Spray Foam Roofing

Spray foam roofing starts out as two liquid components - an isocyanate, known as the "A" component, and a resin (or polyol), the "B" component. When the liquids are mixed at a one-to-one ratio, a chemical reaction occurs and the mixture expands 20 or 30 times forming a solid, monolithic (seamless), closed-cell, fully-adhered roof system that provides excellent water-resistance and thermal insulating abilities.

SPF adheres to just about everything so it can be installed over concrete, wood, steel, and most existing roof systems (EXCEPT APP MODIFIED BITUMEN!) which saves on the expense of roof removal and landfill fees. SPF mechanics can spray apply a tapered roof system with the foam which eliminates the need for costly tapered insulation systems. The cants and vertical wall terminations are also spray applied making them an integral part of the roof system and minimizing additional component costs.

INSTALLATION

The "A" and "B" components of SPF are pumped out of separate 55 gallon drums, are mixed at the spray gun, and are applied in what are known as "passes". A pass is a single application of foam and can vary in thickness from 1/2 inch to 1 inch or so. Therefore, SPF roofs that are several inches thick are applied in multiple passes.

SPF must have a protective elastomeric coating installed over it because it's very susceptible to UV and mechanical damage. Elastomeric means the coating must be able to stretch with the foam and return to its original shape. Coatings are spray applied and can be acrylic, silicone, butyl rubber, and different urethanes. All have different physical characteristics and varying costs. Coatings are usually installed in three stages: a base coat, a mid-coat, and a final coat. Granules can be embedded into the mid and top coat or only the top coat for added protection against UV and mechanical damage and to increase the system's fire resistance.

DURABILITY

When most people hear of a "foam" roof, they automatically think of the type of soft foam similar to that used for seat cushions and are concerned that they won't be able to walk on it without causing problems or damaging the roof. Foam roofs are very durable and can handle foot and construction traffic as well as other roofs. They are still susceptible to damage from dropped tools just as any other roof but the damage is more easily seen and can most often be repaired with some simple polyurethane caulking.

DENSITY & R-VALUE

Density of SPF is important when it comes to strength and Thermal Resistance. Obviously, higher density means increased strength and higher R-value. Most SPF roofs have densities ranging from about 2.5 pounds per cubic foot to 3 pounds per cubic foot. Three pound density foam has a compressive strength of about 50 psi and an R-value of 7.14 installed and 6.86 aged (these numbers may vary slightly depending on the foam manufacturer). Here's an example of how well a good SPF roof insulates. A school district in southern California had recently installed some new, one-room relocatable classroom buildings. During the late spring and early fall, these classrooms were using their air conditioners an average of 50 minutes every hour. The school district installed foam roofs on some of these classrooms in order to see if it would provide an energy savings. The roofs consisted of three pound density foam, 1.5 inches thick with an acrylic coating system. The air conditioner usage was cut down to fifteen minutes every hour. That's a fifty-eight percent savings on energy costs.

Does this mean an SPF roof pay for itself? Absolutely! Texas A&M studies indicate that an SPF roof in Texas and other southern climates can pay for itself in approximately four and a half years.

LIFESPAN

If the coating for an SPF roof is properly maintained, then an SPF roof can last a very long time. Every ten or fifteen years, depending on the type and amount of coating installed, the roof will need to be cleaned, primed, and recoated. If this is done, then a quality SPF roof could last 50 years or longer.

COST

As with all other roof systems, cost depends on several factors. Some of which include building accessibility, complexity of project, foam thickness, foam coating system, and geographical location. Costs may start at about $2.50 per square foot for a cheap system and go up from there.

SOME THINGS YOU SHOULD KNOW

Foam roofing requires a lot quality control by the foam mechanics who do the work. If the gun gets dirty or a hose gets clogged or any one of a hundred things goes wrong, the mechanics must be able to recognize the problem and be willing to shut down operations until the problems can be taken care of. This isn't an easy thing to do because shutting down an operation costs a lot of time and money and may cost the mechanic a bonus for the job. Pride in workmanship is an extremely important factor in a quality foam roof.

