Mastic Smeared Over Screws
- You See
- Black tar mounded over fastener rows and laps.
- What It Means
- Mastic hides failed washers and traps water against the steel. It comes off so screws can be tightened, replaced, and capped properly.
Shively, KY
Shively Metal Roof Coating
We coat metal roofs on older Shively industrial buildings, stripping decades of mastic and patch layers and rebuilding flashing where walls meet the roof, with the plant running below.
- Old Patches Removed
- Base Flashing Rebuilt
- Debris Contained
Decades Of Patches On Shively Metal Roofs
Shively, established in 1938, lists distilleries such as Stitzel-Weller and Michter's among its points of interest, a sign of a long industrial base. Roofs on buildings that old usually carry layer on layer of repairs.
Before any coating, those layers come off: mastic over fasteners, mismatched panels from past additions, rusted base flashing at metal walls, and curbs left from equipment long gone.
- Mastic stripped from fasteners so each screw can be checked
- Mixed panel profiles closed and sealed where additions meet
- Rusted base flashing rebuilt where metal walls meet the roof
- Scraped debris containerized, since Shively Code Enforcement lists debris among common violations
What Years Of Repairs Leave Behind
On long-serving industrial roofs, the old fixes cause as many leaks as the original panels.
Two Panel Profiles Meeting
- You See
- Mismatched ribs where an addition joins the original building.
- What It Means
- Profiles that never nest leave gaps at the joint. Closures and flashing are fitted and sealed with fabric before coating.
Rusted Base Flashing
- You See
- Rust along the line where metal walls meet the roof.
- What It Means
- Water runs down the wall and into that joint. Base flashing gets rebuilt or patched and sealed before the field coat.
Abandoned Curbs And Vent Stacks
- You See
- Curbs and stacks with nothing attached, patched many times over.
- What It Means
- Unused openings come off and get patched with metal and sealed, removing leak points the plant no longer needs.
Dents And Split Sealer After Storms
- You See
- Dented ribs, cracked coating at screws, and broken skylight panels.
- What It Means
- Dents stay cosmetic until sealer splits. Photos with a coin for scale go to the insurer, then cracked spots are cleaned and recoated.
Benefits of Coating Your Roof
What coating does for a Shively plant or warehouse roof that has been patched for decades.
One System Instead Of Patches
Old mastic and spot repairs give way to one continuous coating over the whole roof, so leaks stop moving from patch to patch.
Plant Keeps Running
Work happens on top, section by section, with HVAC intakes covered near the active area and forklift lanes kept clear of lifts and pails.
Steel Kept In Service
Coating solid panels avoids tearing off a large industrial roof, which keeps cost and hauling well below a full replacement.
A Clean Record Going Forward
Each repair is photographed before it disappears under coating, giving maintenance staff a clear record instead of guesswork about old patches.
Commercial Roof Coating Options for Shively
Three ways we coat industrial metal roofs in Shively, chosen once the patch layers are off.
Acrylic Over Primed Panels
Sloped industrial roofs that drain well get acrylic once old patches are gone and rust is primed.
Best on: Warehouses and shops
Silicone On Low Sections
Flat additions and low panels that hold water beside the main roof get silicone.
Best on: Additions and loading dock roofs
Foam Over Heated Plant Space
Heated production space under the roof makes foam worth its cost, with a coating sprayed over it.
Best on: Heated plants and shops
Leaks Moving From Patch To Patch?
Tell us how many patch layers you know of and where stains show inside. Old repairs set the size of the prep.
How We Coat An Older Shively Roof
Paperwork, patch removal, and plant schedules all shape the order of work here.
- INSPECT
Step 1: Inspect Your Roof
We walk every section, probe patches, check base flashing and curbs, and look at purlins and insulation from inside for rust and water.
- CERT
Step 2: Get The Compliance Certificate
Shively issues a Compliance Certificate for construction work, which goes to Louisville Metro for the building permit. Commercial roof jobs pay a fee by square footage and post a bond.
- STRIP
Step 3: Strip Old Repairs
Mastic and loose patches come off, abandoned curbs are removed and patched, and debris goes into a covered container before each crew leaves.
- DETAIL
Step 4: Rebuild Flashing And Fasteners
Base flashing and closures are rebuilt, fasteners tightened or upsized, rust primed, and laps sealed with fabric.
- COAT
Step 5: Coat Around The Schedule
Coats go on one section at a time, timed around shifts and deliveries, with intakes near the work covered.
Metal Roof Coating Near Shively
Our metal roof coating work reaches the towns below too. Systems we use most in Shively: Metal Roof Coating and Spray Foam Roofing. Not sure we cover your address? Call us or send us a message.
Not to scale. Your town is ringed in blue.
- Pleasure Ridge Park
Down Dixie Highway; gutter and downspout work.
- Okolona
South along Preston Highway; R-panel shops.
- St. Matthews
East of downtown; a city letter before permits.
- Lyndon
Farther east; a 30-day registration.
Shively Roof Coating Questions
Hail, plant operations, and city paperwork, answered for Shively building owners.
Question about your own roof?
Call UsWhat does hail do to a coated metal roof?
Hail dents panels, and dents stay cosmetic until the coating cracks or a seam opens; a flexible coating usually stretches with a dent. After a storm, check ridge caps and ribs, coating around screw heads, sealer at end laps, skylights, and gutters. Photograph dents with a coin or tape for scale before any repair, then clean and recoat cracked spots.
Can a warehouse keep operating while the metal roof is coated?
Yes, most do, since the work happens on top of the panels. People inside mostly hear footsteps and notice odor near open intakes. We shut down or cover intakes near the active area, mask vehicles and docks against drift, schedule fastener work over offices for quiet hours, and keep forklift lanes and dock doors clear.
What is the Shively Compliance Certificate for a metal roof project?
It is the city document Shively issues for construction work, and the owner takes it to Louisville Metro to get the building permit. It expires 12 months after work begins. Commercial projects pay a fee based on square footage and post a bond, with exceptions for small projects. Measure true roof surface, since slopes, canopies, and dock roofs add up.
What should owners of older industrial buildings in Shively check before coating?
Start with roof-to-wall flashing, how the panels are attached, and how many patch layers sit on top. Decades-old buildings often show mastic over fasteners, mixed panel profiles from additions, rusted base flashing where metal walls meet the roof, and abandoned curbs or vent stacks. Each is fixed before coating, and scraped material goes into a covered container.
Do old patches have to come off before coating?
Loose patches and mastic over fasteners do, because coating over them traps water and hides failed screws. Patches that are well bonded and compatible can stay after a test patch shows the coating holds. The inspection marks which ones come off.
Get Your Shively Roof Off The Patch Cycle
Tell us about the building and the patches you know of. We will map every layer and plan the coating around your schedule.