Specialty Applications of Spray Polyurethane Foam (SPF)

Spray Polyurethane Foam (SPF) like that offered from Conklin can be used in a variety of different applications

Tanks and Vessels
SPF can be a solution for cold vessel insulation for products such as wine, chemicals, and soft drinks. It is excellent to store products that need controlled temperatures. SPF systems are perfect for these type insulations because of the superior durability and ease of application.

Spray Polyurethane Foam can also be used for hot/warm vessel insulation. If there is a need to maintain temperature control and/or viscosity levels of chemicals or other liquids, SPF fluid-applied systems and protective coatings offer superior performance.

Sealants
Use polyurethane foam sealant to improve your homes “envelope” in its outer walls, ceiling, windows and floors. This is a cost effective way to improve your home’s energy efficiency and comfort in terms of thermal and sound insulation, sealing windows and doors and blocking insects and rodents.

One component can foam is an economical and effective insulating and sealing expanding polyurethane foam. Designed for sealing cracks, seams and smaller gaps, it will eliminate drafts, block insects, deaden sound and repel moisture.

Can foam expands to 2-3 times the original size of the dispensed bead and cures by reacting with the moisture (humidity) present in the air when it is dispensed. This polyurethane foam takes approximately 45 minutes to an hour to cure in 50% relative humidity. While air sealing is the primary use for these materials, they also insulate with R-values (aged) in the 3.5 to 5 inch range.

Two-component polyurethane foams (or froth foam units) come in separate containers, one for each component, and tanks operate conveniently from an upright position. Two-Component Standard Foams are ideal for Insulating and Sealing jobs that require a product designed for spray application over large surface areas or for filling large voids and gaps. Two-Component Foam is a chemically cured foam system. Each Foam pack includes both an “A” & “B” component. Dispensed through the included dispensing tool, the foam “A” and its curing agent “B” are mixed at the nozzle and cure much more quickly than One-Component Foams.

Fast chemical curing results in a higher expansion ratio for two-component polyurethane foams. This makes them suitable for spray-on applications and for filing holes and cavities. They have an R-value (aged) of approximately 6.0 per inch.

Adhesives
Spray polyurethane foam is used as an adhesive in the commercial roofing industry and the manufactured housing industries.

SPF is used to adhere EPDM membranes or boardstock insulation to various roofing substrates. The SPF is used to stick the boardstock to the roof deck and then again stick the membrane to the boardstock. The SPF is spray-applied which reduces application time and labor. The foam provides an added degree of insulation and forms a strong bond, earning it excellent wind uplift ratings.

SPF is also used in manufactured housing. The foam adhesive is used to attach wall panels and ceiling panels to structural stud framing. This has many advantages to the builder, speed of building, added strength, and lower costs.

Cold Storage
The performance of a spray applied polyurethane foam insulation (SPF) system for cold storage facilities can be affected by all the component parts of the building structure, as well as the atmospheric conditions inside and outside the structure. Proper structural design, specifications review, contractor and material selection, coupled with the compatibility and positioning of the various components of the building are a necessity to produce a successful cold storage facility.

Consult with the designer/specifier and the successful contractor to receive written confirmation of their agreement/opinion to all facets of the cold storage project, including, but not be limited to, material selection, moisture vapor transmission, load design, expansion joints, and refrigeration requirements, flashing details, and floor, wall, ceiling preparation, and pull down schedule.

Types of cold storage facilities
Refrigerated warehouses generally have a single function of storing previously processed or frozen food at a constant temperature between -40oC (-40oF) and 10oC (50oF). They are often one room buildings. Packaged goods are stored on pallets or food racks.
Processing plants for meats, poultry, dairy or other food products are multi-functional type structures which are quite complex. They typically consist of many rooms, each with a certain function, operating temperature and humidity condition.

Distribution centers are multi-room buildings for packaged dry goods, frozen foods, fresh produce, baked goods and dairy products. In addition to the above, these centers may contain specialty rooms such as banana rooms or ice cream holding rooms.

Existing facilities may be converted to another use, i.e., a cooler may be converted to a freezer, or a new room may be added within an existing structure.

If you are interested in Spray Polyurethane Foam (SPF) for your home or building, to find a professional Conklin roofing contractor in your area, please click here

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Spray foam could be the best insulation system ever invented

Let's look at the advantages of Spray Polyurethane Foam (SPF) insultation like those offered by Conklin.

On the inside of the wall panel of a building it has an extremely high R value, it has been shown to dramatically increase the racking strength in steel and timber frame buildings, in some instances has been specified to prevent wind uplift in commercial roofing systems.

On the outside of the building it can be used as a combined vapor and air barrier system and is recognized as such when applied to the American Air Barrier Association standards. It can also be used below grade for the insulation of basements and foundation.