EPDM Roofing

Ethylene Propylene Diene Monomer (or Terpolymer which is simply a product consisting of three distinct monomers). EPDM is classified as a Thermoset material which means it is either fully-cured prior to being installed or that it cures during natural weathering after installation. EPDM roofs are single-ply membranes meaning there is only one ply of roofing material, not multiple plies laminated together.

EPDM has been in use on roofs in the USA since the 1960's and is one of the most common types of low-slope roofing materials. This is because it is relatively inexpensive, simple to install, and fairly clean to work with when compared to conventional built-up roofs. There aren't the odors and fumes that accompany built-up roofs which appeals to many property owners and managers.

EPDM is a rubber material whose principal components consist of the compounds ethylene and propylene. A flexible rubber matrix forms when a small amount of diene is added to the mix. EPDM is available reinforced or unreinforced with both commonly used; it's also available in either a cured (vulcanized) or uncured (non-vulcanized) state. Vulcanized EPDM is the most common with non-vulcanized often used for flashing purposes.

EPDM membrane thickness ranges from thirty mils (0.030") to one-hundred mils (0.100") with the most common thicknesses being forty-five mils (0.045") and sixty mils (0.060"). There are three standard application procedures: (1) fully-adhered; (2) mechanically-fastened; (3) loose-laid.   Fully-adhered EPDM uses water or solvent-based adhesives to adhere the rubber to the substrate. Mechanically-fastened EPDM is attached by manufacturer-approved mechanical means to the substrate, and loose-laid membranes are secured only at the perimeters and any penetrations. A ballast of round river rock or concrete pavers is used to hold the materials in place. River rock is usually installed at a rate of 1000 - 1200 pounds per roof square (100 square feet) and the pavers generally weigh approximately 20 pounds per square foot. Structural integrity is important with loose-laid roof systems. The seams of all systems are then sealed using either an adhesive or a splice tape. Splice tapes have tested with a higher tear-strength.

How Long Do They Last?

As with most roofs, EPDM rubber roofs have varying lifespans that depend on numerous criteria. These include environmental conditions such as what type of building (factory or church), how much foot traffic the roof gets, how much water remains on the roof after a rain, and how long it take that water to evaporate. Not to mention geographical location. Roofs in mild climates will outlast roofs in harsher climates. Of course, one of the most important factors in a roof's life expectancy is quality of workmanship. If the roof is not properly installed, then its lifespan will be shortened.

Properly install EPDM rubber roofs should last between 12 and 25 years. Here's a brief breakdown base on observations over the past 15 years::

• 45 Mil Ballasted EPDM Rubber properly installed that drains well - 12 years
• 45 Mil Mechanically Attached roof properly installed that drains well - 12 years
• 45 Mil Adhered roof properly installed that drains well - 12+ years
• 60 Mil Ballasted EPDM Rubber properly installed that drains well - 12+ years
• 60 Mil Mechanically Attached roof properly installed that drains well - 15 years
• 60 Mil Adhered roof properly installed that drains well - 15+ years
• 80+ Mil Mechanically Attached roof properly installed that drains well - 20+ years
• 80+ Mil Adhered roof properly installed that drains well - 20+ years
• 80+ Mil Fleeceback Adhered roof properly installed that drains well - 25+ years

Stone Coated Steel Roofing

Available in daring splashes of color, flaunting classic contours and traditional styles, stone coated steel roofs are becoming more visible on residential and commercial building exteriors. Its strong composition allows it to withstand the elements, but its elegant aesthetic appeal satisfies even the most refined tastes.

Stone coated steel has made its mark in the roofing industry and continues to offer progressive advantages and benefits to homeowners. Well suited for both new construction and renovation, here is what contractors and homeowners should know about stone coated steel.

COMPOSITION

The composition of stone coated steel roofing systems varies by manufacturer.

The panels are made from structural grade steel. To enhance the corrosion resistance of the steel, it is coated with aluminum-zinc alloy or zincalume. The zinc works exceptionally well in protecting exposed areas such as custom cut edges and drilled holes, and extends the corrosion resistance of the underlying steel.

