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The Spray Foam Roofing Guide: Everything You Should Know

When it comes to roofing that lasts longer than your favorite sitcom, spray polyurethane foam (SPF) takes the cake! This superhero of roofing systems boosts energy efficiency and cranks up the cozy factor inside. With insulation and waterproofing powers that leave other materials green with envy, SPF is in a league of its own.

 

In this all-you-can-read guide, we dive into the nitty-gritty of this versatile wonder material, helping homeowners, facility managers and property owners unlock the secrets of SPF and discover how it works its magic!

Sections:

Exclusive for homeowners in the Tucson area: this guide will teach you everything there is to know about investing in a new roof system.

Top 3 Flat Roofs

Know which flat roofs perform best in Tucson's climate

Top 3 Pitched Roofs

Know which sloped roofs perform best in Tucson

Roof Ventilation

Understand what ventilation is and why it's so vital to have

Roof Warranties

Factory and Workmanship warranties explained in depth

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What is Spray Polyurethane Foam?

Spray polyurethane foam (SPF) is a two-component material formed by mixing isocyanate (Component A) and polyol (Component B) using heat and pressure. When these chemicals are sprayed in liquid form, they react upon contact to create a solid, lightweight, and fully adhered roofing membrane. Although spray foam has been available for many years, it remains relatively unfamiliar to many facility managers and property owners.


SPF has been utilized across various industries since the 1940s, but it gained traction in the roofing and construction sectors in the late 1970s due to its exceptional insulating properties. Modern spray polyurethane foam roofing comes in two varieties: open-cell and closed-cell. Closed-cell foam is mainly employed in commercial roofing applications, while open-cell foam is generally used for interior insulation and soundproofing.

The Spray Foam Roofing Essentials

In the spray foam roofing process, Components A and B are mixed and applied directly on-site using a specialized spray foam rig. The two chemicals, stored in separate containers, are pumped through high-pressure hoses to a mixing gun at temperatures ranging from 115 to 130°F. Maintaining the right levels of heat and pressure is crucial for a successful application.

 

As the foam cures, it hardens into a durable, seamless, lightweight, and waterproof membrane. SPF boasts the highest R-value (thermal resistance measure) of any commercial roofing material, making it suitable for various climates.

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Spray Foam Roof-Over Installation:

  1. Existing Substrate

  2. Substrate Primer

  3. Spray Polyurethane Foam

  4. /5. Reflective Roof Coatings

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UV Performance

Although SPF serves as an outstanding waterproofer and insulator, it provides minimal protection against the sun's harmful rays. To address this issue, the foam should be coated with an elastomeric or acrylic roof coating. If you live in Tucson, it is not recommended that you use silicone your spray foam roof because our climate is too dry for silicone roof coatings to perform properly. 

There are high quality acrylic / elastomeric roof coatings on the market that are designed for Tucson's arid environment. Regular maintenance and inspections are key to ensuring that your SPF roof's coating remains effective, especially during monsoon season.

For more information on the best roof coatings to choose in Tucson or Southern Arizona.

Pros of Spray Foam Roofing

Thermal Resistance

Spray foam roofing insulation's the highest R-value of any conventional roofing material (that isn't polyiso). R-Value measures a material's ability to resist the flow of heat. The R-value of roofing grade SPF is approximately 6.5 per 1 inch. However, when you combine this with a reflective roof coating, it is widely held that SPF provides far greater insulation qualities than its R-value suggests.

Strength & Durability

Spray foam systems provide commercial and residential roofs with an incredibly strong, yet remarkably lightweight, protective membrane. In fact, SPF systems, applied at a thickness of 1 inch or greater, are proven to improve a building's structural integrity.

Longevity

A properly installed and maintained SPF roof system can last 20-35+ years, if not longer. SPF roofs must be recoated every 5-10 years depending on the quality of roof coating. This will ensure that UV rays don't degrade the roof's foam layer.

Seamless & Self Flashing

Unlike conventional roofing systems, spray foam roofs are completely seamless and self flashing. SPF is specially designed to conform and adhere to irregular shapes and surfaces. These qualities eliminate the ability for water to enter sensitive areas of the roof like: seams, fasteners, penetrations, and more.

Quick Installation

Compared to most other conventional roofing materials, SPF systems can be installed more quickly and are far less disruptive to building and home occupants. Most of the time spray foam roofs can go directly over your existing roof. (Max. 2 roofing layers allowed in Tucson)

Renewable and Sustainable

Because SPF roofs can be recoated numerous times, they produce little to no waste over the course of their lifespan. This offsets landfill waste concerns and high costs that normally accompany a roof replacement.

When does a roof system reach the end of it's lifecycle?

The lifecycle or lifespan of your desert roofing system depends on a few factors:

  • Quality of material

  • Roof ventilation

  • Quality of the Install

  • Maintenance habits

If your roof appears to have signs of decay... Odds are it's reached the end of its lifespan. Here's how long each roof system can last; but in Tucson, Arizona.

20-30 Years

  • Architectural Shingles

  • Tile roof w/ Premium Underlayment​

  • Built-Up Roof w/ premium roof coating

  • ​TPO Roof 

10-15 Years

  • Single-Ply Built-Up roof w/ elastomeric coating

  • ​Tile roofing FELT underlayment 

35+ Years

  • Standing Seam Metal Roof 
    Tile roof w/ Ultra Premium Underlayment​

  • Premium Shingles

  • ​TPO Roof w/ thicker mil

15-20 Years

  • 3-Tab Shingles (disc.)

  • Mod-Bit Granulated Roof system

  • Spray foam roof w/ premium coating

  • Exposed fastener Metal Roof 

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When do I know I need a new roof?

Waiting for your roof to start leaking doesn't make it last any longer, this only increases your chances of mold growing. On the other hand, some homeowners are skeptical because they've ran across dishonest or inexperienced contractors. 

Some roofing systems in Tucson, such as: built-up roofs, spray foam roofs, some metal roofs, and TPO roofs can be restored when they get closer to that lifespan expiration date. 

Signs that your roof is on it's last breath

Loss of granules, missing shingles, curling/buckling, cracks, fiber-wire sticking through, and heavy storm damage

Shingle Roof

Pooling/standing water, "soft"/spongy areas, excessive amounts of black tar/adhesives visible heavy storm damage

Built-Up Roof w/ Elastomeric Coating

If your roof is leaking and you have silicone coating, the only option is to replace. Unfortunately nothing, not even silicone, adheres to silicone :(

Built-Up Roof w/ Silicone Coating