It does not emit VOCs or hydrocarbons and has a proven track record over the last 20 years.

Commercial Roofing
Spray polyurethane foam (SPF) roofing consists of an application of specifically designed foam covered with an elastomeric coating (typically acrylic, silicone or polyurethane) or aggregate covering to protect the foam from ultraviolet rays.

Specialized equipment mixes two liquid components at the spray gun that applies the SPF to a prepared substrate. The mixed liquid expands many times its original volume in a matter of seconds, forming a rigid foam plastic that chemically bonds to the surface to which it is sprayed. Spraying the foam in ½” to 1-1/2” lifts allows the applicator to reach the desired thickness to fill in low areas, build up slope, and provide insulation.

SPF has a closed cell structure that makes it water resistant. It must, however, be protected by elastomeric coatings or other coverings (such as aggregate) to prevent ultra-violet-induced surface degradation. Such coverings can also be used for other purposes, including, inhibiting moisture vapor transmission, enhancing the aesthetics of the system, increasing the impact and abrasion resistance of the system, achieving non-flammability and meeting code requirements.

SPF roofing systems have good adhesion to a variety of substrates including metal, wood, concrete and built up roofing (BUR). Since SPF adds little weight to existing roof coverings and can build slope to fill in low areas, these systems are used frequently as a recover roofing system. Caution should be used when specifying any recover roofing system. The existing roof covering and roof deck assembly should be thoroughly evaluated by a structural engineer to verify that it can be a safe substrate for SPF roofing systems.

Hail and wind driven missiles (such as tree limbs, broken roof tile, metal flashing, etc.) can damage the SPF roofing system. However, this type of damage typically does not cause leaks and can be repaired later without compromising the long-term performance of the system.

SPF roofing systems also excel when the following conditions exist:
- Additional insulation is required
- There are severe temperatures
- The roof substrate has numerous penetrations
- The roof deck is an unusual configuration
- The roof is in an area where high winds are likely to occur
- Lightweight materials are required
- Slope must be added to provide positive drainage
- Because of the energy saving characteristics and low maintenance costs of SPF roof systems, these roofs are suited to companies or organizations that own their own buildings and must pay their own energy and maintenance costs.

In our next blog post we will look at specialty applications of spray foam insulation.

If you are interested in Spray Polyurethane Foam (SPF) insultation and roofing systems for your home or building, to find a professional Conklin roofing contractor in your area......
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SPF Wall Insulation has BIG Benefits!

Spray Polyurethane Foam (SPF) insulation like that offered from Conklin is rigid, lightweight, flexible, wind resistant, and effective in extreme temperatures and weather conditions. SPF insulation has the highest R-value per square inch of any commercially available insulation material.

Total Comfort Control, Not Just R-Value
The building envelope is a system of construction components which protect against the uncontrolled movement of: heat, air, and moisture.

The true performance of your building envelope can not be measured with the R-value of the insulation alone, but must also consider air movement, moisture control, health, safety, durability, comfort, and energy efficiency.

This is true whether your building is commercial, residential, or multifamily: SPF addresses all these needs in both new construction and improvements to existing structures.

Six mechanisms of heat loss through a wall or ceiling that are bad for your home and bad for your health:
- Conduction
- Radiation
- Convection Currents
- Infiltration (Wind Pressure)
- Intrusion (Wind Wash)
- Moisture Accumulation (Humidity, Dew, and Frost

Did you know?
- Air infiltration can increase energy costs in buildings 10 to 40%.
- SPF reduces air infiltration allowing insulation to be more effective and reducing the demands on HVAC equipment.
- SPF reduces moisture infiltration by reducing air leakage.
- SPF adds structural strength to walls and ceilings.
- SPF reduces sound transfer into buildings. Most sound from outside the building is carried into the building through cracks and air leaks. SPF by stopping the air infiltration also helps keep sound out.
- SPF minimizes dew point problems and condensation.
- SPF resists heat transfers through air infiltration regardless of flow direction.
- SPF provides reliable R-values under the most extreme conditions, dependable and durable protection against heat loss or gain.
- SPF minimizes thermal bridging, which can cause higher energy usage and cost.
- SPF out-performs conventional insulation materials because they trap still dry air and if that air moves or becomes wet, the thermal resistance can drop by 50%.
- According to ASHRAE, a 3% void area in a wall cavity represents a 15% reduction in wall R-value.

If you are interested in Spray Polyurethane Foam (SPF) for your home or building, to find a professional Conklin roofing contractor in your area, please click here.

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About Roof Construction and Maintenance

We've all heard people say that you have to spend money to make money; however, in today's uncertain economic times companies across the country aren't just looking to make money - they're tightening their belts, battening down the hatches, and looking for ways to save money. But even during hard times, it is important to remember that the old "spending" adage can still hold true for savings - sometimes you have to spend money to save money, especially with regard to a building's roof.

