Roof coatings are a great way for commercial roofing contractors to boost revenue while extending the life of existing roof systems—but only if they're applied correctly. Without the right preparation and technique, even the best products won’t work.
Here are 10 common mistakes contractors make when working with roof coatings—and how you can avoid them to ensure long-lasting, high-quality results.
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Inadequate Surface Prep
Coatings are only as good as the surface they’re applied to. One of the biggest—and most costly—mistakes is skipping or rushing surface prep. Dirt, rust, and moisture can severely impact adhesion.
Always follow the manufacturer’s guidelines. For example, Ecodur Roof Coatings are known for their excellent adhesion—even to less-than-perfect substrates—but proper cleaning and drying are still essential for optimal performance.
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Applying Coating to a Wet Surface
Moisture is one of the biggest enemies of coating adhesion. Applying over damp surfaces can lead to blistering, peeling, and premature failure.
Use a moisture meter, core samples, and infrared to make sure your substrate is completely dry before starting the application process.
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Ignoring the Weather Conditions
Temperature, humidity, and even wind can all affect how a roof coating cures and performs.
Always check the recommended temperature and humidity ranges on the product data sheet. Ecodur Roof Coatings, for instance, are highly versatile in different climates and can even be applied in below freezing temperatures, but even they have their limits. Avoid application in extreme conditions unless specifically advised by the manufacturer.
If rain is in the forecast, delay application. Ecodur’s quick cure time can help make up lost time later!
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Improper Mixing or Application Technique
Not mixing the product correctly, using the wrong equipment, or applying too thin a layer can all lead to coating failure.
Ensure your crew is trained on the correct techniques. If you're working with Ecodur, Castagra offers a free, online training program and technical support to make sure you get it right the first time.
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Neglecting Key Details (Flashing, Seams, Penetrations)
Overlooking roof features like seams, fasteners, and flashing can create leak points even when the field is well coated.
Use reinforcement fabric where needed, apply detail coats, and inspect penetrations thoroughly. Check out Ecodur+ (now available in convenient Patch & Repair Kits) for a self-leveling formula that makes detailing easier.
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Misunderstanding the Substrate
Not all roof coatings work well on all surfaces. Applying a coating to an incompatible substrate can lead to adhesion failures.
Know your substrate and make sure to choose a compatible product. Ecodur adheres strongly to a wide range of surfaces including metal, concrete, spray foam, and BUR—without primers in most cases—but always confirm compatibility before application.
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Not Offering Maintenance or Follow-Up Inspections
Many contractors walk away after the job is done, missing out on future work and risking avoidable issues.
Offer an annual inspection or maintenance plan to extend the roof’s life and generate reliable revenue. Regular inspections are typically a requirement to keep your warranty active, if you have one. It’s also a great opportunity to inspect how your coatings are holding up and collect testimonials or referrals.
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Not Training Your Applicators
Even the highest quality products can fail if the applicators aren't properly trained on the specific coating system.
Take advantage of available training resources. Castagra offers a free, online training program that covers everything from surface prep to mixing and applying Ecodur properly. Make training part of your onboarding for every crew member.
Keep in mind—training is an ongoing process. Check in with your manufacturer every year for a refresher and make sure you’re up to date on all the products you’re using.
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Failing to Document or Photograph the Job
Lack of documentation can hurt you if warranty issues or disputes arise. Photographs of great looking projects are also useful for case studies and sharing on your social media platforms.
Take before, during, and after photos, and keep detailed notes on conditions, materials used, and application techniques. It’s a simple habit that protects your business and builds trust with clients.
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Applying the Coating Too Thin
Too thin a layer won’t protect adequately, and can cause issues like cracking and leaking.
Use a wet film gauge and follow manufacturer recommendations for coverage rates. This ensures optimal durability and performance without waste.
By avoiding these common mistakes, you can deliver long-lasting results, strengthen client relationships, and grow your reputation in the commercial roofing space.
At Castagra, we’re committed to supporting contractors with products that are tough, sustainable, and backed by expert support. If you’re ready to get started with Ecodur Roof Coatings, connect with our team or sign up for our free online training program.
Who Are We?
Castagra is a roof coating manufacturer dedicated to providing sustainable and high-performance coating solutions. Learn more about our products here, or contact our team today to learn more about how we can help you!
