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One Application, Three Major Problems Solved – Food Plant Roof Repair Case
Project Background:
A food processing plant in Shandong Province with a factory area of approximately 3,000 m². Its steel sheet roof has been in service for over 8 years.
Customer Pain Points:
Summer workshop temperature exceeds 38°C, significantly reducing worker productivity.
Multiple joint leaks directly above the raw material storage area.
Widespread rust around screw holes on the roof; rust drips onto product packaging, which has already caused customer returns.
Customer Requirements:
No production shutdown, no roof replacement, and solve all three problems in one solution.
Site Inspection & Solution Selection
Roof Condition Assessment:
The baking finish layer is extensively powdered, with many areas of exposed substrate.
Lap joint sealant strips are aged and cracked; 7 leak points identified.
Screw holes are severely rusted, with approximately 30% already loose.
No insulation layer on the roof → strong thermal radiation in summer.
Solution Comparison
| Solution | Advantages | Disadvantages |
| Localized repair | Low cost | Treats the symptoms but not the root cause; problems recur |
| Replace with new steel sheets | Complete renovation | High cost; production shutdown required; long construction period |
| Waterproofing + Cooling Integrated Film (Butyl rubber + radiative cooling layer) | Solves all three problems at once; no production shutdown | Higher initial investment |
Final Selection: Waterproofing + Cooling Integrated Film (Butyl rubber + radiative cooling layer)
Construction Organization: Phased, sectional, no production shutdown
To avoid impacting production, a "zone rotation and off-peak construction" approach was adopted. The roof was divided into 3 zones, which were worked on in sequence. Upon completion and initial curing of each zone, work proceeded to the next, while workshop production continued normally throughout.
Key Note: The butyl rubber provides pressure-sensitive adhesion, delivering immediate waterproofing capability after application – no additional curing time required. Once work in each zone is completed, production in the workshop area below that zone can resume the same shift, achieving truly zero production downtime.
Case Summary
This case demonstrates the feasibility and comprehensive advantages of using the Waterproofing + Cooling Integrated Film for the repair of aged steel sheet roofs under zero-production-shutdown conditions.
Sound Technology
Full-surface butyl rubber adhesion → completely seals out moisture and air, stopping corrosion at the source
Butyl-to-butyl bonding at lap joints → eliminates water migration, ensures reliable waterproofing
Radiative cooling layer → reduces roof surface temperature by 27°C, lowers workshop temperature by 7.5°C
Construction Adaptability
Zone-by-zone, off-peak construction
Immediate waterproofing upon application – no curing time needed
Completed 3,000 m² in 3 effective working days, with zero production downtime throughout
Economically Sound
The electricity cost savings in a single year already cover a considerable portion of the material cost.
Avoids the high investment of roof replacement and the losses from production shutdown.
Significant hidden benefits include reduced customer complaints and improved worker productivity.
Application Reference
This solution is suitable for comprehensive repairs on steel sheet roofs of similar types, especially when the three major problems – leaks + rust + high temperature – coexist and production cannot be interrupted. Under such conditions, the long-term comprehensive cost-effectiveness of the integrated film solution is significantly better than that of localized repairs or full roof replacement.