What's the Best Option To Fix a Commercial Roof Without Replacing It?

Full roof replacement is expensive, disruptive, and often unnecessary. For most commercial roofs with less than 25% wet insulation, restoration is a viable — and far more cost-effective — alternative.

Option 1: Silicone Coating System

The most widely applicable non-replacement solution. A silicone restoration membrane is applied over the existing roof (TPO, EPDM, metal, or modified bitumen), sealing all existing seams and creating a new seamless waterproof surface. Cost: $2–$5 per sq ft. Warranty: 10–20 years renewable.

Option 2: Spray Foam Restoration

Ideal when slope correction, insulation improvement, or complex penetrations are involved. Foam is applied over the existing substrate, creating a seamless surface that can be built up in specific areas for drainage improvement. Cost: $4–$8 per sq ft. Warranty: 10–20 years renewable.

Option 3: Targeted Repairs Plus Coating

For roofs with specific problem areas but otherwise acceptable condition, targeted repairs (seam re-welding, penetration sealing, flashing replacement) combined with a coating system can restore performance at the lowest possible cost.

When Replacement Is Unavoidable

If wet insulation exceeds 25%, the deck is compromised, or building codes require a new roof (due to existing layer count), replacement may be the only option. This determination requires a professional inspection with core samples — not a visual assessment alone.