Cleveland, Ohio | Commercial Roofing Contractor

Bearing Manufacturing - Commercial Metal Roof Restoration in Strongsville, Ohio

Tue, 28 Jul 2026 18:30:59 GMT

Commercial Roof Coating Installation - Strongsville, Ohio

Location: Strongsville, Ohio

Building Type: Manufacturing Facility

Existing Roof: Trapezoidal Metal Roof

Roofing System Installed: High-Solids Silicone Roof Coating System

Warranty: 10-Year Renewable, Non-Prorated, No Dollar Limit (NPR/NDL)

Metal roofs are known for their longevity, but years of exposure to Northeast Ohio's weather can eventually lead to leaks, loose fasteners, failing seams, and aging repairs.

That was the situation at Bearing Manufacturing in Strongsville, Ohio.

Instead of replacing the existing metal roof, the building owner chose to restore it with a high-performance silicone roof coating system.

The result was a watertight roofing system backed by a 10-year renewable warranty, all while avoiding the expense and disruption of a complete roof replacement.

Video: Watch the Project from Start to Finish

Watch the complete project to see the roof before restoration, the preparation process, silicone coating installation, and the finished roof from the air.

This video includes before, in-progress, and completed drone footage, giving you a behind-the-scenes look at how a commercial metal roof is professionally restored.

Inspecting the Existing Roof

Every successful roof restoration begins with a detailed inspection.

Before construction started, our project team met with the building owner to review the roof condition, discuss the scope of work, and finalize the construction schedule.

Although the metal roof had aged over time, it remained structurally sound.

That made it an excellent candidate for restoration instead of replacement—a solution that would save the owner significant time and money while extending the life of the existing roofing system.

During the inspection, our team identified several areas that required additional attention before the new coating system could be installed.

Preparing the Roof for Restoration

Preparation is one of the most important steps in any commercial roof coating project.

The entire roof was cleaned using high-pressure water at a minimum of 2,500 PSI to remove dirt, oxidation, and contaminants that could interfere with proper coating adhesion.

Our technicians then performed detailed repairs throughout the roof.

Missing fasteners were replaced with oversized gasketed fasteners to ensure a secure attachment to the roof deck.

Fasteners along the gutter edge were encapsulated with self-leveling silicone sealant to help prevent future water intrusion at one of the most common leak locations on metal roofs.

The roof ridge, panel seams, and other critical transitions were treated with additional silicone flashing mastic to reinforce vulnerable areas before the field coating was installed.

One unique aspect of this project involved repairing areas previously damaged by fireworks.

Those repairs were reinforced with silicone sealant and reinforcing mesh, creating additional tensile strength and ensuring those sections became an integral part of the restored roofing system.

Installing the Silicone Roof Coating System

Once preparation was complete, restoration of the roof began.

Because metal roofing naturally expands and contracts with temperature changes, an additional silicone coating was applied to the high ribs of the metal panels before the field coating.

This helps seal panel overlaps and strengthen areas that experience the greatest movement over time.

The roof then received a high-solids silicone base coat, installed according to the manufacturer's specifications.

After the base coat cured, it was carefully inspected for proper coverage, film thickness, and any imperfections before the final silicone topcoat was applied.

Together, the two coats created a seamless protective membrane with approximately 20 mils of dry film thickness, providing long-term resistance against water infiltration, ultraviolet exposure, and harsh Ohio weather.

The Finished Result

Once installation was complete, all construction debris and excess materials were removed, leaving the property clean and ready for normal operations.

The restored roof now provides Bearing Manufacturing with a seamless waterproof roofing system designed to protect the facility for years to come.

In addition to improved weather protection, the completed roofing system carries a UL 790 Class A Fire Rating and is backed by a 10-Year Full System Non-Prorated, No Dollar Limit, Renewable Warranty, giving the building owner confidence in the long-term performance of the investment.

Why Restore a Commercial Metal Roof?

Many commercial metal roofs begin leaking long before they actually need to be replaced.

When the roof structure remains in good condition, restoration with a silicone roof coating system can provide substantial benefits, including:

Extending the life of the existing roof
Avoiding the cost of a complete roof replacement
Sealing exposed fasteners and panel seams
Leaving behind a seamless membrane
Reinforcing previous repair areas
Making future maintenance easy
Minimizing disruption to business operations
Providing a renewable long-term warranty

For manufacturing facilities like Bearing Manufacturing, restoring an existing roof often delivers an excellent return on investment while protecting the building for years to come.

Frequently Asked Questions

How much does a roof coating system over metal cost?

In most cases, roof coating systems cost $3.50-$5 per square foot. However, this project cost less than $3.50 per square foot.

How long does a silicone roof coating last?

In short, forever.

The lifespan depends on the coating thickness and warranty selected. This project received a 10-year renewable roofing system, allowing the roof to be maintained and renewed well into the future.

What are the benefits of a silicone roof coating?

Silicone roof coatings create a seamless waterproof membrane that resists ponding water, protects against UV degradation, seals fasteners and seams, and helps extend the life of an existing commercial roof.

Commercial Metal Roofing Contractor Serving Strongsville, Ohio

For more than 45 years, West Roofing Systems has helped manufacturers, warehouses, schools, office buildings, and commercial property owners throughout Ohio extend the life of their roofing systems through restoration.

If your commercial metal roof is beginning to leak or show signs of aging, our team can determine whether restoration with a silicone roof coating system is a cost-effective alternative to replacement.

Contact West Roofing Systems today to schedule a free commercial roof inspection and discover whether your building is a candidate for roof restoration.

Commercial Roofing Medina, OH | Buckeye High School Project

Thu, 23 Jul 2026 19:08:37 GMT

Buckeye High School Commercial Roof Restoration in Medina, Ohio

Project Overview

Location: Medina, Ohio

Facility : Buckeye High School

Roofing Systems : Spray Polyurethane Foam (SPF) Roofing & Silicone Roof Coating System

Warranty : 20-Year Renewable, Non-Prorated, No Dollar Limit (NPR/NDL) Warranty

When a commercial roof begins showing its age, building owners are often faced with an important question:

Can the roof be restored, or does it need to be replaced?

At Buckeye High School in Medina, Ohio , the answer depended on the condition of each individual roof section.

Rather than recommending a complete roof replacement across the entire campus, West Roofing Systems developed a restoration plan that combined silicone roof coating systems with spray polyurethane foam (SPF) roofing .

This approach allowed the school district to restore multiple roof areas while investing additional work only where it was truly needed.

Understanding the Existing Roof System

Large school campuses rarely have one continuous roof.

Over the years, additions, renovations, and repairs often result in multiple roofing systems across a single facility.

Following a detailed inspection with school representatives, our team evaluated each roof section individually.

Several areas remained in good enough condition to be restored using a high-performance silicone roof coating system.

Other sections required additional rehabilitation. In those locations, the existing top roofing layer was removed to expose the original built-up roof before installing a new spray polyurethane foam roofing system.

Matching the roofing solution to each roof's condition helped maximize the district's investment while extending the service life of the campus roofing systems.

Preparing the Roof for Restoration

Every successful roof restoration starts with proper preparation.

For roof sections receiving silicone coatings, our crews thoroughly cleaned the existing roofing membranes using high-pressure water to remove dirt, oxidation, and contaminants that could affect adhesion.

Roof sections receiving spray polyurethane foam required additional preparation.

After removing deteriorated roofing materials, the remaining built-up roof surface was cleaned and inspected before foam application.

Throughout the project, rooftop equipment, piping, HVAC units, vents, and other rooftop components were carefully protected to ensure a clean, professional installation.

Any areas of wet insulation or deteriorated decking discovered during construction would have been replaced to ensure the restored roof system was installed over a sound substrate.

Two Roofing Systems, One Long-Term Solution

One unique aspect of this project was combining two proven commercial roofing systems.

Silicone Roof Coating Restoration

Roof sections that remained structurally sound were restored using a premium high-solids silicone roof coating system.

Before coating, each roof received the appropriate surface preparation, including primers or bleed-blocking materials where required.

Flashings, penetrations, and roof details were reinforced with compatible silicone sealants.

The silicone coating system was then installed to a total thickness of approximately 30 mils, creating a seamless waterproof membrane designed to withstand ponding water, harsh weather, and years of UV exposure.

Several roof sections also received quartz aggregate embedded into the coating surface to improve durability and provide additional traction for rooftop foot traffic.

Spray Polyurethane Foam Roofing

Roof sections requiring additional restoration were sprayed with polyurethane foam.

After removing the deteriorated roofing layer, approximately 1.5 inches of closed-cell spray polyurethane foam was applied directly to the existing roof.

Unlike traditional roofing materials, SPF creates a seamless insulation layer that fully adheres to the roof surface.

During installation, the foam can also be shaped to improve drainage and eliminate low areas where water might otherwise collect.

Once the foam was installed, it received the same high-performance silicone coating system used throughout the project.

These roof sections were finished with ceramic roofing granules embedded into the silicone topcoat, creating a durable walking surface while providing additional protection against weathering and ultraviolet exposure.

Attention to Every Detail

Roof restoration is about much more than installing coatings.

As part of this project, new perimeter edge metal was installed where necessary to ensure proper integration with the new roofing systems.

New 24-gauge Kynar-painted gutters and downspouts were also installed on selected roof sections to improve water management and complement the restored roof.

Throughout construction, the project was supervised by an OSHA 30-hour-trained superintendent, helping ensure safety and quality from start to finish.

When the installation was complete, all construction debris and excess materials were removed, leaving the property clean and ready for normal school operations.

A 20-Year Renewable Roofing System

One of the biggest advantages of restoring the Buckeye High School roof was the long-term protection it provides.

Upon completion, the school district received a 20-year Full System Non-Prorated (NPR), No Dollar Limit (NDL), Renewable warranty.

Rather than simply repairing isolated roof problems, the district now has a restored roofing system designed to provide decades of dependable performance while eliminating the need for a costly tear-off and replacement.

Why School Districts Choose Roof Restoration

For many educational facilities, restoring an existing commercial roof can provide significant financial and operational benefits.

Instead of replacing a roof that still has a sound structural foundation, restoration can:

• Extend the service life of the existing roof

• Reduce capital expenditures compared to full replacement

• Improve waterproofing performance

• Increase insulation value on SPF roof sections

• Minimize disruption to students and staff

• Reduce construction waste sent to landfills

• Qualify for long-term renewable warranty protection

By taking action before roofs deteriorate beyond repair, school districts can preserve valuable roofing assets while making the most of limited maintenance budgets.

Commercial Roofing Contractor Serving Medina, Ohio

West Roofing Systems has helped schools, manufacturing facilities, warehouses, office buildings, and commercial property owners throughout Ohio restore aging commercial roofs for more than 45 years.

If your commercial roof is nearing the end of its service life, our team can determine whether restoration with a silicone roof coating system or spray polyurethane foam roofing can help you avoid the cost of a complete roof replacement.

Contact West Roofing Systems today to schedule a free commercial roof inspection and learn whether your building is a candidate for roof restoration.

Commercial Roofing Project in Chagrin Falls, OH | Timmons Elementary Roof Restoration

Wed, 22 Jul 2026 19:34:52 GMT

Commercial Roof Restoration at School in Chagrin Falls, Ohio

Quick Summary – An elementary school restored a 30-year-old EPDM roof by installing a silicone roof coating system, receiving a new 20-year, renewable, transferable warranty with no tear-off.

Location : Chagrin Falls, Ohio

Building Type : Elementary School

Roof System : EPDM Rubber Roof (Installed in 1995)

Solution : Silicone Roof Coating System with a 20-Year Renewable Warranty

When commercial building owners wait too long to address an aging roof, they often leave themselves with only one option—a complete roof replacement.

Fortunately, that wasn't the case at Timmons Elementary School in Chagrin Falls, Ohio.

Thanks to proactive planning and a roof that was still structurally sound, the school was able to restore its existing EPDM roof with a silicone roof coating system, avoiding the significant expense and disruption of a full tear-off.

How the Project Started

This project actually began because of a relationship built years earlier.

The maintenance supervisor responsible for Timmons Elementary had previously worked for Midview Schools, where West Roofing Systems completed a commercial roofing project in 2019.

After moving to his new position, he already knew our team, our process, and the quality of our work.

When it came time to evaluate the roofs at Timmons Elementary, he reached out to us to perform an inspection.

Relationships and trust matter in commercial roofing, especially when managing public facilities where budgets and long-term planning are critical.

Inspecting a 30-Year-Old EPDM Roof

The school's EPDM roofing system had originally been installed in 1995, making it approximately 30 years old.

At first glance, many building owners assume a roof this old automatically needs to be replaced.

However, age alone doesn't determine whether a roof has reached the end of its service life.

During our inspection, we found that although the roof had aged, the membrane remained in good overall condition.

There was no widespread deterioration that would prevent restoration.

That made the roof a great candidate for a silicone roof coating system.

Why a Silicone Roof Coating Was the Right Solution

Instead of removing thousands of square feet of roofing material and installing a brand-new roof, the existing EPDM roof could be restored.

After cleaning and preparing the roof surface, our crews installed a high-solids silicone roof coating system designed to protect the existing membrane from weather, UV exposure, and future deterioration.

The result is a fully restored roofing system backed by a 20-year renewable and transferable warranty.

This approach provides several advantages:

• Extends the life of the existing roof

• Avoids sending roofing materials to landfills

• Minimizes disruption to students and staff

• Is completed much faster than a roof replacement

• Costs significantly less than a complete tear-off and replacement

• Provides a new long-term warranty

For many schools and commercial buildings, restoring an existing roof is one of the most cost-effective capital improvement projects available.

Timing Is Everything

One of the biggest lessons from this project is that roof restoration only works when a roof is still in restorable condition.

If building owners wait until widespread water infiltration, saturated insulation, or severe membrane deterioration occurs, restoration may no longer be an option.

At that point, the only reasonable solution is a complete roof replacement.

For Timmons Elementary, the maintenance team acted at the right time.

By restoring the roof before it reached the point of failure, the district secured decades of additional service life while avoiding the substantially higher cost of a complete tear-off.

In many cases, a roof replacement can cost at least twice as much as a silicone roof coating system, making proactive maintenance a smart financial decision.

Why Schools Choose Roof Coating Systems

School districts are constantly balancing maintenance needs with limited budgets.

Silicone roof coating systems have become an increasingly popular solution because they enable districts to maximize the value of existing roofing assets rather than replacing them prematurely.

Additional benefits include:

• Having a seamless membrane (loss of seam adhesion is the #1 cause of leaks)

• Long-term leak protection

• Lower lifecycle costs

• Very easy to maintain

• Renewable warranties that can extend roof life for decades

Spray Foam vs. TPO Roofing: Which Roofing System Is Best?

Fri, 10 Jul 2026 17:16:59 GMT

Spray Foam vs. TPO Roofing: Which Roofing System Is Best?

Quick Answer: TPO is best when there aren't many penetrations, walls, pipes, or other objects that can interfere with its rolled-out installation. The more complex a roof is, the more cost-effective spray foam is compared to TPO.

If your commercial roof is leaking, you're collecting quotes, and comparing options, this article is for you.

Perhaps one contractor recommends a spray polyurethane foam (SPF) roofing system, while another recommends a TPO roofing system.

Both contractors seem confident that their solution is the best choice—but how can two experienced roofing companies recommend completely different systems for the same building?

The truth is that there isn't a single "best" commercial roofing system. The right choice depends on your building, your long-term plans, and what you're trying to accomplish.

This article isn't designed to sell you on one roofing system over another. Instead, our goal is to help you understand the strengths and weaknesses of each option so you can make the best decision for your building.

Whether your roof is leaking today or you're planning for a replacement in the next year, this guide will walk you through the differences between spray foam and TPO roofing systems—including cost, lifespan, energy efficiency, maintenance requirements, leak potential, and the situations where each system performs best.

Spray Foam vs. TPO at a Glance

If you're looking for the short answer, here's a quick comparison before we dive into the details.

As you can see, neither roofing system wins every category. Some building owners will benefit more from spray foam, while others will be better served with a TPO roofing system.

The rest of this article explains why.

Understanding the Two Roofing Systems

Before comparing them, it's important to understand that these two roofing systems are installed in completely different ways.

What Is a Spray Polyurethane Foam (SPF) Roof?

A spray polyurethane foam roof is created by combining two liquid components that react almost instantly after leaving the spray gun. Within seconds, the material expands into a rigid, seamless layer of closed-cell insulation.

After the foam has cured, installers apply a protective silicone or acrylic coating over the surface. That coating shields the foam from sunlight, weather, and everyday wear.

The finished roof consists of three primary components:

The existing roof (when restoration is possible)
Spray polyurethane foam
A protective coating with embedded granules

Unlike sheet roofing systems, spray foam is applied as a liquid. It conforms to every contour of the roof, wrapping around rooftop equipment, curbs, drains, skylights, and penetrations without creating seams.

One of the biggest advantages of spray foam is that it serves two purposes at once:

It becomes the waterproof roofing membrane.
It adds insulation that can significantly improve your building's energy efficiency.

What Is a TPO Roofing System?

TPO stands for Thermoplastic Polyolefin, a single-ply roofing membrane commonly installed on commercial buildings throughout the United States.

Instead of being sprayed into place, TPO is manufactured in large rolls that are installed across the roof surface. The individual sheets are joined together using heat-welded seams to create a continuous waterproof membrane.

A typical TPO roofing assembly may include:

Roof deck
Insulation boards
Cover board (optional)
TPO membrane
Heat-welded seams
Mechanical fasteners or adhesive attachment

TPO has become one of the most popular commercial roofing systems because it's durable, reflective, relatively lightweight, and widely available.

When properly installed, welded seams create a strong bond between sheets, making TPO a reliable roofing option for many commercial buildings.

Why Would Two Roofing Contractors Recommend Different Roofing Systems?

This is one of the most common questions we hear.

Imagine two roofing contractors inspect the exact same leaking roof.

One recommends spray foam.

The other recommends TPO.

Does that mean one of them is wrong?

Not necessarily.

Experienced roofing contractors often evaluate buildings differently because they're looking at different priorities.

One contractor may focus on:

Lowest initial investment
Manufacturer preferences
Existing specifications
Familiar installation methods

Another contractor may focus on:

Long-term ownership costs
Energy savings
Eliminating future tear-offs
Improving drainage
Restoring the existing roof instead of replacing it

Neither approach is automatically wrong.

The important thing is understanding why a contractor is recommending a particular system and whether that recommendation aligns with your goals.

For example, if you're planning to own your building for the next 25 years, your priorities may be very different than someone planning to sell the property in three years.

Likewise, a manufacturing facility with high energy costs may place far more value on insulation than a warehouse that is rarely heated or cooled.

The best roofing system isn't simply the one with the lowest price—it's the one that solves the problems that matter most to you.

Spray Foam vs. TPO Cost: Which Roofing System Costs Less?

For many building owners, this is the first question.

Unfortunately, it's also one of the hardest to answer with a single number because every commercial roof is different.

Factors like roof size, existing roof condition, insulation needs, rooftop equipment, warranty length, and labor requirements all influence the final price.

In general, however, spray foam roofing systems and TPO roofing systems often fall within a similar price range when comparing projects of similar scope.

That surprises many people.

There's a common misconception that spray foam is significantly more expensive than TPO. In reality, the difference is often much smaller than building owners expect.

The more important question isn't:

"Which roof costs less today?"

It's:

"Which roof will cost less over the next 30 or 40 years?"

Those are two very different conversations.

Looking Beyond the Initial Price

Imagine two buildings that each need a new roof today.

Building A installs a TPO roofing system.

Building B installs a spray foam roofing system.

Twenty years later, both roofs have reached the end of their warranty period.

The owner of the TPO roof will often be planning for another roof replacement. Depending on the condition of the roof assembly, that may involve removing the existing membrane, disposing of materials, and installing an entirely new roofing system.

The owner of the spray foam roof may have a different option.

If the underlying foam remains in good condition—which is common with proper maintenance—the existing foam can often stay in place. Instead of replacing the roof, the protective coating is cleaned, repaired where needed, and a new coating is applied.

This process is called a roof recoat.

Rather than paying for another complete roofing system, the owner is renewing the waterproof surface while preserving the insulation that was installed years earlier.

Over several decades, this difference can have a significant impact on total ownership costs.

That's one of the reasons many building owners look beyond the initial installation price and instead compare the life-cycle cost of each roofing system.

We'll discuss roof longevity and renewable roofing systems in more detail later in this guide.

Which Roofing System Is Less Likely to Leak?

If you're reading this article because your commercial roof is currently leaking, this may be the most important section.

After all, the primary job of any roofing system is to keep water out of your building.

Both spray foam and TPO are capable of providing decades of leak-free performance when they're installed correctly and properly maintained. However, they achieve waterproofing in very different ways, and understanding those differences can help you make a more informed decision.

How a TPO Roof Prevents Leaks

A TPO roof is made up of large sheets of membrane that are rolled out across the roof and joined together with heat-welded seams.

When installed correctly, these seams create a watertight bond that is often stronger than the membrane itself. Around rooftop penetrations—such as HVAC units, vents, skylights, drains, and pipes—installers use prefabricated boots, flashing, and additional welded membrane to keep water from entering.

A professionally installed TPO roof can perform extremely well for many years.

However, because it is assembled from individual sheets, there are naturally more areas that require careful workmanship. Every seam, flashing detail, curb, penetration, and edge detail must be installed correctly to ensure the roof remains watertight.

If leaks develop over time, they commonly occur because of:

Failed or damaged seams
Punctures from foot traffic or dropped tools
Flashing deterioration around rooftop equipment
Damage from severe weather
Improper installation
Lack of routine maintenance

It's important to note that these issues are not unique to TPO. Every roofing system has areas that require inspection and maintenance throughout its life.

How a Spray Foam Roof Prevents Leaks

Spray polyurethane foam approaches waterproofing in a completely different way.

Instead of installing rolls of membrane, the roofing material is sprayed directly onto the roof as a liquid. Within seconds, it expands into a continuous layer of closed-cell foam.

Once cured, a protective silicone coating is applied over the foam.

Because the foam is sprayed in place, the finished roofing system has no field seams.

Rather than cutting and fitting membrane around rooftop equipment, the foam simply conforms to every penetration, curb, drain, pipe, skylight, and transition.

This creates one continuous roofing surface across the entire building.

That seamless design eliminates one of the most common areas where many roofing systems eventually experience problems.

Of course, that doesn't mean a spray foam roof can never leak.

Leaks may occur if:

The protective coating wears away over many years without being renewed
The foam is physically damaged and left unrepaired
Severe weather damages the roof
The original installation was performed improperly

Like any commercial roof, spray foam still benefits from regular inspections and preventative maintenance.

Does "Seamless" Really Matter?

One of the biggest selling points of spray foam roofing is that it's seamless.

But what does that actually mean for a building owner?

Think about it this way.

Imagine placing a waterproof tarp over your backyard.

If the tarp is one continuous piece, there are very few opportunities for water to work its way underneath.

Now imagine creating that same tarp using dozens of smaller pieces taped together.

Even if every connection is done correctly, you've created many more places that require long-term performance.

The same principle applies to commercial roofing.

Large commercial buildings may contain thousands of linear feet of seams, depending on the roof size and layout.

Those seams are professionally welded during installation and are designed to last for many years. However, they still become part of the roof that should be inspected throughout its service life.

Because spray foam eliminates those field seams entirely, many building owners appreciate the simplicity of a monolithic roofing surface.

Which Roof Is Easier to Repair?

Eventually, every commercial roof requires repairs.

Storm damage happens.

Maintenance workers accidentally drop tools.

Contractors install new rooftop equipment.

Tree branches fall.

The question isn't whether repairs will ever be needed—it's how difficult those repairs are when they become necessary.

Repairing a TPO Roof

When damage occurs to a TPO roof, technicians typically locate the affected area and install a welded repair patch or replace damaged membrane sections.

If moisture has entered beneath the membrane, additional investigation may be needed to determine how far the water traveled before repairs can begin.

Most TPO repairs are straightforward for experienced commercial roofing contractors.

However, repairs usually require specialized welding equipment and technicians trained in TPO installation.

Repairing a Spray Foam Roof

Spray foam repairs are often relatively simple.

If damage occurs, the affected area can usually be cleaned, repaired with compatible spray foam or sealant, and recoated to restore the waterproof surface.

Because the roofing system is seamless, repairs can often blend into the existing roof without introducing additional seams or large replacement sections.

In many cases, routine repairs can be completed quickly, helping extend the life of the roofing system.

What Happens If Water Gets Under the Roof?

This is another important difference between the two systems.

Spray polyurethane foam is made up of closed cells.

Think of the foam as millions of tiny sealed bubbles.

If one area of the roof becomes damaged, water generally remains confined to the immediate area because the individual cells limit how far moisture can travel through the foam.

This characteristic often makes leak investigations more straightforward.

TPO roofing systems rely on insulation boards beneath the membrane.

If water finds its way beneath the membrane through a puncture or flashing issue, moisture can sometimes migrate between insulation boards before the leak becomes visible inside the building.

That doesn't mean TPO leaks are difficult to repair—but it can occasionally make locating the original point of entry more challenging.

Which Roofing System Is More Energy Efficient?

For many commercial buildings, the roof isn't just protection from the weather.

It's also one of the largest opportunities to reduce heating and cooling costs.

This is where spray foam and TPO begin to separate.

TPO Reflects Heat

One reason TPO has become so popular is its highly reflective white surface.

Rather than absorbing large amounts of sunlight, white TPO reflects much of the sun's energy back into the atmosphere.

That reflective surface helps reduce rooftop temperatures during hot summer months.

For buildings in warm climates—or facilities with significant air conditioning loads—this can contribute to lower cooling costs compared to darker roofing materials.

Many building owners choose white TPO specifically because of its solar reflectivity.

Spray Foam Reflects Heat and Adds Insulation

Spray foam roofs also use highly reflective coatings.

However, spray foam offers something TPO alone does not.

Insulation.

Closed-cell spray polyurethane foam has an insulating value of approximately R-6.5 per inch, making it one of the highest-performing roofing insulation materials available.

That added insulation helps reduce heat transfer through the roof year-round.

In the summer, less heat enters the building.

In the winter, less conditioned air escapes.

For buildings with limited roof insulation—or facilities with high heating and cooling costs—this added thermal performance can produce meaningful energy savings over time.

Air Sealing: An Often Overlooked Advantage

Most building owners think only about insulation.

But insulation is only part of the equation.

Air movement also affects energy efficiency.

Because spray foam expands as it's applied, it fills small gaps, cracks, and irregularities across the roof surface.

This creates an additional air barrier that helps reduce uncontrolled air movement through the roof assembly.

Reducing air leakage can improve indoor comfort while allowing HVAC systems to operate more efficiently.

TPO roofing systems do not provide this same air-sealing benefit on their own.

Which Roof Performs Better Over Time?

Both roofing systems can provide decades of reliable service when properly installed and maintained.

The difference is often found in how they age.

TPO membranes gradually weather through exposure to sunlight, temperature changes, and everyday environmental conditions.

Spray foam's waterproofing layer—the protective coating—is also exposed to the elements.

However, unlike replacing an entire roofing system, the coating can often be renewed before significant deterioration occurs.

That distinction becomes especially important when considering the total cost of ownership over several decades.

In the next section, we'll take a closer look at roof lifespan, renewable roofing systems, ponding water, maintenance requirements, and the situations where we would actually recommend a TPO roof over spray foam.

How Long Does a Spray Foam Roof Last Compared to a TPO Roof?

One of the biggest misconceptions in commercial roofing is that every roof eventually has to be torn off and replaced.

That isn't always true.

The expected lifespan of a roofing system depends on several factors, including:

Installation quality
Weather exposure
Building usage
Preventative maintenance
How quickly repairs are made when damage occurs

Both TPO and spray foam roofing systems can provide decades of reliable protection, but they reach that longevity in different ways.

The Lifespan of a TPO Roof

A professionally installed TPO roofing system typically lasts 20 to 30 years, although actual performance depends on the membrane thickness, installation quality, climate, and maintenance history.

Throughout its life, the roof should be inspected regularly to identify punctures, flashing issues, or seam damage before they become leaks.

Eventually, every TPO roof reaches the point where repairs are no longer the most economical solution. At that stage, many building owners begin planning for a roof replacement.

That doesn't mean the roof failed—it simply reached the end of its expected service life.

The Lifespan of a Spray Foam Roof

Spray polyurethane foam works a little differently.

The foam itself doesn't usually wear out.

Instead, it's the protective coating on top of the foam that gradually weathers from years of exposure to sunlight and the elements.

As the coating approaches the end of its service life, it can often be cleaned, repaired where necessary, and recoated with a new layer of protective coating.

The existing foam remains in place.

If inspections are performed regularly and recoats are completed when needed, a spray foam roof can continue performing for decades without requiring a complete tear-off.

That renewable characteristic is one of the reasons many long-term building owners choose spray foam roofing systems.

Understanding Renewable Roofing Systems

Think of a spray foam roof like maintaining the exterior paint on your home.

You don't replace the entire house because the paint has weathered.

You prepare the surface and apply a new protective coating.

A spray foam roof follows a similar concept.

Instead of removing and replacing the entire roofing assembly every few decades, the waterproof coating can often be renewed while preserving the existing insulation underneath.

Of course, not every spray foam roof automatically qualifies for a recoat.

The foam must still be in good condition, and regular inspections and maintenance play an important role in making that possible.

Which Roofing System Handles Ponding Water Better?

Ponding water is one of the most common problems found on commercial roofs.

