Built-Up Roof Repair: Options to Fix and Protect Your Roof

Built-up roofing (BUR) systems are durable but develop specific problems over time. Here are the best repair and restoration options.

Option 1: Surface Maintenance and Spot Repairs

For younger BUR systems with isolated issues, targeted repairs — sealing cracks with compatible mastic, re-embedding gravel, reinforcing specific failure areas — extend system life at minimal cost. Best for roofs under 15 years old with limited problem areas.

Option 2: Silicone Coating Over Smooth BUR

Smooth BUR (without gravel) can receive a silicone coating directly, sealing the existing surface and providing a new waterproof membrane with a 10–20-year warranty. This is the most cost-effective long-term solution for smooth BUR in acceptable condition at $2.50–$4.50/sq ft.

Option 3: Spray Foam After Gravel Removal

For gravel BUR, the best restoration approach is hydro-vacuuming the gravel, replacing wet insulation, and applying spray foam directly to the BUR substrate. Total cost: $4–$7/sq ft with a new 10–20-year warranty — roughly half the cost of BUR replacement at $8–$14/sq ft.

Option 4: Full Replacement

When the BUR substrate has delaminated significantly or wet insulation exceeds 25%, full replacement is required. Choose a system with a renewable warranty to avoid repeating the decision in 20 years.