The aluminum-zinc alloy coated steel has an acrylic coating that is applied to both sides. This acrylic priming system provides a uniform substrate that enhances the adhesion of subsequent coatings.

Next the panel is pressed into shape and a base coat of acrylic resin is applied. This specially formulated coating is made in two colors that blend with the various stone granule colors.

The base coat serves two functions. It provides the adhesive to bond the stone granules to the steel substrate, and it also protects the underlying material from moisture and UV light. Pure acrylic resin, the strongest polymer capable of being made into a water-based paint, provides optimum UV resistance.

To add an attractive finish and provide extra protection, ceramic coated stone granules are applied to the panels. These granules improve the resistance to UV light and ensure maximum coverage of the basecoat.

"The stone granules further protect the steel from the elements and make the tiles aesthetically appealing".

Finally, to complete the composition of the stone coated steel roofing, an acrylic overglaze is applied on the granules to give the panels a semi-gloss appearance. This tough, thin, acrylic finish bonds to the granules and encapsulates them with a coating that provides extra protection.

HAIL

This phenomenon causes widespread concern among contractors and homeowners. Large hail stones can penetrate a roof creating golf-ball sized holes, and has the potential of completely destroying a home's exterior.

Each roof system has its strong points, and stone coated steel is a prominent leader for its hail resistance. Available with the highest hail rating, UL 2218 Class 4 impact resistance, stone coated steel has survived some of the worst hailstorms that have swept through the country.

EARTHQUAKES

Although California is notorious for having earthquakes, they have shaken things up in areas you may not think of, such as New Hampshire, Alaska, Alabama and even Minnesota.

A decade ago, a report was conducted by The McMullen Company Inc., which rated the performance of roofing materials after the 1994 Northridge, CA quake. They found that the roofs with the least damage were made of stone coated steel.

Out of the 122 buildings that were analyzed in Northridge, 93 featured concrete or clay tile roofs, 17 featured stone coated steel, eight featured wood shake roofs and four featured asphalt shingles.

Despite the horrific damage the earthquake caused, the stone coated steel roofs had little structural or roof damage, even in areas of significant destruction. Concrete and clay roof systems displayed the most severe damage, followed by wood shake and asphalt roofing systems.

FIRE RESISTANCE

Aside from roofing options such as wood and asphalt, stone coated steel roofing is a UL-Class A fire rated material, the highest fire rating in the industry. With the devastating effects of fire, stone coated steel's strong resistance to fire is an exceptional benefit that could save homes and commercial buildings from destruction.

WIND RESISTANCE

Stone coated steel has the ability to withstand hurricane force winds, making it ideal for coastal areas, as well as other regions that are exposed to harsh weather conditions. Although it works well in coastal areas, high winds can strike almost anywhere.

Wind warranties for stone coated roofs can be as high as 120 mph. Many stone coated steel roofing systems also use interlocking panels and unique horizontal fastening methods that are usually not an option with other roofing materials.

FREEZE/THAW CYCLING

Water often pools on the roof near cracks and fractures. The freeze thaw cycle eventually allows that water to penetrate the roof and then the attic, walls and ceilings. Freeze/thaw and ice damming are major concerns in northern climates, but they can be prevented with the right roof system.

While other tiles are prone to cracking, splitting and breaking from the strain that this natural climatic change causes, stone coated steel has a non-porous surface, allowing it to resist freeze/thaw cycles.

LIGHTWEIGHT ALTERNATIVE

Although durability is typically accompanied by heavy weight characteristics, such as with slate roofing, this is not the case with stone coated metal roofs. This makes it easier for the contractor to install and puts less stress on the roof deck and structure.

Weighing a mere pound and a half per square foot, stone coated steel is lighter than wood shakes, concrete or slate.

CURB APPEAL

If thoughts of corrugated, red, shiny metal roofs come to mind, it's time to embrace the new generation of metal roofing.
The different profiles can emulate contemporary clay tiles, traditional asphalt shingles and even natural cedar shake.

Both residential and commercial steep slope roofing applications have never looked so good in metal. The array of colors that stone coated steel roofing systems offer can add a unique element to your next roofing project.