It occurs when water remains on the roof for more than 48 hours after a rainfall instead of draining away.

Standing water can increase the amount of time a roof remains wet, add unnecessary weight to the structure, and highlight areas where drainage needs improvement.

If your current roof has ponding water, this section deserves your attention.

How TPO Handles Ponding Water

Modern TPO membranes are designed to resist standing water better than many older roofing materials.

When installed properly, a TPO roof can perform well even if temporary ponding occurs.

However, the membrane itself doesn't solve the drainage problem.

If water consistently collects in the same locations, the roof's slope or drainage system may still need to be improved.

In some situations, tapered insulation can be installed beneath a TPO roof to help direct water toward drains.

How Spray Foam Can Improve Drainage

This is one area where spray foam has a unique advantage.

Because spray foam is applied as a liquid and expands as it's installed, experienced installers can build positive slope into areas where water has historically collected.

Instead of simply covering the low spot, they can gradually raise sections of the roof to encourage water to flow toward existing drains, scuppers, or gutters.

This process is often called corrective slope or positive drainage.

Not every drainage issue can be solved this way, but many ponding water problems can be significantly improved without replacing the roof deck.

For buildings that have struggled with standing water for years, this capability can be a major benefit.

Which Roofing System Requires More Maintenance?

Here's something every building owner should know:

No commercial roof is maintenance-free.

Regardless of which roofing system you choose, annual inspections and routine maintenance are some of the best investments you can make.

Small issues are almost always less expensive to fix than major leaks.

Maintaining a TPO Roof

Routine TPO maintenance typically includes:

Inspecting seams
Examining flashing details
Looking for punctures
Cleaning drains
Removing debris
Repairing damaged membrane areas

These inspections help identify small problems before they become expensive interior leaks.

Maintaining a Spray Foam Roof

Spray foam maintenance is similar in many ways.

Technicians inspect:

The protective coating
Areas of mechanical damage
Sealants around penetrations
Drainage patterns
Rooftop traffic areas

If portions of the protective coating have worn thin, they can often be restored before the foam underneath becomes exposed.

Routine maintenance helps maximize the life of both roofing systems.

Which Roofing System Is Better for Buildings With Lots of Rooftop Equipment?

Take a look at your roof.

Do you have:

HVAC units?
Exhaust fans?
Skylights?
Pipes?
Electrical conduit?
Satellite equipment?
Solar panels?

Every rooftop penetration creates another area that must remain watertight.

TPO Around Rooftop Penetrations

TPO systems use flashing materials, boots, and welded membrane to seal around each rooftop penetration.

When installed properly, these details perform very well.

However, every penetration requires additional labor and additional waterproofing details.

As the number of rooftop units increases, so does the complexity of the installation.

Spray Foam Around Rooftop Penetrations

Spray foam naturally conforms around rooftop equipment.

Instead of cutting membrane pieces to fit every curb or pipe, the foam expands tightly around those irregular shapes before receiving its protective coating.

Buildings with numerous penetrations often benefit from this seamless application process.

It's one of the reasons spray foam is commonly selected for manufacturing facilities, schools, hospitals, and industrial buildings that have extensive rooftop mechanical equipment.

When We Would Recommend a TPO Roof Instead of Spray Foam

Since we install spray foam roofing systems, you might assume we'd recommend it for every building.

We don't.

There are situations where we genuinely believe a TPO roof is the better solution.

For example, we may recommend TPO if:

The project is new construction with a roofing specification already calling for TPO.
The building experiences constant heavy foot traffic from maintenance personnel.
The owner prefers a traditional single-ply roofing system.
Existing building conditions make spray foam an unsuitable option.
The owner's primary goal is obtaining a new roofing system with a lower emphasis on energy savings or renewable restoration.

Every building is different.

Our responsibility is to recommend the roofing system that best fits your building—not simply the one we install most often.

When We Believe Spray Foam Is the Better Choice

There are also situations where spray foam offers clear advantages.

We often recommend spray foam when a building owner wants to:

Avoid a costly tear-off whenever possible.
Increase insulation and reduce energy costs.
Eliminate thousands of linear feet of field seams.
Improve drainage in areas with chronic ponding water.
Restore an existing roof instead of replacing it.
Extend the life of their roofing investment through future recoats.
Create a seamless roofing system around numerous rooftop penetrations.

For many existing commercial buildings, these benefits make spray foam one of the most cost-effective long-term roofing solutions available.

The key is determining whether your particular building is a good candidate.

There is no roofing system that's perfect for every situation.

Questions Every Building Owner Should Ask Before Choosing a Roofing System

Choosing a new commercial roofing system is a major decision.

A roof protects your building, equipment, inventory, employees, and everything inside your facility. It also represents a significant investment, so it's important to look beyond the initial proposal price and understand exactly what you are getting.

Before signing a contract, we recommend asking every roofing contractor the following questions.

1. Why Are You Recommending This Roofing System for My Building?

A good roofing contractor should be able to explain why they are recommending a specific system—not just tell you what system they install.

Ask questions like:

What makes this roofing system a good fit for my building?
What problems with my existing roof does this system solve?
Are there any concerns with my current roof that need to be addressed first?
Are you recommending this system because it is the best option or because it is the system your company prefers to install?

The best contractors don't simply sell roofing systems. They evaluate buildings and recommend solutions.

2. What Pr oblems With My Existing Roof Will This System Solve?

Every commercial roof has different challenges.

One building may have:

Frequent leaks
Poor drainage
Aging insulation
Multiple rooftop penetrations
Previous repair attempts
High heating and cooling costs

Another building may simply need a durable, cost-effective replacement.

The right roofing system should address the specific problems your building is experiencing.

For example:

If your building struggles with energy costs, additional insulation may be a major consideration.
If your roof has chronic ponding water, drainage improvements may be important.
If your roof has numerous seams and penetrations, a seamless roofing system may provide advantages.
If your building has heavy rooftop traffic, durability and access may be higher priorities.

A roofing recommendation should be based on your building—not just a product brochure.

3. What Maintenance Will This Roof Require Over the Next 20 Years?

Many building owners focus heavily on installation costs but don't ask enough questions about what happens after installation.

Every commercial roofing system requires maintenance.

Ask your contractor:

How often should this roof be inspected?
What maintenance tasks should be performed?
What problems should we watch for?
What happens if damage occurs?
How can we maximize the lifespan of this roof?

A proactive maintenance plan can help identify small problems before they become expensive repairs.

4. What Happens When the Warranty Expires?

A roofing warranty is important, but it's only one part of the decision.

Many building owners focus on whether they are getting a 10-year, 15-year, or 20-year warranty without asking what happens afterward.

Consider asking:

Can the roof be repaired or renewed?
Will the entire system need to be replaced?
What are the expected costs after the warranty period?
What maintenance is required to extend the roof's service life?

Understanding the long-term plan for your roof is just as important as understanding the initial installation.

5. What Are the Disadvantages of This Roofing System?

This may be the most important question you can ask.

Every roofing system has advantages.

Every roofing system also has limitations.

A contractor who refuses to discuss the disadvantages of their recommended system may not be giving you the complete picture.

For example:

Spray foam roofing offers excellent insulation, seamless waterproofing, and renewable life cycles—but it may not be the ideal choice for every building, especially those requiring constant heavy rooftop traffic.

TPO roofing offers durability, proven performance, and excellent walkability—but it relies on properly installed seams and does not provide the same insulation benefits as a spray foam system.

The right roofing decision comes from understanding both the benefits and limitations of each option.

Frequently Asked Questions About Spray Foam vs. TPO Roofing

 Is spray foam roofing more expensive than TPO?

In many cases, spray foam and TPO roofing systems have similar installation costs.

The final price depends on many factors, including roof size, existing roof conditions, insulation requirements, warranty length, and the complexity of the building.

The more important comparison is often the long-term cost of ownership.

A lower initial price does not always mean the lowest overall cost over the life of the roof.

Can spray foam roofing be installed over my existing roof?

In many cases, yes.

One of the biggest advantages of spray foam roofing is that it can often be installed over an existing roof system without a complete tear-off.

However, the existing roof must first be evaluated.

Factors such as moisture, structural conditions, roof deck integrity, and previous repairs all play a role in determining whether a roof is a good candidate for restoration.

Can spray foam roofs leak?

No roofing system is completely immune to damage, but spray foam roofing has a major advantage because it is installed as a seamless membrane.

Since there are no field seams, there are fewer potential areas where water can enter.

If damage does occur, repairs can typically be completed by restoring the affected area and recoating the surface.

Does TPO roofing leak more than spray foam?

Not necessarily.

A properly installed TPO roof can provide excellent protection for many years.

The difference is that TPO relies on welded seams and flashing details to create a waterproof system, while spray foam creates a continuous seamless surface.

Both systems depend heavily on proper installation and regular maintenance.

Which roofing system lasts longer: spray foam or TPO?

Both systems can provide decades of service.

TPO roofs commonly last approximately 20 to 30 years depending on installation quality, environmental conditions, and maintenance.

Spray foam roofs can continue performing beyond their original warranty period because the protective coating can often be renewed without removing the existing foam.

The lifespan of either system depends heavily on how well the roof is maintained.

Is spray foam roofing good for buildings with ponding water?

Spray foam can be an excellent option for buildings with drainage issues because installers can build slope into low areas to help move water toward drains.

However, the cause of the ponding water should always be evaluated first.

Not every drainage issue can be solved with foam alone.

Can TPO be repaired?

Yes.

TPO roofing systems can be repaired by trained roofing professionals using compatible membrane and welding techniques.

Routine inspections can help identify damaged seams, punctures, and flashing issues before they lead to interior leaks.

Which roof is better for energy savings?

Spray foam generally has an advantage because it provides insulation in addition to a reflective coating.

TPO can help reduce heat gain because of its reflective surface, but it does not provide the same insulation value unless additional insulation is installed beneath the membrane.

For buildings with high heating and cooling costs, the added insulation from spray foam may provide significant long-term benefits.

Is spray foam roofing environmentally friendly?

Spray foam roofing can be an environmentally responsible choice because it often allows building owners to restore an existing roof instead of removing it and sending old roofing materials to a landfill.

Additionally, the improved insulation can help reduce energy consumption over the life of the building.

Can contractors walk on a spray foam roof?

Yes, but like any commercial roof, traffic should be managed.

Areas that receive frequent foot traffic can be protected with designated walk pads or pathways.

If your building requires constant rooftop access, discuss those needs with your roofing contractor before selecting a system.

Final Thoughts: Spray Foam vs. TPO Roofing

So, which roofing system is better: spray foam or TPO?

The answer depends on your building.

TPO is an excellent roofing system that has become popular for good reasons. It offers durability, a proven track record, and strong performance when installed correctly.

Spray foam is also an excellent roofing system, especially for existing commercial buildings where energy efficiency, seamless waterproofing, drainage improvements, and long-term restoration are priorities.

The best roofing contractors will take the time to understand your building, explain your options, and help you choose the system that makes the most sense for your situation.

The right question isn't:

"Which roofing system is the best?"

The better question is:

"Which roofing system is the best fit for my building, my budget, and my long-term goals?"

Making that decision with accurate information is the first step toward protecting your building for decades to come.

How Much Does a Silicone Roof Coating System Cost?

Wed, 08 Jul 2026 13:53:15 GMT

How Much Does a Silicone Roof Coating System Cost?

Quick Answer: As of July 2026, the ballpark cost is $3.50-$7.00 per square foot. Several factors influence cost, such as the length of warranty desired (10, 15, or 20 years), how much tear-off and replacement (if any) is required, and location from the contractor.

If you're considering restoring your commercial roof with a silicone roof coating system, one of your first questions is probably:

"How much is this going to cost?"

The short answer is that most silicone roof coating systems cost between $3.50 and $7.00 per square foot.

For example:

20,000 sq. ft. roof: Approximately $70,000 - $140,000
50,000 sq. ft. roof: Approximately $175,000 - $350,000
100,000 sq. ft. roof: Approximately $350,000 - $700,000

While that provides a good starting point, every commercial roof is different. Several factors can push the price toward the lower or upper end of that range.

In this article, we'll explain exactly what those factors are so you can better estimate your project's cost.

What Determines the Cost of a Silicone Roof Coating System?

Several variables affect the final price of a roof coating project.

1. Warranty Length (and Coating Thickness)

One of the biggest pricing factors is the warranty you choose.

Unlike many roofing systems, the warranty on a silicone roof coating system is directly tied to the amount of coating installed. More material means a thicker waterproof membrane and a longer-lasting roof.

Typical warranty thicknesses are:

Simply put:

More coating = Longer warranty = Higher cost.

The additional material increases both product and labor costs, but it also gives you more years of protection before the roof needs to be renewed.

If you're planning to own your building for many years, investing in a longer warranty often provides excellent long-term value.

2. How Much Wet Insulation Needs to Be Replaced

Before installing any coating system, the existing roof must be evaluated.

Most reputable contractors perform roof core samples, an infrared moisture survey, or both to determine whether water has become trapped inside the roofing system.

If wet insulation is discovered, it must be removed and replaced before the coating is installed.

Why?

Because coating over wet insulation doesn't solve the problem—it hides it.

Moisture trapped beneath a coating system can:

Create blisters as water vapor expands
Freeze during winter and damage the roof assembly
Continue migrating through the roof system until it eventually leaks into the building

Consider two identical 100,000-square-foot buildings.

Building A has 1% wet insulation.
Building B has 10% wet insulation.

The roofing systems may appear identical from the ground, but Building B will require substantially more tear-out and replacement work before the coating can even begin.

That additional labor and materials can significantly increase the overall project cost.

3. Distance From the Roofing Contractor

Travel costs are another factor many building owners overlook.

If your contractor must:

Fly crews to your location
Pay for hotel stays
Transport equipment long distances
Ship materials across the country

those expenses become part of the project.

That doesn't necessarily mean you should always hire the closest contractor.

In commercial roofing, experience often matters more than geography.

A highly qualified contractor located several states away may ultimately save you money by installing the roof correctly the first time, while an inexperienced local contractor could leave you dealing with premature failures, leaks, and expensive repairs.

If you're evaluating contractors, it's worth learning what separates reputable roofing companies from those that cut corners.

Read our article on the warning signs to watch for:

Why Are Some Coating Companies More Expensive?

If you've received multiple proposals, you've probably noticed that prices can vary dramatically.

There are good reasons for that.

Experience

Experienced commercial roofers command higher wages than entry-level workers.

A crew member with 30 years of commercial roofing experience has installed thousands of roofing squares and understands how to properly detail penetrations, drains, seams, flashing, and other critical areas.

That expertise helps prevent leaks and callbacks.

Lower labor rates often come with less experience, and roofing mistakes can become very expensive later.

Manufacturer Certifications

Not every roofing contractor is certified to install every manufacturer's products.

Many manufacturers require contractors to complete training and demonstrate quality workmanship before they can offer manufacturer-backed warranties.

Certification helps ensure the roof is installed according to manufacturer specifications.

Safety Programs

Professional roofing companies also invest heavily in safety.

OSHA training, safety managers, equipment inspections, fall protection systems, insurance, and ongoing education all add overhead—but they also reduce risk for both workers and building owners.

Companies that ignore these investments may submit lower bids, but that doesn't necessarily make them the better value.

Where Does West Roofing Systems Fall?

At West Roofing Systems, we're rarely the cheapest proposal, and we're usually not the most expensive either.

Our pricing reflects the quality of the work we provide.

When you work with us, you're hiring a contractor that invests in doing the job correctly.

Our team includes:

Commercial roofing professionals with decades of experience
SPFA-certified installers
OSHA-compliant safety personnel
Manufacturer-trained crews
Proven installation processes developed over more than 45 years in business

Our goal isn't simply to install a coating system.

It's to install one that performs for decades.

Looking Beyond the Initial Cost

Many building owners focus only on today's project cost.

A better question is:

What will this roof cost over its entire lifetime?

A silicone coating system allows many commercial roofs to avoid a complete tear-off when the warranty expires.

Instead of removing the existing roof and sending thousands of pounds of material to a landfill, the roof can often be cleaned, repaired where necessary, and recoated.

That creates something many facility managers value:

Financial predictability.

Rather than facing a massive capital expense every few decades, roof restoration allows you to plan for periodic renewals at a much lower cost.

If you'd like to learn more about this concept, read our article on why financial predictability is one of the most underrated benefits of roof coatings:

Are Silicone Roof Coating Systems Worth It?

For many commercial buildings, absolutely.

A properly installed silicone roof coating system provides benefits that extend well beyond simply stopping leaks.

Some of the biggest advantages include :

Creates a seamless waterproof membrane with no exposed fasteners or seams
Extends the life of an existing roof without a costly tear-off
Makes future maintenance easier
Allows the roof to be renewed with additional coating instead of replaced
Reflects sunlight to help reduce roof temperatures and improve HVAC efficiency
Minimizes disruption to building occupants during installa tion

When a roof is a good candidate for restoration, a silicone coating system can provide decades of reliable performance while significantly reducing lifetime roofing costs.

Recently Completed Silicone Roof Coating Projects

Project Name: Bearing Manufacturing

Location: Strongsville, Ohio

Size: 63,950 square feet

Warranty: 10-years

Project Type: Silicone roof coating system over existing metal roof

Completed Date: May 2026

Project Name: Wooster Orthopedics

Location: Wooster, Ohio

Size: 21,128 square feet

Warranty: 20-years

Project Type: Silicone roof coating system over existing EPDM roof

Completed Date: July 2025

Final Thoughts

Most silicone roof coating systems cost between $3.50 and $7.00 per square foot, but the final price depends on several factors.

The biggest cost drivers include:

The warranty length you choose
The amount of wet insulation that must be replaced
The contractor's travel requirements
The experience, certifications, and quality of the roofing company performing the work

While every building is different, understanding these factors will help you evaluate proposals and make a more informed decision.

If you'd like an accurate price for your building, the best first step is a roof inspection. A qualified contractor can evaluate your roof's condition, determine whether it's a good candidate for a silicone coating system, and provide a detailed estimate based on your specific needs.

The Problems Roof Coating Systems Have (And How to Avoid Them)

Wed, 08 Jul 2026 12:29:17 GMT

The Problems Roof Coating Systems Have (And How to Avoid Them)

Quick Answer: the problems roof coating systems have is that they get dirty quickly, they have strict eligibility (to get a warranty), in an effort to be the lowest bid, some contractors install them over bad candidate roofs, and nothing sticks to silicone besides more silicone.

Roof coating systems have become one of the most popular alternatives to a commercial roof replacement. When installed on the right roof, they can extend the life of a roofing system by 10, 15, or even 20 years while avoiding a costly tear-off.

However, roof coatings are not perfect.

Like every roofing system, they have disadvantages. Understanding these limitations can help building owners determine whether a roof coating is the right investment—or whether another solution would better protect their building.

In this article, we'll discuss the most common problems roof coating systems have, why they occur, and how to avoid them.

Problem #1: Some Contractors Install Coatings on Roofs That Should Be Replaced

This is perhaps the biggest problem in the roof coating industry.

Roof coatings generally cost less than a complete roof replacement.

Because of this, some contractors recommend coatings simply because they can submit a lower bid and increase their chances of winning the project.

Unfortunately, a lower price doesn't always mean it's the right solution.

If a roof has extensive water damage, deteriorated insulation, structural issues, or widespread membrane failure, installing a coating may only hide problems instead of solving them.

What can happen?

Several serious issues may develop after coating an unsuitable roof.

Blistering

Moisture trapped inside the roofing system can evaporate during hot weather.

As vapor pressure builds beneath the coating, blisters may begin forming on the roof surface.

Premature Loss of Adhesion

If the existing roof wasn't properly prepared—or if the substrate wasn't suitable—the coating may begin peeling, separating, or losing adhesion years before it should.

Continued Water Intrusion

Coating over saturated insulation doesn't remove the trapped moisture.

In many cases, water continues migrating throughout the roofing system, causing interior leaks and additional damage.

Eventually, the building owner may end up paying for both the coating and a complete roof replacement.

How to protect yourself

Ask your contractor:

Did you perform a moisture scan?
How much wet insulation was found?
Why is this roof a good candidate for restoration?
What conditions would make you recommend replacement instead?

A reputable contractor should have no problem answering these questions.

The takeaway: Roof coatings are excellent solutions—but only when installed on roofs that truly qualify.

Problem #2: Not Every Roof Qualifies for a Coating System

One of the biggest misconceptions about roof coatings is that every roof can be restored.

That's simply not true.

A coating system is only as good as the roof beneath it.

Before recommending a restoration, a qualified contractor should inspect several critical factors.

The roof should have:

Sound seams that can be repaired if necessary
Limited moisture within the insulation
A history of routine roof maintenance
A structurally sound roof deck

One important guideline many contractors follow is that less than approximately 25% of the insulation should be wet.

If moisture is widespread throughout the insulation, coating over the roof typically isn't the right solution. The wet insulation should usually be removed and replaced first.

This is why infrared moisture scans or core samples are often performed before recommending a coating system.

The takeaway: Roof coatings have strict eligibility requirements. A proper inspection should determine whether your roof is actually a candidate.

Problem #3 Roof Coatings Get Dirty—Especially White Roofs

White roof coatings are designed to reflect sunlight and reduce heat absorbed by the building.

Over time, though, that bright white surface begins collecting dirt, dust, pollen, soot, algae, and other airborne contaminants.

A roof that was bright white immediately after installation may appear gray only a year or two later.

Does this mean the coating failed?

No.

The roof is simply dirty.

Most commercial roof coatings continue to perform well even after becoming discolored. However, excessive dirt can gradually reduce solar reflectivity, meaning the roof won't stay quite as cool as it did when it was new.

If maintaining maximum reflectivity is important, the roof can often be cleaned during routine maintenance.

The takeaway: Dirt is mostly an appearance and energy-efficiency issue—not necessarily a roofing problem.

Problem #4: Silicone Roof Coatings Limit Future Roofing Options

Silicone coatings are extremely durable and highly resistant to ponding water.

They've become one of the most common restoration systems in commercial roofing.

However, they come with one important drawback.

Very few materials adhere well to cured silicone.

Once a high-solids silicone coating has cured, most roofing products—including acrylics, urethanes, adhesives, and many membranes—will not bond properly to it.

In practical terms, this means future repairs or restoration options may become more limited.

If another coating system is desired years later, it's often necessary to install additional silicone rather than switching to another coating chemistry.

While this isn't necessarily a deal breaker, it's something building owners should understand before selecting a roofing system.

The takeaway: Silicone performs extremely well—but it can limit your future restoration options because most roofing materials won't reliably stick to it.

Are Roof Coating Systems Still Worth It?

Absolutely.

When installed on the right roof, a coating system can:

Extend roof life by decades
Avoid a costly tear-off
Reduce landfill waste
Minimize disruption to building operations
Lower lifecycle roofing costs

The key is making sure your roof actually qualifies.

A trustworthy roofing contractor should be willing to tell you when a coating is not the right solution—even if it means recommending a more expensive roof replacement.

In the long run, honesty during the inspection is far less expensive than installing the wrong roofing system.

Frequently Asked Questions

What is the biggest disadvantage of a roof coating system?

The biggest disadvantage is that roof coatings cannot fix major underlying roofing problems. If a roof has widespread wet insulation, structural issues, or poor adhesion, a coating may fail prematurely.

Can every commercial roof receive a roof coating?

No. The existing roof must be in good enough condition to support a restoration. A professional inspection should determine whether the roof qualifies.

Do white roof coatings stay white?

Not perfectly white. White coatings naturally collect dirt, dust, and airborne contaminants over time. This discoloration is normal and doesn't impact performance.

Can you install another roofing system over silicone?

It's difficult. Most roofing materials do not adhere well to cured high-solids silicone, which often means future restoration work will require another silicone coating.

TPO Roofing: Costs to Install and How to Fix Leaks

Wed, 08 Jul 2026 09:57:21 GMT

TPO Roofing: Costs to Install and How to Fix Leaks

TPO (thermoplastic polyolefin) is one of the most popular commercial roofing materials. Here's a complete guide for building owners evaluating TPO.

What Is TPO?

TPO is a single-ply membrane manufactured from thermoplastic polyolefin compounds. It comes in rolls that are heat-welded together during installation. Available in white, gray, and tan colors, with white being most common for energy efficiency (solar reflectance 0.70–0.80).

TPO Installation Cost

New TPO installation: $5–$9/sq ft including materials, labor, and warranty. Over existing roofing (without tear-off): $5–$8/sq ft. Full replacement with tear-off: $7–$12/sq ft. 10–20-year manufacturer warranties available.

TPO Installation Process

Substrate preparation → insulation installation (if needed) → coverboard → TPO membrane unrolled and positioned → seams heat-welded with hot-air gun → edge terminations installed → penetration boots installed and welded → quality inspection.

TPO Maintenance

Semi-annual inspections checking seam adhesion, flashing conditions, and mechanical damage. Seam re-welding as needed. Drain cleaning. Prompt repair of any punctures. Seam inspection is the most critical maintenance task — TPO's primary failure mode is seam separation.

TPO Limitations

Seams fail over time and require ongoing maintenance. No insulation value added (R-0 for the membrane). At end of warranty, full replacement is typically required. No renewable warranty option. For long-term building ownership, lifecycle cost comparison with spray foam restoration systems is strongly recommended.

What to do with a TPO roof that's leaking?

If your TPO roof is leaking, you have a few options:

Complete tear-off and replacement (most expensive)
Install spray polyurethane foam over it (next expensive)
Install a spray-on roof coating system over it (least expensive)

The most popular option is the spray-on roof coating system. Here are some common questions regarding roof coating systems and TPO:

How much does a roof coating system cost?

As of June 2026, the ballpark cost is $3.50 to $7 per square foot.

The price greatly fluctuates depending on how much of the existing roof needs to be removed and replaced (you cannot install coating over poor-conditioned membrane, loose seams, or wet insulation), and how long of a warranty you would like (a 20-year warranty gets a 50% thicker application of coating than a 10-year warranty).

How long of a warranty can you get?

Most contractors offer 10-20-year warranties.

The 10-year warranty gets a 20 mil dry film thickness of coating.
The 15-year warranty gets a 25 mil dry film thickness of coating.
The 20-year warranty gets a 30 mil dry film thickness of coating.

The warranty can be handled through the contractor or the coating manufacturer. It's best to get a warranty through the manufacturer because it remains active if the roofing contractor goes out of business.

Are there any problems with roof coating systems?

Yes.

There are 3 types of coatings that are used for commercial roofing projects:

Acrylic (least expensive, least coverage rate, best for non-flat roofs)
Silicone (best overall in terms of coverage and performance)
Urethane (better than silicone, most expensive)

If you live in Ohio and install acrylic on a flat roof, you may be in trouble, as acrylics do not handle the elements as well as silicone.

Another problem is that nothing sticks to silicone besides more silicone. If you install silicone and want to install a new roofing system, you likely need to install a board over the top first.

The last problem with coatings is that they are usually installed in white or light grey. This is to maximize the UV reflectivity. The color will get dingy with weather, dirt, debris, etc. This won't hurt performance; it's just an aesthetic issue.

Recently Completed Projects

Project Name: The Orbit Hotel

Size: 10,622 square feet

Location: Cleveland, Ohio

Project Type: spray foam installed over an existing TPO roof

Completed Date: October 2025

Warranty Length: 10 years

Project Name: Portsmouth City Schools

Size: 47,142 square feet

Location: Portsmouth, Ohio

Project Type: Silicone roof coating system installed over an existing TPO roof

Completed Date: June 2024

Warranty Length: 10 years

Leaking Metal Roof? 4 Effective Repair Options

Wed, 08 Jul 2026 09:50:16 GMT

Leaking Metal Roof? 4 Effective Repair Options

Quick Summary: The four options, from least to most comprehensive, are targeted sealant repairs, reinforced tape systems, silicone coating restoration ($3.50–$7.00/sq ft), and spray foam plus silicone ($5.00–$10.00/sq ft).

A leaking commercial metal roof doesn't always require replacement. Here are 4 effective options from least to most comprehensive.

Option 1: Targeted Sealant Repairs

For isolated leaks at specific fasteners or seams, targeted sealant application is the fastest and lowest-cost fix. Clean the area, apply compatible metal roof sealant, and seal the specific failure point. Best for: one or two isolated problems on an otherwise sound system.

Option 2: Reinforced Tape System

Reinforced fabric tape embedded in compatible sealant is used to seal longer seam runs, flashing transitions, and areas with multiple small failures. More comprehensive than point repairs but still targeted. Best for: a section of roof with concentrated failures.

Option 3: Silicone Coating Restoration

A full silicone coating restoration seals the entire roof simultaneously — all fasteners, all seams, all rust spots — under a continuous new waterproof membrane with a 10–20-year renewable warranty.

Best for: roofs with widespread fastener and seam failures across large areas. Cost: $3.50–$7.00/sq ft.

Option 4: Spray Foam Plus Silicone

When insulation improvement is also needed, spray foam applied before the silicone topcoat adds R-6.5 per inch. Best for: metal roofs with both leak and insulation problems, particularly when the building has high energy costs. Cost: $5.00–$10.00/sq ft.

When Replacement Is Required

If the metal panels themselves are structurally compromised — severe corrosion, panel collapse, or structural failure — replacement is necessary. Get a structural assessment before investing in restoration.

Frequently Asked Questions

How much does it cost per square foot to restore a metal roof in Ohio and get it under warranty?

A ballpark cost for a roof coating system over an existing metal roof is $4-$6 per square foot. A ballpark cost for a spray foam roofing system installed over an existing metal roof is $5 - $7 per square foot.

