spray foam commercial roofing
The Future of Roofing is Seamless! ™
Spray polyurethane foam (SPF) roofs excel in durability and effectiveness for commercial roofing. They offer superior insulation and water resistance, enhancing energy efficiency and comfort. A study in the Journal of Architectural Engineering confirmed that SPF roofs deliver efficient insulation and thermal resistance, resulting in heightened indoor comfort and occupant satisfaction.
What Is Spray Polyurethane Foam?
Spray polyurethane foam (SPF) is a revolutionary roofing material created by precisely blending isocyanate and polyol components with heat and pressure, forming a lightweight, seamless membrane. Although used in various industries since the 1940s, SPF's remarkable insulative properties were harnessed for roofing in the late 1970s, sparking a paradigm shift in energy-efficient construction.
The closed-cell variant excels in commercial roofing, offering superior thermal performance and moisture resistance through its impermeable structure. SPF's seamless application eliminates leaks while reducing energy demands through its exceptional insulative qualities.
Benefits of Spray Foam Roofing
Thermal Resistance (R-Value)
Spray foam roofing excels in regulating building temperature year-round, boasting superior thermal insulation properties that outperform conventional materials, despite its official R-value.
Extended Lifespan
Spray foam roofs offer a durable investment for the future. With proper care, they can last for decades. Regular recoating every decade ensures continued protection against UV rays.
Easy Maintenance
Maintaining SPF roofs is simple, with minor damage easily fixed using specialized sealants. Severe damage necessitates thorough repairs to uphold waterproofing and protect the foam membrane from exposure.
Eco-Friendly and Sustainable
SPF roofs can be recoated multiple times, reducing waste and landfill costs. The materials are eco-friendly, providing a sustainable alternative to traditional roof tear-off and replacement methods.
Strength & Durability
Spray foam roofing systems offer a rare combination of strength and lightness. Despite their remarkable durability, they add minimal weight to your structure, which is crucial for long-term structural integrity.
Seamless and Watertight
Seamlessly applied spray foam roofs eliminate vulnerable seams and joints, drastically reducing water ingress risks and providing unparalleled watertight protection during heavy rains and storms.
Efficient Installation
SPF roofs are faster to install and less disruptive for occupants. They go directly onto the roof, usually without removing old roofing materials, unlike traditional options.
Enhanced Energy Efficiency
Reduce energy costs and environmental impact while improving comfort and sustainability for your business.
Appropriate Roofing Substrates
Foam roofing insulation demonstrates remarkable versatility, making it compatible with various commercial roofing substrates, including:
Built-up roofing
Modified bitumen
EPDM (with cover board)
PVC (with cover board)
TPO (with cover board)
Metal
Concrete
While the type of roofing substrate is relevant, its condition ultimately dictates suitability for an SPF system. Over time, commercial roofs may deteriorate beyond the optimal conditions for SPF application. Hence, we highly recommend conducting an infrared survey on most substrates to assess potential saturation levels and ensure compatibility with the roofing assembly.
SPF Roofing Installation Process
For a typical commercial roof measuring around 20,000 sq. ft., the installation of a spray foam system usually takes about 2 weeks, depending on weather conditions. Here's a breakdown of the installation process:
Surface Preparation
The initial step involves thorough surface preparation. This includes pressure washing the existing roof substrate to eliminate all dirt, dust, debris, and other contaminants. This ensures optimal adhesion of the foam to the underlying material. In some cases, a primer may be necessary to achieve proper adhesion.
Spray Polyurethane Foam Application
Next, spray polyurethane foam is applied to the roof surface, typically at a minimum thickness of 1 inch. However, it can be applied at greater thicknesses to enhance insulation. Additionally, the foam can be used to create slopes around specific areas of the roof to ensure proper drainage.
Elastomeric Roof Coating
Following the foam application, an elastomeric roof coating is applied to the SPF system to protect against UV degradation. This coating is applied in multiple passes to ensure uniform thickness and coverage. For steep-slope roofs, acrylic coatings are commonly used, while silicones or urethanes are preferred for flat roofs due to their ability to withstand ponding water.
Roofing Granules
To further enhance the system's durability and UV protection, #11-grade roofing granules are broadcast into the elastomeric top coat. This step provides added strength and resistance to wildlife. Strong Contractors Inc. mandates the addition of roofing granules to SPF systems for qualification for an NDL warranty.
It's important to note that Strong Contractors Inc. Approved Contractors adhere to specific Application Guidelines to ensure consistent quality standards during system installations. These guidelines outline a step-by-step process tailored to different roofing substrates.
Repairing an SPF Roofing System
When fixing a sprayed polyurethane foam roofing system, it's crucial to rely on experienced professionals. For small damages, specific roofing mastic or sealant works effectively to fill gaps and holes. Choose the right product for the job, especially for SPF roofs with a silicone top coat, requiring a silicone-based mastic or sealant.
For larger issues caused by sun damage or excessive moisture, more extensive repairs are necessary. Damaged foam must be carefully removed with a special grinder to expose undamaged foam underneath. After priming, new foam (at least 1 inch thick) is applied to ensure proper adhesion.
Finally, several layers of a special roof coating are applied, along with roofing granules for added sun protection and durability.
Recoating a Spray Foam Roof
Ensuring the longevity of a spray foam roof requires regular maintenance, including recoating every 10 to 15 years. This process helps to keep the roof in top condition and extends its lifespan.
The recoating process involves several steps:
Repairing any areas of the foam that have been damaged by UV rays or moisture.
Thoroughly cleaning the entire roof surface to remove dirt, dust, and debris.
Applying a primer if necessary to promote adhesion.
Adding new coats of the same type of coating originally used.
We provide warranties for both materials and non-deteriorating systems for spray foam recoating. To qualify for these warranties, an in-depth inspection by one of our approved contractors is necessary, including the use of infrared technology to assess the condition of the existing SPF system.
SPF maintenance tips
Regular maintenance is essential for preserving the integrity and performance of spray polyurethane foam (SPF) roofing. This includes periodic inspections to identify and address any damage promptly, clearing debris to prevent water ponding, sealing gaps and cracks to maintain the system's integrity, and monitoring drainage systems to ensure proper water runoff.
Additionally, addressing leaks promptly and preventing vegetation growth near the roof are crucial for extending the lifespan of SPF roofing.
Strong Contractors Inc. Certified Partnerships
Strong Contractors Inc. is deeply rooted in the industry, boasting partnerships with renowned companies like Gaco, American Weatherstar, Spray Polyurethane Foam Alliance, American Chemistry Council, PPG, The Versa Flex Companies, Rhino Linings Protective Coatings, and Carlisle Coating & Waterproofing.
These esteemed affiliations reflect our unwavering dedication to excellence and ensure that every project we undertake is executed with top-tier quality and professionalism.