Spray polyurethane foam, commonly referred to as SPF and used in many San Jose commercial roofing projects, is a spray-applied insulating foam plastic. The two chemical components are combined as they pass through the spray gun and contact the substrate as a liquid. As the two components chemically react they expand in volume by 20 times and form a strong, rigid material with a density of 2.5 to 3.0 pounds per cubic foot and a compressive strength of 40 to 50 pound per square inch.
Specialized equipment is used to apply the SPF and proper technical training is essential to obtain the best results for any roof in Silicon Valley, San Jose, the East Bay and over the entire Central and Northern California area.
When used as a roofing material in a San Jose Commercial roofing project, SPF provides:
- A waterproof roofing membrane
- Added insulation
- An air barrier
- Sound attenuation
- Structural properties
- Fire retardancy
- Light weight
- Condensation control
SPF is the king of roof building material multi-tasking. In insulation, it can provide high levels of R-value, while providing air barriers and assistance in moisture control in buildings. In roofing, it insulates and eliminates thermal bridging through fasteners and gaps in insulation boards.
SPF roofing is “green” roofing, renewable and sustainable. With proper maintenance and recoating at 20 year intervals an SPF roof will last the life of the building. Bright white topcoat meets “Cool Roof,” Energy Star, and LEED Certification requirements.
Spray Foam Insulation
There is no better insulating material to seal a building from air and moisture intrusion, save on costly utility bills, and strengthen your roof than Spray Foam Insulation.
Benefits of Spray Foam Insulation
- Stops air and moisture infiltration
- Makes a building more comfortable
- Saves on energy costs
- Adds strength to the building structure
- It is permanent and will not sag
- Keeps dust and pollen out
- Reduces capacity requirements, maintenance, and wear of HVAC equipment
Sprayed polyurethane foam has an aged R-value of approximately 6.4 per 1-inch thickness (depending on the particular formulation and application, higher values can be achieved), enabling it to provide more thermal resistance with less material than any other type of commercial insulation material. SPF systems are frequently used to insulate and protect a wide variety of residential, commercial, and industrial buildings.
Energy and utility savings
Central Coating Co utilizes a newly developed energy calculator, the Energy Performance Matrix Toolbox (EPMT) to predict the energy savings from insulating with sprayed polyurethane foam.
Prevents Air, Moisture and Gas Infiltration
Because SPF seals all joints and gaps found in the building envelope, it stops air infiltration which can result in a significant part of a building’s total energy loss.
A Cool Roof is a roof that has a light colored coating which reflects the sun’s heat and UV rays. When combined with SPF insulation these materials improve the building’s energy performance. Cool Roofs can reduce air conditioning costs, reduce smog, and help the environment. Roof surface temperatures can be reduced up to 70º F when compared to a dark colored roof. Air infiltration will be eliminated and electric bills can be significantly reduced.
With proper maintenance and periodic recoating an SPF roof will last the life of a building. An important advantage of an SPF roof is that it can be renewed by recoating at the end of its “design life” instead of being completely replaced like other roof systems. Design life refers to the period of time between the roof installation and the first recoat. The Design Life of Central Coating roofs is at least 20 to 25 years meaning that your foam roof will provide 20 to 25 years of service before the first recoat is required. The Design Life can be extended by increasing the thickness of the acrylic coating system during initial roof installation. The addition of roofing granules in the top pass of the coating system further enhances the life of the coating system.
The acrylic coating which protects the foam from UV radiation is the wearing component of the roof system. When the acrylic coating begins to wear thin it will need to be recoated but the foam component of the roof system does not need to be removed or replaced.
How we recoat your roof
- Powerwash the roof to remove dirt, debris, and oxidized coating.
- Repair any damage that has occurred over the life of the roof.
- Update any details to current installation standards.
- Seal any new penetrations to current standards.
- Inspect all drains, flashings, edge metal, etc. Replace or repair as required.
- Install an additional coat of acrylic coating.
- Install granules into the coating system.
- Reissue leak free warranty and maintenance agreement
Central Coating maintains relationships with long-term customers and will recommend that recoats be performed when necessary. CCC can also service foam roofs installed by other contractors.