Although they are perhaps the least visible portion of buildings, roofs can account for up to 50% of a building's total surface area, and they can represent up to 25% of total building value. By proactively investing resources in building and maintaining a solid roof, building owners may extend the lives of their 15-year roofs to 25-year roofs by heading off leaks and other adverse conditions, which translates into significant long-term cost savings.

Preventive investment in the life of a roof happens in two primary areas: during the construction process of a new building, or as preventive maintenance for an existing roof. The goal of each is to extend the life or primary envelope function of the roof, but the different stages require two different types of oversight.

New Construction
Like any area of construction, roofs require unique expertise to maximize their effectiveness. Having an expert involved during the building's design all the way through construction, can ensure that the roof is designed, engineered, fabricated, and assembled to provide the building and its contents with watertight protection.

The optimal time to get a roof expert involved in the construction of a building is during the design phase, while the architectural team is still working on its detailed plans. A pre-design meeting between the owner/developer, architect, and roofing expert can help highlight issues that architects may need to address in the design - especially issues that may be unique to a particular climate.

An architect designing in South Florida, for example, will need to plan for stronger attachment of all roof components due to calculated uplift pressure requirements outlined in hurricane-related building codes. In northern climates, though, considerations must be made for snow weight and removal, ice dams, and the expansion and contraction associated with building materials in extreme climates. In either situation, it can be helpful for an architect to have a roofing expert available to alert him/her to potential issues before they arise.

As the design progresses, the roofing consultant should review architectural drawings and CSI Division 7 specifications related to waterproofing and roofing. The goal here is twofold: to ensure that the architectural team designs and specifies a roofing system that will adequately protect the building, and to ensure that the drawings and specifications are detailed and accurate enough for the general contractor to obtain accurate bids from roofing subcontractors. Accurate and detailed drawings at this stage can prevent the necessity of time-consuming architectural drawing changes and costly rebids or bid-change orders later in the building process.

In general, the roof expert will be looking at the design drawings and specifications for things like:

• Membrane components and flashing. Are the appropriate membrane and flashing specified for the design, and do they reflect the specifications manual?
• Detailed method of attachment. How the roof is attached is a major factor in its longevity and effectiveness. Do the design drawings provide adequate details and specifications relating to the geographical location?
• Product compatibility. Just like any construction application, some products work together; some don't. For example, most silicone sealants can't be painted, and spray foam and asphalt products never go together. The consultant will assess compatibilities. Will the specified roof-system products that intersect with other subcontractor products (e.g. a glass and glazing curtainwall) work together?
• Sequencing of installation. Roofing layers must be applied in a certain order, depending on the system, to maximize effectiveness. Do designs call for the right sequence?
• Overall layout. Certain areas of a roof, such as those where HVAC units are located, will have higher foot traffic and maintenance-activity requirements. This should be accounted for in the roof design, with traffic and protection pads to protect the roof membrane and waterproofing materials. Is there enough protection in the right places?

Product Submittals

One common mistake in many projects is specification of the wrong type of fasteners. For example, roofing subcontractors for projects in coastal Florida may propose using galvanized screws to secure flashing; however, in Florida, the salt air will rust galvanized screws, so a roofing consultant would call out his or her recommendation to use stainless steel. It's a small detail, but it can have tremendous impact on the life of a roof and the necessity of future repairs.

After a roofing contractor has been selected, the contractor must submit full specifications for the system and all the components he/she intends to use. The roofing consultant should review these submittals to ensure that they coincide with the original specifications, and to be sure all details are appropriate for the system and the climate.

Pre-Installation Conference

Many of the various subcontractors involved in a building project will require roof access at some point to complete their portions of the building. Many may actually need to penetrate the roof to install pipes, vents, conduits, or machinery. To coordinate these efforts and ensure that they don't cause damage to the roof, a pre-installation conference should be a top priority.

At this meeting, the roof consultant will sit down with the architect, general contractor, roof manufacturer, and any subcontractors whose work may impact the roof to coordinate schedules and plans. This conference can also help determine where extra roof protection pads may be needed.

"Another issue we often address is the spacing and separation of all roof penetrations," says Jon B. Blehar, an architect in Lake Worth, FL. "We need to be sure that all pipes, vents, and conduits are spaced far enough apart that they leave enough room for the roofers to properly flash them. Lack of proper flashing can cause leaks and may affect the roof manufacturer's warranty."

Quality-Assurance Inspections

After all plans, submittals, and products are approved, and the actual work begins, quality-assurance inspections should be conducted at various points throughout the installation. The number of inspections varies from as few as two to as many as eight to 12, depending on the project. Four is a good guideline: one at the beginning to be sure everything is off to a good start, one in the middle as a progress check, one toward the end, and a punch-list inspection at the very end.