Should I go with a roof coating system or a spray foam roofing system?

It depends on your needs. If you need added insulation, go with spray foam as silicone has no R-value and spray foam has the best R-value per inch of any roofing insulation.

If there's a lot of rust, go with spray foam.

And it depends on the metal profile. If the ribs are deep, go with a coating system. Spray foam may crack if it has to go up and down in such a small area. Plywood into the ribs and then spray foam might be a cost-effective option.

How long of a warranty do you get?

For both coating and foam roofing systems, the warranty is the same:

For a 10-year warranty, 20 total dry mils of coating are installed
For a 15-year warranty, 25 total dry mils of coating are installed
For a 20-year warranty, 30 total dry mils of coating are installed

A spray foam roofing system is protected by installing a silicone coating over the foam.

Metal Roof Restorations in Ohio

Bearing Manufacturing

Location: Strongville, Ohio

Size: 63,950 square feet

Job: Silicone roof coating system over metal

Warranty: 10-years

Completed Date: May 2026

Elyria Ice Rink

Location: Elyria , Ohio

Size: 56,100 square feet

Job: Silicone roof coating system over metal

Warranty: 10-years

Completed Date: August 2025

Planning a Commercial Roof Installation in Akron: Key Considerations

Fri, 03 Jul 2026 05:00:03 GMT

Planning a Commercial Roof Installation in Akron: Key Considerations

When you're planning a commercial roof installation in Akron, OH, choosing the right system and contractor determines long-term performance, energy efficiency, and return on investment for your property. West Roofing Systems specializes in spray foam and silicone coating installations that deliver seamless waterproofing, superior insulation, and renewable warranties for new construction and retrofit projects across industrial and commercial facilities.

What Factors Drive Roof System Selection?

Your building's use, structural capacity, local climate, and budget all influence the choice between spray foam, coatings, single-ply membranes, and traditional built-up systems.

Flat and low-slope roofs benefit from spray polyurethane foam's ability to create positive drainage and eliminate seams where leaks commonly start. Manufacturing facilities with temperature-sensitive operations prioritize insulation values that reduce energy costs and stabilize indoor conditions.

Retrofit projects often require lightweight systems that avoid adding load to aging structures, making spray foam an ideal choice for upgrading older roofs in Akron, OH. For property managers near me evaluating new installation options, understanding these trade-offs ensures your investment aligns with operational needs and lifecycle expectations.

How Do Drainage and Insulation Impact Design?

Proper drainage prevents ponding water that accelerates roof deterioration, while adequate insulation lowers utility expenses and protects interior assets from temperature extremes.

Spray foam installations build slope toward drains and scuppers, directing water off the roof even when existing decks have settled or deflected. The foam's closed-cell structure provides high R-values per inch, reducing heat transfer through the roof assembly year-round.

When combined with a reflective silicone topcoat, spray foam roofs meet or exceed energy code requirements and qualify for utility rebates in many jurisdictions. Our design process includes thermal imaging and moisture surveys to identify problem areas before installation begins. Learn more about complementary solutions through our commercial roof replacement services in Akron, OH .

Can Installation Proceed Without Disrupting Operations?

Yes, experienced crews plan installation sequences and work schedules to minimize impact on daily business activities and maintain safety throughout the project.

Spray foam and coating systems cure quickly and generate less noise and debris compared to tear-off and mechanical fastening methods. Phased application allows portions of the roof to remain functional while work progresses in adjacent zones.

Safety protocols include fall protection, air quality monitoring, and coordination with facility managers to avoid conflicts with production schedules or customer access. Most commercial roof installations in Akron, OH proceed with minimal interruption when contractors use proven staging and communication practices.

Our teams follow OSHA standards and maintain clean work areas to protect both building occupants and surrounding properties.

What Role Do Akron's Industrial Zones Play in Material Selection?

Akron's manufacturing heritage and proximity to polymer and chemical industries create roof environments exposed to airborne contaminants, temperature cycling, and heavy equipment vibration.

Silicone coatings resist chemical attack and maintain adhesion even when exposed to industrial emissions common in this region. Spray foam's monolithic bond prevents delamination caused by building movement or rooftop equipment operation.

These materials also tolerate the thermal expansion and contraction cycles inherent in metal-clad warehouses and production facilities, reducing maintenance needs and extending roof lifespan. Selecting systems proven in Akron's industrial corridor ensures your investment withstands local environmental stresses.

West Roofing Systems has installed commercial roofs across the East Coast since 1979, using only in-house crews trained in spray foam and coating applications. We offer renewable ten- to twenty-year warranties backed by decades of industry experience.

Start your project with a customized proposal—call West Roofing Systems at 440-355-9929 or review our silicone roof coatings services in Akron, OH for restoration alternatives.

The Most Underrated Benefit of Roof Coatings: Financial Predictability

Thu, 18 Jun 2026 13:49:36 GMT

The Most Underrated Benefit of Roof Coatings: Financial Predictability

When people discuss roof coating systems, they typically focus on benefits such as:

• Minimal tear-off and disruption

• Improved reflectivity

• A seamless, fastener-free waterproofing membrane

• Renewable and transferable warranties ranging from 10 to 20 years

These are all important benefits.

However, there's one major one that rarely gets discussed:

Financial predictability.

For many building owners, the ability to accurately forecast future roofing expenses can be just as valuable as the roofing system itself.

Why Roof Coatings Are So Predictable

Let's use a 20-year roof coating warranty as an example.

Most coating manufacturers offer a 20-year warranty when the coating is installed at a specific thickness.

In many cases, that means approximately 30 mils of total dry film thickness applied in multiple coats.

Manufacturers know from decades of field performance and testing that when their coating is installed at the proper thickness, it will 99.99999% of the time provide protection throughout the warranty period.

Of course, no roofing system is immune to extraordinary events such as:

• Hurricanes or extreme wind events

• Animal damage

• Impact from debris

• Deliberate human damage

But under normal conditions, the coating is designed to remain in place and continue protecting the roof for the full warranty term.

What Happens After 20 Years?

The answer is simple: the roof is recoated.

A recoat involves:

1. Cleaning the existing roof surface

2. Performing any necessary repairs

3. Applying a new coating layer

If the building owner wants another 20-year warranty, a new 30-mil coating application is installed.

The process can be repeated again and again.

Unlike many traditional roofing systems, there’s no need for a costly tear-off and replacement every few decades.

The Financial Advantage of Spray-on Roof Coating Systems

Because the lifecycle is so predictable, building owners can accurately budget for future roofing expenses.

The formula is straightforward:

• Perform preventative maintenance twice per year.

• Set aside funds for the future recoat.

• Avoid unexpected capital expenditures.

Instead of wondering when the next roofing emergency will occur, you know exactly what your long-term roofing plan looks like.

What Does a 20-Year Financial Plan Look Like?

Let's assume a 100,000-square-foot roof.

Year 0: Initial Installation

Roof coating system installed at approximately $4.00 per square foot.

Investment: $400,000

Years 1-19: Preventative Maintenance

Roof inspections and maintenance are performed twice annually—typically once in the spring and once in the fall.

For a 100,000-square-foot roof located approximately 30 minutes from the contractor, a typical maintenance visit may cost around $2,400 per visit.

NOTE: The $2400 is our best estimate. However, the ballpark cost for commercial roof maintenance can vary greatly and is usually $0.02-$0.10 per square foot.

Annual Maintenance Cost:

• Spring maintenance: $2,400

• Fall maintenance: $2,400

Total Annual Cost: $4,800

Over the first 19 years, the total maintenance investment would be:

$4,800 × 19 years = $91,200.

Compared with the initial $400,000 roofing investment and future recoat costs, these maintenance expenses are relatively small and help identify minor issues before they become major problems.

Year 20: Recoat

A recoat costs approximately 40% of the original installation in today’s dollars.

Using an inflation calculator, the estimated recoat cost is $262,432.

Because this expense is anticipated years in advance, building owners have ample time to plan and budget accordingly.

The Cost of Uncertainty

The alternative to financial predictability is financial surprise.

A roof leak can occur during any storm, at any time.

For some businesses, the consequences go far beyond the cost of repairing the roof.

Imagine:

• A medical equipment manufacturer whose inventory is damaged by water intrusion.

• A warehouse operation that stores customer products and experiences inventory loss.

• A production facility forced to halt operations due to water entering the building.

The costs can quickly extend beyond roofing, affecting operations, customers, production schedules, and revenue.

Even worse, these expenses often occur when they are least expected and when capital budgets are already committed elsewhere.

Final Thoughts

*Cost is an estimation. The estimated maintenance costs did not account for inflation.

A roof coating system does more than waterproof a building.

It creates predictable financial forecasting.

When building owners know what maintenance is required, when future work will occur, and approximately what it will cost, they gain something every facility manager values:

The ability to plan ahead with confidence.

How to Repair a Commercial Roof Without a Tear-Off (and Avoid Costly Disruption)

Thu, 11 Jun 2026 14:14:12 GMT

How to Repair a Commercial Roof Without a Tear-Off (and Avoid Costly Disruption)

Most building owners think a failing roof means one thing: Tear it off and start over.

For one of our recent clients, that assumption came with a $5.2 million price tag—and that didn’t even include the cost of protecting the interior or the risk of disrupting daily operations.

But they didn’t go that route.

Instead, they chose a roof restoration system that solved their leaks, avoided a complete tear-off (less than 1% of the roof was removed and replaced), and saved approximately $4.2 million in the process.

Here’s how—and whether the same approach could work for your building.

Quick Note: This article has been read, edited, and approved for publishing by Chris West, President of West Roofing Systems, who has 30+ years of commercial roofing experience.

The Hidden Cost of Tearing Off a Commercial Roof

Most roofing conversations focus on material and labor costs.

But for many commercial facilities, the bigger concern is what happens inside the building during a tear-off .

A full roof replacement often involves:

Exposing sections of the building to the elements
Coordinating interior protection to prevent damage
Increased noise and safety concerns
Potential production slowdowns—or even temporary shutdowns

While the exact cost of disruption varies by facility, one thing is consistent:

A tear-off introduces risk that goes far beyond the roof itself.

Is It Possible to Repair a Roof Without a Tear-Off?

Yes—but not every roof qualifies.

In many cases, a commercial roof can be restored rather than replaced, provided the underlying system remains structurally sound.

A restoration system works by repairing or reinforcing problematic roof areas and installing a fully adhered, fluid-applied, seamless membrane over the existing roof.

This eliminates leaks without removing the original system.

However, restoration may not be an option if:

• More than 25% of the roof’s insulation is wet

• The seams have lost a great deal of adhesion

• No annual maintenance has been performed

• The roof system is in a state of failure

That’s why a proper inspection—including core samples and moisture analysis—is critical before any work begins.

The Best Commercial Roofing Options Without a Tear-Off

If your roof qualifies, there are two primary restoration solutions:

Silicone Roof Coating Systems

Silicone coatings are ideal for roofs like EPDM, TPO, and Metal.

They create a seamless, waterproof membrane that:

• Stops leaks

• Extends the life of the existing roof

• Reduces roof’s temperature; therefore, increasing HVAC longevity and performance

• Provides a 10–20-year, renewable warranty

Best of all, they can typically be installed with minimal disruption to your operations.

Spray Polyurethane Foam (SPF) Roofing Systems

Spray foam is especially effective over gravel built-up roofs, but is installed over TPO, EPDM, Granulated Modified, Metal, and Smooth Modified’s every single season.

It expands into a fully adhered and monolithic, insulated roofing system that:

• Seals the entire surface with no seams

• Adds a tremendous amount of insulation value (reducing energy costs)

For buildings with many penetrations and/or rough or irregular surfaces, SPF is often the most cost-effective solution.

Real Project Example: $4.2 Million Saved Without a Tear-Off

Manufacturing Plant with a roof greater than 100,000 square feet.

Original plan projected by their internal engineers:

• Full tear-off and replacement

• Total budget: $5.2 million

• Interior protection required

• High potential for lost revenue due to operational disruption

Our Recommendation:

• After the infrared survey, less than 1% of the existing roof needed to be removed and replaced

• Install a restoration system over the existing roof

Final Outcome:

• Project cost: approximately $1.0 million

• Direct savings: ~$4.2 million

• No full tear-off required

• Minimal disruption to daily operations

• No interior protection needed

• Lower roof temperature = increased HVAC performance

• 20-year, renewable, manufacturer’s warranty

What About Production Downtime?

For many facilities, this is a major area of focus when evaluating the overall cost of a roofing project.

Simple Example: A big box store must close for 2 weeks for a roofing project. It’s not just the cost of the roofing project that matters; the 2-week loss of revenue adds to the overall cost.

A tear-off isn’t just a construction project; it’s filled with other negative connotations, such as:

• Weather exposure during installation

• Debris or contaminants entering the building

• Safety risks for employees

• Noise impacting productivity

• Coordination challenges across departments

Because this project avoided a tear-off, the customer avoided these risks as well.

While it’s difficult to assign an exact dollar amount to downtime, the impact can be significant—especially in manufacturing or production environments.

When Is Tearing Off a Commercial Roof the Right Choice?

Not every roof can—or should—be restored.

A full replacement may be necessary if:

• The roof’s insulation is more than 25% saturated

• The seams have completely lost adhesion

• No one has been on the roof for maintenance in multiple years

In these cases, a tear-off is your only option. If someone recommends a coating system or tries to sell you on putting ANY roofing system over what you have, there will be many issues, such as:

• Poor adhesion/delamination of materials to existing substrate or membrane.

• Failure of existing membrane and seams even after installation of new silicone coating.

• Continued leaks after coating application are dependent on the amount of wet insulation found.

How to Know Which Option Is Right for Your Building

The only way to know for sure is with a detailed roof evaluation.

This typically includes:

• Visual inspection

• Core samples to assess insulation

• Moisture scanning

• Review of leak history

From there, you can determine whether a restoration system can solve the problem—or if replacement is necessary.

Tear-Off vs. Restoration: A Quick Comparison

This is a comparison of an actual roof coating project completed in 2025:

Want to Avoid a Tear-Off? Start with an Inspection

If your roof is leaking or nearing the end of its life, a full replacement might not be your only option.

In many cases, a properly designed restoration system can:

• Stop leaks

• Extend roof life

• Reduce costs

• Avoid disruption to your business

• Provide long-term warranties

And as this project shows, the savings can be substantial.

The key is knowing whether your roof qualifies.

�� Schedule a Roof Evaluation

If shutting down your facility—even for a short time—isn’t an option, we can help you determine whether your roof can be restored without a tear-off.

We’ll evaluate your system, walk you through your options, and give you clear, honest recommendations based on your building—not a one-size-fits-all solution.

The Ultimate Guide to Spray Foam Roofing (Costs, Problems, and Alternatives)

Wed, 03 Jun 2026 22:18:36 GMT

The Ultimate Guide to Spray Foam Roofing (Costs, Problems, and Alternatives)

Here's what's covered:

How much does a spray foam roof cost per square foot?
What common problems do spray foam roofs have?
SPF vs TPO - which system is better?
How is a spray foam roof installed?
How does maintenance work after a spray foam roof is installed?
What warranty options are available?
How long will a spray foam roof last?

1. How much does a spray foam roof cost per square foot?

A spray foam roof usually costs $5-$10 per square foot. There are many variables that influence cost, such as warranty length, spray foam thickness, and roof preparation.

This article explains all the variables that can influence the cost of a spray foam roofing system.

2. What common problems do spray foam roofs have?

Common problems are that very few know how to install a spray foam roof properly, and there's overspray risk.

This article explains all the problems with spray foam roofing systems.

3. SPF vs TPO - which system is better?

For a flat roof with no ponding water and very few penetrations, TPO is likely more cost-effective on the install. For everything else, spray foam is more cost-effective.

This article explains the scenarios in which spray foam or TPO is the better option.

4. How is a spray foam roof installed?

Two 55-gallon drums (an A-side and a B-side) are pumped, heated, and transferred through a hose to a spray gun, where the spray foam comes out as a liquid.

This article explains how a spray foam roof is installed.

If you want to see video, it's below:

5. How does maintenance work after a spray foam roof is installed?

A contractor shows up at least once per year to inspect for any punctures in the roof, thin coating, and drainage issues.

This article explains in more detail how to maintain a spray foam roof.

6. What warranty options are available after a spray foam roof is installed?

10, 15, or 20-years are the current options. The thickness of the protective coating installed over the spray foam determines the warranty length.

10 years = 20 total mils of coating
15 years = 25 total mils of coating
20 years = 30 total mils of coating

This article explains in more detail how the warranty is granted after a spray foam roofing installation.

7. How long will a spray foam roof last?

A spray foam roof should last as long as the building is up. The reason is renewability. A spray foam roof can be recoated over and over again without losing performance.

This article explains in more detail how renewability (and sustainability) works on a spray foam roof.

How Silicone Roof Coatings Extend Your Roof Lifespan in Cleveland

Wed, 03 Jun 2026 05:00:16 GMT

How Silicone Roof Coatings Extend Your Roof Lifespan in Cleveland

If your commercial roof in Cleveland, OH shows signs of weathering but hasn't failed structurally, silicone roof coatings provide a restoration solution that extends service life without the expense of full replacement. Silicone systems resist UV degradation, tolerate ponding water, and form a seamless protective layer over metal, single-ply, and spray foam substrates, making them ideal for Cleveland's variable climate and industrial exposure.

What Are Silicone Roof Coatings?

Silicone roof coatings are elastomeric liquid membranes applied directly over existing commercial roofing materials to restore waterproofing and reflectivity.

Unlike acrylic or asphalt-based products, silicone formulations maintain flexibility and adhesion even when submerged in standing water. This makes them especially effective on flat roofs with drainage challenges common in older Cleveland, OH buildings.

The coating cures into a monolithic barrier that bridges cracks, seals seams, and protects underlying materials from moisture intrusion and ultraviolet damage. Businesses near me searching for cost-effective roof restoration often choose silicone coatings because they avoid the disruption and landfill waste associated with tear-off projects.

Which Roof Types Benefit Most from Silicone Coatings?

Silicone coatings adhere to metal panels, TPO and EPDM membranes, built-up roofing, modified bitumen, and existing spray polyurethane foam systems.

Metal roofs with rust spots or failing fasteners regain watertight integrity when coated with silicone, which bonds chemically to bare steel and galvanized surfaces. Single-ply membranes suffering from seam separation or UV embrittlement receive a new protective layer that stops leaks and reflects solar heat.

Spray foam roofs nearing the end of their topcoat warranty can be recoated with silicone to renew waterproofing and extend service life by another decade or more. For commercial roof repair services in Cleveland, OH , silicone restoration often proves more economical than membrane replacement while delivering comparable performance.

Do Silicone Coatings Withstand Cleveland's Weather Extremes?

Yes, silicone formulations are engineered to endure wide temperature swings, heavy precipitation, and the freeze-thaw cycles typical of Northeast Ohio winters.

The coating remains elastic below freezing and resists cracking when ice forms on the roof surface. During summer, silicone's high solar reflectance reduces roof temperatures by twenty to thirty degrees, lowering cooling costs and slowing thermal degradation of the substrate.

Cleveland's industrial corridor exposes roofs to airborne particulates and acid rain, but silicone coatings resist chemical attack and maintain adhesion even in polluted environments. Our crews apply coatings during dry weather windows, ensuring proper cure and long-term bond strength.

How Does Application Impact Your Business Operations?

Silicone roof coating projects typically involve minimal downtime because the application process does not require removing the existing roof or interrupting indoor activities.

Crews clean and prepare the surface, make spot repairs as needed, then apply the coating in multiple passes using rollers or spray equipment. Most commercial buildings remain fully operational throughout the project, with work scheduled during off-peak hours when necessary.

The coating cures quickly, often within hours, allowing phased application across large roof areas without prolonged exposure to the elements. This stands in contrast to full replacement projects that demand extensive staging, debris removal, and building closures.

West Roofing Systems brings decades of coating expertise to every Cleveland, OH project. Our in-house teams use only proven silicone formulations and back installations with renewable ten- to twenty-year warranties.

Request a roof evaluation to determine if your facility qualifies for coating restoration—connect with West Roofing Systems at 440-355-9929 or explore our spray foam roofing services in Cleveland, OH for complementary solutions.

Is Flute Fill + TPO Better Than a Silicone Roof Coating System?

Tue, 05 May 2026 13:52:00 GMT

It depends on your objective, whether you want to add insulation or want waterproofing, and if cost is a big factor.

Image source: Insulfoam – Flute Fill Insulation System

We recently had an operations manager ask whether a flute fill system with TPO was “better” than a silicone roof coating. The short answer: it depends on the goal—but in most cases, it’s not the better value.

In this article, you’ll learn about:

Cost
Seams vs Seamless
Do you need waterproofing or insulation?
What happens 10-20 years from now?
The risk of trapped moisture

If you’re collecting quotes from different contractors offering different solutions, you might be thinking, “Which solution really is best?”

Chris West, one of the owners of West Roofing Systems with over 30 years of commercial roofing experience, says it is important to understand the differences between the two roofing systems before deciding, as there are instances in which both systems win.

1. Cost: Significant Difference

Flute fill + TPO will cost significantly more than a silicone roof coating system .

Why?

Flute filler boards must be custom-cut to match the metal roof profile
A board needs to go on top of that
The TPO goes on top of the board

Flute fill + TPO involves more steps, is more time-consuming, and more complex than installing a coating system.

If your roof doesn’t need insulation, you’re paying for something you don’t need.

2. Seams vs. Seamless

TPO systems have seams, the #1 cause of roof leaks .

Here’s a photo of an older TPO roof:

A silicone roof coating system is fully seamless :

No laps. No welds. No weak points.

If your main concern is stopping leaks and keeping water out, eliminating seams is a major advantage.

3. Waterproofing vs. Insulation

This is the key question:
What does your building actually need?

If you need R-value and energy performance , insulation may make sense
If you need waterproofing , a coating system solves the problem directly

Many metal roofs leak—not because they lack insulation, but because they lack a watertight surface.

4. What happens 10-20 years from now?

Silicone coatings are renewable . They come with a 10–20-year warranty, depending on coating thickness.

At the end of the warranty period:

Clean the roof
Apply another coating layer
Get a new warranty

No tear-off. No disruption.

With TPO, you’re dealing with a full membrane system. While restoration options may exist later, they’re not as simple or cost-effective as recoating.

5. Risk of Trapped Moisture

Adding insulation introduces another potential issue: water intrusion into the system .

If moisture gets into the insulation layer through a hole in the membrane, it can:

Reduce performance
Go unnoticed
Lead to bigger issues over time

A coating system avoids this entirely—no added layers, no hidden moisture risks.

Bottom Line

For stopping leaks and extending roof life , a silicone coating system is typically:

More cost-effective
Lower risk
Easier to maintain long-term

If your goal is to add insulation , then a more complex system like flute fill + TPO may be worth exploring.

If you want insulation AND a seamless membrane, the spray polyurethane foam roofing system is worth exploring.

Most building owners want a leak-free roof, not more layers.

Our advice : get a quote for both (so you can get actual project cost numbers), then weigh the pros and cons with your team.

Spray Foam Roofing Solutions for Commercial Buildings in Lagrange

Mon, 04 May 2026 12:15:00 GMT

Spray Foam Roofing Solutions for Commercial Buildings in LaGrange

Commercial property owners in Lagrange, OH benefit from spray polyurethane foam roofing systems that create seamless, fully adhered surfaces across flat and low-slope roofs. Since 1979, West Roofing Systems has specialized in spray foam applications that deliver superior insulation, eliminate leaks, and lower long-term operating costs for warehouses, manufacturing facilities, and retail centers throughout Northeast Ohio.

What Is Spray Polyurethane Foam Roofing?

Spray foam roofing is a two-component liquid system that expands into a solid, seamless layer directly bonded to your existing roof substrate.

When applied by trained crews, the foam forms a monolithic barrier with no seams or joints where water can penetrate. This fully adhered membrane conforms to complex roof shapes and penetrations without the gaps common in traditional sheet systems.

The result is a lightweight, self-flashing surface that adds minimal load to your building structure. For commercial properties near me in Lagrange, OH and across the East Coast, spray foam offers a proven alternative to tear-off and complete replacement projects.

How Does Spray Foam Improve Energy Efficiency?

The closed-cell structure of spray polyurethane foam delivers exceptional insulation values, reducing heat transfer through your roof assembly year-round.

Higher R-values translate directly into lower heating bills during Ohio winters and reduced cooling demand when summer temperatures climb. Many facility managers report energy savings of fifteen to thirty percent after upgrading to spray foam systems.

By sealing air leaks and thermal bridges, spray foam also improves indoor comfort and reduces strain on HVAC equipment. If you're searching for spray foam roofing services in Lagrange, OH , you'll find that these systems pay for themselves through utility cost reductions over their service life.

Can Spray Foam Eliminate Persistent Roof Leaks?

Yes, the seamless application and full adhesion of spray foam roofing effectively stop water intrusion across flat and low-slope commercial roofs.

Traditional roofing membranes rely on seams, fasteners, and penetration flashings that degrade over time and create entry points for moisture. Spray foam bonds directly to the substrate, forming a continuous waterproof layer that self-flashes around vents, HVAC curbs, and roof drains.

This eliminates the weak points where most commercial roof leaks originate. Even roofs with ponding water issues benefit from the foam's resistance to moisture absorption and its ability to build slope for positive drainage.

How Do Winter Conditions in Lagrange Affect Spray Foam Performance?

Northeast Ohio's freeze-thaw cycles and heavy snow loads demand roofing systems that maintain flexibility and adhesion without cracking or delaminating.

Spray polyurethane foam remains stable across a wide temperature range and resists the expansion and contraction that damages conventional membranes. The foam's lightweight profile—typically less than one pound per square foot—prevents structural stress even under wet, heavy snowpack common in Lagrange, OH during January and February.

When protected with a silicone topcoat, spray foam roofs withstand decades of UV exposure, seasonal weather shifts, and the industrial pollutants present in manufacturing zones near Cleveland. Our crews apply foam year-round, adjusting procedures to ensure proper curing in cold weather.

West Roofing Systems has served commercial property owners across Northeast Ohio and the East Coast since 1979. Our in-house teams deliver spray foam installations backed by renewable ten- to twenty-year warranties.

Schedule a roof inspection to see if spray foam is right for your facility—call West Roofing Systems at 440-355-9929 or visit our silicone roof coatings services in Lagrange, OH page to explore complementary restoration options.

What Happens if the Foam Is Exposed on a Spray Foam Roof?

Tue, 24 Mar 2026 13:06:00 GMT

Quick Answer: Then you may have a serious problem. In most cases, it’s because the foam was not recoated in time. Exposed foam will degrade within 72 hours from UV rays. If foam is exposed, your roof is slowly degrading under UV exposure. The faster you have someone evaluate your roof, the less expensive the repair or restoration will be. The problem can only get worse.

Quick Story: I was manning our booth at the Ohio School Board Association in November 2025. A curious Director of Facilities saw a sample of a spray foam roof sitting on our table:

And they asked me, “What happens if the foam is exposed?”

The Complete Answer: A spray foam roof has four parts:

The base and topcoat of coating are there for a few reasons, but the most important is to keep the foam protected from UV rays.

The coating comes in a variety of thicknesses. The thickness determines the warranty length:

A 20-mil dry film thickness will get you a 10-year warranty.
A 25-mil dry film thickness will get you a 15-year warranty.
A 30-mil dry film thickness will get you a 20-year warranty.

When the warranty period is over, there’s less mils of coating left due to weathering effects. At that time, a recoat is recommended.

In simple terms, a recoat is making the sure the roof is clean and dry, then installing another layer of protective coating on.

Here is a short video showing a recoat installation:

A recoat makes a new warranty possible. And the process can repeat over and over again.

Maybe you ask…in what scenarios would there be exposed foam? Here are some:

The building owner never did a maintenance plan, and the roof was neglected when minor damage occurred
When the warranty was over, a recoat was not performed
Bad foam was installed
The coating wasn’t installed uniformly to provide proper coverage, or too thin

Let’s talk about each one of these a little bit:

Four ways your commercial roof can have exposed foam

No maintenance plan

Once the spray foam roof is installed, it needs basic maintenance to last just like every other roofing system. It’s no different than your car. You can expect a new car to last 10 years, but how long would it last if the oil was never changed?

When there’s no maintenance on a spray foam roof (actually…any roofing system, TPO, EPDM, Metal, any of them) the roof will simply not last.

A simple example is when flying debris, or a maintenance guy drops a tool on the roof and foam is exposed.

If there was a maintenance plan, an experienced eye would’ve been on that roof the next Spring or Fall, saw the damage, and could easily repair it, and the foam is no longer exposed.

If no one goes onto the roof for multiple years, a small repair today could turn into a much larger (and expensive) repair later.

Not performing a recoat

Sometimes the phrase “if it’s not broke, don’t fix it” comes into play in commercial roofing. If the roof isn’t leaking, then why spend money on it?

Sometimes building owners change and the new owner is unaware of how the spray foam roofing system works.

And a recoat isn’t cheap. It costs roughly 1/3 to ½ of the initial installation.

Either way, at some point, the coating isn’t going to last forever, and the foam will become exposed.

Bad foam was installed

There’s a science and an art to installing a good closed-cell spray polyurethane foam roof.

There’s required heat, pressures, spray patterns, speeds of foam, different cure rates, and probably a hundred more variables that can affect whether good foam is installed or not.

It’s absolutely critical to find a contractor who knows what they are doing and how to adapt to these requirements.

If you chose a contractor solely based off price, location, whatever it may be, and they aren’t experts in spray foam, a bad foam roof could be installed.

