TPO Roof Restoration at a Regional Airport Terminal in Middletown PA

BeforeAfter

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Drag to compare the roof before and after restoration.

The terminal building at a regional airport in Middletown, Pennsylvania, had been protected by the same TPO single-ply roof for more than two decades. The membrane showed noticeable wear, and airport management had growing concerns about its efficiency and long-term integrity. Instead of scheduling a disruptive tear-off at an active transportation facility, the airport restored the 14,000-square-foot roof with a fluid-applied system from American WeatherStar.

The Challenge

Replacing a roof over an operating airport terminal is a logistical headache: passenger traffic, security zones, and constant building operations all limit how and when crews can work. The aging TPO membrane still had structural value as a substrate, which made restoration attractive, but the system chosen needed to bond reliably to a weathered thermoplastic surface and stand up to decades more service.

The Coating Solution

Crews cleaned the membrane with EcoCleaner 925 to remove contaminants and prepare the surface for adhesion. Penetrations and problem areas were sealed with Aromatic Urethane 520, giving the roof’s most leak-prone details a reinforced waterproof layer. The team then applied an intermediate coat of Silicone 410 across the field, followed by a top coat of Silicone 410 blended with roofing granules, which adds abrasion resistance and improves traction on the finished surface.

The Results

An independent third-party inspection confirmed the quality of the completed restoration, and the system carries a 15-year material warranty covering normal weathering and manufacturing defects. The terminal gained improved durability, weather resistance, and energy efficiency without a single day of tear-off disruption, and the airport deferred the capital cost of full replacement by well over a decade.