Common problems encountered in these inspections include everything from waterproofing seam failures to damaged flashing and debris left on the roof. See Roof Disarray, below, for an example of one project's inspection finds. The ultimate goal is a secure building envelope and a watertight roof that's in accordance with required codes and specifications.

Preventive Maintenance: Roof Asset Management

All roofs have a limited lifespan and will eventually require replacement, retrofit, repair, or restoration. Whether a roofing consultant was involved in the construction of the building or not, developing a preventive maintenance plan can further extend the life of a roof and save money by correcting problems before they become major leaks that could cause structural damage. Over time, a roof asset management program can optimize roof performance, save money, and allow for roof replacement or repairs on a planned basis - not in reaction to a crisis.

If a roof is new and has been inspected by a roofing consultant throughout construction, the final inspection report should provide enough information to establish a maintenance plan and inspection timetable.

For an existing roof, a consultant should thoroughly inspect the roof and provide a written report of findings with a photo survey of roof conditions for future reference. Based on those findings, the consultant will develop projected life-cycle budget cost estimates and establish plans for upcoming maintenance, replacement, or repair.

From this point, a good roof-management program should include annual inspections for an inspector to look for damage, including membrane deterioration, water blisters, ponding water, coping impact damage, rusting metal, spray foam oxidation, and membrane split.

If the roof shows signs of deterioration, the consultant may recommend moisture testing, such as:

• Moisture probes, which are used to check distressed areas for the presence of moisture by probing through the roof surface and taking readings from the moisture meter.
• Infrared scans, which are infrared snapshots of a roof area taken to detect the possible presence of moisture by recording temperature differentials.
• Nuclear scans, which utilize a roof grid survey to detect subsurface moisture.Roof cores, where an investigative hole is cut through the roof and insulation to document conditions in suspect areas. This hole is patched upon completion.

Ultimately, the goal of both new construction roofing review and ongoing roof-management programs is to protect the interest of building owners, extend the life of the roof, and prevent costly leaks and damage. In today's business climate, many building owners and businesses are understandably looking for ways to cut costs; however, involving a roofing consultant in construction or an ongoing maintenance program will end up saving you more than you spend.

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About Reflective Roof Coatings

Light-colored roof coatings like those offered by Conklin are commonly used in climates that use cooling because dark colors absorb heat, and light colors reflect heat. Roofs have intense solar heat gain (energy) because of their relatively flat exposure to the sun. The intense solar gain raises the temperature of the roof membrane (sometimes near 200F), which increases cooling load in the building and shortens life of the roof. You can lower cooling costs and extend roof life by hiring a certified professional roofing contractor to install a light colored coating (also called cool-coating system) over an existing roof.

Light-colored roofs do reflect some of the incident solar energy. A term used as a measure of reflectivity and absorptivity is albedo. The higher the albedo of a surface, the less energy it absorbs, and the cooler a temperature it maintains. Typical built-up flat roof surface materials such as modified bitumen and tar and gravel (with albedos from 0.10 to 0.20) can absorb over 70% of the solar energy that falls on them and can reach temperatures of 170–200F.

Ultraviolet (UV) light rays can penetrate roofing membranes and cause accelerated chemical degradation of the roofing materials. High-performance elastomeric white reflective coating systems contain substantial levels of UV-blocking pigments that keep heat away. A cool surface reflects the sun’s ultraviolet rays and slows down roof aging. Roofing materials also contract and expand daily as they heat up during the day and cool down at night. A roof with a cool coating doesn’t experience such large daily temperature fluctuations, so it undergoes less thermal fatigue. Reflective roof coatings are usually sold as maintenance products because they extend the life of the roof.

Application

This product is best for low slope or flat roofs which have low insulation levels and mineral cap sheet or single-ply roof membranes. Adding a cool coating is most beneficial for a building which:

♦ Is in a climate with hot, sunny weather during at least part of the year

♦ Uses significant cooling energy and/or has problems maintaining comfort

♦ Has a large roof area compared to the rest of the building’s surface area

♦ Has roofing which tends to crack and age prematurely from sun damage

Prior to 1998 there were few standards regarding effectiveness or quality of products. The industry formed the Cool Roof Rating Council (CRRC) in 1998 to provide information and develop a comparative rating system. Look for reflective information or Energy Star labeling on roofing products.

Performance & Costs

When a dark single-ply roof is coated with a white reflective coating, the albedo can rise from 0.20 to 0.65-0.85 and surface temperatures will remain below 135F in sunny weather. With a lightly insulated roof on a low-rise building in a cooling climate, heat reflective coatings can save over 40% of cooling energy used by the building and have a lifetime of 10 to 15 years. Roof lifetimes will be extended because of the reduced temperatures.