Bad foam can blister or split and become exposed to the sun before you expected it to.

Coating not installed uniformly or too thin

The elastomeric coating that’s installed over foam is the only thing protecting the foam from UV rays. If someone says they are going to install 20 mils, and they put down 10, your foam is highly likely to see the sun well before the contractor told you it would.

This is where contractor integrity matters.

As a building owner, property manager, etc. Someone not knee-deep into roofing materials every day. Would you be able to tell a 20-mil thickness versus 10?

A mil is one thousandth of 1 inch. The naked eye would have a very hard time telling the difference.

An installer uses a comb gauge to measure wet film thickness and/or a digital or magnetic gauge to determine thickness after the coating cures.

An installer could cut corners by using less material than they said they would, taking advantage of an uneducated client.

A thin application of coating will expose foam sooner than expected.

Conclusion: Exposed Foam Demands Immediate Action

When spray foam is exposed, deterioration begins immediately — and the longer it’s left unaddressed, the more expensive the solution becomes.

Closed-cell spray polyurethane foam is not intended to be exposed to UV light. Once the protective coating is gone, the sun immediately begins breaking it down. What may look like a small, harmless patch can quickly turn into chalking, cracking, pitting, and eventually water infiltration.

The good news?

If caught early, the damage can often be repaired and the roof can be recoated — extending its life for another 10, 15, or even 20 years.

If ignored, what could have been a recoat may turn into a scarf or complete tear-off.

If you suspect exposed foam:

Do not wait for a leak.
Do not assume it will “be fine.”
Have the roof inspected as soon as possible.

Spray foam roofs are one of the most renewable roofing systems in commercial construction — but only if the foam remains protected.

Exposed foam is not something to monitor.

It’s something to address.

If you are unsure whether your foam is exposed, have a qualified spray foam roofing contractor inspect it. A free, 30-minute inspection today could save you hundreds of thousands in replacement costs later.

Spray Foam Roofing Recoat Installed on 97,100 SF School Roof and Domes in Parma, OH

Thu, 05 Feb 2026 15:09:00 GMT

In this project profile, you’ll learn:

Project overview
The problem
Why a recoat was chosen
The scope-of-work
Before, in-progress, and after installation photos and videos
Results

Before we start, perhaps the coolest part of the project was installing the Petina Green-colored topcoat on the domes. The color represents landmarks used by the FAA for flight instructions. Maintaining this relationship was paramount, as the color is also a landmark for Parma residents.

Video Summary: We highly recommend you view this 1 min and 20-second video that shows the project from start to finish:

Project Overview

Location: Parma, OH
Building Type: School
Roof Type: Spray Polyurethane Foam
System Installed: Spray Foam Recoat
3rd Wing Classroom Roof and Two Domes: 97,100 SF
Project Goal: Minimize tear-off and cost, extend roof life, get roof under new and renewable warranty

The Problem

We’ve been working with the same facilities director for multiple decades. He retired mid-project. So we had to bring the new director up to speed on the status/conditions of all the roofs in the Parma District. One issue that was avoided is that when new directors take over, they like to manage roofing systems they are familiar with, whether that’s metal, TPO, etc.

We had to thoroughly explain the spray foam roofing system. Along with the pros and cons of it and other alternative methods they could’ve chosen.

Why a Spray Foam Recoat Was Chosen

It’s the most cost-effective solution. The alternative of a complete tear-off and replacement would cost at least 4x as much as a recoat.

The total square footage was 97,100, and the bid included only 5,760 square feet of roof removal and replacement. Roughly 5.93%.

This meant that roughly 94% of the existing roof stayed. Minimizing tear-off reduces labor, materials, and landfill costs.

Removing 100% of the roof would’ve cost astronomically high.

Summary of Scope of Work

The project includes:

Site preparation and safety setup
Thorough cleaning of the roof and domes using high-pressure washing
Remove 5,700 square feet of wet spray foam
Install one-way vents and drain covers
Install spray foam at 1.5″ thick
Applying high-solids silicone coatings to specified thicknesses
Install Petina Green topcoat on domes to continue the relationship with the FAA

The project concludes with a full site cleanup, oversight by an OSHA 30-hour-trained superintendent, and a 20-year warranty provided to the owner upon completion.

Before, In-progress, and After Installation Photos and Videos

Before:

In-progress:

After:

Now that you’ve seen some photos, here are a few videos of the installation:

Results

The project was completed in roughly 57 days, including many days where no work was performed due to weather and holidays.

The client’s desire to renew the existing roof before school started, maintain the current color scheme, and obtain a renewable 20-year warranty was achieved at the most cost-effective price.

Important Links

Want to learn more about spray foam recoats, such as how much they usually cost, common issues they have, and what kind of roofs are eligible for them:

Silicone Roof Coating System Installed on 36,300 SF Metal Roof in Elyria, OH

Thu, 15 Jan 2026 14:26:00 GMT

In this project profile, you’ll learn:

Project overview
The problem
Why a silicone roof coating system was chosen
The scope-of-work
Before, in-progress, and after installation photos and videos
Results

NOTE: Before you view the text below, we highly recommend you view this 1 min and 20-second video that shows the project from start to finish:

Project Overview

Location: Elyria, OH
Building Type: Ice Rink
Roof Type: Metal Roof
System Installed: GAF High-Solids Silicone Roof Coating System
Roof, Perimeter Walls, and Concrete Walls Size: 56,100 SF
Project Goal: Avoid tear-off, extend roof life, minimize cost, change building/roof color

The Problem

“Gross” – an actual term used by the client to describe how the current roof and building look.

A modern look was greatly desired.

The existing metal roof was also nearing the end of its service life and experiencing recurring leaks. A full tear-off would have disrupted the public and significantly increased project costs.

Why a Silicone Roof Coating Project Was Chosen

It’s the most cost-effective solution. The alternative of a complete tear-off and replacement would cost at least 2x as much as the coating system.

An acrylic application was brought up, but due to acrylic requiring extra coats and more labor, that wasn’t cost-effective either. Plus, because aesthetics are very important to the client, acrylics absorb more of the elements and lose their shine/brightness much faster than silicone.

GAF's High-Solids Silicone was also selected because it can be installed directly over the existing metal roof, providing a seamless waterproofing system.

Many leaks were occurring at loose fasteners and seams between the metal panels. With silicone being fluid-applied, all penetrations are completely sealed.

Summary of Scope of Work

The project includes:

Site preparation and safety setup
Thorough cleaning of the roof and perimeter walls using high-pressure washing
Roof repairs involve sealing screw heads, seams, and penetrations with silicone materials
Masking all mechanical equipment
Applying high-solids silicone coatings to specified thicknesses
Damaged metal wall panels will be replaced
Both the roof and metal walls will receive a full silicone topcoat
Concrete walls will be repaired as needed, primed, and coated with acrylic elastomeric coating
Existing gutters will be removed and replaced with new 24-gauge steel Kynar-finished gutters and downspouts

The project concludes with a full site cleanup, oversight by an OSHA 30-hour-trained superintendent, and a warranty provided to the owner upon completion.

Before, In-progress, and After Installation Photos and Videos

Elyria Ice Rink In-Progress:

Elyria Ice Rink Finished:

Now that you’ve seen some photos, here are a few videos of the installation:

Drone overview of roof/preparing fasteners and seams:

Coating Installation:

Preparing Seams and Fasteners:

Results

The project was completed in roughly 61 days, including many days where no work was performed due to weather.

The client’s desire to renew the existing roof and walls, stop leaks, minimize interruption, change the color, and obtain a renewable warranty was accomplished in the most cost-effective way.

Important Links

Want to learn more about silicone roof coating systems, such as how much they usually cost, common issues they have, and what kind of roofs are eligible for them:

What Happens When the Coating Wears Away on a Roof Coating System?

Tue, 06 Jan 2026 18:25:00 GMT

Quick answer: You just powerwash the roof clean and apply additional coating.

Quick video with answer and explanation:

Quick Story: I was manning our booth at the Ohio School Board Association in November 2025. Two different people saw a sample of a roof coating system sitting on our table:

And they asked me, “What happens when the coating wears away?”

The Complete Answer: When an elastomeric roof coating system is installed, the warranty is determined by the coating thickness.

A 20-mil dry-film thickness will provide a 10-year warranty.
A 25-mil dry-film thickness will provide a 15-year warranty.
A 30-mil dry-film thickness will provide a 20-year warranty.

Let’s say that the 30-mil/20-year warranty system was installed.

In year 20, there should be a few mils of coating left.

The elastomeric coating is designed to wear away naturally over time.

Coating manufacturers have done extensive testing to determine how long a certain coating thickness will last. I’m not sure, but I bet if 30 mils are installed…there’s almost a 99.999% chance there will be coating left after year 20.

Now that we got that out of the way, what happens next…

When a coating system is installed, a maintenance contract may be included. This allows the installing contractor to visit the roof twice per year and look for many things, including:

If drains are clogged
If gutters are clogged
If there’s any evidence of thin coating
Any weather-related damages, such as hail damage
Damage from animals

Amongst many other things.

The point is to ensure the coating system is functioning as intended and that nothing interferes with its performance.

Fast forward to year 20.

The roof is in good condition (it’s been maintained every Spring/Fall for the past 20 years) and has 3 mils of coating remaining.

The contractor simply powerwashes the roof clean at the specified PSI per manufacturer specifications, ensuring a clean membrane.

The membrane needs to be very, very clean so that the new coating being installed adheres to what’s already there.

The contractor then installs a new 30-mil-thickness of coating. And a new 20-year warranty is granted.

Conclusion

The simple answer is that the coating naturally wears away; when it’s almost gone, the roof is cleaned, and more coating is installed.

Hopefully, after this post, you’ve learned that there are other things involved, such as maintenance.

Want to learn more about roof coating systems? Here are some other questions property managers want to know about:

If videos are your thing, we have over 450 videos on our YouTube Channel . Many are 15-30-second clips of roof-coating installations.

St. Vladimir Church – Roof Recoat & Restoration (Parma, OH)

Tue, 06 Jan 2026 15:47:00 GMT

Introduction

St. Vladimir Church, a longstanding parish serving the Parma, Ohio community since 1957, required a durable roof maintenance solution in 2025. West Roofing Systems returned to the site — having installed the original spray foam roof in 1993 and a first recoat in 2003 — to perform a roof recoat system that would extend the service life of the existing roof while addressing internal drainage challenges.

Project Overview

Project Year: 2025
Location: Parma, Ohio
Roof Size: Approximately 10,000 sq ft
System Installed: Acrylic recoat over existing coating
Manufacturer: Sherwin-Williams
Warranty: 10-Year Full System, Non-Prorated, No-Dollar-Limit, Renewable contractor warranty

Project Challenges

The roof had been recoated in 2003 and required a high-performance recoating system to protect the substrate.
The building’s internal gutter system was contributing to ponding and water retention, requiring improved slope and coating work.
Since the roof system had work performed in prior decades, the recoating solution had to be compatible with existing materials to avoid a full tear-off.

Our Solution

West Roofing Systems selected a high-solids acrylic roof recoat system by Sherwin-Williams to provide renewed protection over the decades-old coating. The process included:

Adjusting the slope of the internal gutter system to enhance water drainage and reduce ponding.
Preparing and cleaning the existing roof surface to ensure product adhesion.
Applying an acrylic base coat and intermediate coat to refresh the roof field.
Installing a tinted topcoat to provide a glossy, long-lasting finish.
Using a total dry mil thickness of approximately 20 mils for optimal durability and weather resistance.

Warranty & Protection

The completed system was backed by a 10-year , non-prorated, no-dollar-limit, renewable full-system warranty, giving St. Vladimir Church long-term confidence in the roof’s performance.

Results & Benefits

Extended Roof Life: The acrylic recoat refreshes the waterproofing and extends the roof’s service life.
Improved Drainage: Adjusting the internal gutter slope significantly reduced ponding water.
Cost-Effective Solution: A full tear-off wasn’t required, saving the parish substantial cost and disruption.
Warranty Protection: The 10-year full-system warranty provides peace of mind and can be renewed as needed.

Want to see the scope-of-work and before/after photos? View the PDF below

Need a free quote?

The Hidden Costs of Roof Tear-Offs: Why Silicone Roof Coatings Save

Tue, 09 Dec 2025 14:12:00 GMT

When most building owners think about replacing their roof, they focus on the visible costs: materials, labor, and disposal. But there are hidden expenses that can dramatically increase your total project cost — especially when a complete tear-off is involved.

One of the biggest advantages of installing a silicone roof coating system over your existing roof is that it can eliminate the 100% tear-off , saving you time, money, and logistical headaches.

It CAN eliminate…

Yes.

You can’t simply apply a coating over any existing roof and expect it to be fine. Well, I guess you can…but that would be a very unethical thing for a contractor to do.

To get a manufacturer’s warranty, there are three conditions the roof must meet:

Around 75% or more of the roof’s insulation is dry
The seams and flashings have a good amount of adhesion (they are not blown open)
And there must have been annual maintenance on the roof

This article provides a detailed explanation of the three conditions.

In some cases, 3% of the roof’s insulation and membrane need to be removed and replaced before the coating prep process can begin. Other times it’s 0%. And other times it’s 20%.

But if 50% of the roof is wet. It’s beneficial to the building owner to rip everything off and start over.

The point is, minimizing tear-off is a good thing. And if the building owner/representative is proactive enough, having zero tear-off and avoiding the following “hidden” costs can really save money.

Let’s break down what those hidden costs are.

1. The Tear-Off Adds More Than Just Labor

Tearing off an existing roof isn’t just noisy and disruptive — it creates several expensive ripple effects:

Landfill costs : Every square foot of old roofing that’s removed must be disposed of. That’s thousands of pounds of material heading to landfills.
Labor intensity : Tear-offs require large crews and long hours just to remove and clean up debris before a new system can even begin.
Material replacement : Once you tear off, you have to replace what you removed — insulation, cover board, and sometimes even the deck itself.

These factors alone can increase the cost of a traditional tear-off to twice that of a restoration project using silicone coatings.

You know what else adds to hidden costs…

2. The Cost of Interior Protection

One cost that’s often overlooked is interior protection — temporary barriers and netting systems installed inside the building to protect sensitive equipment, products, and workers from falling debris or dust during a tear-off.

Depending on your facility, this can range from $2.50 to $10 per square foot.

Basic interior protection: $2.50–$5 per sq. ft.
Netting systems (for heavier debris or deck replacement): $6–$10 per sq. ft.

These costs vary based on the type of facility and the level of access the interior protection company has to complete their work.

For example, a recent discussion with one of our project managers, Ryan Mains , revealed a real-world scenario:

“A customer with an 80,000 sq. ft. production warehouse was paying around $2.50 per sq. ft. for interior protection just for a small section of roof work,” he explained.

“They were producing medical-grade electronics, so even a speck of dust or a static charge could ruin equipment. Their protection system stayed up for the entire two-week project.”

In some cases, especially in electronics or food production facilities , interior protection isn’t optional — it’s mandatory for safety and compliance reasons.

NOTE: Even if there’s no deck replacement, interior protection may be needed. With the medical-grade electronics facility, roofers using shovels for tear-off would cause dust to fall from the ceiling. Same with a food processing plant. Even though the roof is being torn off down to the deck and the deck remains in place, work on the roof may still require interior protection.

3. Work Schedule Greatly Impacts the Cost

Another factor that drives up the price is how often the interior protection crew can work .

If your building allows consecutive workdays (Monday through Sunday) , the setup and removal of interior protection occur only once — saving time and money.

But if work is limited to weekends only , the cost skyrockets. Crews must remobilize each weekend.

“Some places only allow weekend work to avoid interrupting production,” our rep explained. “Instead of finishing in five straight days, you’re looking at two or three weekends — which means more labor, more trips, and higher costs.”

4. Why Silicone Roof Coatings Avoid All of This

With a silicone roof coating system , your existing roof stays in place. There’s minimal tear-off, no debris, and no need for interior protection.

No landfill waste
No downtime for your facility
No interior protection
No exposure to weather during deck replacement (if necessary)

Instead, your roof is cleaned, repaired, and coated , creating a seamless, watertight membrane that extends the life of your roof by 10–20 years.

5. Be Proactive — Don’t Wait for Leaks

When it comes to roof coatings, timing is everything. Too many building owners wait until the roof leaks to take action — and by then, it’s often too late for a coating system to be a simple solution.

Once water has saturated over 25% of the total roof’s insulation, a complete tear-off becomes unavoidable, which means higher costs, more downtime, and potential interior protection requirements.

A proactive approach is key. If your roof is in good condition and under warranty, the best time to consider a coating system is when the warranty expires . Being proactive allows you to:

Extend the life of your existing roof before problems start
Avoid the surprise of leaks and emergency repairs
Plan for predictable maintenance cycles
Maintain warranty coverage through renewals every 10, 15, or 20 years

For large corporations, this also means predictable budgeting . With a renewable coating system, you can forecast roofing costs years in advance, rather than reacting to unexpected failures.

On the other hand, waiting until the roof fails can result in:

Sudden leaks and water damage
Emergency tear-offs
Production interruptions
The need for costly interior protection
Overall costs that are 3–5x higher than a proactive coating system

Taking a proactive approach not only protects your roof — it protects your budget , operations , and provides peace of mind .

NOTE: It’s 100% true…a complete tear-off and replacement, along with interior protection and lost labor can be 5x more expensive than installing a coating system. We are on a project right now in October 2025, installing a coating system. They ran the numbers over a 5 year period on what the roof costs would be if they did (or did not) install a coating system. If they waited, the costs would be 5x higher…resulting in millions of extra dollars spent that would’ve been avoidable.

6. The Bottom Line

When comparing roof replacement options, always factor in the hidden costs of a full tear-off — not just materials and labor, but also interior protection, downtime, and risk.

In many cases, a silicone roof coating system can save building owners $3 to $10 per square foot simply by avoiding those hidden expenses.

Interested in Learning If Your Roof Qualifies?

We can evaluate your existing roof and determine whether a silicone restoration system is a fit.

Commercial Roofing Options in Cleveland, Ohio

Tue, 02 Dec 2025 14:25:00 GMT

Quick Answer: In Cleveland’s climate, the best commercial roof options are silicone coatings (for roofs in decent shape), spray foam (for built-up or gravel roofs), or full replacement (for roofs with severe moisture or structural damage).

If you manage or own a commercial building in Northeast Ohio, you know your roof takes a beating. Between lake-effect snow, freeze-thaw cycles, and humid summers, commercial roofs around Cleveland face constant stress.

If your building’s roof is leaking or very old, you’re probably wondering: What are my options?

The good news is that replacing your roof isn’t always your only choice.

In fact, we hate replacing roofs. Sometimes it’s unavoidable, but in many cases, it’s cost-effective to install “something” over top and minimize tear-off.

Today, property managers in places like Cleveland, Chagrin Falls, Mentor, and Strongsville have several cost-effective restoration options depending on their existing roof type and condition.

Common Commercial Roof Types Around Cleveland

Before talking about options, let’s look at what’s already on most commercial buildings in Northeast Ohio:

TPO and EPDM: Common single-ply membranes used on flat or low-slope roofs.
Gravel-Built-Up Roofs (BUR): Older buildings often have these heavy, layered roofs that hold up well but can be hard to maintain and to detect where leaks are occuring.
Modified Bitumen: Popular in the ’90s and early 2000s for small to mid-sized buildings.
Metal Roofing: Common on warehouses and industrial facilities.

Each of these roof types reacts differently to Cleveland’s weather — and that determines whether restoration or replacement makes sense.

Your Options for a Commercial Roof in Cleveland

1. Silicone Roof Coating System

(Best for TPO, EPDM, or Metal roofs in decent-to-good condition)

If your roof’s seams are in decent shape, there’s been at least annual maintenance, and there’s less than 25% wet insulation, a silicone coating system can restore it without a tear-off.

The coating is applied in liquid form and cures into a seamless, waterproof membrane.

Benefits:

The cheapest roofing system available – roughly $3.50 – $7.50 per square foot. Many variables influence cost.
The absolute minimum tear-off (If any). Only wet or damaged materials are removed and replaced.
Covers microscopic openings
Can be used to manipulate the slope to stop ponding water
Reflective surface lowers energy bills
Creates a seamless membrane. Most leaks occur due to loss of seam adhesion. With no seams, this leaking variable is eliminated.
Renewable 10-20-year warranty

2. Spray Polyurethane Foam Roofing

(Best for Gravel or Built-Up Roofs)

Spray foam roofing is one of the best options for older office buildings with gravel or built-up roofs, which are common across Cleveland suburbs like Bedford Heights and Parma.

The foam is sprayed directly over the existing roof (not loose gravel; after it’s removed, you can apply foam to the grainy, unlevel surface). The foam expands to create a new insulated layer. Then, it’s coated with a protective silicone topcoat.

Benefits:

Adds the best R-value available (6.5 per inch of thickness), which lowers energy costs
Fully adheres to grainy surfaces
Eliminates seams (where leaks occur most often)
Minimal tear-off occurs
Can be re-coated and renewed every 10–20 years

Best for: Older, rough-surfaced roofs that are difficult or expensive to tear off. The more penetrations, the more spray foam is cost-effective versus traditional installations. Because spray foam is fluid-applied, it can be installed around every pipe, drain, HVAC unit, curb, etc., without stopping, unlike traditional roofing systems, which require extra steps (like cutting and applying sealants) to become watertight.

NOTE: Keep in mind that per building code, two is the maximum number of roofing systems that a commercial roof can have. Installing spray foam over an existing roof would add another system. If there’s only one roofing system, you have nothing to worry about. If you have two, you might need to remove at least one complete roofing system before installing spray foam.

3. Full Roof Replacement

(Best for Severely Damaged Roofs)

If 25% or more of the roof’s insulation is wet or your deck is failing, a tear-off and full replacement might be your only option. In this case, any roofing system is an option. It would be best to get quotes for TPO, Metal, and Spray Foam, as these are the most popular roofing systems offered today.

Best for: Roofs with excessive trapped moisture, ripped wide-open seams, structural issues, or multiple failed repairs.

Cleveland Weather and Roof Performance

Cleveland’s climate makes roof performance especially critical:

Freeze-thaw cycles cause cracks and seam separation.
Lake-effect snow can lead to ponding water and extra weight.
Summer humidity and UV exposure shorten membrane lifespan.

That’s why restoration options like silicone coatings and spray foam systems are so effective here — they seal existing roofs against moisture and movement without the disruption of a tear-off.

What’s unique about Cleveland weather is that we get all 4 seasons. Your roof needs to perform in the heat and the snow, which is unlike many areas of the country.

In fact, when we install a coating, one would think it’s always the color white to maximize the sun’s reflectivity. In actuality, we frequently use a light grey topcoat.

The reason is to have some reflectivity (versus a black roof), while retaining some heat in the Fall/Winter.

Local Example: Office Building Roof in Solon

Valtronics reached out about their office building in Solon. Their existing smooth modified bitumen roof was close to failing.

As a manufacturer of medical devices, a speck of dust….let alone rain from a leaking roof, would greatly interrupt business.

After evaluating the roof, our team determined it was a great candidate for a hybrid system (a combination of spray foam and a coating system). We installed foam around their penetrations and installed coatings-only over the rest of the roof.

The result? A watertight, energy-efficient roof that cost 50% less than replacement — and came with a 15-year, renewable warranty.

NOTE: The “cost less” statement is only based on the money spent on the operation of restoration versus replacement. It does not include business interruption if a complete tear-off would occur.

Here’s the link to Valtronic’s project profile . It’s filled with before/after photos, scope of work, background info, etc.

There are over 20 project profiles on commercial roofing projects on our website , where you can view the scope of work and photos of before, in-progress, and finished work.

Next Steps: Get a Roof Evaluation in Northeast Ohio

If your office building or commercial property in the Cleveland area has an aging roof, you have options. The best way to know what’s possible is through a professional roof evaluation.

At West Roofing Systems , we’ll inspect your roof, document the condition, and determine whether restoration or replacement makes the most sense.

Midview High School – Silicone Roof Restoration

Fri, 14 Nov 2025 16:41:00 GMT

Introduction

Midview High School in Northeast Ohio faced a critical decision: its aging roof’s seams were failing, and the roof’s expected lifespan was only a few years.

Rather than re-roofing, West Roofing Systems proposed a Silicone Restoration Membrane (SRM) system that extended the roof’s life by more than a decade — delivering a dependable, cost-effective solution with a full-system warranty that takes them through year 11.

Project Challenges

The existing roof had seams that were losing adhesion, putting it at risk for leaks.
The school planned to move to a new building in ~11 years — investing in a temporary but high-quality solution made sense.
Budget constraints: a full re-roof was costly, while the school needed reliability in the short- to mid-term.

Our Solution

Conducted a full roof assessment , including nine adhesion tests on the existing membrane.
Power-washed the roof to remove debris and prepare for coating.
Striped all roof seams with 25 mils of silicone coating to reinforce weak areas.
Applied a 25-mil thick full silicone membrane over the entire roof surface to restore protection.
Provided an 11-year full-system warranty — aligning with the school’s timeline.

Results & Benefits

The restored roof is leak-free and fully warrantied through year 11 , exactly matching the school’s planned occupancy timeline.
The silicone system is much more affordable than a full tear-off but still offers durable, long-term protection.
By rejuvenating the existing membrane, West Roofing saved the school significant re-roof costs.
The project delivered a high-performance, low-risk solution aligned with the school’s future plans.

Want to see the scope of work and more before/after photos? View the PDF below:

Need a free roof assessment?

The Foundry (Medina, OH) – Historic Building Roof Restoration with Spray Foam

Thu, 06 Nov 2025 14:01:00 GMT

Introduction

Nestled in Medina, Ohio, The Foundry Social & High Voltage Indoor Karting operates out of a beautifully restored building originally built in the 1870s.

When roof leaks and aging materials threatened the integrity of this historic structure, West Roofing Systems stepped in with a spray polyurethane foam (SPF) restoration — reinforcing the roof, preserving the building’s character, and delivering long-term performance.

Project Challenges

The building is historic (1870s), so preservation was a top priority — work couldn’t drastically alter the building’s look
The existing roof had deteriorated and was prone to leaks, exposing the interior to weather risk
The team needed a durable solution that would protect the building while aligning with its architectural character
The roof required a system that would adhere well, seal seams, and handle transitions without compromising aesthetics

Our Solution

Thoroughly cleaned and prepped the existing roof substrate to ensure adhesion
Applied spray polyurethane foam (SPF) to build a seamless, continuous layer that restores insulation and water protection
Over the foam, installed a high-performance silicone coating system to reflect UV and add durability
Embedded granules into the coating in key areas to improve resistance and longevity
Sealed all penetrations, flashing details, and transitions to maintain a watertight, monolithic surface
Preserved the building’s historic character by using minimally invasive techniques and careful detailing

Warranty & Protection

Delivered a 20-year full-system warranty to ensure long-term protection and peace of mind

Results & Benefits

Created a watertight, insulated roof that protects the historic building from leaks and weather
Maintained architectural integrity — no unsightly modifications, just a restoration that works
Improved energy efficiency thanks to the insulating properties of the SPF
Reduced long-term maintenance costs compared to repeated patch repairs or a full tear-off
Long-lasting performance backed by the warranty

View the scope of work and before/after images in the PDF:

Need a commercial roofing quote?

MTD Facility – Robotic Spray Foam Roof Restoration (384,000 sq ft)

Tue, 04 Nov 2025 19:21:37 GMT

MTD Facility – Robotic Spray Foam Roof Restoration (384,000 sq ft)

Introduction

MTD entrusted West Roofing Systems to restore its 384,000 sq ft metal roof. Three spray-foam robots worked together to apply 2.5″ of closed-cell SPF in a single pass. The project was completed in 52 days by a 14-person crew, delivering a high-performance roof backed by a 20-year full-system warranty.

Project Challenges

The project presented several challenges: a massive 384,000 sq ft metal roof, a tight 52-day schedule, overspray risks from high-output robotic sprayers, temperature fluctuations during installation, and maintaining building operations throughout.

Our Solution

West Roofing first tested a 16,000 sq ft section over five years before committing to the full roof. Three spray-foam robots applied PremiSEAL 60R averaging ~7,384 sq ft/day. Custom foam-blocking skirts and wind screens managed overspray. After foam, 30 mil SeamlesSEAL ULTRA HS silicone coating was applied for UV protection and waterproofing, completed with new metal edge flashing, gutters, and downspouts.

Warranty & Protection

The system is backed by a 20-year manufacturer's total system warranty. The new roof also provides R-28 insulation value — more than double the previous R-value.

Results & Benefits

The robotic application completed the roof in under two months. The high R-value reduces energy costs significantly. Instead of tearing off the metal roof, this restoration reused the substrate, minimizing waste and cost.

Metzenbaum Center – Spray Foam Roof Restoration in Cleveland, OH

Thu, 30 Oct 2025 14:01:12 GMT

Metzenbaum Center – Spray Foam Roof Restoration in Cleveland, OH

The Metzenbaum Center, a developmental disability center in Cleveland, Ohio, needed a reliable and long-lasting roof solution. West Roofing Systems proposed a restorative spray polyurethane foam (SPF) roof system topped with silicone coating.

The Challenge

The existing roof was aging and experiencing leaks that threatened the facility's operations. A cost-effective solution was needed that would minimize disruption to the center's vulnerable population.

The Solution

West Roofing Systems applied spray polyurethane foam directly over the existing roof, creating a seamless monolithic surface. A silicone topcoat was then applied for UV protection and long-term waterproofing.

