The case for restoration: A more profitable alternative for roofing contractors

By John Walker, APOC.

Compared with traditional tear-offs and reroofs, roof restoration has emerged as a cost-effective, minimally disruptive and effective option for professional roofing contractors and their customers alike.

Reroofing a commercial building can be a cumbersome but necessary task for major structures anywhere. Such projects can last for weeks, cause disruption to internal activities and can invite the potential for installation error that can compromise long-term performance. 

But the truth is that a full reroof is not always as necessary as it may seem. And that means opportunity for both roofing contractors and their customers.  

Commercial roof restoration has emerged as a increasingly viable alternative for any roof type. Restoration techniques that are performed with high-quality materials are effective in ensuring commercial roofs regain and maintain their full performance potential over the course of their lifetimes and at a fraction of the cost for a full replacement. Not only does restoration reduce the likelihood of failure, but it also extends the longevity of your commercial roof, regardless of type.  

Recent research proves this to be true. Cotney Consulting Group, a business consulting firm specializing in the commercial roofing industry, recently conducted a thorough study comparing commercial roof restoration performed with high-performance coatings versus reroofing, including recover and tear-off methods. The results were significant, showing that roof restoration can lead to improved profit productivity, enhanced labor efficiency, greater time efficiency and stronger margins for contractors.  

Indeed, restoration can be an effective and profitable strategy. In this article, we’ll explore how to determine if a roof is a good candidate for restoration, the basics of sound restoration techniques and specific findings from the Cotney Consulting Group’s report. Let’s explore:  

Determining if a roof is a good restoration candidate 

First, contractors must determine if the existing roof is in good enough condition for restoration techniques to be effective. To start, a good rule of thumb is that roofs that are 20%-25% (or more) saturated will likely need to be replaced in their entirety based on varying building codes and standards. But a thorough assessment of the roof is necessary to get the full picture.  

This process begins with a visual inspection, which should involve clearing off any trash or accumulated debris that could disguise hidden problem areas. Some initial clues may include:  

• A splitting membrane that is visible to the naked eye for experienced professionals
• A soft area underfoot that is an indicator of saturated insulation
• Rusted, rotted or cracked decking that can be seen from the inside of the building
• Ponding water that could indicate structural sagging in the deck

Infrared thermography along with field verification can be deployed for a more thorough assessment of wet insulation. Small, hand-held infrared cameras are great for smaller roofs. For very large roofs, aerial infrared photography, when possible, can be effective.  

Visual findings should be confirmed through a series of tests, including:  

• A peel adhesion test that can help determine the viability of coating solutions
• Core cutting, which while destructive, can be eye-opening, helping to validate the visual moisture survey and helping to confirm how many layers of roofing actually exist
• Wind uplift testing when necessary can be used to determine the state of the membrane—remember that membranes can become decimated by a storm but may stay in place

Finally, a licensed structural engineer should be retained if there is any evidence of structural failure or additional loading on the roof (condensing units, blowers, metal screens, ballasted antennas, etc.).  

When the roof inspection is complete, it’s time to determine a path forward. Roofs with low to moderate damage and saturation levels are often good candidates for roof restoration rather than a full reroof and can be a cost-effective option when the circumstances call for it. Reroofs will be required in more extreme scenarios such as elevated levels of insulation saturation, decking deterioration and more. 

Evaluating a building’s needs 

In addition to the physical characteristics and condition of the roof, it is also worth evaluating the anticipated service life of the building.  

Not every structure merits the same level of repair work. For example, a small retail store that sits in the path of a proposed freeway expansion might not need a repair that ensures 20 years of performance. A major museum in the hub of a cultural district, by contrast, will require a long-term solution.  

Also worth consideration is potential expansion plans for the structure. It is generally more economical to reroof a structure in conjunction with an expansion rather than splitting the project across multiple years. The need for roof access and the impact on building operations can be greatly reduced if both projects can be performed at the same time. 

In any case, proven repair solutions are available to best suit the needs of the given situation. 

The basics of roof restoration 

It’s helpful to explore the basics of roof restoration and the benefits restoration can bring for contractors and building owners alike when compared to tear-off and replacement jobs. Generally, a restoration project looks like this: 

1 - Contractors can begin by removing any debris and thoroughly cleaning the roof (performed in conjunction with your initial assessment and inspection) to best uncover areas that are to be repaired and to create a workable surface for the rest of the project.  

2 - A high-performance primer is applied to the roof membrane to ensure good adhesion for patching, stain blocking and rust inhibition.  

3 - A high-performance patch system is applied to seal the roof and ensure all parts of the system are watertight and deliver reliable waterproofing protection.  

4 - Supplemental protective coatings can be applied to better protect against common forms of roof damage, helping to ensure greater overall longevity for the roof system. 

This work generally does not require specialized equipment and does not leave the building interior exposed while the job takes place. And if you can successfully bring an existing roof back up to its original performance level with restoration methods, you can move on to your next job more quickly. 

It’s also important to remember that performing quality restoration work requires sourcing reliable, proven products from a trusted supplier. High-performing primers, coatings, adhesives, caulks, sealants and other materials will help to ensure longevity and performance your customers can trust.  

Major benefits for contractors 

In its recent study, Cotney Consulting Group sought to compare restoration with reroofing based on four key factors: Profit productivity, time efficiency, labor efficiency and margin strength. The study evaluated 118 commercial roof restoration projects, analyzing actual costs, contract value and gross profit metrics. This data was cross-referenced with historical project data from the National Roofing Contractors Association (NRCA) and adjusted for inflation. 

The findings were significant, including: 

Improved profit productivity. Findings showed that restoration generates ~85% higher modeled gross profit per crew day vs. reroof options. Further, restoration can deliver nearly double the profit per crew day compared to reroofing. From a dollar perspective, restoration averages ~$8,000 in gross profit per crew day compared to ~$4,300 for reroof projects. 

Enhanced labor efficiency. Results showed that restoration can require materially lower labor intensity—up to ~85% less vs. tear-off benchmarks. Time on job decreases significantly as well, with restoration requiring up to ~50% fewer labor hours than recover scenarios. For contractors, these figures show that restoration jobs can be performed with a 33% smaller crew required compared with reroof projects. 

Greater time efficiency. Restoration averages ~eight crew days compared to 13 for recovery and 26–30 for tear-off. Findings also showed that restoration can be completed in roughly one-third the time of tear-off projects. These results were consistent across a range of building square footages. 

Stronger margins for contractors. Results found that restoration generates stronger average gross margins compared to study comparison ranges for reroof alternatives by a weighted average gross margin of ~43%. That can make a major impact for roofing contractors and their businesses. 

Overall, roof restoration offers commercial building owners a practical, cost-effective way to extend roof life and restore performance without the disruption and expense of a full replacement. For roofing contractors, it also represents a valuable growth opportunity that can help meet customer needs, strengthen long-term relationships and support a more profitable business.