Numerous studies confirm that coatings can reduce surface temperatures by 50-80F and save significant amounts of cooling energy during summer months. Regardless of the amount of roof insulation, buildings tend to show reductions of 25-67% in cooling energy usage.

Typical coating costs can vary from 50 cents to $1 per square foot depending on quality of coating and roof condition. Reflective coatings will extend the life of an existing roof by lowering temperatures, but it cannot repair a failed roof. A high quality coating may last for over 10 years on a roof in good condition and extend the life of that roof.

Availability

Roof coatings are readily available through a large number of manufacturers, including Conklin. The primary barrier to use of this product is the fact that it is viewed by many installers as a maintenance product and not recognized for its energy performance.

If you are interested in white roof coatings for your building, to find a professional Conklin roofing contractor in your area, please click here.

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Spray Foam Adhesives Strengthen Your Building’s Roof (Part 3)

Also see Part 1 and Part 2 of this blog series.
According to NCFI Polyurethanes, their product complies with the requirements for use both inside and outside High Velocity Hurricane Zones (HVHZ) as listed in their Florida Product Approval #9975. ”We worked long hours with the University of Florida to get that initial Florida Product Approval. They make sure products are safe and work for the state’s homeowners. Since then, we’ve tested our products at a Miami-Dade approved third-party laboratory and are expecting a Miami-Dade NOA approval on InsulStar® in the very near future,” Hoerter said.

There are several application techniques that NCFI promotes for spray foam usage in wind destruction mitigation that can also accomplish insulation and potential energy savings as well.

Level-1 is simply for wind destruction mitigation and involves the application of the spray foam adhesive ”fillet” at the junction of the roof wood sheathing and rafter/truss.

Level-2 maintains the traditional vented attic assembly, follows all the Level -1 steps for wind destruction mitigation, but also includes the application of 1/2 to 1 inch of foam across all of the roof sheathing. This thin application foam provides just enough insulation to keep the attic temperature significantly lower than normal in the hot southern climates. Reduction of the hot temperature in the attic space can have positive results on the cooling efficiency of the home and moisture/condensation issues with HVAC equipment in that space.

Level-3 (also the most energy efficient) method includes all of the Level-1 wind destruction mitigation application, but instead of maintaining a vented attic assembly, a full covering of several inches of sprayed polyurethane foam is applied to the entire underside of the roof area covering all vents and completely sealing the attic space to create a much more energy efficient unvented attic space.

Extensive testing by universities, SPF manufacturers (like Conklin Company) and third party groups now demonstrate that closed-cell insulating sprayfoam adhesive provides solid structural benefits to the home, insulation value, and water barrier properties.

The state of Florida requires insurance companies to offer Florida homeowner’s discounts or credits for construction techniques that reduce damage and loss in windstorms. The wind portion of their total homeowners insurance premium can be a substantial amount and the savings from installing spray foam insulation are generally 60 to 80 percent of the windstorm premium and 25 and 60 percent of the total annual premium.

Savings tend to be greater for homes built before 2002 and greatest for homes close to the coast. Every insurance company’s discount structure is different, but some homeowners located near the coast report premiums reduced by more than half after application of closed cell spray foam insulation in the attic, bonded to the underside of the roof sheathing.

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Spray Foam Adhesives Strengthen Your Building’s Roof (Part 2)

Also see Part 1 of this blog series

In a test conducted by Clemson University’s Civil Engineering Department in 1998, it was demonstrated that roofs with SPF adhesive like the ones made by Conklin can withstand 2 to 3.5 times more uplift resistance than roofs held together with nails alone. In one test sequence using 5/8 nailed OSB, the roof system had an uplift resistance of 87 pounds per square foot. The addition of SPF adhesive increased the uplift resistance to 314 pounds per square foot.

To prevent water intrusion, the spray foam is also applied across all the sheathing seams. When roof sheathing is installed, there is often a small gap left between the sheathing panels, often as large as 1/8 to 1/4 inch wide. This small space can allow water to enter the home if the external roof shingles or tiles are compromised. The external roof shingles or tiles are typically the first part of a roof system to fail in hurricane-force winds. With the spray foam protecting these gaps as a secondary barrier, water cannot penetrate the roof if the shingles are blown away.

In a recent interview with Jason Hoerter, Sr. Product Manager and building science engineer with NCFI Polyurethanes, we learned about NCFI’s focus on this market sector and the company’s recent accomplishments with third party qualified testing and Florida Product Approvals for their InsulStar® product line.

Hoerter mentions, ”The 2007 University of Florida tests were substantial in their ability to prove concept for spray foam as a wind destruction mitigation product solution. But the bar has been raised significantly higher now that we have actual third party qualified test results and a Product Approval from the state of Florida for InsulStar® spray foam.”