Results

The Metzenbaum Center received a 20-year renewable manufacturer's warranty, eliminated all leaks, and improved the building's energy efficiency — all without the disruption of a tear-off and replacement.

Peppertree II Condos – Spray Foam Roof Restoration in Boca Raton, FL

Mon, 27 Oct 2025 19:43:09 GMT

Peppertree II Condos – Spray Foam Roof Restoration in Boca Raton, FL

At Peppertree II Condos in Boca Raton, Florida, twenty aging roofs (25 years old) were experiencing chronic leaks and dangerous ponding due to zero slope. Rather than a costly replacement, West Roofing Systems delivered a spray foam restoration across all 20 units.

The Challenge

Twenty roofs with zero slope caused persistent ponding water and leaks. At 25 years old, the existing roofing system was at end of life. A solution was needed that could address drainage while avoiding full tear-off across the entire complex.

The Solution

Spray polyurethane foam was applied to all 20 roofs, building slope into the system to direct water toward drains and eliminate ponding. The seamless foam surface was then topped with a silicone coating for long-term waterproofing and UV resistance.

Results

All 20 roofs received a 20-year manufacturer's warranty. Ponding was eliminated, leaks stopped, and the HOA avoided the enormous cost of tearing off and replacing 20 roofs.

Mercer County Career Center – Spray Foam Roof Restoration in Mercer, PA

Fri, 24 Oct 2025 19:55:03 GMT

Mercer County Career Center – Spray Foam Roof Restoration in Mercer, PA

Mercer County Career Center (Mercer, PA) had a 106,000+ sq. ft. granulated modified bitumen roof nearing the end of its life. Instead of a full tear-off, West Roofing Systems restored the roof with spray foam and silicone coating.

The Challenge

The aging granulated mod-bit roof was experiencing leaks and deterioration. With over 106,000 sq ft to address and a school facility requiring minimal disruption, a restoration approach was preferred over full replacement.

The Solution

West Roofing Systems applied spray polyurethane foam over the existing modified bitumen roof, then topped it with a silicone coating system. This approach avoided tear-off, added insulation, and created a seamless waterproof surface.

Results

The career center received a new manufacturer's warranty, eliminated leaks, and gained improved insulation — all without the cost or disruption of removing and replacing over 100,000 sq ft of roofing.

Oakview Elementary School – Spray Foam Roof Restoration in Stoneboro, PA

Thu, 23 Oct 2025 18:00:45 GMT

Oakview Elementary School – Spray Foam Roof Restoration in Stoneboro, PA

When Oakview Elementary School in Stoneboro, Pennsylvania needed a new roof, cost was the top priority. The Lakeview School District selected West Roofing Systems to install a spray foam roof — avoiding a costly tear-off while achieving a new warranty.

The Challenge

The school district needed a durable, cost-effective roofing solution that would minimize disruption during the school year and stay within a tight budget. The existing roof required replacement but a full tear-off would be expensive.

The Solution

West Roofing Systems installed a spray polyurethane foam roofing system over the existing roof. The foam added insulation value and created a seamless, waterproof surface. A silicone topcoat provided UV protection and long-term durability.

Results

Oakview Elementary received a new manufacturer's warranty at a fraction of the cost of traditional replacement. The school district avoided tear-off costs and gained improved energy efficiency from the added insulation.

Spencer Forge & Manufacturing – Spray Foam over Metal & Shingle Roof

Wed, 22 Oct 2025 15:09:05 GMT

Spencer Forge & Manufacturing – Spray Foam over Metal & Shingle Roof

The historic 125-year-old Spencer Forge & Manufacturing facility in Spencer, Ohio required a full roof restoration across three separate roof sections totaling 26,500 sq ft — including metal panels and shingles.

The Challenge

Three different roof types across a historic facility: metal panels, shingle sections, and complex penetrations. A traditional replacement would require significant structural work and disruption to manufacturing operations.

The Solution

West Roofing Systems applied spray polyurethane foam over all three roof sections. The foam conformed to the varied surfaces, sealed all penetrations, and created a unified seamless waterproof membrane. A silicone coating completed the system.

Results

All three roof sections were restored with a single system, receiving a new manufacturer's warranty. The historic facility was protected without a tear-off, preserving the structure and avoiding operational disruption.

University Studios – Spray Foam Roof Restoration in Cleveland, OH

Tue, 21 Oct 2025 14:55:24 GMT

University Studios – Spray Foam Roof Restoration in Cleveland, OH

Located in Cleveland, Ohio, University Studios is a multi-roof apartment building that was experiencing leaks and energy inefficiencies. West Roofing Systems restored 12,000 sq ft across three separate roofs using spray polyurethane foam.

The Challenge

Multiple roof sections with different conditions, active leaks, and residents living in the building below — requiring a solution that was fast, minimally disruptive, and long-lasting.

The Solution

Spray foam was applied across all three roof sections, creating a seamless monolithic surface on each. The foam added insulation and eliminated all seams. A silicone coating was applied for waterproofing and UV protection.

Results

All three roofs received a new manufacturer's warranty. Leaks were eliminated, energy efficiency improved, and residents experienced minimal disruption during the restoration process.

Heskett Middle School – Spray Foam Roof Restoration Over 104,000 sq ft

Mon, 20 Oct 2025 18:14:15 GMT

Heskett Middle School – Spray Foam Roof Restoration Over 104,000 sq ft

When the 20-year-old built-up roof at Heskett Middle School in Bedford Heights, Ohio began leaking, the school district faced a costly and time-sensitive problem. West Roofing Systems completed the 104,000 sq ft restoration in just 37 days — saving an estimated $1M over a full replacement.

The Challenge

A 104,000 sq ft aging built-up roof with active leaks, a tight summer schedule before school resumed, and a budget constraint that made full replacement impractical.

The Solution

West Roofing applied spray polyurethane foam over the existing built-up roof, then finished with a silicone coating. The entire project was completed in 37 days during summer break, well before students returned.

Results

The school district saved approximately $1M compared to a full tear-off replacement, received a new manufacturer's warranty, and had zero disruption to the school year. The foam also added significant insulation value, improving energy efficiency.

Maryland Court – Spray Foam over Smooth BUR Roof Restoration

Tue, 14 Oct 2025 18:34:39 GMT

Maryland Court – Spray Foam over Smooth BUR Roof Restoration

In 2023, West Roofing Systems completed a 16,560 sq. ft. roof restoration at Maryland Court using spray polyurethane foam (SPF) and silicone coatings over an existing smooth BUR roof.

The Challenge

The existing smooth built-up roof was showing signs of wear and experiencing leaks. The property needed a durable long-term solution without the expense and disruption of a full tear-off.

The Solution

Spray foam was applied over the existing smooth BUR surface, filling in any low spots and creating a seamless monolithic membrane. A silicone coating was then applied for waterproofing and UV resistance.

Results

Maryland Court received a 15-year full-system warranty, eliminated all leaks, and gained improved insulation — all while avoiding the cost of tearing off the existing BUR system.

Sharpsville Container – Spray Foam Roof Restoration & Coatings

Mon, 13 Oct 2025 14:59:28 GMT

Sharpsville Container – Spray Foam Roof Restoration & Coatings

Sharpsville Container, a commercial/industrial facility, required a durable, high-performance roof restoration after its existing roof showed signs of aging and wear. West Roofing Systems implemented a spray foam roof restoration system.

The Challenge

An aging industrial roof with wear and potential leak points needed a long-lasting solution that could withstand the demands of a manufacturing environment without disrupting operations.

The Solution

West Roofing Systems applied spray polyurethane foam over the existing roof surface, creating a seamless waterproof membrane. A high-performance silicone coating was then applied to protect the foam and provide UV resistance.

Results

Sharpsville Container received a new manufacturer's warranty and a durable roof system built for the demands of an industrial facility — without the cost and disruption of a full tear-off.

Elyria Foundry – Spray Foam & Silicone Roof Restoration

Fri, 10 Oct 2025 18:02:10 GMT

Elyria Foundry – Spray Foam & Silicone Roof Restoration

Introduction

Elyria Foundry in Ohio required a resilient, high-performance roof system to rehabilitate its aging roof. West Roofing Systems applied a spray polyurethane foam (SPF) system combined with silicone coatings to deliver a seamless, long-lasting roof system that restores protection and extends the life of the structure.

Project Challenges

The existing roofing materials had deteriorated and allowed leaks Surface irregularities, seams, and transitions needed smoothing and sealing Maintaining minimal disruption to business operations during roof work Ensuring the coating adhered properly to the substrate and remained durable Too much water was building up in areas. A water re-route needs to happen.

Our Solution

Built new structures to re-route water 4 different ways Applied spray polyurethane foam (SPF) to build up a consistent substrate Installed high-performance silicone coating system over the foam (base + topcoat) Embedded granules into the topcoat for UV protection and durability Sealed all transitions, penetration areas, and roof edges to ensure continuity

Warranty & Protection

10-year Full-system, No Dollar Limit, Non-prorated warranty issued.

Project Results & Benefits

A continuous, watertight roofing envelope Improved insulation and energy efficiency Restored roof protection without full roof replacement Minimized maintenance and leak risks

Want more details, along with more before and after photos? View the PDF below.

View the Elyria Foundry Full Project Profile (PDF)

Need a free quote?

Is your roof showing signs of failure or aging? Request a free quote with West Roofing Systems today to see how our spray foam + silicone solutions can restore and protect your investment — without a full tear-off.

Landmark Recovery (TN) – Spray Foam & Silicone Roof Restoration

Thu, 09 Oct 2025 14:50:28 GMT

Landmark Recovery (TN) – Spray Foam & Silicone Roof Restoration

Introduction

Landmark Recovery in Tennessee needed a durable, high-performance roof system to replace their failing membrane. West Roofing Systems applied a combination of spray polyurethane foam (SPF) and silicone coatings to deliver a seamless, watertight roof backed by a long-term warranty.

Project Challenges

Failing existing membrane with leaks and compromised integrity Roof surface irregularities needing smoothing and leveling Maintaining facility operations during the roofing process Need for a solution with long-term durability and minimal maintenance

Our Solution

Removed and prepared the existing roof substrate Applied spray foam to build up a uniform, solid base Over the foam, installed a silicone coating system (base + topcoat) Embedded protective granules into the topcoat for added UV resistance and durability Ensured transitions and penetrations were sealed and waterproofed

Warranty Coverage

20-year full-system, No Dollar Limit, non-prorated warranty issued

Results & Benefits

Seamless, monolithic roof system eliminated leak points Improved insulation and energy efficiency Extended roof life without full tear-off The roof is easy to maintain Strong warranty provides long-term peace of mind

Want to learn more details? And see more before, in-progress, and after photos?

View the Landmark Recovery (TN) Full Project Profile (PDF)

Need a free roof quote?

Is your roof struggling with leaks or nearing end-of-life? Contact West Roofing Systems to explore our spray foam + silicone coating solutions — proven, durable, and backed by warranties.

Spray Foam Roof Over Low-Slope Metal & Gravel in Chardon, Ohio

Wed, 08 Oct 2025 14:23:56 GMT

Spray Foam Roof Over Low-Slope Metal & Gravel in Chardon, Ohio

Introduction

In 2023, West Roofing Systems completed a 28,553 sq ft roof restoration in Chardon, Ohio, applying spray foam over an existing low-slope metal roof and gravel BUR. The roof's shape is unique — it slopes in all directions, meaning there is no flat area. Spray foam's seamless fluid application made the job more efficient and cost-effective than traditional roofing systems.

Project Details & Challenges

Roof size: 28,553 sq ft Completion: 29 days Roof composition: low-slope metal sections + gravel BUR The shape is complex — every foot slopes up or down Gravel had to be removed (hydro-vacuum) Skylights and sensitive areas covered for protection during install

Our Solution

Removed all loose gravel using hydro-vacuum methods Covered skylights & exposed roof areas with plywood to protect them Applied an average of 1.5 inches of closed-cell polyurethane foam (SPF) Installed 20 mils of urethane coating over the foam Manufacturer specs: Foam: SWD Coating: Neogard Issued a 10-year full-system renewable warranty after completion

Results & Benefits

Seamless, waterproof, and durable roof over a difficult, highly sloped surface Eliminated risk of leaks at transitions or slopes thanks to fluid SPF Cost savings compared to a full tear-off and re-roof Long-term protection backed by a 10-year warranty

Want more project details and before, in-progress, and after photos? View the PDF

View the Chardon Roof Case Study (PDF)

Need a free quote for your commercial roofing project?

Have a complex or sloped roof that seems impossible to restore conventionally? Contact West Roofing Systems today — we specialize in spray foam systems that adapt to challenging geometries, protect your structure, and come with solid warranties.

Granger Lakes Condos – Spray Foam Over Granulated Mod-Bit Roofing

Tue, 07 Oct 2025 15:07:46 GMT

Granger Lakes Condos – Spray Foam Over Granulated Mod-Bit Roofing

Introduction

In 2023, West Roofing Systems completed a full roof restoration across 10 condominium units at Granger Lakes in Northeast Ohio. We applied spray foam over granulated mod-bit roofing, replaced parapet wall shingles, and added a matching silicone coating — all with a 10-year full-system renewable warranty.

Project Details & Challenges

Total size: 47,680 sq ft across 10 condos, 20 owners. Each roof had a shingle-shake parapet wall. The shingles were removed. Existing roofs had ponding water issues. Need for uniform appearance across multiple units (matching with shingles color, etc.).

Our Solution

Installed an average of 1.25" spray polyurethane foam (SPF) over the granulated mod-bit. Foam extended up and over parapet walls, continuing seamlessly onto adjoining roof sections. Removed shingle-shake parapet walls and replaced with foam and new finished coating. Applied a custom shade of brown silicone coating on parapet walls to match adjacent shingle surfaces. Eliminated the need for a tapered system by using foam to level surfaces and improve drainage.

Warranty & Protection

Each condo received a 10-year full-system renewable warranty covering the roof system.

Results & Benefits

Improved thermal performance: ~R-8 added to existing insulation levels. Ponding issues were resolved without installing a costly tapered roof structure. Consistent aesthetics: Parapet walls match the shingles with a custom color coating. A long-term guarantee gives owners peace of mind. Good cost-effectiveness: projected payback of 7-8 years.

Want to see more details, as well as before, in-progress, and after photos?

View the Granger Lakes Full Project Profile (PDF)

Need a free quote?

Thinking your condo or building complex could benefit from a cost-effective, long-lasting roof solution that improves drainage and matches your building's look? Contact West Roofing Systems to get your own spray foam + coating roof restoration plan.

Valtronics – Hybrid Spray Foam + Coating System over Mod-Bit Roof

Mon, 06 Oct 2025 18:59:14 GMT

Valtronics – Hybrid Spray Foam + Coating System over Mod-Bit Roof

Introduction

Valtronics Technology in Solon, Ohio was nearing roof failure. In 2023, West Roofing Systems implemented a hybrid roof restoration system, combining spray foam and high-performance silicone coatings over an existing smooth mod-bit membrane. The project covered 61,175 sq ft and was completed in just 11 days.

Project Challenges

The mod-bit roof was close to failure, with a weakened surface and an aging membrane Deck repairs needed while avoiding dust intrusion into facility interiors Numerous unused penetrations needed removal or sealing The roof perimeter required new edge metal with a foam termination detail HVAC ductwork needed encapsulation to maintain insulation and avoid air pathways

Our Solution

Foam & Coating System (Hybrid Approach) Around the roof perimeter and all roof penetrations, spray foam was applied to reinforce transitions HVAC ductwork was fully encapsulated in spray foam for seamless insulation Removed ~20 unused penetrations, decked over, and sealed Installed walkways for safe roof access (non-slip surfaces) Edge detail: new 24-gauge Kynar-finished foam stop termination metal All work done under strict dust control: interior plastic containment installed under the roof deck to protect sensitive equipment below

Warranty & Protection

Roof System: 15-Year Full System, renewable warranty was issued upon final walkthrough

Project Results & Benefits

Rescued a failing mod-bit roof without full tear-off Seamless, durable roof envelope with both structural foam support and protective coatings Interior operations remained dust-free, protecting sensitive manufacturing Long-term protection with a 15-year system warranty Encapsulated HVAC ducts, improved transitions, sealed penetrations

Want more details and before/after photos? View the PDF below

View the Valtronics Full Project Profile (PDF)

Need a quote?

Worried your commercial roof is reaching the end of its life? Contact West Roofing Systems to explore hybrid spray foam + coating solutions that save your substrate, protect interiors, and come with long-term warranties.

Tubular Steel – Spray Foam Roofing over Metal Panels

Fri, 03 Oct 2025 17:43:01 GMT

Tubular Steel – Spray Foam Roofing over Metal Panels

Introduction

In 2024, West Roofing Systems tackled a 3,712 sq ft roof restoration project at Tubular Steel in Lorain, Ohio. The existing trapezoid metal panel roof presented challenges in aesthetic leveling and insulation. Our solution: strategic substrate installation and spray foam application to deliver a seamless, cost-effective, high-performance roof.

Project Challenges

The metal roof had deep trapezoidal panels, requiring extra foam to level Installing 3" of foam across the board would have been very expensive Desired solution needed to balance aesthetics, cost, and structural safety Preventing water infiltration under panel ends and panel gaps

Our Solution

Fastened 3/4" plywood strips (30" wide) in between each metal panel to serve as a leveling substrate This approach reduced the required foam thickness from 3" down to 1.5", saving on material and cost Applied 1.5" of spray polyurethane foam (SPF) over the newly prepared surface Specified manufacturer: Carlisle for SPF Coating manufacturer: Progressive Materials Installed a flanged-back gutter system to prevent water backup under panels and sealed panel ends to stop wildlife infiltration.

Project Details

Project Year: 2024 Location: Lorain, Ohio Size: 3,712 sq ft Completion Time: 7 days

Warranty & Protection

20-Year Full System, No Dollar Limit, Non-pro-rated Warranty

Project Results & Benefits

A visually level, uniform roof surface over formerly deep trapezoid panels Lowered foam thickness while retaining performance, yielding cost savings Added drainage and prevention of water entry beneath panels A robust commercial roofing system over an existing metal substrate

Want to learn more and see before, in-progress, and finished photos?

View the Tubular Steel Full Project Profile (PDF)

Need a quote?

Looking to restore or level a metal roof cost-effectively? Contact West Roofing Systems today — we'll design a custom spray foam roofing solution that balances performance, aesthetics, and budget.

Parma Police Station & Justice Center – Spray Foam Roofing over EPDM

Thu, 02 Oct 2025 17:56:10 GMT

Parma Police Station & Justice Center – Spray Foam Roofing over EPDM

Intro

In 2024, West Roofing Systems completed a full roof restoration at the Parma Police Station & Justice Center in Parma, Ohio. We replaced the existing EPDM roofing system with high-performance spray foam and coatings, delivering a durable and energy-efficient roof that comes with a 20-year renewable, non-prorated warranty.

Project Challenges

The existing EPDM membrane had aged and was failing Wet insulation beneath the membrane was compromising thermal performance Gravel ballast and weather exposure caused surface wear and degradation Roof penetrations and lighting protection systems needed secure reinstatement

Our Solution

Removed existing EPDM membrane and gravel ballast Removed and replaced any wet insulation found under the roof deck Installed 1/2-inch fiberboard over the insulation for a level substrate Removed old lightning rod protection (for reinstatement) Applied 1.5-inch spray polyurethane foam uniformly across the roof surface Applied 15 mils of basecoat followed by 15 mils of topcoat silicone coating Embedded granules into the topcoat for UV protection and improved durability Installed walkways around roof penetrations to provide safe access Reinstalled the lightning rod protection system after roofing is complete

Warranty Coverage

Roof System: 20-Year Full System Warranty – Non-Prorated (NPR), No-Dollar-Limit (NDL), Renewable

Project Results

A restored roof with upgraded thermal performance and waterproofing Uniform protective coating system over a sound substrate Longevity increased significantly over the old EPDM roof Reduced future maintenance, fewer leaks, and improved building envelope protection

Want to learn more and see more before/after photos:

View the Parma Police Station & Justice Center Case Study (PDF)

Want a free quote?

Thinking about upgrading your roof to something more durable and long-lasting? Contact West Roofing Systems today to see how spray foam and coating systems can protect your building.

Ironrock Building #1 – Spray Foam Roof & Metal Wall Restoration

Tue, 30 Sep 2025 19:58:24 GMT

Ironrock Building #1 – Spray Foam Roof & Metal Wall Restoration

At West Roofing Systems, we recently completed a large-scale restoration at Ironrock Building #1, where an aging metal roof and vertical wall panels needed long-term protection. Instead of a costly tear-off and replacement, our team installed a spray polyurethane foam (SPF) roofing system with silicone coatings and granules. The result: a watertight, energy-efficient system backed by a 15-year renewable warranty.

Project Challenges

Ironrock Building #1 had multiple issues: Aging TPO membrane and insulation layers Flute fill and iso-board that had reached the end of their service life Vertical wall panels that needed reinforcement to keep water out Rather than remove the entire metal roof, our approach was to preserve the existing structure while building a new system directly over it.

Our Solution

Removed the existing TPO, iso-board, and flute fill Kept the original metal roof in place as a stable substrate Installed an average of 1.5 inches of spray polyurethane foam (SPF) across the roof surface Applied 15 mils of silicone basecoat and 10 mils of silicone topcoat Embedded granules into the topcoat for added durability, UV protection, and slip resistance Installed 10 mils of silicone around all vertical metal wall panels on every side of the building

Warranty Coverage

Roof System: 15-Year Full System Warranty – Non-Prorated, No-Dollar-Limit (NDL), and renewable Vertical Walls: 5-Year Warranty

Project Results

The Ironrock Building #1 restoration created a roof and wall system that is: Watertight – no more leaks or failures from the old system Energy-Efficient – spray foam adds insulation value and lowers heating/cooling costs Sustainable – instead of a tear-off, we extended the life of the existing roof Backed by Warranty – peace of mind with a renewable 15-year system warranty

See the Full Case Study

We documented the entire process with photos of the roof before, during, and after the installation. View the Full Ironrock Project Profile (PDF) Interested in learning how spray foam can restore a metal roof like this one? Contact our team today to discuss your building's needs.

The Cost of Waiting for a Commercial Roof Leak

Tue, 12 Aug 2025 18:58:57 GMT

The Cost of Waiting for a Commercial Roof Leak

NOTE: This article is perfect for any commercial property with a 15+ year old roof that's not leaking. For most commercial building owners, the roof is out of sight and out of mind—until it leaks. And by the time water starts dripping inside, the damage is already done: wet insulation, stained ceilings, tenant complaints, and in some cases, operations coming to a halt. But what if there was a way to avoid that disruption—and save money while you're at it? That's exactly what a roof coating system offers: a proactive approach that keeps your building dry, extends the life of your roof, and protects your bottom line.

The Problem: Reactive Roofing Is Expensive and Risky

Let's be honest—most commercial roofs don't get attention until something goes wrong. But by then, the options are limited and expensive. A leak might mean: Damage to insulation, decking, or the interior Emergency repair costs Tenant disruption or loss of business Full roof replacement if the system is too far gone Waiting for a leak turns roofing into a fire drill—and one you didn't budget for. We did mention "expensive". Did you know that a full replacement is roughly 50% more costly than a coating system? It's also more time-consuming, more disruptive to business (safety setup, moving/covering cars, some decking can be removed and replaced, leaving the roof open, etc.), and it contributes (usually unnecessary) materials to landfills.

The Solution: Roof Coating Systems as Preventive Maintenance

A roof coating system is like a shield applied over your existing roof. It restores the surface, seals seams and penetrations, and adds a seamless waterproof barrier. More importantly, it allows you to take control before damage occurs.

Benefits of going proactive with a roof coating system:

Extends the life of your existing roof by 10–20 years Avoids a costly tear-off or full replacement Reflects UV rays, lowering energy costs Applied with minimal disruption to your operations Comes with a renewable 10-20-year warranty Leaves you with a seamless membrane. Seams are the #1 location of roof leaks.

But What If My Roof Isn't Leaking?

That's the perfect time to act. Roof coatings work best on roofs that are still structurally sound. If your roof is approaching 15+ years old, showing signs of wear, or has had patch jobs in recent years, you're an ideal candidate for a coating system. Think of it like putting sealant on your driveway or changing the oil in your car—it's what protects your investment for the long haul.

Final Thoughts: Out of Sight Shouldn't Mean Out of Mind

You don't have to wait for a leak to take action. In fact, the best time to protect your roof is before it becomes a problem. If you're managing a commercial building and want to avoid surprises (such as angry tenants, loss of operations, and/or panic when it comes to finances), consider a proactive approach with a roof coating system. Let's evaluate your roof and show you how to add 10–20 years of life—without interrupting business or draining your budget.

5 Myths About Spray Foam Roofing Debunked (With 45+ Years of Proof)

Mon, 14 Jul 2025 17:37:59 GMT

5 Myths About Spray Foam Roofing Debunked (With 45+ Years of Proof)

Are you worried that a spray foam roof won't hold up against foot traffic, is only a temporary solution, or is difficult for contractors to install correctly? In this article, we'll tackle the five biggest myths about spray foam roofs, back them up with real facts, and share what we've learned from over 45 years of installing SPF roofs across the country.

Myth 1: Spray Foam Roofing Is Just a Temporary Fix

Many building owners think spray foam is a short-term patch, not a real roofing system. The truth? A properly installed and maintained SPF roof can last decades — not just a few years. Some of the roofs we installed in the early 1980s are still performing well today. Instead of full tear-offs, SPF roofs can be recoated every 10–20 years, extending their life at a fraction of the cost of replacement.

Myth 2: Spray Foam Roofs Are Too Weak for Foot Traffic

We often hear, "Won't spray foam dent or get damaged if someone walks on it?" Not when it's installed correctly. The average compression strength of spray polyurethane foam is 60 PSI. This is stronger than the commonly used "ISO-Board". Spray foam roofs are topped with a protective coating embedded with granules, adding strength and slip resistance. For areas with regular foot traffic, we install designated walkways with extra sand or coating layers for stability and safety.

Myth 3: Spray Foam Roofing Is New and Unproven

While SPF roofing might feel like a newer system compared to older ones like gravel built-ups or metal, it's far from new or unproven. Our company began installing commercial spray foam roofs back in 1979. That makes SPF older than TPO membranes. Today, spray foam is trusted on schools, warehouses, government facilities, factories, and even high-wind coastal buildings.

Myth 4: Spray Foam Is Hard to Install Correctly

Here's a partial truth: Spray foam installation does take skill and experience. For Spray foam to be laid down correctly, it needs three types of energy: Electrical, Environmental, and Exothermic. It's exactly why fewer contractors do it — and why you should only trust spray foam roofing professionals. Our crews go through ongoing training and follow strict manufacturer application specifications to ensure the roof performs as promised.

Myth 5: Hardly Anyone Installs Spray Foam Roofing

Some building owners assume finding a qualified spray foam contractor is impossible. It's true there's a higher barrier to entry — the rigs are expensive, and the crews must be skilled. But there are far more qualified SPF contractors than most people think — and the market has grown steadily as more building owners see the benefits. Ready to Learn More? Take the next step by checking out our Ultimate Guide to Spray Foam Roofing or request a free roof assessment to see if SPF is right for your building.

Think Twice Before Choosing Acrylic Over Silicone Coatings

Mon, 02 Jun 2025 16:46:27 GMT

Think Twice Before Choosing Acrylic Over Silicone Coatings

Are you weighing restoration options for your commercial roof — and trying to decide between silicone and acrylic coatings? At West Roofing Systems, we've helped hundreds of building owners navigate this exact decision. In this article, you'll learn the key differences between acrylic and silicone coatings, when each performs best, and why your contractor's expertise may matter more than the product itself.

Key Differences Between Acrylic and Silicone Roof Coatings

The most important distinction is solids content — how much of the product remains on your roof after it dries. Acrylic coatings are typically around 55% solids, meaning roughly 45% evaporates during curing. High-solids silicone coatings are typically 95% solids, so nearly everything you apply stays on the roof. To reach the same dry film thickness that silicone achieves in a single coat, acrylic may require two, three, or even four coats — meaning more labor and more material.

When Acrylic Roof Coatings Might Cost More Over Time

Acrylic coatings are commonly marketed as more affordable — and in terms of initial material cost, that's often true. But in regions with heavy rainfall, snow loads, or flat roofs with standing water, acrylic coatings may require frequent recoats. Missing a recoat deadline will void the manufacturer's warranty, and each recoat typically costs around 50% of the original installation. Over a 20-year span, these costs can surpass the investment of going with silicone from the start.

When Acrylic Roof Coatings Are a Good Fit

Acrylic can be a smart, cost-effective choice in the right environment — specifically dry, warm regions with minimal snow or ponding water, where the roof has proper slope and drainage. Some newer high-build acrylics are closing the gap in thickness and durability, making them viable in select applications. The key takeaway: acrylic isn't a bad product — it's just not the best solution for every roof.

Why Choosing the Right Contractor Matters

The product you choose is only as good as the contractor who applies it. A knowledgeable contractor will assess your roof's condition, slope, insulation, and drainage, then determine which coating makes the most sense. At West Roofing Systems, we make recommendations based on your building's actual needs — not what's easiest or cheapest to sell.

Making the Right Choice for Your Roof

Silicone coatings typically deliver better long-term performance on flat or low-slope roofs in wet or snowy climates. Acrylic may be suitable for buildings in dry, warm climates with good drainage. The right decision depends on your building's climate, roof slope and condition, budget, and the experience of the contractor you hire.

