Flat Roof Refurbishment · Overlay Systems

Flat Roof Refurbishment & Overlay — Extend Your Roof’s Life by 20 Years

Your roof is tired, not finished. A seamless GacoFlex liquid overlay restores felt, single-ply, built-up and metal roofs at 60–80% below replacement cost — no strip-off, no disruption to the building below.

60–80% below replacement cost 20-year manufacturer-backed warranty No tear-off — building stays open
Aerial view of a commercial flat roof finished with a seamless grey GacoFlex overlayGacoFlex liquid overlay60–80% below replacement cost
60–80%
Below replacement cost
20-yr
Manufacturer-backed warranty
Free
Site survey & fixed quote
85%
Solar radiation reflected (white)
Tired, Not Failed

Refurbish or replace? What the survey tells you

Most ageing commercial flat roofs don’t need stripping — they need a new waterproof layer. A liquid overlay is applied directly over the existing substrate without tear-off, forms a seamless membrane with no joints to fail, and conforms to complex roof details.

Overlay suits most sound-but-weathered roofs. We confirm suitability on a free site survey — substrate condition, drainage, access — and only then price the work, fixed.

Verdict: for sound-but-weathered roofs, overlay wins — 60–80% below replacement cost, no strip-off.

Felt, single-ply & built-up flat roofs — overlaid without tear-off

Profiled metal — steel, aluminium, zinc & coated sheets

Asbestos-cement & cement-fibre roofs — refurbished without removal

Concrete decks — including foam-insulated pitched decks

Faster and less disruptive than sheet systems or replacement

Aged asphalt flat roof with ponding water and leaks, surveyed before overlay refurbishment
Sound but weathered — exactly the roof the free survey confirms for a liquid overlay
The Numbers

Refurbishment vs replacement — how the cost compares

GacoFlex refurbishment (silicone or heavy-duty urethane) is priced after a free site survey, based on roof size, condition and access. It keeps the existing roof in place, so it typically costs a fraction of full replacement.

Complete-system prices, fully installed — preparation, reinforcement and application included. Confirmed as a fixed price after a free site survey. What moves the price: substrate condition and prep, roof access, the system specified, reinforcement at laps and details (non-negotiable on profiled metal), and project size — larger roofs attract better unit rates.
The Overlay System

How a liquid overlay works

GacoFlex liquid overlay being applied to an existing commercial flat roof

Liquid roof waterproofing is a cold-applied coating rolled, brushed or sprayed straight onto your existing roof. It cures into a seamless, fully-bonded elastomeric membrane with no joints, laps or mechanical fixings — sealing exactly the points where flat roofs fail.

Preparation is straightforward: pressure washing, treatment of any rust, repair of damaged areas and a compatible primer where required. Then the overlay goes on — no tear-off, no re-sheeting, no closing the building.

  • Cold-applied — no hot works, no flame, no torch-on fire risk
  • Typical project: 1–3 weeks · a 1,000 m² roof takes about 5–7 working days
  • Building fully operational throughout
  • Recoatable at end of life — no strip-off next time either
Refurbish The Roof, Lift The BER

A white overlay that helps lift your BER

GacoFlex cool-roof coatings use a highly reflective white finish to cut roof surface temperatures, reduce cooling costs and improve BER ratings. White reflective coatings reflect up to 85% of solar radiation and can lower internal temperatures by up to 10°C in summer.

Refurbishing the roof and improving the BER in one project is why landlords choose a reflective overlay.

Reflective white GacoFlex cool-roof overlay on a commercial building
Finished Roofs

Recently refurbished commercial roofs

Completed reflective GacoFlex overlay on a refurbished commercial roof
Cool-roof reflective overlay
Top-down aerial of a commercial roof finished with a seamless GacoFlex overlay
Seamless overlay — no joints to fail
Completed GacoFlex S42 silicone flat roof waterproofing systee GacoFlex
Asphalt flat roof — S42 system complete, 20-year warranty
Commercial flat roof in Heanor freshly recoated with grey GacoFlex silicone
Commercial flat roof — recoated in 5 days, Heanor, England
Asbestos-cement roof refurbished by encapsulation with Gaco silicone
Asbestos-cement roof — encapsulated
Commercial gutter lined with seamless Gaco coating
Gutter lining — watertight
Recent Duratite project in the UK

Case study: commercial flat roof refurbishment — Heanor, near Nottingham, England

BeforeTired commercial flat roof in Heanor with gravel, moss and ponding water before refurbishment
ApplicationGacoFlex silicone overlay part-applied across the cleaned Heanor flat roof
FinishedAerial view of the Heanor commercial flat roof fully recoated in grey GacoFlex silicone

A tired commercial flat roof in Heanor, near Nottingham, England, brought back in five working days. The roof was cleaned off, the loose gravel stripped away to leave a sound deck, and the whole area recoated with a seamless GacoFlex silicone overlay — no tear-off, exactly the refurbishment approach priced in the table above.

