Detailed FlexArmor Explanation

flexarmor comparisonQuality work and proper surfaces preparation are critical in a successful FlexArmor roof. Each authorized location attends training at the corporate headquarters before applying the roof at their location. Once the applicator has completed their training,, Inc. travels to the location to ensure the shop is set up correctly and supervises the first few roofs done by the new applicator. This training ensures quality and that processes are completed the same from location to location across the country.

Every FlexArmor location provides the same basic services.

Each roof is completed in doors in fully equipped shops. RVs are protected from dust and overspray by being wrapped in plastic, the only exposed area left is the roof. Inside your RV, blankets or other protective materials are laid down under openings like air conditioner holes. These holes are papered off but the protective sheet is extra protection against accidents. FlexArmor locations are required to have scaffolds that surround the RV. These scaffolds allow for efficient work practices and put the applicator at the perfect height to apply the sprayed roof on the sides of the RV. Completing roofs indoors provides the added benefit of protecting the RV from the elements while work is being completed.

Preparation is the most important aspect of completing an RV roof correctly.

The first step of this process is inspecting the current RV roof and making sure all the wood is sound and dry. At FlexArmor locations, every roof is inspected for soft spots or other signs of water intrusion. If signs of water damage are found, the current roof is opened up to determine the next step. Water intrusion can be handled two different ways.

  1. If the wood is just damp but still solid with no signs of rot, the wood is dried out completely with fans. Once the wood is dried out, it can be prepared for a FlexArmor roof.
  2. If the wood is rotted, the wood is cut out and then replaced with the same thickness of wood. This bare wood is then prepared for the FlexArmor roof.

Wood damage on vacuum bonded roofs is handled slightly different.

This style of roof is Luan glued to structural Styrofoam in a press. If this top layer of wood has gotten wet it wrinkles like paper. If the roof is still structurally sound, the old wood is removed, and the area dried out. Once it is dried out, a new sheet of Luan, bigger than the effected area, is put in place before applying the FlexArmor roof.

RV Roof takes it all off.

The next step is stripping all the old caulking, rolled on roof coatings and sealant tapes like Eternabond tapes. It is important to strip your roof components down the basic surfaces. The FlexArmor system works by forming a chemical bond with components and edges, forming a watertight seal that does not require yearly caulking. Depending on the component and the material it is made of, the process includes profiling the surface and chemically cleaning for maximum adhesion. This part of the process is the most time consuming and typically takes a day and a half of the 2 ½ day process. When this part of the process is done, all your roof openings are papered and the only the areas to be sprayed with the new FlexArmor roof are exposed.

We evaluate your existing roof before we start the application.

There is one other important factor in the roof preparation process. Most RVs currently have one of the following roof types:

  • EPDM Rubber
  • TPO Vinyl
  • Fiberglass (Filon)
  • Aluminum

The first thing that is evaluated is what condition is the existing rv roof. Typically EPDM or TPO roofs are left on the roof if they are still adhered well to the wood substrate. When these roof types are adhered well, taking them off destroys a layer of wood. FlexArmor rv roofs do not require new wood for adhesion so most completed FlexArmor roofs are done over the existing membrane. If there has been water damage, the roof material is old, loose or damaged, it is removed, and the applicator prepares the wood for the FlexArmor roof. Fiberglass and aluminum roofs are also evaluated for water damage but are rarely removed since in most designs, they are a part of the structural strength and integrity of those style rvs. Roof repairs are not always simple and applicators have to make changes to processes from time to time. In the end, the applicator is making sure the substrate is solid and repaired properly before applying the FlexArmor rv roof.

We clean before we apply FlexArmor.

The final step before the sprayed roof application is cleaning the exposed surfaces. All the dust and dirt from taking apart components is blown and swept off the rv roof. After the bigger debris is removed, the surfaces are chemically cleaned to remove final dust and oils from the spray surfaces. The trained FlexArmor applicator then sprays the new rv roof on after one final inspection.

Final Result: A lifetime of no worries.

The final result is the only RV roof that is 187 mils thick, has a tensile strength of over 3500 psi, 600 + elongation, is totally seamless and guaranteed not to leak for the lifetime of the RV


If you are ready to discuss the benefits of having a FlexArmor roof put on your RV, fill out this simple quote request:

* = required

Your preferred service center*:

Looking for less details? We have a simple explanation for you.

FlexArmor® is guaranteed not to leak for the lifetime of the RV!

Want to see the pictures of FlexArmor on RV Roofs?  Check out the photo gallery.