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Spray Foam Adhesives Strengthen Your Building’s Roof (Part 1)

More and more hurricanes continue to slam to the U.S. eastern coastline each year. In the past decade, billions of  dollars worth of property damage and lost lives have prompted research and product development to help prevent this continued destruction to our homes and businesses.

Since 1989, over $130 billion in losses were filed due to hurricane related insurance claims. A startling $85 billion of destruction occurred in 2004 and 2005 alone. A large percentage of these losses were directly caused by severe wind and rain exposure from failed roof decks, according to a 1998 study by Clemson University. Many of these roof deck failures can be traced to outmoded nailing schedules or poor workmanship. Even well constructed roofs are often sorely unqualified to deal with the kind of weather extremes experienced in the southeastern coastal states.

Spray polyurethane foam (SPF) is most widely known for its superior energy saving insulation qualities in residential and commercial building. Unknown to many folks, is that spray foam (like the one made by Conklin) is also being used a construction adhesive to make residential roofs stronger and resist the wind and water damage effects of hurricanes and high winds.

Roof uplift is the main threat to an overhanging roof in a high-wind event. In hurricane force winds, roof system failure occurs when the roof cannot withstand the uplift pressure exerted on the eaves and overhangs. When the wind is blowing perpendicular to the ridge of a roof, positive pressure is created on the windward side and negative pressure is created on the other side. This produces high uplift forces in these areas, which can cause all or parts of the roof to blow off.

In this application, spray foam is applied from inside the attic to the underside of the roof structure. Specifically, the SPF is applied into the corner areas where the joists (trusses) meet the roof sheathing. Instead of traditional ”one-point” adhesion from just the nails through the sheathing, there is now ”three-point” adhesion. This comes from the nails at the top, and foam adhesive that spans nearly three inches down the joist and out onto the sheathing, on both sides of every joist. The foam adhesive also runs the entire length of the joist in a continuous glue-like bead, or fillet.

The spray foam adhesive creates a tenacious bond between the roof sheathing and joist structure that helps to resist and protect the roof structure from severe winds.

According to tests conducted in 2007 by the University of Florida and various spray foam manufacturing companies, spray foam provides up to three to four times the amount of uplift wind resistance over roof construction that uses nails alone.

* Please check back for Parts 2 and 3 of this blog post series. *


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What You Need To Know About Flat Roof Coatings

Flat roof coatings like those from Conklin can be a good investment for many facilities. A flat roof coating can extend the life of a roof because it lowers the roof temperature. It can also lead to additional energy savings as the temperature is reduced.

Still, because there are so many different types of roofs in use today, specifying a flat roof coating isn't easy. Different substrates require different coatings. A coating’s adhesion might depend as much on the substrate’s characteristics as on the coating type. In general, it is more difficult for coatings to adhere to hard, smooth, chemically inert surfaces and easier on rough, irregular, chemically active surfaces.

A coating’s adhesion to a substrate often improves when the installers put down a primer or base coat. Coatings manufacturers recommend certain primers or base coats to match a specific topcoat with a specific substrate. You should use only the base coat or primer specified by the coating’s manufacturer.

With the introduction of roof membranes such as ethylene propylene diene monomer (EPDM), polyvinyl chloride (PVC), thermal polyolefin (TPO), Hypalon, modified bitumen, and built-up roofing, manufacturers have developed a variety of roof coatings to address multiple substrates with different adhesion and weathering characteristics.

You can specify asphaltic and tar-based coatings for use with coal-tar-pitch built-up roof systems. Non-asphaltic coatings, including urethanes, acrylics, and polyureas, are most commonly used on single-ply systems.

Each of these coatings has different cost and performance factors. Due to variations in coating formulations, you should work closely with a roof consultant and the manufacturer to make sure they specify the right coating for the roof substrate and that workers perform the correct repairs before applying the coating. Manufacturer representatives and product data sheets also can assist in specifying coatings.

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Conklin Roofing Contractor Completes University Stadium Job

Yoder's Roofing, a Conklin roofing contractor in Montezuma, GA recently completed a spray foam insulation job at the Allen E. Paulson Stadium at Georgia Southern University.
The job required Eli Yoder and his team to apply spray foam insulation to a 12,000 square-foot modified bitumen roof system that developed leaks and at the time, seemed unrepairable.

The roof was approximately 30 feet above the upper level seats and had several small air conditioning units resting on four-by-four wood curbs. “We sprayed 2.8 pound-density polyurethane BASF/FE foam at the minimum of one-inch thickness to the entire roof,” Yoder said. “Low areas of the roof were ‘built up’ with additional thickness of foam application to create proper drainage."

Following the application of the foam, Yoder and his team applied 1.9 gallons of Conklin Benchmark Base coating to every 100 square feet to all foamed areas. “We allowed the coating to cure after about 24 hours,” Yoder said. The team then applied 1.9 gallons of Conklin Benchmark Top Coat coating to every 100 square feet to all foamed areas.
During the job, Yoder’s team faced minimal challenges.

