Saving a Modern Marvel: How Acrylabs Revived the Thin Shell Concrete Roof at St. Athanasius Church

Tucked in the leafy suburbs of Reading, MA, St. Athanasius Church stands out—not just for its spiritual significance, but for its bold architecture. Designed in the early 1960s, the church features a stunning thin shell concrete roof formed in a hyperbolic paraboloid, or “saddle roof.” It’s a modernist structure with sweeping, sculptural lines that embody both elegance and engineering ingenuity.

But as with many architectural pioneers, time and the elements started to take a toll. Over the decades, the original waterproofing systems failed repeatedly. Water intrusion, cracked coatings, and general deterioration left this once-cutting-edge roof vulnerable and in need of a serious solution. That’s when the Acrylabs System stepped in.

The Challenge: Thin Concrete, Heavy Problems

The unique structure of the roof presented both aesthetic and engineering challenges. The concrete shell is only 2 to 3 inches thick and is suspended, meaning it can't bear the weight of conventional roofing materials, such as modified bitumen, torch-down membranes, or bulky insulation systems.

After years of stopgap fixes and patch jobs, a local architect recommended something different: a lightweight, high-performance membrane system that could preserve the roof’s form while solving its waterproofing issues. Acrylabs was the answer.

The Solution: A Durable, Lightweight Membrane System

Acrylabs’ elastomeric membrane system offered the perfect balance of strength, flexibility, and weight. Using a combination of liquid-applied base and finish coats, reinforced with specially engineered fabric, the system is designed to conform to even the most complex roofing geometries. And this roof? It’s all curves.

Before the application began, the roof was power-washed, revealing layers upon layers of failed waterproofing attempts. That alone showed how critical it was to get this fix right—not just cosmetically, but structurally. Water infiltration in such a thin concrete shell can spell serious long-term damage.

The crew used a spray technique to embed the reinforcement fabric into the base coat, ensuring full adhesion and seamless integration with the roof’s contours. The finished result isn’t just watertight—it actually enhances the visual appeal of the structure by emphasizing its elegant, sculptural design.

More Than Just a Roof—A Community Boost

What’s most remarkable about this project isn’t just the technical success. After the Acrylabs restoration was completed, church attendance and community donations reportedly improved. When a place of worship is restored with care and respect to its original vision, it resonates deeply with its congregation.

This project is a perfect example of how roofing systems can be about more than just function. The Acrylabs System didn’t just protect a roof—it preserved a piece of architectural history and revitalized a community hub.

Why It Matters for Contractors and Architects

For contractors, this project is a case study in how innovative materials can solve problems traditional systems can’t touch. For architects, it’s a reminder that your boldest designs don’t have to be compromised by maintenance concerns—if you specify the right system.

Whether you’re dealing with historic restoration, custom curved structures, or lightweight substrates, the Acrylabs Liquid Applied Roofing Membrane - System offers an innovative, flexible solution. As this project proves, it can even breathe new life into buildings that seemed beyond repair.