Tile Roofing

A tile roof is a roof with an uppermost layer made from tiles. Terra cotta tiles such as pantiles which are designed to overlap to create a ridge and gutter design are a classic choice of material for tile roofing, although there are a variety of alternatives on the market. Many people associate tile roofing with Mediterranean-style architecture and design, especially Spanish-style buildings. They are commonly seen in temperate climates. Home supply stores often sell roofing tiles, with the ability to order specialty versions for their customers, and they can also be supplied through roofing companies.

Tile is a very durable, long-lasting roofing material. A tile roof can last up to 100 years, and sometimes even longer, in special cases. In addition to terra cotta tile, it is also possible to find slate or stone tiles, ceramic tiles, and tiles made from concrete. Both molded tiles and tile shingles are available. Some firms specialize in using recycled materials for their tile roofing, such as concrete made with recycled aggregate, thereby making the structure more environmentally friendly.

The main problem with a tile roof is that it requires a great deal of structural support. Tile is extremely heavy, which means that the roof must be reinforced. In climates where snow is common, a tile roof can become even heavier in the winter, with a heavy load of snow on top which will strain the support structure of the home. After all of the reinforcement for the roof is completed, a home will be substantially more expensive, although it will also be sturdier.

In addition to the classic red terra cotta, tile roofs can also be made with cream, yellow, or gray tiles. In some regions, painted tiles or tiles with decorative raised designs may be used. Ornamental tile endcaps may be utilized to make the roof more visually interesting, and to creatively conceal gutters, joins, and other less attractive parts of roof construction.

When remodeling a home with a tile roof, people may want to get several estimates for any work necessary for the roof to ensure that they pay a fair price. It is also a good idea to order extra tiles so that if roof tiles break or become damaged, they can be replaced with tiles which will match. If home owners want to add a tile roof to a home to replace an existing roof, they should be prepared to pay extra for the necessary reinforcement which will ensure that the roof is sound.

Shake Roofing

Cedar shake roofs have many positive qualities. When installed properly, they are extremely wind resistant. Believe it or not, they actually have twice the insulating value of standard asphalt shingles. Hail does not easily damage cedar shakes. When treated with certain chemicals, cedar shakes can be made permanently fire resistant.

Cedar shake roofs, no doubt, have a certain amount of prestige as a roofing material. That explains why many of the other roofing product companies manufacture materials that simulate real cedar shakes. The texture, color, and appearance of a cedar shake roof is undeniably appealing. However, this beauty comes with a price tag. Cedar shake roofs do require a certain amount of maintenance to maximize their useful life. The enemies of cedar shakes, as you might expect, are water
and sunlight.

Many people know that cedar contains high amounts of naturally occurring chemicals which help preserve the wood. These chemicals are called extractives. They dissolve easily in water. Need I say more. In certain conditions, rainfall can leach these chemicals from the cedar shakes in less than 10 years.

Ultraviolet light (UV) from the sun actually causes the surface cells of the cedar to break down. This microscopic refuse is washed away with each rainfall. UV rays also cause very tiny cracks to develop which allows water to drive deeper into the shakes. This simply accelerates the process of dissolving the extractive chemicals.

The key to maintaining a cedar shake roof is to keep it dry. Yes, I realize that sounds funny. What I mean is that after a rainfall, a cedar roof needs to dry out as rapidly as possible. The shakes must be free of moss, fungus, debris (twigs, pine needles, leaves, etc.), or any other thing that can trap and hold moisture. Overhanging tree branches must be sufficiently high so as to provide good air circulation above the roof.

Chemical preservatives are available which can be applied to cedar shakes. These preservatives when applied to clean, dry cedar shakes can dramatically add years of life to a cedar roof. Most of these chemicals can be applied with a hand held sprayer. Professionals who treat cedar roofs for a living have pressurized machines that allow them to do large roof areas in a short amount of time.

If you decide to clean and treat your roof yourself, you need to exercise extreme caution. You need to protect yourself from the dangers of falling. You need to protect your roof from the dangers of cleaning. Cedar shake roofs that are damp, covered with moss, or any object can be extremely slippery. I once stepped on some moss on a low pitched cedar roof and ended up at the gutter before I realized what had happened. Serious and fatal injuries are a very realistic threat.