SPF roofing is “green” roofing, renewable and sustainable. With proper maintenance and recoating at 20 to 25 year intervals an SPF roof will last the life of the building. Bright white topcoat meets “Cool Roof,” Energy Star, and LEED Certification requirements.
Architects, general contractors, and building owners are choosing SPF roofs as the preferred solution for new construction, and the advantages over built-up asphalt and single-ply rubber roofs are compelling.
- Superior waterproofing—provides a one-inch thick or greater waterproof membrane
- Seamless Application—eliminates the most common failure point in other roof systems
- Superior Insulation—choose the insulation value to meet your needs. A one-inch thick foam roof delivers an insulation value of R-6.4. Thicker roofs provide R-19, R-30, and up to R-60 in freezer applications.
- SPF is the roof membrane and the insulation. Having the insulation on the outside of the building provides superior insulation performance.
- SPF is often installed over insulation boards, improving their insulation efficiency by eliminating the thermal shorts attributable to fasteners and gaps.
- Ease of application. The self flashing nature of SPF allows most HVAC curbs and pipe penetrations to be sealed without the complicated sheet metal flashings required by other types of roofing. By fully adhering to penetrations SPF eliminates air infiltration and water leaks.
- SPF can be installed to form slope to drain. By installing the SPF in tapered passes a flat roof deck can be sloped at ¼ inch per foot (or whatever slope is required). The added foam thickness provides added insulation. In these cases the SPF roof provides the roof slope, the insulation, and the roof membrane. That’s three scopes of work being completed by one trade at a substantial cost savings.
SPF Roofing is Compatible With All Types of Roof Deck Construction
- Steel Deck
- Wood Deck
- Concrete Deck
The advantages for re-roofing with SPF are compelling:
- Your new SPF roof can be installed without removing the existing built up roof. Tearing off a roof is costly and can be a large inconvenience to a building’s tenants due to noise and dust falling from the roof deck. Also, foaming over an existing roof reduces liability for all parties as the roof is never “open” and subject to catastrophic water damage.
- The SPF roof will be the last roof ever installed on the building. With proper maintenance and recoating at 20 to 25 year intervals the SPF roof should last the life of the building. This reduces a building’s life-cycle costs and is also environmentally friendly. By breaking the cycle of tear-off and re-roof the burden on landfills due to roofing debris is eliminated.
- Due to the sprayed in place nature of SPF it can be installed in varying thickness to promote drainage, fill in low areas and eliminate ponding. Ponding is the bane of all roofing systems as it causes rapid deterioration and leads to premature failure. Ponding water is heavy which causes deck deflection which causes even more ponding. Re-roofing with SPF stops this snow ball effect.
- CCC has developed comprehensive installation guidelines as well as over 140 installation details. These are used by CCC’s estimators to design your new roof and are incorporated into the contract documents. They are then used by CCC’s crews to ensure that your new roof is installed as specified and satisfies CCC’s quality control requirements as well as the client’s expectations.
- As part of the re-roofing process CCC will replace all edge metal andwill upgrade mechanical equipment supports to work with SPF roofing. Wood pipe support blocks are replaced with fiberglass reinforced polyester (FRP) blocks. The end product of this work is a roof system that is isolated from the other components of the roof. For example an HVAC unit can be replaced without disturbing or damaging the roof. A deteriorating wood sightscreen will not lead to roof leaks.
- In most cases CCC can re-roof a building without removing the HVAC equipment or disrupting the tenant’s operations. While there is a small amount of noise associated with the preparation work, the impact on a building’s tenant is much less than the impact caused by other types of re-roofing.
- Let us evaluate your roof to see if it’s a candidate for an ElectroRoof® installation. With a photovoltaic array you can convert an expense to a revenue producer.
SmartStand is an innovative new solar racking system, manufactured and installed by Central Coating Company – California’s Leader in Sprayed Polyurethane Foam roofing design and installation. With the use of SmartStand racking and a Sprayed Polyurethane Foam roof system, or a fluid applied “Cool Roof” membrane, Central Coating Company can provide a complete solution and solve the challenges faced by other commercial PV installations.