“The only challenge we faced was dealing with over spray from the wind,” Yoder said. “To remedy that problem, we set up masking procedures to catch the over spray.”

Yoder and his team successfully completed the job in about four days with positive reception from the Georgia Southern University staff. “They were very happy with the job because they no longer had to worry about leaks,” Yoder said. “Everything has been great since the job was completed.”

Since the completion of the stadium job, Yoder expects to work with Georgia Southern University on future projects. “We’ve worked with the university before, and I look forward to working with them again,” Yoder said.


If you are interested in white roof coatings for your building, to find a professional Conklin roofing contractor in your area, please click here.

If you are interested in becoming a Conklin roofing contractor, please contact Randy Patton at (309) 303-3128 or email rpatton55@comcast.com. Feel free to also visit http://www.whiteroofingsystems.com for more information.

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An Overview of White Roof Coatings: Part 3

Permeability

Many white roof coatings (like those from Conklin) are waterproof, but some are not. The property of permeability (perm rating) to liquid water, water vapor, and gases varies greatly, depending on the type of coating.

• Acrylic roof coatings are breathable, which means they have a high moisture vapor transmission rate or permeability.
• Silicone roof coatings are also classified as breathable types.
• Butyl rubbers, hypalons, and neoprenes have a very low permeability, i.e., they are highly resistant to moisture transmission.

Keep in mind that the perm rating should not be confused with weatherability, or resistance to weathering. A roof coating with low permeability still may require a protective topcoat, to ensure satisfactory weathering resistance.

Cleanliness & Aging

Roofs that have white coatings in arid, dusty regions, or in places where farm plowing or construction exposes the earth to wind, are likely to accumulate dirt more than in areas with greenery or where occasional rainfall washes away the dirt. The frequency and intensity of precipitation and the slope of the roof also affect the cleanliness of the coatings over time.  As with other white surfaces, white coatings discolor and darken slightly after several years of service.

Two values of reflectivity are often quoted to represent the performance of new coatings and three-year-old weathered white coatings, respectively. Generally, a small decrease in reflectivity occurs over time, depending on several factors. Wind-blown dirt and dust can decrease the reflectivity of white coatings, depending on the age of the coating and regional climate characteristics.

UV radiation tends to be blocked rather than reflected by a white coating. A white roof coating still protects against UV radiation even when foreign particles reduce the reflectivity.  To maintain their reflectivity, roofs may be periodically refreshed with a new topcoat, typically for less than the cost of the initial coating.

The maintenance schedule depends on the type of coating, type of roof, the purpose of the coating, and regional climate differences. Typically, white roof coatings should be refreshed every three to seven years.

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An Overview of White Roof Coatings: Part 2

Compatibility with Membranes

White roof coatings like those from Conklin can be applied to practically any roofing membrane or system. They are commonly applied to sprayed polyurethane roofs, metal roofs, single-ply rubber roofs, and modified bitumen roofs. They can even be applied to certain kinds of asphalt built-up roofs.

It is important to establish compatibility between the white coating and the underlying roof surface. Manufacturers recommendations should be consulted for detailed information about specific coatings.

Primers & Surface Preparation
Primers are useful for improving adhesion between roof surfaces and coatings or for imparting additional properties to the roof coating systems.  For example, a rubber roof coating may provide better adhesion to a rubber roof membrane or better permeability (“perm”) rating on a sprayed polyurethane roof. Most white roof coatings impart greater reflectivity and UV protection to the system.

Manufacturer literature should be consulted and followed to properly prepare the surface for the coating. Professional roofing contractors should be employed for most coating installations. For certain systems, contractors may need to be specially trained by the manufacturer in the application of the coating. Proper application of the roof coating factors strongly in the subsequent life and performance of the coating.

Surfaces should be clean and dry, and they must have a positive slope to drains.  Application of white coatings over dirty, wet, or contaminated surfaces may produce unsatisfactory results. Acrylic latex coatings are sensitive to dew, rain, and other moisture during curing. It is important that the application be done with strict adherence to the manufacturers recommendations.

Application
Coatings are typically applied by airless spraying, rolling, or brushing. Due to the variety of coating types, climatic conditions, and surfaces to be coated, it is important to consult the manufacturer for proper application rates and related recommendations.

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An Overview of White Roof Coatings: Part 1

There are two main purposes of white roof coatings like those from Conklin. The first is to protect roof membranes and provide longer roof life cycles. The second is to reflect solar radiation and lower energy costs. Generally speaking, a white roof coating consists of a binder blended with pigments and other additives. Most roof coatings can be conveniently classified according to the binder they use.