The use of mechanical power washing equipment used in untrained hands can seriously damage your shakes. Cedar is a soft wood. Cedar that is covered with damp moss is even softer. A power washer that has too much pressure or is too close to the shakes can erode the wood. Simply use some common sense when cleaning.

A great cleaner for cedar shake roofs or decks is oxygen bleach. This non-toxic cleaner is a powder you mix with water. It will not harm the cedar roofing nor anything else it contacts. You must saturate the shakes for about 10 minutes with the solution making sure it does not evaporate. Lightly scrub the shingles with a push broom and rinse with a garden hose. The shakes will look brand new!

Shingle Roofing

Roof shingles are a roof covering consisting of individual overlapping elements. These elements are normally flat rectangular shapes that are laid in rows without the side edges overlapping, a single layer is used to ensure a water-resistant result. Shingles are laid from the bottom edge of the roof up, with the bottom edge of each row overlapping the previous row by about one third its length. Historically, at the roof ridge there was a cap consisting of copper or lead sheeting which in modern times has been substituted by shingles with a plastic underlay.

Shingles have been made of various materials such as wood, slate, asbestos-cement, bitumen-soaked paper covered with aggregate (asphalt shingle) or ceramic. Due to increased fire hazard, wood shingles and paper-based asphalt shingles have become less common than fiberglass-based asphalt shingles. In the United States, fiberglass-based asphalt shingles are by far the most common roofing material used for residential roofing applications.

An asphalt shingle is a type of roof shingle. They are one of the most widely used roofing covers because they are relatively inexpensive and fairly simple to install.

Types of Shingles

Two types of asphalt shingles are used: organic and fiberglass or glass fiber. Organic shingles are generally paper (waste paper) saturated with asphalt to make it waterproof, then a top coating of adhesive asphalt is applied and ceramic granules are then embedded. In the case of algae-resistant shingles, a portion of the granules contain leachable copper ceramically coated, designed to protect against discoloration from algae on the roof. This does not protect from moss growth but does slow the growth. Moss likes to feed on algae and any other debris on the roof. Most manufactures offer a 5- to 10-year warranty against algae growth; 3M (scotchgard TM) offers a 20-year warranty.

Shingles are judged by warranty and ASTM test standards. Organic shingles contain around 40% more asphalt per square (100 sq ft.) than fiberglass shingles. But this extra needed asphalt makes them less environmentally friendly (despite its "organic" nickname). The paper-based nature of "organic" shingles leaves them more prone to fire damage, and their highest FM rating for fire is class "B". Shingle durability is ranked by warranted life, ranging from 20 years to 50 years; in some cases lifetime warranties are available.

Fiberglass shingles have a base layer of glass fiber reinforcing mat. The mat is made from wet, random-laid fiberglass bonded with urea-formaldehyde resin. The mat is then coated with asphalt which contains mineral fillers and makes the fiberglass shingle waterproof. Fiberglass shingles typically obtain a class "A" fire rating as the fiberglass mat resists fire better than organic/paper mats. Fiberglass reinforcement was devised as the replacement for asbestos paper reinforcement of roofing shingles and typically ranges from 1.8 to 2.3 pounds/square foot.

The older organic (wood and paper pulp product) versions were very durable and hard to tear, an important property when considering wind uplift of shingles in heavy storms. Fiberglass is slowly replacing felt reinforcement in Canada and has replaced mostly all in the United States. Widespread hurricane damage in Florida during the 1990s prompted the industry to adhere to a 1700-gram tear value on finished asphalt shingles.

A newer design of fiberglass asphalt shingle, called laminated or architectural, uses two distinct layers which are bonded together with asphalt sealant. Laminate shingles are heavier, more expensive, and arguably more durable than traditional 3-tab shingle designs. Laminated shingles also give a more varied, contoured visual effect to a roof surface.

