Spray Polyurethane Foam Restoration for Manufacturing Facility

Issue:

This 53,000 square foot South Carolina manufacturing facility had an aging modified bitumen roof that was leaking and in need of extensive repairs or replacement . The owner could not afford the down time of a roof tear-off or the cost of complete roof replacement.

Solution:

The ALDOCOAT approved contractor determined that a spray polyurethane foam and coating system would be an ideal solution for restoration of the roof. The solution prescribed would be cost effective, long lasting and sustainable enabling the owner to continue operations rather than shutting down the facility for roof replacement.

The restoration process started with thorough cleaning and priming of the existing roof substrate. The contractor then applied 1.5 inches of 2.8 lb. density BASF roofing foam. ALDOCOAT 374 was applied to the foam with a coverage rate of 3.0 gallons per 100 square feet in two coats (base coat = 1.5; top coat = 1.5). The final application by the contractor included broadcasting of 3M roofing granules into the top coat in order to enhance the roofing system’s durability.

Results:

The owner realized an enduring solution without business interruption, a solution that will extend the life of the roof by at least 10 years.

The spray polyurethane foam system utilized has both economic and environmental benefits saving landfill, roof tear-off, transportation, and replacement costs; and the roof can be re-coated in 10 years.After project completion, the owner was most satisfied with the polyurethane foam and coating system employed and the financial, operational and sustainable benefits realized for the facility and the community.