Is Spray Foam Roofing Right for My Building?

Thu, 08 May 2025 16:45:53 GMT

Is Spray Foam Roofing Right for My Building?

If you're trying to fix a leaky, aging roof without spending a fortune on tear-off and replacement, you've likely heard about spray foam roofing. At West Roofing Systems, we've applied foam to thousands of roofs and seen exactly where it shines — and where it may not be the best fit.

Who Is a Good Fit for a Spray Foam Roof?

Gravel BUR roofs are ideal candidates for spray polyurethane foam (SPF). After gravel is removed via hydro-vacuuming, the existing substrate is perfect for foam to adhere to — eliminating the need for a complete tear-off. Spray foam also excels on roofs with many penetrations like HVAC units and skylights, where traditional systems require custom cutting and fitting. SPF's fluid-applied application seals all penetrations in one pass. Additionally, buildings with low spots or ponding water are great candidates — foam can be applied thicker in low areas to build slope and direct water toward drains.

Why Spray Foam Outperforms Seamed Systems

TPO, EPDM, PVC, metal, and modified systems all rely on seams. As the roof temperature fluctuates daily, the membrane expands and contracts, creating stress on seams that can lose adhesion over time. Even a microscopic opening becomes a water entry point. Spray foam creates a completely seamless membrane — eliminating the #1 cause of roof leaks.

Who Is NOT a Good Fit for Spray Foam?

Spray foam isn't the right choice for every situation. Highly visible roofs on homes or buildings with rooftop patios may not benefit aesthetically. Building owners committed to single-ply systems regardless of project goals may not be good candidates. And facilities like car dealerships — where overspray on vehicles is a major concern — present challenges that other systems avoid.

Bottom Line

Spray foam is an energy-efficient, low-disruption option — but only if your building is the right fit. If you're facing leaks, insulation issues, or an aging gravel BUR roof, this could be the solution you've been looking for. Still evaluating options? Contact West Roofing Systems for an honest assessment.

6 Reasons Some Commercial Roofing Quotes Are Higher Than Others

Tue, 08 Apr 2025 17:42:56 GMT

6 Reasons Some Commercial Roofing Quotes Are Higher Than Others

If you've received multiple quotes for a commercial roofing project, you might wonder why some are significantly higher than others. Understanding what goes into a roofing quote helps you make an informed decision — rather than simply choosing the lowest bid.

1. Travel Costs

If your contractor travels a considerable distance, fuel, hotel stays, and crew travel expenses typically add 5–10% to the total project price. A high-quality contractor from out of town may still be the better option if they install a better system and have a stronger track record.

2. Experienced Workers

A well-trained, experienced roofing crew costs more than lower-paid, less-experienced workers. Lower quotes often come from companies relying on temporary labor or contractors with little longevity. Compromising quality for cost is rarely wise.

3. Top-of-the-Line Materials

Manufacturers don't sell their products to just anyone — they require approved contractors with extensive training. High-quality silicone coatings and spray foam cost more than single-ply alternatives, but they deliver superior performance and longer lifespans.

4. The Cost of Doing Things Right

Ethical contractors assess current roof conditions thoroughly — checking drainage, insulation moisture, ventilation, and slope — and recommend the right solution rather than the highest-dollar one. Removing wet insulation, recommending restoration over tear-off, and keeping your budget in mind all reflect doing the job right.

5. The Learning Curve for Certain Systems

Spray polyurethane foam requires significant training and skill to apply correctly. That expertise costs more — but is essential to get a system that actually performs.

6. Material vs. Labor Cost Structure

For spray foam, roughly 60% of project cost is materials, 40% labor. For most traditional systems it's the reverse. Materials work on your roof for 10+ years; labor disappears when installation ends. A higher materials ratio is actually a better investment.

How Spray Foam Roofing's Seamless Membrane Helps Military

Tue, 18 Mar 2025 18:30:59 GMT

How Spray Foam Roofing's Seamless Membrane Helps Military

In 2008, the US soldiers at the Jabala Military Base in Iraq faced a serious problem. The metal roofs in the barracks had aged and cracked, allowing animals, dust, moisture, and extreme heat to enter. In Iraq, where temperatures regularly exceed 100°F, efficient HVAC is critical. The U.S. Army Corps of Engineers called West Roofing Systems to install spray foam roofing systems across six buildings.

The Problem with Traditional Roof Systems

Traditional roofing systems with ballasts make leak detection incredibly difficult — there's no clear way to inspect the membrane beneath gravel. Similarly, seamed systems like TPO and EPDM present challenges: even a slight uplift in a seam can become a water entry point that's nearly impossible to detect and costly to repair.

The Benefits of a Seamless Roof

Spray polyurethane foam creates a continuous, monolithic membrane that adheres directly to any surface, eliminating the risk of leaks from seams, cracks, or gaps. It also increases R-value, improving thermal insulation and reducing HVAC load — critical for extreme climates.

Real-World Application: Jabala Military Base, Iraq

West Roofing Systems applied a minimum of 1.25 inches of spray foam directly to the original transite panels, covering 150,000 sq ft across six buildings. The existing roof contained asbestos fastened from the inside through the roof, leaving thousands of exposed bolts — the foam encapsulated all of them. Two coats of silicone were then applied to protect the foam from UV rays.

Results

The seamless system eliminated pest infiltration, reduced dust, stopped all moisture penetration, and significantly improved energy efficiency — allowing HVAC systems to maintain comfortable temperatures for military personnel for the first time.

Commercial Wall Coatings – Why It's Better Than Paint

Tue, 11 Mar 2025 12:32:54 GMT

Commercial Wall Coatings – Why It's Better Than Paint

Many owners turn to traditional paint when a commercial building's exterior walls need restoration. But what happens when the paint chips, fades, or wears down? This is where a high-solids silicone coating offers significant long-term benefits.

Thicker Application

Traditional paint has a much thinner protective layer — typically around 50% solids, meaning half the product evaporates as it dries. A high-solids silicone coating is 95% solids, creating a much thicker, more durable, and longer-lasting finish that resists environmental factors like UV rays, extreme weather, and temperature fluctuations.

Durability and Longevity

Commercial buildings in the Midwest face storms, high winds, and temperatures ranging from 100°F in summer to -10°F in winter. Silicone coatings are far more resistant to cracking and peeling than paint, and come with a 10-year manufacturer's warranty — compared to the typical 1-year warranty from painters.

Warranty Renewal

At the 10-year mark, the silicone coating can be renewed with a simple power wash and reapplication of 20 mils — renewing the warranty for another 10 years. No other exterior wall solution offers this kind of long-term renewability.

Cost-Effectiveness Over Time

While the initial cost of silicone coating is roughly 20% more than paint, the 10-year renewable warranty and reduced maintenance costs make it far more cost-effective in the long run. Building owners don't need to worry about annual repainting or frequent repairs.

Best and Worst Way to Manage a 15–20-Year-Old TPO Roof?

Thu, 06 Mar 2025 15:46:46 GMT

Best and Worst Way to Manage a 15–20-Year-Old TPO Roof?

Quick Summary: The best solution is to minimize tear-off and install a roof coating system. The worst option is to rip it all off and install a new roof. Why is this an issue? TPO contractors will likely not offer a coating system — they want the bigger dollar that comes with a full replacement.

Why Aging TPO Roofs Are Great Coating Candidates

When a TPO roof hits 15–20 years, most property managers contact their original installer, who typically recommends a complete tear-off and replacement. But these roofs are usually great candidates for restoration with an elastomeric coating system — at 1/3 to 1/2 the cost of replacement.

Why Coating Systems Cost Less

A coating restoration minimizes tear-off — only damaged membrane or wet insulation is removed and replaced. A complete tear-off removes 100% of the TPO and insulation, requiring far more labor hours, more materials, and maximum landfill costs. When you add those costs together, it's no surprise that coating systems are significantly more affordable.

Other Benefits of a Coating System

Roof coating systems come with 10, 15, or 20-year warranties depending on coating thickness, and can be recoated at the end of the warranty period for a new warranty. Since the application is fluid, you're left with a seamless membrane — eliminating seam-related leaks entirely. And because tear-off is minimized, landfill contributions are minimal, which is better for the environment.

The Bottom Line

If your TPO roof is 15–20 years old, don't automatically assume you need a full replacement. Get a quote for a coating restoration and compare. In most cases, restoration is the smarter, more cost-effective choice.

What's the Best Thing to Do With an Old Spray Foam Roof?

Fri, 21 Feb 2025 16:30:39 GMT

What's the Best Thing to Do With an Old Spray Foam Roof?

Quick Summary: If you have an older spray foam roof, it's possible it can be recoated with an elastomeric coating. Automatically assuming you need a complete tear-off can be a costly mistake.

Assess the Condition First

The first step with any aging spray foam roof is a professional inspection. A qualified contractor will assess the foam's condition, check for UV degradation, inspect the existing topcoat thickness, and determine whether the substrate is still structurally sound. Not all old foam roofs are in the same condition.

When Recoating Is the Right Answer

If the foam is in acceptable condition — meaning it hasn't degraded significantly and there are no major areas of exposed or compromised foam — a recoat is typically the best option. The process involves power washing, any necessary spot repairs, and applying a fresh topcoat to restore the warranty. This is far less expensive than a full tear-off.

When Tear-Off May Be Necessary

If the foam has been exposed to UV for an extended period without a topcoat, or if significant sections have deteriorated, a full tear-off may be the only viable option. The same applies if moisture has infiltrated the foam system and wet insulation is present beneath.

The Bottom Line

Don't assume the worst before getting an inspection. Many spray foam roofs that look rough on the surface are still candidates for restoration — saving building owners thousands compared to replacement. Contact West Roofing Systems for an honest assessment of your existing foam roof.

The Best Roofing Systems for Schools and Universities

Wed, 30 Oct 2024 18:37:51 GMT

The Best Roofing Systems for Schools and Universities

When selecting the right roofing system for schools and universities, longevity, energy efficiency, and predictable maintenance costs are the key factors. Two roofing solutions stand out above the rest for educational facilities.

Why Schools Have Unique Roofing Needs

Educational facilities face tight budgets, strict timelines (work must often happen during summer break), and long-term planning horizons. A roofing solution that minimizes disruption, reduces lifecycle costs, and comes with a renewable warranty is ideal.

Spray Polyurethane Foam Roofing

Spray foam excels on school roofs for several reasons. It can be applied over existing roofing systems, avoiding costly tear-offs. It adds significant insulation value, reducing HVAC costs year-round. And it creates a seamless, watertight surface with no seams to fail. Projects like Heskett Middle School (104,000 sq ft completed in 37 days) and Oakview Elementary demonstrate how foam delivers major cost savings for school districts.

Silicone Roof Coating Systems

For schools with TPO or other single-ply roofs approaching end of warranty, a silicone restoration membrane is often the best choice. It seals failing seams, creates a fully waterproof surface, and comes with a new 10–20-year manufacturer's warranty — at a fraction of replacement cost.

The Bottom Line

For most schools and universities, the combination of avoiding tear-off, gaining insulation value, and receiving a long-term renewable warranty makes spray foam or silicone coating systems the clear winners over traditional replacement.

3 Repair Options for a Leaking Rubber Roof

Tue, 22 Oct 2024 13:38:02 GMT

3 Repair Options for a Leaking Rubber Roof

Quick Answer – spot repairs, installing a roof coating system, and installing a spray foam roofing system are three options for repairing or restoring an existing rubber EPDM roof.

Option #1 – Spot Repairs

If the leaks are isolated to specific areas — failed seams, punctures, or flashing issues — spot repairs may be a viable short-term solution.

A contractor applies EPDM patches or sealant to the problem areas.

This is the least expensive option upfront but doesn't address underlying wear across the entire membrane.

Option #2 – Install Roof Coating System over Rubber Roof

Roof coating systems are very popular nowadays.

The reason?

If the roof qualifies, you can install the system without a complete tear-off and get a new 10-20-year warranty.

Here are some popular questions that get brought up when talking about roof coating over rubber roofs:

How much do they cost per square foot?

The ballpark is $3.50-$7 per square foot. Many factors influence price.

The most popular is the amount of membrane/insulation that needs to be removed and replaced before the coating system can be installed. Sometimes it’s 1%, sometimes it’s 20%.

Another factor is the desired warranty length.

A 10-year warranty gets 20 dry mils of coating installed. A 20-year warranty gets 30 dry mils of coating installed. That’s 50% more coating on the 20 vs the 10.

How do I know if my rubber roof qualifies for a roof coating install?

There are three factors:

1) The amount of wet insulation/damaged membrane

2) Seam adhesion

3) How has the roof been maintained?

Every contractor and coating manufacturer is different, but if more than 25% of the roof’s insulation is wet, it will not qualify for a roof coating system. The roof will need to be torn off and replaced.

For seam adhesion, if the seams are loose or have little adhesion, it will not qualify.

Coatings are liquids that rely on the existing roof to stay put.

Seam reinforcement is part of the silicone roof coating system, but it needs a good foundation for that to make sense.

For roof maintenance, if the roof has been neglected for years, it most likely will not qualify.

This goes hand in hand with the other two requirements.

If small repairs were noticed, then they would be repaired, and there would be little wet insulation.

If left alone for years, small repairs turn into big ones and usually push the roof past the 25% mark.

Acrylic, Silicone, Urethane…does the type of coating matter?

Yes. Greatly.

Urethanes are expensive and rarely get used.

Silicone is the best bang for the buck. Great for all weather, especially in colder climates because it handles ponding water (or snow loads) better than acrylic.

Acrylic is the cheapest, but it needs a thicker application because much of the product evaporates.

Sometimes as much as twice the amount of acrylic is needed to apply the same thickness as one pass of silicone.

Acrylics don’t perform well with ponding water. They are best used in warmer climates and sloped roofs.

Option #3 – Install Spray Foam Roofing over Rubber Roof

If the roof qualifies for a coating system, but you’re looking for more insulation, then the spray foam roofing system is a great option.

Spray foam has an R-value of 6.5 per inch, which is higher than any other roofing insulation.

Facilities that use a lot of air conditioning (or heat) or need extensive climate control would greatly benefit from the spray foam roofing system.

Here are some popular questions that get brought up when talking about spray foam roofing systems over rubber roofs:

How much do spray foam roofs cost per square foot?

The cost is $5 - $10 per square foot. Some variables that influence cost is the desired R-value increase. More foam = more material = higher cost.

Other than that, it’s the same factors as the coating system (how much tear-off/replacement and desired warranty length).

What does the spray foam system look like? How is it installed?

This would be better explained through video; take a look:

Spray foam is applied as a liquid that expands into foam when it hits the rubber.

It expands 1-2 inches.

It’s then protected by installing two coats of an elastomeric coating (usually silicone) over top.

Embedded granules in the topcoat of the coating are usually installed for stability and added protection.

Analyzing Material and Labor Costs for Commercial Roofing Projects

Tue, 15 Oct 2024 17:26:41 GMT

Analyzing Material and Labor Costs for Commercial Roofing Projects

When you get a quote for a commercial roofing project, it's important to understand how costs break down between materials and labor. This knowledge helps you make smarter decisions when comparing bids.

The Material vs. Labor Split

For spray polyurethane foam roofing, approximately 60% of the total project cost is materials and 40% is labor. For most traditional single-ply systems (TPO, EPDM), this ratio is roughly reversed — more labor, less materials. Think about what that means: with spray foam, the majority of your investment goes into a product that sits on your roof working for 10+ years. With single-ply, more of your money pays for labor that's gone once installation ends.

Why Material Quality Matters

Not all roofing materials are equal. Premium silicone coatings and spray foam systems purchased through approved manufacturer channels cost more than commodity products, but they deliver superior performance, longer warranties, and lower long-term maintenance costs.

Hidden Labor Costs in Tear-Offs

Full roof replacements carry significant hidden labor costs — tear-off, disposal, deck preparation, and installation all add up. Restoration systems that go over existing roofing eliminate most of these costs, which is a major reason coating systems are typically 50–70% less expensive than replacement.

The Bottom Line

When comparing quotes, look at the material-to-labor ratio and ask what each line item includes. A higher total quote with better materials and more thorough preparation is almost always a better investment than a lower bid that cuts corners.

Silicone Roof Coatings Over Metal: Everything You Need to Know

Tue, 03 Sep 2024 14:50:19 GMT

Silicone Roof Coatings Over Metal: Everything You Need to Know

If you have a metal roof with issues — leaks, rust, failing fasteners — a silicone roof coating system may be the best solution available. Here's everything you need to know.

Why Silicone Works Well on Metal

Silicone coatings adhere directly to metal surfaces and create a fully seamless, waterproof membrane. Unlike traditional metal roof repairs that patch individual problem areas, a silicone coating covers the entire roof in one application — sealing all fasteners, seams, rust spots, and transitions simultaneously.

Preparation Is Critical

A successful silicone installation on metal requires thorough preparation: cleaning the surface of dirt, oxidation, and loose rust; treating rust spots with a rust-inhibiting primer; sealing all fasteners and seams with reinforced fabric tape and sealant; and applying the silicone topcoat at the required mil thickness for warranty coverage.

Benefits of Silicone Over Metal

Silicone coatings are 95% solids, highly UV-resistant, and remain flexible across extreme temperature swings — critical for metal roofs that expand and contract daily. They also reflect solar heat, reducing roof surface temperatures and lowering cooling costs. Warranties of 10–20 years are available depending on coating thickness.

Cost vs. Replacement

A silicone coating restoration typically costs 40–60% less than tearing off and replacing a metal roof. And unlike replacement, there's no disruption from tear-off or risk of exposing your building interior to weather during installation.

How Roof Coating Systems Are Installed on TPO Roofs

Wed, 14 Aug 2024 17:53:40 GMT

How Roof Coating Systems Are Installed on TPO Roofs

When it comes to extending the life of your TPO roof and getting a renewable 10–20-year warranty, installing a roof coating system is an efficient and effective solution. Here's exactly how the process works.

Step 1: Inspection and Assessment

Before any coating is applied, a qualified contractor inspects the existing TPO membrane for seam failures, punctures, delamination, and wet insulation. Any areas of wet insulation must be removed and replaced before coating — skipping this step will cause problems down the road.

Step 2: Cleaning

The entire roof surface is power-washed to remove dirt, algae, oxidation, and any contaminants that would prevent the coating from adhering properly. A clean surface is essential to coating performance and warranty compliance.

Step 3: Repairs

Failed seams, punctures, and damaged areas are repaired using reinforced fabric tape and sealant. All penetrations, flashings, and edges are sealed before the coating is applied.

Step 4: Primer (if required)

Depending on the TPO manufacturer's specifications and the coating system being used, a primer coat may be required to ensure proper adhesion between the existing TPO and the new coating.

Step 5: Coating Application

The silicone coating is applied at the required mil thickness — typically 20–30 mils for a 10–20-year warranty. The seamless application covers the entire roof surface in one continuous membrane, eliminating all seams.

The Result

A restored TPO roof with a new manufacturer's warranty, a fully seamless waterproof surface, and improved UV reflectivity — at a fraction of replacement cost.

Commercial Roof Inspections – Everything You Need to Know

Wed, 07 Aug 2024 18:44:57 GMT

Commercial Roof Inspections – Everything You Need to Know

If you're facing roofing issues with your commercial property, it's imperative to get a professional assessment to understand the extent of the problem and find the best solution.

Why Get a Commercial Roof Inspection?

A professional inspection gives you an accurate picture of your roof's current condition — identifying leaks, failed seams, wet insulation, ponding water issues, and drainage problems. Without this information, you're making expensive decisions blind.

What Does an Inspection Include?

A thorough commercial roof inspection covers: visual assessment of the entire membrane surface, seam inspection for adhesion failures, flashing and penetration inspection, drainage and slope assessment, and — critically — core samples to check for moisture in the insulation below. An infrared scan may also be used to identify wet insulation that isn't visible to the naked eye.

Core Samples: Why They Matter

Core samples are small plugs removed from the roof to inspect the insulation beneath. If moisture has infiltrated the insulation, it must be removed before any restoration can be performed. Skipping this step and coating over wet insulation leads to blistering, failed adhesion, and continued leaks.

When to Get an Inspection

You should get a commercial roof inspection when: you notice active leaks or water stains inside the building; your roof warranty is approaching expiration; you're considering a roof restoration or replacement; or as part of an annual preventive maintenance program.

What Happens After the Inspection?

A reputable contractor will provide a written report with findings and a recommendation — whether that's spot repairs, a full restoration system, or replacement. The inspection gives you the information needed to make the right decision for your building and budget.

Everything You Need to Know About Commercial Roofing

Thu, 25 Jul 2024 19:42:03 GMT

Everything You Need to Know About Commercial Roofing

When it comes to commercial roofing, making the right decision can save building and property owners thousands of dollars and countless headaches. Here's a comprehensive guide to help you navigate the options.

Types of Commercial Roofing Systems

The most common commercial roofing systems include TPO (thermoplastic polyolefin), EPDM (ethylene propylene diene monomer or rubber roofing), PVC, metal roofing, built-up roofing (BUR or gravel roofs), modified bitumen, spray polyurethane foam (SPF), and silicone roof coating systems. Each has different performance characteristics, costs, and ideal use cases.

Restoration vs. Replacement

One of the most important decisions in commercial roofing is whether to restore an existing roof or replace it entirely. Restoration systems — spray foam and silicone coatings — go over the existing roof, avoiding tear-off costs and typically costing 50–70% less than replacement. They're viable when the existing substrate is in acceptable condition and moisture levels in the insulation are below 25%.

Key Factors When Choosing a System

The right system depends on your existing roof type and condition, your building's climate and drainage, your budget, and your long-term goals. A building owner planning to hold the property for 20+ years has different needs than one planning to sell in 5 years.

The Importance of Choosing the Right Contractor

Commercial roofing is a significant investment. Work with a contractor who is manufacturer-approved, has verifiable experience with your specific roof type, and provides honest recommendations rather than automatically pushing the highest-dollar solution.

What Are the Requirements Needed to Install a Roof Coating System?

Tue, 02 Jul 2024 12:41:59 GMT

What Are the Requirements Needed to Install a Roof Coating System?

The three requirements needed to install a roof coating system and get a manufacturer's warranty are: the existing membrane must be in acceptable condition, wet insulation must be removed, and the contractor must be manufacturer-approved. Here's why each matters.

1. Acceptable Membrane Condition

A coating system goes over the existing roof — it doesn't fix structural problems beneath it. The existing membrane must be adhered (not delaminating), free of major punctures or failures, and have no more than approximately 25% wet insulation. If the membrane is in poor shape, a restoration won't hold up and won't qualify for a manufacturer's warranty.

2. Wet Insulation Must Be Removed

This is non-negotiable. Wet insulation left beneath a new coating will cause blistering, failed adhesion, and continued leaks. A core sample inspection identifies wet areas, which must be cut out and replaced with dry insulation before coating is applied. Skipping this step is a major red flag in any contractor's proposal.

3. Manufacturer-Approved Contractor

Manufacturers don't sell their coating products to just anyone. Contractors must complete approved training, demonstrate installation experience, and maintain ongoing certification to purchase materials and issue manufacturer warranties. Always verify that your contractor is manufacturer-approved for the specific system they're proposing.

Is Your Roof Eligible?

The only way to know for certain is a professional inspection with core samples. If all three requirements are met, a coating system restoration is likely your most cost-effective long-term option.

What's the Best Roofing System for a Large Warehouse?

Thu, 27 Jun 2024 17:08:06 GMT

What's the Best Roofing System for a Large Warehouse?

When choosing the best roofing system for a large warehouse, spray polyurethane foam (SPF) is often the best choice. The system offers several advantages over traditional roofing systems that make it ideal for large industrial facilities.

Why Spray Foam Excels on Large Warehouses

Large warehouses typically have metal or built-up roofs with significant square footage, many penetrations, and high energy costs. Spray foam addresses all of these challenges simultaneously. It goes over the existing roof (no tear-off), seals all penetrations in one seamless application, and adds significant insulation value — often R-25 or higher depending on thickness.

Energy Savings at Scale

For a large warehouse, improved roof insulation can translate to substantial annual energy savings. Spray foam's closed-cell structure provides R-6.5 per inch — the highest R-value per inch of any roofing insulation. On a 100,000+ sq ft facility, the energy savings alone can significantly offset the installation cost over the warranty period.

Minimal Operational Disruption

Warehouse operations often can't stop for a roof replacement. Spray foam installation is fast and doesn't require tearing off the existing roof, meaning there's no risk of exposing inventory or equipment to weather. Large crews can cover substantial square footage quickly.

Long-Term Value

A spray foam roof with silicone topcoat comes with a 10–20-year renewable warranty. At the end of the warranty period, a simple recoat renews coverage — no replacement needed. For a large warehouse with significant square footage, this renewable approach saves enormously over a 40-year building lifecycle.

What Is the Energy Efficiency of Silicone Roof Coatings?

Tue, 28 May 2024 14:49:20 GMT

What Is the Energy Efficiency of Silicone Roof Coatings?

Summary: The official R-value of silicone roof coatings is negligible, or close to 0. However, they increase energy efficiency by adding reflectivity, lowering roof temperature, and reducing the load on HVAC systems.

R-Value vs. Reflectivity

R-value measures resistance to heat flow through insulation. Silicone coatings, being thin (20–30 mils), add essentially no R-value on their own. But energy efficiency isn't only about insulation — it's also about how much heat a roof absorbs in the first place. This is where silicone excels.

Solar Reflectance and Thermal Emittance

High-quality silicone coatings achieve solar reflectance values of 85%+ and thermal emittance of 90%+. This means they reflect the majority of solar energy away from the building rather than absorbing it. On a hot summer day, an uncoated dark roof can reach 150–180°F. A silicone-coated roof may stay at 90–100°F under the same conditions.

Real-World Energy Impact

Lower roof surface temperatures translate directly to reduced cooling loads. Buildings in warm climates or with flat roofs exposed to significant solar radiation can see meaningful HVAC savings after a silicone coating installation — often 10–20% reduction in cooling costs depending on the building.

Combining Silicone with Spray Foam

For maximum energy efficiency, spray polyurethane foam (R-6.5 per inch) combined with a silicone topcoat delivers both high insulation value AND high reflectivity — the best of both worlds for commercial roofs.

Commercial Roof Maintenance: Why It Matters and What It Costs

Wed, 22 May 2024 13:16:44 GMT

Commercial Roof Maintenance: Why It Matters and What It Costs

A commercial roof is out-of-sight, out-of-mind to most building owners. The only trigger that creates action is when the roof leaks — by which point damage has often already occurred inside the building. Preventative maintenance changes this equation entirely.

Why Maintenance Matters

Small issues — a cracked seam, a clogged drain, minor flashing separation — are inexpensive to fix when caught early. Left unaddressed, they become leaks that damage insulation, decking, interior finishes, and equipment. A $500 maintenance visit can prevent a $50,000 interior damage claim.

What a Maintenance Plan Includes

A typical commercial roof maintenance plan includes: semi-annual or annual inspections, cleaning of drains and gutters, sealing of minor seam and flashing issues, documentation of roof condition with photos, and a written report with recommendations. Some manufacturers require documented maintenance to keep warranties active.

What Does It Cost?

Commercial roof maintenance typically costs $0.02–$0.07 per square foot per year, depending on roof size, complexity, and location. For a 50,000 sq ft roof, that's roughly $1,000–$3,500 annually. Compare that to the cost of an emergency repair or premature replacement.

The ROI of Maintenance

Studies consistently show that maintained roofs last significantly longer than unmaintained ones. A well-maintained roof can exceed its expected lifespan by 25–50%. For a building owner, that means deferring a major capital expense by years — potentially decades.

9 Red Flags Commercial Roofing Contractors Can Have

Mon, 13 May 2024 15:27:48 GMT

9 Red Flags Commercial Roofing Contractors Can Have

When your roof has been leaking and you're ready to get quotes, the last thing you want is to hand a large check to the wrong contractor. Here are 9 red flags to watch for.

1. No Manufacturer Approval

If a contractor is proposing a coating or foam system but isn't manufacturer-approved, they can't issue a manufacturer's warranty. Always verify certification directly with the manufacturer.

2. Recommending Full Tear-Off Without an Inspection

Any contractor recommending a complete tear-off without first doing a thorough inspection with core samples is either cutting corners or chasing the bigger job. Restoration is viable for most roofs with less than 25% wet insulation.

3. Unusually Low Bid

The lowest bid almost always means something is being left out — cheaper materials, skipped steps, or less experienced labor. Compare scopes of work carefully, not just final numbers.

4. No Written Proposal

A legitimate contractor provides a detailed written proposal specifying materials, application thickness, warranty terms, and scope of work. Verbal agreements aren't acceptable for projects of this size.

5. High-Pressure Sales Tactics

"This price is only good today" or "I can start tomorrow if you sign now" are pressure tactics designed to prevent you from getting competing quotes. A reputable contractor lets you take time to decide.

6. No Verifiable References or Case Studies

Ask for references from similar projects. A contractor who can't provide verifiable references on commercial work is a red flag.

7. Not Addressing Wet Insulation

If a contractor's proposal doesn't mention core samples or wet insulation testing, they're planning to coat over whatever is there — which leads to system failure.

8. No Safety Plan

Commercial roofing has real safety risks. A contractor without a documented safety program and proper insurance is a liability for your business.

9. Cash-Only or Unusual Payment Terms

Legitimate contractors invoice professionally and accept standard payment methods. Requests for large cash payments upfront or unusual deposit structures are warning signs.

Does My Commercial Roof Need 100% Torn-Off?

