcing equipment downtime, one of the central advantages of fluid-applied restoration over tear-off. The bright white silicone finish also improves the building’s energy profile by reflecting solar heat away from the production space. For a fraction of replacement cost, the plant gained a renewed roof and a dry interior.