Binders, Pigments & Liquid Carriers

Binders are usually made of an organic or silicone compound. Most binders are elastic polymers with elongation and tensile characteristics (also known as elastomers) which have the ability to return to their original shape after being stretched or deformed. In white roof coatings, the elastomer binder is the viscous, pliant material that bonds the pigments and makes them adhere to the surface. Common elastomers used as binders in white coatings include acrylic, silicone, rubber, vinyl, and urethane.

Titanium dioxide and zinc oxide are the common pigments that impart a bright white color to the coatings, although other pigments can be combined with these to yield a variety of pastel colors.

The majority of white roof coatings are water-based. These products (often referred to as latex coatings) are available in a variety of polymer types. The water in latex coatings serves as a liquid carrier, allowing the pigment and binder to be spread onto the surface as a thin coating. For some white roof coatings, organic solvents are used as the liquid carrier, while others (often referred to as reactive coatings) may have sufficient flowability to eliminate the need for a liquid carrier. Reactive coatings are generally prepared with multiple-part resins often blended on site, before curing.

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Reflectance and the Future of Roof Coatings

Reflectance is measured according to strict standards. A perfect reflector would have a value of 100 percent for all wavelengths of light. When just one value of reflectance is given, it usually represents an average value weighted according to intensity across the solar spectrum.

With the growing recognition of reflectance as an important design parameter, reflectance values are being thoroughly measured across the entire solar spectrum (including infrared wavelengths) and accurate values for specific materials and coatings are becoming readily available.

The beauty of a white roof coating like those from Conklin is that the pigments, such as zinc oxide (ZnO) or titanium dioxide (TiO2), scatter a large fraction of the incident photons back into the sky, optimized for reflection in the visible and nearinfrared bands. Metal-oxide pigments used in white coatings scatter light by the same mechanism that light is scattered with by the water droplets in a cloud, or fog; the scattering is due to the tiny particle size. Except for the small particle size, these materials would be transparent to light, because the metal atoms are oxidized, i.e., the valence electrons of the metals are held by the oxygen and do not interact with the incoming photons.

Most white coatings have a very high reflectance across all visible wavelengths and also have a high reflectance for near-infrared radiation (NIR). Typical reflectance values averaged over these wavelengths are in the neighborhood of 70 percent or 80 percent.

Interested in white roof coatings for your building?

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For Roof Coatings, Longevity is also Important

California lawmakers deserve applause for encouraging the use of white roof coatings like those from Conklin to reduce energy costs. But lower energy use is not the only benefit that accrues from the use of white roof coatings.

White coatings can extend the life expectancy of many different types of commercial roofing systems simply by avoiding the high roof temperatures associated with exposure to the sun.

The technical term for exposure is “insolation,” and it is measured in terms of the rate of solar radiation received per unit area (typically expressed in Watts per square meter). Under very clear skies, up to 1,220 W/m2 of solar radiation reaches the rooftop. Imagine ordinary household hair dryers every 10 feet in both directions of a twodimensional array: that is the intensity of the sun’s energy incident upon a rooftop. Heavily insulated roof systems block this heat from penetrating the building as heat; however, in summer months, convective heat transfer to the surrounding air and radiant heat transfer are inefficient. Consequently, the heat has nowhere to go and roofing membrane temperatures can soar.

For commercial roofing systems made from organic materials, high temperatures can shorten the life of the roofing system. Rubber as well as other synthetic polymers and especially asphalt, is susceptible to damage at these elevated temperatures. Roof temperatures can rise above ambient air temperatures by as much as 90°F. Meanwhile, the rate of degradation of the roofing materials begins to accelerate at modestly elevated temperatures, for example at 140°F. Significant damage can begin to occur at these elevated temperatures, causing both short-term and long-term performance issues.

As temperatures rise to the peak of this range, degradation of roofing systems increases exponentially. Lighter and hence more volatile organic compounds may evaporate into the atmosphere, and chemical reaction rates with water, oxygen and contaminants also increase. As a result, roof life expectancies are shortened. A rule of thumb for thermal aging is that service life is cut in half for every 18°F increase in temperature (weighted and averaged over time).

Most people appreciate that white coatings result in savings on cooling costs, but enhanced roof longevity, especially in northern states, can be another major benefit that results in at least as much savings. Without white coatings, roof temperatures can skyrocket in the summer months, especially for buildings in northern climates, because they typically have a lot of insulation to help keep in the heat during the winter months.

The inverse correlation between insulation thickness and roof life is well documented by roof asset management firms. Since ripping out the insulation every summer is of course impractical, white coatings are one of the best means available to counteract the deleterious effects of high heat levels and enhance the prospects for a long-lasting roofing system.

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Patton Services | (309) 303-3128 | rpatton55@comcast.net | http://www.whiteroofingsystems.com