Concrete Silo Roof Coating

in Benson, IL

Services Performed

Concrete Floor Repair and Resurfacing, Corrosion Control, Epoxy Flooring, Industrial Exterior Painting, Industrial Flooring, Joint Sealing and Caulking

Location

Benson, Illinois

Two workers on the flat roof of a large concrete silo spread coating with long-handled tools; vents and pipes dot the roof, and a spherical tank labeled “BENSON” sits beyond the silo with green farmland stretching to the horizon.

Client and Facility Overview

Our client operates a facility in Benson, IL that specializes in grain and feed storage. The facility includes several silos that are essential to their operations, ensuring the safe and efficient storage of valuable commodities. Their focus on maintaining high standards in their storage solutions underscores their commitment to quality and reliability in the grain and feed industry.

Requested Maintenance

This project focused on the complete removal and replacement of the existing roof systems, as well as detailed repairs and coatings to prevent future problems and extend the life of the silos.

Decision Driver and Timing

Preventative maintenance was the primary driver for this project. Silos often suffer from neglect until a problem, such as a leak, becomes apparent. Given the valuable commodities stored within, the client opted for preemptive measures to avoid costly disruptions.

Scope of Work

Complete Roof System Removal: The existing, failing roof systems were entirely removed to pave the way for improved replacements.
Surface Preparation: A diamond grinder was used to open the pores of the concrete to ensure optimal adhesion for subsequent coatings.
Re-flashing Protrusions and Vents: A three-step process involving elastomeric flashing and polyester fabric was applied.
Crack and Leak Repairs: Ground out all cracks, installed backer rod, and filled the cracks with a polyurethane crack filler to stop existing leaks.
Surface Smoothing: Pitted and spalled areas were filled with a slope building compound to create a level surface for the final coating.
Elastomeric Coating Application: The elastomeric coating was applied to accommodate the expansion and contraction of the concrete throughout the seasons.
Anti-slip Surface: An aggregate was broadcast into the topcoat to provide an anti-slip finish for increased safety.

Notable Details

Painters USA is proud to offer a 10-year warranty on this project, subject to annual inspections and minor maintenance by our team.

This is the third project Painters USA has completed for this client, demonstrating a strong, ongoing relationship. Our commitment to excellence has also led to referrals within the grain and feed industry.

All work was performed under strict safety guidelines to ensure a safe environment for both the crew and the client's staff. We've adhered to OSHA standards and incorporated measures such as elastomeric coatings that provide long-term resistance to environmental stressors.

Client Satisfaction

The client has consistently chosen Painters USA for their critical maintenance needs, a testament to our quality, professionalism, and reliability. The projects we've completed for them reinforce their confidence in our services, laying the groundwork for future collaborations.