
A few weeks ago the weather Gods finally smiled on us and we had a stretch of weather to replace our roof. The old system was the traditional rubber and bitumen with asphalt sealant. We decided to replace that with a more environmentally friendly and energy efficient acrylic system.
The first step was to remove the entire roof surface. Once the space was opened, we took that opportunity to insulate the gap between the second floor ceiling and the roof. Using and expanding foam insulation all of the gaps were sealed. Then cellulose insulation was blown in to give an R value of 30. On top of that we place a radiant barrier to prevent temperatures from penetrating through the insulation.
After finishing the insulation, 4x8 sheets of 3/4" underlayment were hauled up to the roof and fastened in place like decking. There were expansion gaps put in place to prevent buckling but those gaps were caulked to provide a surface of adhesion for the acrylic material.
Once the wood was attached and the surface caulked and cleaned, we began the final process. You begin by painting on a liberal (think Susan Sarandon) coat of acrylic paint and then rolling nylon fabric over it. After the nylon is in place and you remove as many of the wrinkles as you can, you paint over it with another layer of paint. Let it dry over night and ShaZam! - you now have a waterproof roof.
Once dry, I needed to apply more and more layers of paint until all of the material was gone. it took another 4 days but it wasn't that difficult to do.
We decided to use white as the final color to reflect heat but the lower two layers are gray so that uneven wear can be seen for future applications. Overall, it's pretty sweet and opens itself up to having a roof deck...but I doubt that will happen.