The SmartStand stanchion uses a foam‑filled metal tube as a structural support for the Photovoltaic modules. By injecting high density polyurethane foam into a sheet metal tube, we create a composite structure that is far stronger than the sum of its parts. Foam-filled composites are used throughout the automotive, marine, construction, and aerospace industries. SmartStand was inspired by this proven technology.
SmartStand stanchions provide a robust attachment between the building and the PV modules. Each stanchion is mechanically fastened to the roof deck. Due to its large footprint and fastening pattern the stanchion does not need to be located above or fastened to the underlying roof structure. This makes for a fast installation and allows the modules to align with the sun, even when the building doesn’t.
Each SmartStand stanchion can resist over 600 pounds of wind uplift force. This exceeds IBC and CBC wind uplift requirements with a 3-to-1 safety factor. SmartStand is a more simple and economical solution than most penetrating racking systems. Because the stanchion is the rack, there are fewer parts, lower costs, and faster installations. SmartStand is much stronger than non‑penetrating systems that use thousands of pounds of ballast to secure the module to the roof – a method that puts unnecessary stress on roof structures. The SmartStand weighs just 11.5 pounds per module (in a typical installation using 230-watt modules). 5,10,15 & 20 degree tilt angle with both portrait and landscape orientations are easily accommodated.
After being fastened in place the SmartStand stanchion is sealed with polyurethane foam. This provides a durable, waterproof seal – guaranteed.
SmartStand is installed by the roofing contractor following the layout provided by the solar designer / installer. The installation of the modules, wiring and connection will be completed by the solar installer. All hardware is included to allow the solar installer to easily attach the modules to the racking. Because the racking is installed by the roofer all penetrations are incorporated into the roof warranty.
The Roofing Leader
Most PV modules are designed to last at least 20 years. When designing a PV system the question needs to be asked. “Will the roof last as long as the solar panels?” In the case of most existing roofs, the answer is “no.” If the roof system requires replacement during the life of the modules the entire PV system will need to be temporarily removed to allow for a re-roof. This expense is not accounted for in many payback calculations.
SmartStand is optimized to work with SPF roof systems and Cool Roof coating systems. For buildings with existing SPF or Cool Roofs, SmartStand can be integrated into the existing roof. Depending on the roof’s condition, a recoat may be recommended at the time of the Smart Stand installation.
For buildings with other types of roof systems SmartStand will be installed as part of the installation of a new SPF or Cool Roof System. Depending on the type and condition of the existing roof, the amount of existing insulation, and the use of the building, CCC will recommend either a new SPF roof or a new Cool Roof system. In either case, the use of SmartStand provides the best, fastest and most cost effective way to install a new roof and racking for a photovoltaic system.
The Roofing Solutions
Sprayed Polyurethane Foam:
- The best roof for new construction
- A replacement roof system which can be installed over the existing roof system or over roof deck if the existing roof needs to be removed.
- Provides excellent waterproofing while adding insulation to the building. Each inch of SPF provides R-6.4 of additional insulation which can greatly increase energy efficiency on poorly insulated buildings.
- Bright white, highly reflective “Cool Roof” coating reduces surface temperatures, saves energy and reduces “urban heat islands.”
- Foam can be sprayed to fill in low areas and eliminate ponding water.
- A renewable roof system. Recoat the roof every 20 to 25 years with no tear off required. The recoat should coincide with the replacement of the PV modules.
- Long term leak free warranty.
- SPF roofing is recommended for roofs that are at the end of their useful life or for buildings that are underinsulated, or have ponding issues.
Fluid Applied “Cool Roof” Membrane:
Sprayed Polyurethane Foam:
- A coating system installed over the existing asphalt or single-ply roof membrane. A fluid applied membrane renews the existing roof system and can dramatically extend its life.
- Depending on the type of the existing roof and its condition the coating system will be reinforced, either partially or completely with reinforcing cloth.
- Bright white, highly reflective “Cool Roof” coating reduces surface temperatures, saves energy and reduces “urban heat islands”.
- Fluid applied membranes are a good option for roofs which are not yet at the end of their useful life, but will need to be replaced in several years requiring the PV system to be removed.