Per 2003 International Building Code Sections 1507.2.1 and 1507.2.2, asphalt shingles shall only be used on roof slopes of two units vertical in 12 units horizontal (17% slope) or greater. Asphalt shingles shall be fastened to solidly sheathed decks.
Durability

Asphalt shingles usually last longer in cooler climates than warmer ones. Thermal shock is one thing that is damaging to shingles (thermal shock is what roofing materials experience when the ambient temperature changes dramatically within a very short period of time). Another factor affecting asphalt shingle roofs is attic ventilation. Proper roof ventilation has been known to extend the service life of a roof. Shingles should not be applied during cold weather. Each shingle must seal to the layer below it to form a monolithic structure. Thus, when constructing a roof, the underlying exposed asphalt must be softened by sunlight and heat.

Aging of asphalt shingles

The protective nature of asphalt shingles primarily comes from the long-chain hydrocarbons impregnating the paper. Over time in the hot sun, the hydrocarbons soften and when rain falls the hydrocarbons are gradually washed out of the shingles and down onto the ground. Along eaves and complex rooflines more water is channeled so in these areas the loss occurs more quickly.

Eventually the loss of the heavy oils causes the fibers to shrink, exposing the nail heads under the shingle flaps. The shrinkage also breaks up the surface coating of sand adhered to the surface of the paper, and eventually causes the paper to begin to tear itself apart.

Once the nail heads are exposed, water running down the roof can seep into the building around the nail shank, resulting in rotting of roof building materials and causing moisture damage to ceilings and paint inside.

Metal Roofing

Metal Roofing has become one of the most popular roof coatings available. A metal roof in today's industry is a roofing system made from metal panels or tiles. It is the most important part of protecting a buildings content. Metal Roofs have many advantages because of their lightweight attractive design and overall cost.

Advantages of Installing a Metal Roof

• A metal roof sheet is extremely light-weight, and easy to handle or install.
• Metal roofs are are ideal for most commercial applications because of their high strength to weight ratio.
• A Metal Roof Increases the thermal efficiency of buildings in high temperature areas with its cool roof paints and high emissivity.
• Metal Roofs are fire and spark resistant.
• Metal Roofing is Hail resistant.
• Metal Roofing is Wind resistant.
• Painted metal roofs are usually snow-shedding. Snow can usually collect when it is fresh and lighter weight. As soon as the ambient temperature rises a couple degrees, the snow usually just slides off. A huge benefit for homes in cold climates that receive high volumes of snow fall.
• Metal is readily recyclable. Aluminum and Copper roofing products are available with over 95% recycled content. Most metals can be recycled over and over without losing any valuable properties.
• Recycling is very efficient. As an example: recycled Aluminum only requires 5% of the energy to produce as does new Aluminum.
• Durability. The lowest end metal roofing (thin gage with acrylic or polyester paints) commonly called AG (agricultural) or Utility panels will last 15-25 years which is roughly 3 times the lifespan of an average asphalt roof (in snow zones). Most metal roofing products today come with a lifetime replacement warranty. These warranties usually cover materials and labor without being prorated.
• Sheet Metal Roofing materials like stainless steel, copper, zinc and aluminum are inherently durable; the oxidization of the base material forms a protective patina.
• Some modern steel roof sheet materials are coated with an alloy of zinc and aluminum to give it some of the durability of each of those materials at a lower cost and higher strength than either.
• The coatings and fixings on a meta roof sheet can be designed for different environments including industrial and marine locations.
• Design flexibility
• Large sprung curves.
• Rolled bull-nose shapes.
• Copper and Zinc details have historically been proved to last upwards of 100 years with little or no maintenance.
• A Metal Roof is Energy Efficient.
• Metal Roof Coatings with high reflectivity like Kynar with "cool roof" pigments commonly save 20-30% on air-conditioning costs due to reflecting away much of the sun's heat.
• The average life-span of asphalt shingles today (since 2001) is 6-9 years, while residential and commercial grade metal roofing usually lasts from 50-100+ years, depending on the type.
• Metal Roofing is easy to Install.
• Some Steel and Metal Roof products can be installed over open framing, or on a solid substrate.
• Most metal roofing products require very little or no maintenance.