Cleaned & gravel removed Recoated in 5 days GacoFlex silicone overlay 20-year system available

Installed by J & B Contract Services Limited — an approved Gaco installer based in Heanor, England.

Heanor flat roof stripped of gravel and cleaned back to a sound deck ready for coating Completed seamless GacoFlex silicone membrane across the Heanor commercial flat roof

More GacoFlex flat-roof projects

How It Works

From enquiry to a warrantied roof

Duratite is your single point of contact: we survey and specify the system, then match you with a vetted contractor from our Ireland-wide approved network to carry out the work.

1

You enquire

Owners, tenants and facilities managers send the building, roof and a few photos.

2

Free site survey

Substrate, ponding, cut edges, access and drainage assessed on site.

3

Design & fixed quote

System, reinforcement and any traffic top coat — at a fixed price.

4

Approved contractor installs

Cold-applied over the live building — no tear-off, building stays open.

5

Warranty & handover

20-year manufacturer-backed product warranty and documentation.

Refurbishment In Practice

Academy in the West Midlands, England — replacement rejected, roof restored

Persistent leaks and classroom-ceiling condensation on a 1,150 m² school roof, with full replacement rejected by the trust. GacoFlex 127 acrylic was applied in a two-coat system with a white reflective topcoat for cool-roof BER uplift — delivered across two half-term windows with no disruption to teaching. The trust now plans to coat all six academy roofs.

1,150 m²
School roof
2
Half-term windows
0
Days of lost teaching
6
More roofs now planned
White reflective GacoFlex roof refurbishment like the academy cool-roof project
Why Overlay Wins

Life extension, by the numbers

20+yrsadded roof life from one seamless overlay
60–80% below replacementRecoatable at end of lifeBuilding stays open
60–80%
Saving vs full replacement
20-yr
Manufacturer-backed warranty
5–7 days
Typical 1,000 m² programme
85%
Solar radiation reflected (white)
Straight Answers

Flat roof refurbishment questions

How long does a refurbished roof last?
GacoFlex silicone and acrylic roof coating systems are backed by manufacturer warranties of up to 20 years. With proper maintenance, coated roofs can last significantly longer. At end of life, the coating can be recoated without tear-off, providing continued protection decade after decade.
Is EPDM or liquid waterproofing better for refurbishing a commercial roof?
Liquid-applied coatings like GacoFlex offer significant advantages over EPDM for commercial roof refurbishment. Liquid systems are applied directly over existing substrates without tear-off, form a seamless membrane with no joints to fail, and conform to complex roof details. EPDM requires mechanical fixing or adhesive bonding, creates seams that can fail over time, and typically requires removal of the existing roof covering. For new-build flat roofs, EPDM can be appropriate, but for refurbishment of existing commercial roofs, liquid waterproofing is faster, less disruptive and more cost-effective.
Do you need planning permission for flat roof refurbishment?
In most cases, no. Applying a liquid waterproof coating over an existing commercial roof is classified as maintenance and repair, not a material alteration, so planning permission is not required. However, listed buildings or properties in conservation areas may have additional requirements. Duratite can advise on any regulatory considerations during your free roof survey.
What preparation is needed before a roof overlay?
Surface preparation includes pressure washing or mechanical cleaning to remove dirt, moss and loose material; treatment of any rust or corrosion on metal substrates; repair of damaged areas, holes or failed fixings; and application of a compatible primer where required. GacoFlex systems bond to most existing roof substrates including metal, felt, single-ply membranes, asbestos cement and concrete. No tear-off of the existing roof is needed.
Do roof coatings reduce energy costs?
Yes. GacoFlex white reflective roof coatings reflect up to 85% of solar radiation, significantly reducing heat absorption through the roof. This can lower internal temperatures by up to 10°C in summer, reducing air conditioning and cooling costs. Cool roof coatings also contribute to a better BER (Building Energy Rating).
What is the most durable flat roof refurbishment system?
For long-term durability on commercial flat roofs, GacoFlex 100% silicone roof coating is the industry benchmark. Unlike organic coatings, silicone does not break down under UV exposure, does not become brittle with age, and permanently resists ponding water. It maintains its flexibility and waterproofing performance for 20+ years. At end of life, it can be recoated without removal, providing indefinite roof protection.
Free Survey · Fixed Price

Give your roof 20 more years — for a fraction of a re-roof

Send the building type, the roof and a few photos and we’ll book your free site survey. We design the right GacoFlex overlay and issue a fixed quote with a 20-year manufacturer-backed warranty.

Prefer to talk it through?

Speak to a roof coatings specialist about refurbishment options — no obligation, no hard sell.

info@duratite.ie · Mon–Fri, 8am–5pm
Free Site Survey

Get a Free Site Survey & Quote

Tell us about your building and we’ll recommend the right system — foam, waterproofing or both — surveyed, specified and quoted at no cost.

  • Reviewed by a Duratite specialist
  • No obligation, no hard sell
  • One team from survey to warranty
  • Ireland and Northern Ireland coverage
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