Tue, 07 May 2024 17:59:01 GMT

Does My Commercial Roof Need 100% Torn-Off?

Not necessarily — and automatically assuming it does can be a very expensive mistake. Here's how to determine whether a full tear-off is truly necessary for your commercial roof.

The 25% Rule

The industry standard threshold for restoration vs. replacement is approximately 25% wet insulation. If moisture has infiltrated less than 25% of your roof's insulation, the damaged sections can be cut out and replaced, and a coating system can restore the remaining roof. Above 25%, a full replacement becomes more cost-effective.

How to Know How Much Is Wet

The only accurate way to assess moisture content is through core samples and — for larger roofs — an infrared scan performed at dusk. These tools identify wet insulation that isn't visible from the surface. Any reputable contractor should perform this assessment before recommending a course of action.

When a Full Tear-Off IS Necessary

A full tear-off is warranted when: wet insulation exceeds 25% of the total roof area, the decking beneath is rotted or structurally compromised, the membrane has delaminated extensively, or building code requires a new roof due to existing layers.

When Restoration Is the Better Choice

When moisture is below the threshold and the membrane is still structurally sound, a coating restoration — at 50–70% less cost than replacement — is almost always the smarter financial decision. Get an honest inspection before agreeing to a full tear-off.

What R-Value Can Be Achieved on a Bare Metal Roof?

Wed, 01 May 2024 12:42:16 GMT

What R-Value Can Be Achieved on a Bare Metal Roof?

A bare metal roof typically has an R-value near zero — metal is an excellent heat conductor, providing essentially no insulation. The good news is that several systems can dramatically improve this.

Spray Polyurethane Foam: The Best Option

Spray foam provides R-6.5 per inch of thickness. Applied at 2 inches, you achieve R-13. At 3 inches, R-19.5. At 4 inches, R-26. This is the highest R-value per inch of any roofing insulation available, and it can be applied directly over the metal roof in one seamless application.

Rigid Board Insulation

Polyiso board insulation provides approximately R-6 per inch but requires a new membrane over the top. This approach involves more materials, more labor, and more cost — and introduces seams that foam avoids entirely.

Silicone Coating Alone

A silicone coating without added foam provides essentially no R-value improvement. It does, however, add significant solar reflectance — reducing heat absorption and lowering cooling loads without adding insulation.

The Best Approach for Most Metal Roofs

For maximum energy performance, spray foam applied directly to the metal at the desired thickness, topped with a silicone coating, delivers both high R-value and high reflectivity — transforming a bare metal roof into a high-performance roofing system.

Commercial Roofing 101: The Latest Trends

Tue, 23 Apr 2024 18:02:11 GMT

Commercial Roofing 101: The Latest Trends

The commercial roofing industry is evolving. Here are the most significant trends shaping how building owners and contractors approach roof systems today.

1. Renewable Coating Systems Over Replacement

The shift toward coating system restoration over full tear-off replacement continues to accelerate. As building owners become more educated about the cost and disruption of replacement, renewable silicone and SPF systems are gaining significant market share.

2. Robotic and Technology-Assisted Installation

For large commercial and industrial roofs, robotic spray foam application — as demonstrated in West Roofing's MTD facility project — is becoming more viable. Robotic systems improve consistency, speed, and safety on large-scale projects.

3. Sustainability and Waste Reduction

Environmental regulations and corporate sustainability goals are pushing more building owners toward restoration over replacement. Coating systems generate virtually no landfill waste compared to tear-off replacements.

4. Cool Roofing and Energy Codes

Energy codes are increasingly requiring minimum solar reflectance values on commercial roofs. High-solids silicone coatings easily meet or exceed these requirements, making them a go-to choice for compliance-driven projects.

5. Longer Warranties

Manufacturer warranties on coating systems are extending, with 20-year renewable options becoming more common. This long-term warranty protection is a major selling point for building owners planning multi-decade facility ownership.

Ballpark Cost to Restore TPO and EPDM With Silicone Coating

Wed, 03 Apr 2024 15:04:00 GMT

Ballpark Cost to Restore TPO and EPDM With Silicone Coating

One of the most common questions we receive: what does it actually cost to restore a TPO or EPDM roof with a silicone coating system? Here's an honest ballpark range.

Typical Cost Range

Silicone coating restoration on TPO or EPDM roofs typically ranges from $2.00–$4.50 per square foot, depending on roof size, condition, required prep work, and coating thickness. For a 20,000 sq ft roof, that's roughly $40,000–$90,000. Compare that to full TPO replacement at $7–$12 per square foot, or $140,000–$240,000 for the same roof.

Factors That Affect Price

The main cost drivers are: amount of wet insulation that must be replaced, extent of seam and flashing repairs needed before coating, required coating thickness (more mils = longer warranty = higher cost), roof accessibility and complexity, and travel distance for the contractor.

Why Size Matters

Larger roofs typically have lower per-square-foot costs due to economies of scale in labor and material delivery. A 100,000 sq ft restoration will cost significantly less per square foot than a 5,000 sq ft restoration.

Getting an Accurate Quote

The only way to get an accurate price is a site inspection with core samples. Ballpark numbers give you a planning range, but actual costs depend on your specific roof's condition and requirements.

What's the Ballpark Cost to Restore a Commercial Metal Roof?

Wed, 27 Mar 2024 17:45:39 GMT

What's the Ballpark Cost to Restore a Commercial Metal Roof?

Metal roof restoration costs vary based on whether you're applying silicone coating alone or spray foam plus coating. Here are the typical ranges.

Silicone Coating Only on Metal

A silicone coating restoration on a commercial metal roof typically costs $2.50–$5.00 per square foot. This includes surface prep, rust treatment, fastener and seam sealing with reinforced fabric, and the silicone topcoat at the required mil thickness.

Spray Foam Plus Silicone on Metal

Adding spray polyurethane foam for insulation value increases the cost to approximately $4.00–$8.00 per square foot, depending on foam thickness. Each additional inch of foam adds roughly $1.00–$1.50 per square foot but delivers R-6.5 of insulation value per inch.

Compared to Metal Roof Replacement

A full metal roof replacement typically runs $8–$15 per square foot or more, depending on panel type and complexity. Restoration at 30–60% of replacement cost — while also avoiding the significant disruption of tear-off — makes it the preferred option for most metal roofs in adequate condition.

Key Cost Variables

Factors affecting price include: degree of rust and surface preparation needed, fastener count and seam length, roof pitch and complexity, foam thickness (if applicable), and overall roof square footage.

Why You Should Never Install TPO Over Gravel Built-up Roof

Thu, 21 Mar 2024 15:02:36 GMT

Why You Should Never Install TPO Over Gravel Built-up Roof

When a gravel built-up roof (BUR) reaches end of life, the question becomes: what goes on top? TPO over gravel is sometimes proposed — but it's not standard practice and creates serious problems.

The Gravel Problem

Gravel BUR roofs have an uneven, jagged surface covered in loose stones. TPO is a sheet membrane that requires a smooth, flat substrate for proper adhesion and performance. Installing TPO directly over gravel results in: poor adhesion, potential punctures from sharp aggregate, uneven surface that creates stress points, and an installation that most TPO manufacturers will not warranty.

What Contractors Sometimes Do

Some contractors remove the gravel, then install a cover board over the existing BUR before laying TPO. This works but adds significant cost and labor — and still leaves you with a seamed membrane that will face the same aging issues as any TPO installation.

The Better Alternative: Spray Foam

Spray polyurethane foam is specifically designed for gravel BUR applications. After hydro-vacuuming the gravel, foam is applied directly to the existing BUR substrate — which, once gravel is removed, provides an ideal bonding surface. The foam fills in all irregularities, adds insulation, and creates a completely seamless waterproof membrane. This is the industry-preferred approach for gravel BUR restoration.

Cannot Locate Leak on Commercial Roof: What to Do?

Thu, 08 Feb 2024 14:26:32 GMT

Cannot Locate Leak on Commercial Roof: What to Do?

One of the most frustrating roofing problems: water is getting in, but you can't find where it's coming from. Here's a systematic approach to finding and fixing elusive commercial roof leaks.

Why Commercial Leaks Are Hard to Find

Water doesn't always drip straight down. It can enter the roof in one location, travel along the membrane or through insulation, and exit the ceiling 20–30 feet away from the actual breach. This makes visual inspection of the interior useless for pinpointing the source.

Step 1: Systematic Roof Inspection

Start on the roof and systematically inspect every potential entry point: seams, flashings, penetrations (HVAC units, pipes, drains), parapet walls, and any areas where the membrane transitions. These are where 90%+ of leaks originate.

Step 2: Infrared Scan

An infrared (thermal) scan performed at dusk can identify wet insulation by detecting temperature differences as the roof cools. Wet areas retain heat longer than dry areas, appearing as warm spots on the scan. This is the most effective tool for locating hidden moisture infiltration.

Step 3: Electronic Leak Detection

For roofs that are difficult to scan, electronic leak detection systems can apply a low-voltage charge to the membrane and identify breaches through electrical conductivity testing.

The Spray Foam Solution

For roofs with chronic, hard-to-locate leaks, a spray foam restoration eliminates the problem entirely. Rather than hunting for individual breaches, foam creates a completely new seamless surface over the entire roof — eliminating every existing entry point at once.

8 Ways Spray Foam Roofing Saves Money

Thu, 01 Feb 2024 15:13:00 GMT

8 Ways Spray Foam Roofing Saves Money

Spray polyurethane foam roofing isn't just a high-performance roofing system — it's also one of the most cost-effective options available. Here are 8 specific ways it saves money.

1. No Tear-Off Required

Foam goes over the existing roof, eliminating tear-off labor, disposal fees, and the risk of exposing your building interior. Tear-off alone can add $1–$3 per square foot to a project.

2. Avoids New Construction R-Value Requirements

A full tear-off triggers "new construction" codes in most municipalities, requiring minimum R-values that add significant insulation cost. Restoration avoids this entirely.

3. Highest R-Value Per Inch

At R-6.5 per inch, spray foam provides the highest insulation value of any roofing material — reducing heating and cooling costs immediately after installation.

4. Renewable Warranty

Instead of replacing the roof every 20 years, a recoat restores the warranty. Over a 40-year period, you pay for restoration twice instead of replacement twice — a major lifecycle cost difference.

5. Seamless = Fewer Leaks

Seams are the #1 cause of commercial roof leaks. A seamless foam roof eliminates this failure mode, reducing repair costs over the roof's life.

6. No New Roofing Layers Needed

Building codes limit the number of roofing layers on a structure. Foam restoration doesn't add a "layer" in the traditional sense, extending the time before a mandated full replacement.

7. Lower Insurance Premiums

Some insurers offer reduced premiums for buildings with newer, warrantied roofing systems. A fresh foam roof with a manufacturer's warranty can qualify for better rates.

8. Faster Installation = Less Downtime

Large foam projects can be completed significantly faster than traditional replacement. Less downtime means less operational disruption and lower soft costs for the building owner.

Ballpark Cost to Restore a Commercial Gravel Built-up Roof

Thu, 25 Jan 2024 14:34:10 GMT

Ballpark Cost to Restore a Commercial Gravel Built-up Roof

Gravel built-up roofs (BUR) present unique restoration challenges — primarily the need to remove the gravel before any new system can be applied. Here's what to expect cost-wise.

Step 1: Gravel Removal

Gravel must be removed before spray foam can be applied. The most common method is hydro-vacuuming, which costs approximately $0.50–$1.00 per square foot depending on gravel depth and roof accessibility.

Spray Foam Restoration on BUR

After gravel removal, spray foam is applied directly to the existing BUR substrate. Total installed cost — including gravel removal, foam application, and silicone topcoat — typically runs $4.00–$7.00 per square foot depending on foam thickness and roof size.

Compared to BUR Replacement

A full tear-off and replacement of a gravel BUR roof typically costs $8–$14 per square foot. Restoration at roughly half that cost — while also avoiding the significant disruption of removing thousands of pounds of gravel and multiple plies of roofing — makes it the preferred approach for most BUR roofs in reasonable condition.

The Key Variable: Wet Insulation

As with all roof restorations, the extent of wet insulation is the critical cost variable. More wet insulation means more cut-and-replace work before foam can be applied, which increases cost. A core sample inspection is essential before finalizing a budget.

How to Easily Raise Low Spots on a Commercial Roof?

Thu, 18 Jan 2024 16:16:50 GMT

How to Easily Raise Low Spots on a Commercial Roof?

Low spots on commercial roofs create ponding water — and ponding water accelerates membrane deterioration, increases leak risk, and can add structural load. Here's the easiest solution.

Why Low Spots Develop

Low spots typically form when insulation beneath the membrane becomes saturated with moisture and compresses over time. The resulting sag creates a depression that water pools in rather than draining toward outlets.

Traditional Approach: Labor-Intensive and Imprecise

With traditional roofing systems, raising low spots requires removing the existing membrane, cutting out and replacing compressed insulation with new material of varying thickness, then re-installing the membrane. This is labor-intensive, costly, and prone to imprecision.

The Spray Foam Approach: Simple and Effective

Spray foam is fluid-applied and can be feathered in at any thickness. After removing the wet insulation in the low area, foam is applied at greater thickness in the depression and tapered out to match the surrounding roof level — or to redirect drainage toward existing outlets. The process is fast, precise, and creates a seamless surface with no joints or transitions.

When It's Part of a Full Restoration

Slope correction is most cost-effective when combined with a full foam restoration. The entire roof gets a new seamless surface, drainage is optimized, and the building receives a new manufacturer's warranty — all in one project.

3 Costly Mistakes Building Owners Make With Their Roof

Fri, 12 Jan 2024 20:16:23 GMT

3 Costly Mistakes Building Owners Make With Their Roof

After decades in commercial roofing, West Roofing Systems has seen the same costly mistakes repeated by building owners. Here are the three most common — and how to avoid them.

Mistake 1: Waiting Too Long to Address Problems

The most expensive roofing mistake is ignoring early warning signs. A small leak that's ignored for a season can saturate insulation across a large area, turn a restorable roof into a replacement candidate, and cause significant interior damage. Annual inspections and prompt attention to minor issues prevent major expenses.

Mistake 2: Automatically Accepting a Tear-Off Recommendation

Many building owners accept a contractor's recommendation for full tear-off and replacement without getting a second opinion or verifying through core sample testing that restoration isn't viable. In most cases where moisture is below 25%, a coating restoration is the smarter financial decision — at 50–70% less cost.

Mistake 3: Choosing the Lowest Bid

The lowest bid almost always means something is being left out — cheaper materials, skipping wet insulation removal, or less experienced labor. A roof that fails prematurely or causes interior damage costs far more than the savings on the original bid. Compare scopes of work carefully and choose quality over price.

The Common Thread

All three mistakes share the same root cause: making decisions without complete information. An honest, thorough inspection from a reputable contractor is the foundation of every smart commercial roofing decision.

How to Get an Existing Commercial Roof Under New Warranty?

Tue, 21 Nov 2023 20:56:31 GMT

How to Get an Existing Commercial Roof Under New Warranty?

Your roof's warranty has expired — or is about to. You don't want to pay for a full replacement, but you need ongoing warranty protection. Here's how a coating restoration gets your roof under a new manufacturer's warranty.

The Requirements

To qualify for a new manufacturer's warranty through restoration, three conditions must be met: the existing membrane must be in acceptable condition (not delaminating or extensively failed), wet insulation must be removed and replaced, and the work must be performed by a manufacturer-approved contractor using approved materials.

The Process

A qualified contractor performs a thorough inspection with core samples to assess moisture levels. Wet sections are replaced. The existing surface is power-washed and repaired. A coating system is applied at the required mil thickness — and the manufacturer issues a new 10–20-year warranty.

Cost vs. Replacement

Getting an existing roof under a new warranty through coating restoration typically costs 50–70% less than a full replacement. For building owners who need warranty coverage but aren't ready for a major capital expense, restoration is often the clear solution.

What Warranty Length Is Available?

Most manufacturers offer 10, 15, or 20-year warranty options depending on coating thickness applied. Thicker coating = longer warranty. A contractor can help you choose the right option based on your budget and timeline goals.

9 Out-of-the-Box Considerations Before Selecting a Commercial Roofing System

Tue, 19 Sep 2023 18:03:49 GMT

9 Out-of-the-Box Considerations Before Selecting a Commercial Roofing System

Most building owners focus on cost and material type when choosing a commercial roofing system. But there are 9 often-overlooked considerations that can significantly affect which system is the right choice.

1. Building Code Requirements

A full tear-off may trigger new construction codes requiring minimum R-values. Know before you commit whether restoration or replacement changes your code obligations.

2. Number of Existing Roof Layers

Most jurisdictions limit roofs to two layers. If you're at the limit, your next project requires a full tear-off regardless of roof condition.

3. Roof Drain Capacity

Adding foam or insulation changes the roof's slope and drainage patterns. Confirm existing drains can handle water flow before restoration.

4. Penetration Count

Roofs with many HVAC units, pipes, and skylight penetrations are better suited to fluid-applied systems like spray foam than seamed membranes.

5. Operational Sensitivity

If your operation cannot tolerate exposure to weather during installation, a restoration system that doesn't require tear-off is significantly lower risk.

6. Ownership Timeline

Planning to sell in 5 years? A 10-year warranty restoration may be sufficient. Planning 30-year ownership? A renewable system makes more sense than periodic replacements.

7. Insulation Goals

If your building has poor thermal performance, this is an opportunity to add R-value. Not all roofing systems offer meaningful insulation improvement.

8. Overspray Risk

Adjacent properties, vehicles, or sensitive equipment near the building should factor into whether spray-applied systems are feasible.

9. Contractor's Warranty Support

Some contractors issue warranties they can't back up if they go out of business. Manufacturer-backed warranties provide protection independent of the installing contractor.

Spray-On Roofing Systems: Costs, Benefits & Installation Guide

Thu, 31 Aug 2023 20:13:23 GMT

Spray-On Roofing Systems: Costs, Benefits & Installation Guide

Spray-on roofing systems — primarily spray polyurethane foam (SPF) and silicone coating systems — are gaining significant popularity in commercial roofing. Here's a complete overview.

What Are Spray-On Roofing Systems?

Spray-on systems are fluid-applied directly to the existing roof surface. SPF systems combine polyurethane foam (applied first for insulation and structure) with a silicone or acrylic topcoat for waterproofing and UV protection. Silicone-only systems apply a high-solids coating directly over existing membranes like TPO, EPDM, or metal.

Key Benefits

Spray-on systems offer several advantages: no tear-off required (applied over existing roofing), seamless application eliminating seam-related leaks, renewable warranties of 10–20 years, high R-value (for foam systems), and superior UV and weather resistance (for silicone systems).

Typical Costs

Silicone coating systems: $3.50–$7.00 per sq ft. Spray foam plus silicone: $5.00–$10.00 per sq ft, depending on foam thickness. Both options are significantly less expensive than full roof replacement at a minimum of $15 per sq ft.

Installation Process

The process involves inspection and core sampling, wet insulation removal, surface cleaning, repairs to existing membrane, primer (if required), application of foam and/or coating at required thickness, and final quality inspection. The entire process for most commercial roofs can be completed in days to weeks.

Which Roofing System Minimizes Business Interruption?

Fri, 18 Aug 2023 19:55:21 GMT

Which Roofing System Minimizes Business Interruption?

For businesses operating under their roof — manufacturers, retailers, offices, healthcare facilities — roof installation downtime has a real dollar cost. Here's how different systems compare.

Full Tear-Off: Most Disruptive

A full tear-off temporarily removes the weather barrier from your building. Rain during installation can damage inventory, equipment, or interior finishes. Operations may need to halt or relocate. Tear-offs also generate noise, debris, and foot traffic that disrupts employees and customers.

Traditional Single-Ply (TPO/EPDM): Moderate Disruption

Single-ply installations don't require a tear-off (when going over existing roofing) but still involve significant crew presence, noise, and mechanical equipment on the roof over an extended period.

Spray Foam Restoration: Least Disruptive

Spray foam restoration is the least disruptive commercial roofing option. No tear-off means the weather barrier is never removed. Installation is relatively quiet. Odors from the foam are minimal at the interior level. Projects are completed faster than traditional systems. Most businesses operate normally throughout the installation process.

Planning for Minimal Disruption

Regardless of system, work with your contractor to schedule installation during off-hours, weekends, or seasonal slow periods if even minor disruption is a concern. A reputable contractor will accommodate your operational needs.

How to Cost-Effectively Restore a Unique or Unusual Roofing System?

Mon, 31 Jul 2023 14:23:09 GMT

How to Cost-Effectively Restore a Unique or Unusual Roofing System?

Not all commercial roofs are simple flat rectangles. Domes, steep slopes, irregular geometries, complex penetrations, and unusual substrate materials present challenges that traditional roofing systems handle poorly — or expensively. Here's where spray foam excels.

Why Traditional Systems Struggle

Sheet membranes like TPO and EPDM require flat, uniform surfaces. Cutting, fitting, and welding around complex shapes, domes, or dense penetration fields is labor-intensive and creates numerous potential failure points at each seam and transition.

Spray Foam: Built for Complexity

Spray foam is fluid-applied and conforms to any shape or substrate. Whether it's a dome, a curved surface, a roof with dozens of penetrations, or a multi-level building with dozens of transition points — foam flows into every crevice and creates a continuous seamless surface regardless of complexity. No cutting, no fitting, no seams.

Real Examples

West Roofing Systems has applied spray foam to domes, steep-slope metal roofs, historic buildings with irregular profiles, military facilities with corrugated panels, and roofs with HVAC penetrations every few feet. In each case, foam delivered a seamless result that sheet membrane systems couldn't match at any price.

Cost Implications

Because foam doesn't require custom cutting or fitting, labor costs scale much less aggressively with complexity than sheet membranes. A highly complex roof that would cost significantly more to cover with TPO might cost only modestly more with foam.

11 Common Roofing Issues Solved Easier with Spray Foam

Thu, 20 Jul 2023 18:26:08 GMT

11 Common Roofing Issues Solved Easier with Spray Foam

Spray polyurethane foam doesn't just provide a new roof — it solves specific roofing problems that traditional systems handle poorly. Here are 11 common issues that foam addresses better than the alternatives.

1. Ponding Water

Foam builds slope where needed, directing water toward drains and eliminating ponding — something no sheet membrane can do.

2. Failing Seams

Foam eliminates seams entirely, removing the #1 cause of commercial roof leaks.

3. Multiple Penetrations

Foam seals all penetrations in a single application with no custom cutting or fitting required.

4. Gravel BUR Roofs

After hydro-vacuuming, foam bonds directly to the existing BUR substrate — the ideal solution for aging gravel roofs.

5. Irregular Roof Geometry

Foam conforms to any shape — domes, curved surfaces, transitions — without seams or custom fabrication.

6. Missing or Poor Insulation

Foam adds R-6.5 per inch of thickness, addressing insulation deficiencies in one application.

7. Asbestos Encapsulation

In some applications, foam can encapsulate existing asbestos-containing materials, avoiding costly abatement.

8. Corrugated or Profiled Substrates

Foam fills in corrugations on metal panels, creating a flat, smooth surface without additional materials.

9. Exposed Fasteners

Foam encapsulates exposed fasteners and bolts that would otherwise be chronic leak points.

10. Hard-to-Find Leaks

Rather than hunting for individual breaches, foam covers the entire surface — eliminating every existing entry point at once.

11. End-of-Life Roofs

When an existing roof is near end of life but doesn't qualify for replacement (under warranty or budget constraints), foam restoration can extend its life significantly at a fraction of replacement cost.

Spray Foam Roofing: UV Protection, Thickness, Colors, Slipperiness

Thu, 13 Jul 2023 17:47:33 GMT

Spray Foam Roofing: UV Protection, Thickness, Colors, Slipperiness

These are among the most common questions we receive about spray foam roofing. Here are direct answers to all four.

Does Spray Foam Need UV Protection?

Yes — spray polyurethane foam must always be protected from UV radiation. Unprotected foam degrades rapidly when exposed to sunlight, breaking down within days to weeks depending on UV intensity. This is why every spray foam roof requires a protective topcoat — typically silicone or acrylic — applied immediately after the foam. The topcoat handles UV resistance while the foam provides insulation and waterproofing.

How Thick Does Spray Foam Need to Be?

Minimum thickness requirements vary by application. For insulation and waterproofing, most manufacturers require a minimum of 1.5–2 inches of foam. For roofs requiring specific R-values (such as new construction triggering energy codes), thickness is calculated based on R-6.5 per inch. For slope correction, foam can be applied at any thickness to achieve desired drainage.

What Colors Are Available?

The foam itself is typically light yellow or off-white. The final color comes from the topcoat. White or light gray are most common for energy efficiency (maximum reflectance). However, silicone topcoats are available in a range of colors — including custom colors for specific aesthetic requirements. The West Roofing Systems project at Normandy High School used a distinctive Patina Green topcoat on the school's iconic domes.

Is a Spray Foam Roof Slippery?

A smooth silicone topcoat can be slippery when wet. For areas with regular foot traffic — around HVAC units, hatches, or walkway paths — contractors apply granules or a textured coating to improve traction. Always specify foot traffic needs to your contractor so appropriate safety measures are incorporated into the system design.

What Maintenance Is Required After a Spray Foam Roof Is Installed?

Tue, 30 May 2023 17:55:09 GMT

What Maintenance Is Required After a Spray Foam Roof Is Installed?

Spray foam roofs are low-maintenance compared to seamed systems, but specific maintenance is required to protect your warranty and maximize roof life.

Semi-Annual Inspections

Most manufacturers recommend inspections twice per year — typically spring and fall. These inspections look for: mechanical damage to the topcoat (from foot traffic, hail, or debris), areas where coating has worn thin, issues around penetrations and flashings, and clogged drains. Catching issues early prevents minor problems from becoming costly repairs.

Keeping Drains Clear

Clogged drains lead to ponding water, which accelerates topcoat wear. Regular drain cleaning — especially after storms and in fall when leaves are an issue — is essential maintenance for any flat roof.

Prompt Repair of Mechanical Damage

If the topcoat is damaged by foot traffic, equipment, or impact, it should be repaired promptly before UV exposure can degrade the underlying foam. Most repairs are simple: clean the area, apply compatible sealant or coating, and the warranty is maintained.

The Recoat Schedule

The most critical maintenance requirement is following the recoat schedule outlined in your warranty. When the warranty period ends (10, 15, or 20 years), the roof must be inspected, cleaned, and recoated to renew the warranty. Missing this window allows the topcoat to wear away and exposes the foam to UV damage.

Documented Maintenance

Many manufacturers require documented maintenance records to honor warranty claims. Keep records of all inspections and repairs throughout the warranty period.

What Are the Capabilities of Spray Foam Roofing?

Mon, 15 May 2023 17:04:10 GMT

What Are the Capabilities of Spray Foam Roofing?

Spray polyurethane foam is one of the most versatile roofing materials available. Here's a complete overview of what it can do.

Seamless Waterproofing

Foam creates a monolithic, seamless waterproof surface over the entire roof — eliminating the seams that cause 90%+ of commercial roof leaks. This capability extends to complex geometries, penetrations, and transitions that sheet membranes cannot address without creating seam failure points.

Superior Insulation

At R-6.5 per inch, foam provides the highest insulation value per inch of any roofing material. This can significantly reduce HVAC costs, especially in extreme climates.

Slope Correction

Foam can be applied at varying thicknesses to correct negative slope, eliminate ponding water, and direct drainage toward existing outlets. No other roofing system offers this capability without major structural modifications.

Application Over Virtually Any Substrate

Foam adheres to metal, concrete, wood, existing membranes (TPO, EPDM, BUR), and even corrugated panels — making it the most universally compatible roofing restoration system.

Encapsulation

Foam can encapsulate problematic materials including exposed fasteners, asbestos-containing substrates (in applicable situations), and deteriorated panel edges.

Renewability

Unlike any other roofing system, foam roofs can be renewed indefinitely with periodic recoating — making them potentially the last roof a building ever needs.

What's the Best Option to Fix a Flat, Commercial Roof

Thu, 04 May 2023 17:53:25 GMT

What's the Best Option to Fix a Flat, Commercial Roof

Flat commercial roofs present specific challenges — ponding water, seam failures, and limited drainage options. Here's how to choose the best fix for your situation.

Option 1: Spot Repairs

For isolated problems — a failed seam, a puncture near a drain — spot repairs are the fastest and least expensive short-term fix. However, they don't address overall membrane aging and typically buy 1–3 years before the next problem appears.

Option 2: Silicone Coating Restoration

For flat roofs with aging TPO, EPDM, or metal membranes in acceptable condition, a silicone coating system is often the best long-term solution. It seals all existing seams and weak points, creates a new seamless waterproof surface, and comes with a 10–20 year renewable warranty at 50–70% less cost than replacement.

Option 3: Spray Foam Restoration

For flat roofs with significant ponding water issues, aged gravel BUR, or multiple complex penetrations, spray foam is the superior choice. It corrects slope, eliminates ponding, seals all penetrations, and adds insulation — capabilities no other system offers.

Option 4: Full Replacement

When wet insulation exceeds 25% of the roof area, the deck is compromised, or the roof simply can't be restored, full replacement is necessary. It's the most expensive option but sometimes unavoidable.

How to Decide

Get a professional inspection with core samples. The moisture level in your insulation is the key variable that determines which option is right for your specific flat roof.

What's the Best Way To Restore a Metal Roof?

Fri, 28 Apr 2023 19:50:56 GMT

What's the Best Way To Restore a Metal Roof?

Metal roofs are durable, but over time they develop leaks at fasteners and seams, rust, and thermal expansion issues. Here's the best approach to restoration.

Why Metal Roofs Leak

The most common failure points on metal roofs are: fastener holes that enlarge over time from thermal expansion and contraction, seam separations, rust penetrating through the panel, and failed flashing at edges, penetrations, and transitions. Traditional patching addresses individual failures but not the root cause — an aging system with dozens of potential failure points.

Silicone Coating: The Best Restoration Option

A silicone coating restoration addresses all failure points simultaneously. The process: clean and degrease the surface, treat rust with inhibiting primer, seal all fasteners and seams with reinforced fabric tape and compatible sealant, then apply full silicone coating at the required mil thickness. The result is a completely seamless waterproof surface over the entire roof — with a 10–20 year renewable warranty.

Adding Spray Foam for Insulation

If insulation is also a goal, spray foam can be applied directly to the metal before the silicone topcoat. This transforms a bare metal roof (near zero R-value) into a high-performance insulated system at R-6.5 per inch of foam thickness.

Cost vs. Metal Roof Replacement

Metal restoration typically costs 40–60% less than tear-off and replacement, with no disruption from tearing off the existing panels. For most metal roofs in adequate structural condition, restoration is the clear financial winner.

Old TPO Roof? Here's the Best Way to Restore It

Wed, 26 Apr 2023 19:10:37 GMT

Old TPO Roof? Here's the Best Way to Restore It

Your TPO roof is aging — seams are losing adhesion, the membrane is showing wear, and the warranty has expired or is about to. Here's the best restoration path.

Why TPO Roofs Age the Way They Do

TPO membranes are excellent when new, but the heat-welded seams are their Achilles heel. Daily thermal cycling causes the membrane to expand and contract, gradually stressing seam adhesion. Over 10–20 years, seams can develop microscopic separations that become active leaks. The membrane surface also oxidizes and becomes more brittle with age.

The Best Solution: Silicone Restoration Membrane

A silicone restoration membrane (SRM) applied over the existing TPO is typically the best value for aging TPO roofs. The process involves: power washing the surface, repairing failed seams with reinforced fabric tape and sealant, applying primer if required, and installing 20–30 mils of silicone coating. This seals every seam on the existing roof under a new continuous membrane and issues a new 10–20 year manufacturer's warranty.

What About the Wet Insulation Requirement?

Before restoration, core samples are taken to identify wet insulation. Wet sections are removed and replaced — this is non-negotiable for warranty compliance. A roof with less than 25% wet insulation is typically a good candidate for restoration.

Cost Comparison

SRM restoration typically costs $2.50–$4.50 per square foot. Full TPO replacement runs $7–$12 per square foot. The math strongly favors restoration for most aging TPO roofs.

What's the Best Option To Fix a Commercial Roof Without Replacing It?

Tue, 14 Mar 2023 12:37:47 GMT

What's the Best Option To Fix a Commercial Roof Without Replacing It?

Full roof replacement is expensive, disruptive, and often unnecessary. For most commercial roofs with less than 25% wet insulation, restoration is a viable — and far more cost-effective — alternative.

Option 1: Silicone Coating System

The most widely applicable non-replacement solution. A silicone restoration membrane is applied over the existing roof (TPO, EPDM, metal, or modified bitumen), sealing all existing seams and creating a new seamless waterproof surface. Cost: $2–$5 per sq ft. Warranty: 10–20 years renewable.

Option 2: Spray Foam Restoration

Ideal when slope correction, insulation improvement, or complex penetrations are involved. Foam is applied over the existing substrate, creating a seamless surface that can be built up in specific areas for drainage improvement. Cost: $4–$8 per sq ft. Warranty: 10–20 years renewable.

Option 3: Targeted Repairs Plus Coating

For roofs with specific problem areas but otherwise acceptable condition, targeted repairs (seam re-welding, penetration sealing, flashing replacement) combined with a coating system can restore performance at the lowest possible cost.

When Replacement Is Unavoidable

If wet insulation exceeds 25%, the deck is compromised, or building codes require a new roof (due to existing layer count), replacement may be the only option. This determination requires a professional inspection with core samples — not a visual assessment alone.

Best Roof To Install With High Foot Traffic

Tue, 07 Mar 2023 08:51:02 GMT

Best Roof To Install With High Foot Traffic

Commercial roofs with rooftop HVAC units, mechanical equipment, or accessible terraces see regular foot traffic. Not all roofing systems handle this equally well. Here's what you need to know.

The Challenge with High Foot Traffic

Foot traffic can damage roofing membranes through punctures, abrasion, and compression. Systems that rely on thin membranes or expose vulnerable materials to direct contact are most at risk. The goal is a system that's durable enough to handle regular traffic without voiding the warranty or compromising waterproofing.

Spray Foam: Surprisingly Durable

Closed-cell spray foam is surprisingly resistant to compressive loads. Studies have shown it can support significant weight without permanent deformation. The key is the topcoat — a standard silicone topcoat can be slippery when wet. For high-traffic areas, contractors add granules or a textured topcoat to improve traction and durability.

TPO and EPDM: Moderate Traffic Tolerance

Single-ply membranes handle moderate foot traffic reasonably well when walk pads are installed in high-traffic paths. Without walk pads, foot traffic over time can cause membrane abrasion and seam stress.

Best Practice for Any System

Regardless of roofing system, designated walkways with walk pads should be installed anywhere regular foot traffic occurs. Rooftop HVAC paths, hatch access points, and service routes should all have walk pads to protect the membrane and maintain warranty coverage.

Flat Roof Renewal Costs: What Affects the Price per Square Foot

Mon, 27 Feb 2023 15:53:39 GMT

Flat Roof Renewal Costs: What Affects the Price per Square Foot

Flat roof renewal cost varies widely depending on the system chosen, roof condition, and several other factors. Here's what drives the price — and what to budget.

Typical Price Ranges by System

Silicone coating over TPO/EPDM: $2.00–$4.50/sq ft. Silicone coating over metal: $2.50–$5.00/sq ft. Spray foam plus silicone (new installation): $4.00–$8.00/sq ft. Gravel BUR restoration (including hydro-vac): $4.00–$7.00/sq ft. Full flat roof replacement: $7.00–$14.00/sq ft depending on system.

Factor 1: Wet Insulation Extent

The single biggest variable. Every sq ft of wet insulation requires cut-and-replace work before coating can be applied. Roofs with 5% wet insulation are far less expensive to restore than roofs with 20% wet insulation.

Factor 2: Coating Thickness

More mil thickness = longer warranty = more material cost. A 10-year warranty typically requires 20 mils; a 20-year warranty requires 30+ mils. The cost difference between warranty tiers is real but often worth it for long-term ownership.

Factor 3: Roof Size

Larger roofs cost less per square foot due to economies of scale. Mobilization, setup, and overhead costs are distributed across more square footage on larger projects.

Factor 4: Roof Complexity

More penetrations, difficult access, multiple levels, and unusual geometries all add labor cost. A simple 50,000 sq ft warehouse roof will cost less per square foot than a 10,000 sq ft retail roof with 30 penetrations.

4 Tips on Making the Best Decision With Commercial Roofing Information

Wed, 25 Jan 2023 14:03:48 GMT

4 Tips on Making the Best Decision With Commercial Roofing Information

Commercial roofing decisions involve significant money and long-term building performance. With a lot of conflicting information available, here are 4 tips to help you cut through the noise.

Tip 1: Verify Who Is Providing the Information

A TPO contractor will tell you TPO is the best system. A foam contractor will recommend foam. Everyone has an inherent bias toward what they sell. Seek out contractors who offer multiple systems and can give you an objective comparison, or consult independent sources before making a decision.

Tip 2: Get Core Samples Before Trusting Any Recommendation

No contractor should recommend replacement or restoration without first performing core sample testing. Any recommendation made without core samples is based on assumptions, not facts. Insist on data before accepting a proposal.

Tip 3: Compare Scopes of Work, Not Just Prices

Two bids at very different prices usually mean very different scopes of work. Before comparing costs, compare exactly what each proposal includes — wet insulation removal, coating thickness, warranty terms, prep work, and materials. A lower bid that skips critical steps is not a bargain.

Tip 4: Think in Total Cost of Ownership

The best roofing decision isn't always the lowest upfront cost. Consider: how long will the system last? What does recoating or replacement cost at the end of the warranty? What are the energy savings? A system that costs 20% more upfront but lasts twice as long and is renewable is almost always the better investment.

How Strong Is a Spray Foam and Coating Roof? The Truth About Durability

Mon, 16 Jan 2023 14:33:32 GMT

How Strong Is a Spray Foam and Coating Roof? The Truth About Durability

Spray foam roofing skeptics often question whether foam is "strong enough" to be a serious commercial roofing solution. Here's what the data and decades of real-world performance actually show.

Compressive Strength

Closed-cell spray polyurethane foam used in roofing applications typically has compressive strength of 25–60 PSI, depending on density. This means it can support hundreds of pounds per square foot — far more than any commercial roofing crew or HVAC equipment would exert during normal foot traffic or maintenance.

Wind Uplift Resistance

Because spray foam adheres directly to the substrate in a monolithic bond, it has exceptional wind uplift resistance. Unlike sheet membranes that can be peeled away at seams and edges, foam is bonded across its entire surface with no vulnerable edges or seams.

Hail Resistance

Spray foam absorbs and distributes impact energy rather than puncturing or cracking under hail impact. The foam's cellular structure provides natural impact resistance that thin membranes don't offer.

Longevity: 45+ Years of Proof

West Roofing Systems has been installing spray foam roofs since 1979. Many of those original installations, properly maintained and recoated, are still performing today. The renewable nature of foam roofing means that with proper maintenance, there is no theoretical end to the system's life.

The Bottom Line

Spray foam is not a fragile or temporary system. It is one of the most durable commercial roofing options available — backed by decades of real-world performance across thousands of installations.

What is the Minimum Slope Needed for a Flat Roof?

Tue, 03 Jan 2023 19:36:48 GMT

What is the Minimum Slope Needed for a Flat Roof?

Despite the name, "flat" commercial roofs are never truly flat — they require some slope to drain water. Here's what the standards say and what to do when your roof has inadequate slope.

Industry Standard Minimum Slope

Most roofing system manufacturers and building codes require a minimum slope of 1/4 inch per foot (approximately 2%) for low-slope commercial roofing systems. This ensures water drains toward outlets rather than ponding on the membrane surface.

Why Inadequate Slope Is a Problem

Ponding water — water that remains on a roof surface for more than 48 hours after rain — accelerates membrane deterioration, adds structural load, and can lead to premature system failure. Most roofing warranties specify that the manufacturer is not responsible for damage caused by ponding water on roofs with inadequate slope.

What Happens When Your Roof Doesn't Have Enough Slope

Low spots typically develop when insulation beneath the membrane becomes saturated and compresses over time. This creates depressions where water pools rather than draining. Traditional roofing systems struggle to correct this — slope correction requires removing and replacing insulation at varying thicknesses, which is labor-intensive and imprecise.

The Spray Foam Solution

Spray foam is the ideal solution for slope correction. Because it's fluid-applied, foam can be applied at varying thicknesses — thicker in low spots, tapered to match surrounding areas — to create positive slope toward drains. This correction happens in a single application as part of the restoration, without structural modifications.

The 17 Most Common Questions About Spray Foam Roofing

Tue, 13 Dec 2022 17:02:16 GMT

The 17 Most Common Questions About Spray Foam Roofing

Whether you're considering spray foam for the first time or evaluating it against other systems, here are the 17 most common questions — answered directly.

1. What is spray foam roofing?

Spray polyurethane foam (SPF) is a two-component liquid system applied to existing roofing. The components react and expand into a rigid, closed-cell foam that adheres to the substrate. A protective topcoat is then applied over the foam.

2. How long does spray foam roofing last?

With proper maintenance and recoating, indefinitely. West Roofing has foam installations from 1979 still performing today.

3. How much does it cost?

Typically $4–$8 per square foot for foam plus coating, depending on thickness and roof conditions.

4. Does spray foam need a topcoat?

Yes — always. Unprotected foam degrades within days of UV exposure.

5. Can spray foam go over my existing roof?

In most cases, yes — over TPO, EPDM, metal, BUR, and modified bitumen systems that are in acceptable condition.

6. What warranty is available?

Most manufacturers offer 10, 15, or 20-year warranties. At the end of the warranty, a recoat renews coverage.

7. How is the warranty renewed?

Power wash, inspect, repair any issues, apply fresh topcoat at required thickness, receive new warranty.

8. Is spray foam slippery?

Smooth silicone topcoats can be slippery when wet. Granules or textured coatings are used in foot traffic areas.

9. How does foam compare to TPO cost?

Similar upfront, but foam's renewable warranty creates enormous lifecycle cost savings over TPO replacement cycles.

10. Can spray foam correct ponding water?

Yes — this is one of foam's unique capabilities. It can be applied at varying thicknesses to build slope and direct drainage.

11. Does foam add insulation?

Yes — R-6.5 per inch, the highest of any roofing insulation.

12. How long does installation take?

Days to weeks depending on roof size. Large projects can cover tens of thousands of square feet per day.

13. Is foam installation disruptive?

Minimal. No tear-off, relatively quiet, business operations typically continue normally.

14. What maintenance is required?

Semi-annual inspections, drain cleaning, prompt repair of mechanical damage, and recoating per the warranty schedule.

15. Can spray foam be used on unusual roof shapes?

Yes — it's one of foam's greatest advantages. It conforms to any shape, including domes, curved surfaces, and complex penetration fields.

16. Is spray foam environmentally friendly?

More so than replacement systems — no landfill waste from tear-off, and energy savings from improved insulation.

17. How do I know if my roof qualifies for foam restoration?

A professional inspection with core samples will determine moisture levels and membrane condition. Contact West Roofing Systems for a free assessment.

What's the Best Commercial Roofing System To Install on a Tight Deadline?

Tue, 29 Nov 2022 17:54:41 GMT

What's the Best Commercial Roofing System To Install on a Tight Deadline?

Roof installations often have hard deadlines — school openings, tenant move-ins, or weather windows. Here's which systems deliver speed without sacrificing quality.

Why Some Systems Take Longer

Full tear-off and replacement is the slowest option. Removing the existing roof, disposing of materials, preparing the deck, and installing a new system all take significant time. Weather delays are also more likely since the building is exposed during tear-off.

Spray Foam: Fastest Restoration Option

Spray foam restoration is typically the fastest commercial roofing option. Large crews with high-output equipment can apply thousands of square feet per day. At the MTD facility project, West Roofing Systems covered 384,000 sq ft in 52 days using robotic application.

Key Speed Advantages of Spray Foam

No tear-off eliminates the slowest part of any roofing project. Foam adheres to the existing substrate in a single pass. Complex penetrations don't require custom fabrication. There's no waiting for seam welds or adhesive cure times between sections.

Silicone Coating Systems

For roofs where foam isn't required, silicone coating systems are also fast. Most commercial roofs can be coated in days to a week depending on size.

When You Have a Tight Deadline

Be upfront with your contractor about the timeline. A reputable contractor will tell you honestly whether the deadline is achievable and what resources are needed to meet it.

How to Seal the Crevices in a Commercial Roof?

Mon, 31 Oct 2022 19:22:01 GMT

How to Seal the Crevices in a Commercial Roof?

Crevices, gaps, and openings in commercial roofs — around penetrations, at transitions, between panels, and along edges — are among the most common sources of leaks. Here's how to seal them effectively.

Common Crevice Locations

The most problematic crevice locations on commercial roofs include: gaps around HVAC pipe penetrations, openings where roof sections transition at different elevations, separations between metal panels from thermal expansion, gaps at parapet wall-to-roof transitions, and openings around drains and other rooftop equipment.

Traditional Sealant Approach

Traditional sealants (caulk, mastic, or rubberized compounds) can address individual crevices. However, they require regular inspection and reapplication as they crack and lose adhesion over time — especially in climates with extreme temperature swings. This approach is reactive rather than preventive.

Spray Foam: Permanent Sealing

Spray polyurethane foam is the most comprehensive crevice-sealing solution available. Because it's fluid-applied and expands to fill any void, foam penetrates and seals every gap, crevice, and opening simultaneously. At the Jabala Military Base project, foam sealed thousands of exposed fastener holes in a single application. On any commercial roof, foam addresses every potential entry point in one pass.

For Targeted Repairs

For roofs that don't require full restoration, targeted application of compatible sealant and reinforced fabric tape at specific crevice locations — properly prepared and primed — can provide effective short-to-medium term leak prevention.

What Kind of Spray Foam Do Roofers Use?

Wed, 26 Oct 2022 13:39:28 GMT

What Kind of Spray Foam Do Roofers Use?

There are two main types of spray polyurethane foam: open-cell and closed-cell. For roofing applications, only one is appropriate.

Open-Cell vs. Closed-Cell Foam

Open-cell foam is soft, spongy, and has a lower R-value (approximately R-3.7 per inch). It absorbs water and is not waterproof — making it completely unsuitable for exterior roofing applications. It's used primarily for interior sound dampening and air sealing in walls and attic spaces.

Closed-Cell Foam: The Only Roofing Option

Closed-cell spray polyurethane foam has a rigid, dense structure with cells that are completely sealed. This makes it: waterproof (it doesn't absorb water), structurally rigid (compressive strength of 25–60 PSI), an excellent insulator (R-6.5 per inch), and a vapor barrier. These properties are essential for a roofing application that must withstand UV exposure, rain, wind, foot traffic, and temperature cycling.

Roofing-Grade Formulations

Not all closed-cell foam products are identical. Roofing-grade SPF products are specifically formulated for exterior applications and tested to meet roofing-specific performance standards. Contractors must use manufacturer-approved products to qualify for a warranted system.

The Topcoat Requirement

Regardless of foam density, spray foam for roofing always requires a protective topcoat — typically silicone or acrylic — applied immediately after the foam. The topcoat provides UV resistance and maintains the waterproofing integrity of the system.

How To Determine Saturated Roofing Insulation

Tue, 11 Oct 2022 12:28:16 GMT

How To Determine Saturated Roofing Insulation

Whether a commercial roof can be restored or must be replaced depends heavily on how much insulation beneath the membrane has been saturated with moisture. Here's how to accurately assess it.

Why Wet Insulation Matters

Wet insulation beneath a roofing membrane creates multiple problems: it loses R-value, promotes mold growth, compresses and creates low spots that lead to ponding, and — if a restoration coating is applied over it — causes blistering and adhesion failure. Any coating restoration requires wet insulation to be removed and replaced first.

Method 1: Core Samples

Core sampling is the most definitive method. A contractor removes small plugs (typically 4–6 inches in diameter) from various locations across the roof. Each core reveals the condition of the membrane and insulation at that specific location. A contractor can visually inspect whether the insulation is dry, damp, or saturated. This method provides accurate localized data.

Method 2: Infrared (Thermal) Scanning

An infrared scan performed at dusk — as the roof cools after a sunny day — identifies wet insulation by detecting temperature differences. Wet areas retain heat longer than dry areas and appear as warm spots on the thermal image. IR scanning can cover large roof areas efficiently and identifies wet areas that aren't visible from the surface.

Method 3: Nuclear Gauge Testing

A nuclear moisture gauge measures hydrogen content in the roofing system, which correlates to moisture levels. This is a non-destructive method that can complement core sampling for more precise measurement.

The 25% Rule

If wet insulation comprises less than 25% of the total roof area, restoration is typically viable. Above 25%, full replacement becomes more cost-effective. Only accurate testing — not visual inspection alone — can determine where your roof falls.

What Affects the Cost of a Commercial Roofing System?

Thu, 22 Sep 2022 12:56:16 GMT

What Affects the Cost of a Commercial Roofing System?

Commercial roofing costs vary significantly — from $2 per square foot for a simple coating restoration to $14+ for a full replacement. Here are the key factors that drive price.

1. System Type

Coating restoration systems are the least expensive. Spray foam systems are mid-range. Full replacement with single-ply or built-up systems is most expensive. The system you choose has the largest single impact on project cost.

2. Roof Size

Larger roofs cost less per square foot due to economies of scale in mobilization, labor efficiency, and material delivery. A 100,000 sq ft project will have a lower per-square-foot cost than a 5,000 sq ft project.

3. Wet Insulation Extent

Every square foot of wet insulation requires cut-and-replace before restoration can proceed. More wet insulation means more labor and material costs before the new system even goes on.

4. Roof Complexity

Penetration count, multiple levels, unusual geometry, access difficulty, and parapet height all add labor. Simple warehouse roofs cost less per square foot than complex retail or institutional roofs.

5. Required Coating Thickness

For coating systems, more mil thickness = longer warranty = higher material cost. The difference between 10- and 20-year warranty tiers is real but often worthwhile for long-term ownership.

6. Travel and Mobilization

Contractors who must travel significant distances add fuel, lodging, and equipment transport costs. Local contractors may reduce mobilization costs, but expertise should take priority over proximity.

7. Material Quality

Premium manufacturer-approved materials cost more than commodity alternatives, but they deliver better performance, longer warranties, and lower maintenance costs over time.

Why Do Spray Foam Roofs Need Recoated?

Tue, 13 Sep 2022 18:34:05 GMT

Why Do Spray Foam Roofs Need Recoated?

Spray foam roofing is often described as permanent — so why does it need to be recoated? Here's the complete explanation.

The Foam Itself Is Permanent

Closed-cell spray polyurethane foam, once properly applied and protected, does not degrade on its own. West Roofing Systems has foam installations from 1979 still intact today. The foam substrate is not what requires periodic renewal.

The Topcoat Is What Wears

The silicone or acrylic topcoat over the foam gradually wears away from UV exposure, weather, and foot traffic. This is intentional — the topcoat sacrifices itself to protect the foam beneath. Most manufacturers design the coating to last 10–20 years before wearing thin enough to warrant renewal.

What Happens If Recoating Is Skipped

If the topcoat wears away completely without recoating, the foam becomes exposed to UV radiation. Unprotected foam degrades rapidly — breaking down within days to weeks depending on UV intensity. Once significant degradation occurs, sections of foam may need to be removed and replaced before the roof can be recoated, which is more expensive than a timely recoat would have been.

The Recoating Process

Recoating is straightforward: power wash the roof, inspect and repair any areas of concern, apply fresh coating at the required mil thickness, receive a new manufacturer's warranty. The process is typically completed in a day or two for most commercial roofs.

The Financial Argument for Recoating

Recoating costs approximately $1–$2 per square foot. A full tear-off and replacement costs $7–$14 per square foot. Staying on the recoat schedule is among the best returns on investment in building maintenance.

What's the Best Way to Flash a Roof Against a Vertical Wall?

Fri, 09 Sep 2022 15:05:38 GMT

What's the Best Way to Flash a Roof Against a Vertical Wall?

The transition where a flat or low-slope roof meets a vertical wall is one of the most common leak locations on commercial buildings. Here's how to seal it correctly.

Why Wall-to-Roof Transitions Leak

This transition is vulnerable because the roof membrane must make a 90-degree turn up the wall surface. Over time, thermal expansion and contraction stress the flashing at this angle. Traditional metal or bituminous flashings can crack, separate, or allow water to infiltrate behind them.

Traditional Flashing Methods

Standard approaches include metal counterflashing embedded in the wall, bituminous membrane flashing turned up the wall, and EPDM or TPO flashing strips. All of these create seams and attachment points that can fail over time.

Spray Foam: Seamless Wall Flashing

Spray foam is one of the best solutions for wall-to-roof transitions. Applied as part of a foam restoration, the foam flows up the wall face and creates a completely seamless, monolithic waterproof surface from the roof field through the transition and up the vertical surface. There are no seams, no attachment points, and no gaps for water to infiltrate.

Silicone Coating Reinforcement

For roofs being restored with a silicone coating system, the wall-to-roof transition is typically reinforced with fabric tape embedded in compatible sealant before the coating is applied over the top. This provides a flexible, reinforced waterproof transition that accommodates thermal movement without cracking.

The Bottom Line

Any restoration or replacement project should pay special attention to wall-to-roof transitions. A flashing failure at these locations will cause leaks regardless of how well the rest of the roof is performing.

The Best Roof for a Shopping Center

Tue, 23 Aug 2022 14:50:16 GMT

The Best Roof for a Shopping Center

Shopping centers present unique roofing challenges: large flat roofs, dozens of HVAC penetrations, tenants who can't afford downtime, and the need for a long-term cost-effective solution. Here's what works best.

The Challenges

Shopping center roofs typically have high penetration counts from tenant HVAC units, complex drainage systems, and roof surfaces that see regular maintenance foot traffic. Tenants require operational continuity — prolonged installation or tear-off that disrupts business operations is a real cost to property owners.

Why Spray Foam Excels

Spray foam is purpose-built for exactly this type of roof. It seals all HVAC penetrations simultaneously in one application, builds slope where needed to eliminate ponding near drains, and requires no tear-off — keeping tenant operations uninterrupted. For shopping centers with aging gravel BUR systems, foam is the preferred restoration approach.

Silicone Coating for TPO/EPDM Shopping Centers

For shopping centers with single-ply roofing approaching end of warranty, a silicone coating restoration seals all seams, renews the warranty, and is completed faster than replacement — minimizing any roof work that might affect tenants below.

Long-Term Value for Property Owners

Shopping center owners managing properties for 20+ years benefit enormously from renewable coating systems. Instead of full replacement every 20 years across potentially hundreds of thousands of square feet, a recoat cycle at 50–70% lower cost preserves the investment without disruption.

How To Remove Loose Gravel off a Commercial Roof?

Wed, 17 Aug 2022 15:02:08 GMT

How To Remove Loose Gravel off a Commercial Roof?

Gravel built-up roofs (BUR) can't be coated or restored without first removing the gravel layer. Here's how it's done and what to expect.

Why Gravel Must Be Removed

Gravel provides ballast and UV protection for the underlying BUR membrane, but it prevents any restoration coating or spray foam from adhering properly to the substrate. The irregular, jagged surface also makes it impossible to install a sheet membrane overlay without a cover board. Gravel removal is a required first step for any non-replacement restoration approach.

Method 1: Hydro-Vacuuming (Preferred)

Hydro-vacuuming uses high-pressure water and a vacuum system to loosen and remove gravel without damaging the underlying membrane. It's the fastest and least damaging method, preserving the existing BUR substrate for foam bonding. Cost is typically $0.50–$1.00 per square foot depending on gravel depth and roof accessibility.

Method 2: Mechanical Sweeping

Some contractors use mechanical sweepers or blowers to push gravel to the roof edges for collection. This is less precise than hydro-vacuuming and can leave more residual gravel on the surface, requiring additional cleanup.

After Gravel Removal

Once gravel is removed, the existing BUR substrate is inspected for moisture and condition. If the substrate is in acceptable condition (under 25% wet insulation), spray foam can be applied directly to it — the existing BUR provides an ideal bonding surface for the foam.

How Does a Company Install the Correct Thickness of Foam?

Mon, 01 Aug 2022 15:51:00 GMT

How Does a Company Install the Correct Thickness of Foam?

Spray foam thickness directly determines insulation value and warranty eligibility. Here's how qualified contractors ensure the specified thickness is achieved consistently.

Why Thickness Matters

Too thin means inadequate insulation value and potential warranty non-compliance. Too thick wastes expensive material. Consistent thickness across the entire roof ensures uniform performance and prevents low spots or high spots that could affect drainage.

Pre-Installation Planning

Before installation, the contractor determines the required foam thickness based on the project goals — whether that's meeting a specific R-value, achieving slope correction in certain areas, or satisfying warranty minimums. A spray plan is developed that accounts for areas requiring different thicknesses.

Equipment Calibration

Professional spray foam equipment is calibrated to maintain precise mixing ratios and output rates. Consistent equipment performance is essential to consistent foam density and thickness.

Test Lifts and Measurement

Crews perform test sections and measure foam thickness using a depth probe before proceeding with the full installation. Throughout the project, thickness is periodically verified using probes inserted into the freshly applied foam.

Third-Party Inspection

On manufacturer-warranted systems, a third-party inspector (often employed by the manufacturer) may verify thickness measurements and application quality before the warranty is issued. This provides independent verification that specifications were met.

How Does Spray Foam Get Secured to an Existing Roof?

Thu, 28 Jul 2022 19:56:42 GMT

How Does Spray Foam Get Secured to an Existing Roof?

Unlike sheet membranes that require mechanical fasteners or adhesives to attach to the substrate, spray foam creates its own chemical and mechanical bond. Here's how it works.

Chemical Adhesion

When spray polyurethane foam is applied to a properly prepared surface, the two-component liquid mixture reacts and expands, creating a chemical bond with the substrate surface. This bond forms at the molecular level as the foam cures — no separate adhesive is needed.

Surface Preparation Is Critical

The strength of the bond depends heavily on surface preparation. The substrate must be clean, dry, and free of contaminants — oil, dirt, loose material, and moisture all reduce bond strength. This is why proper cleaning and priming (where required) before foam application is non-negotiable for quality installation.

Mechanical Interlocking

In addition to chemical adhesion, foam also interlocks mechanically with surface irregularities — filling small crevices, seams, and texture variations in the substrate. This creates additional holding strength beyond the chemical bond alone.

Wind Uplift Performance

The combination of chemical and mechanical bonding gives spray foam exceptional wind uplift resistance. Unlike sheet membranes that can be peeled from edges and seams, foam is bonded across its entire surface area with no vulnerable attachment points.

Primer Requirements

Some substrates — particularly certain metals and smooth TPO — require a primer coat before foam application to ensure adequate adhesion. A qualified contractor will specify primer requirements based on the substrate type and manufacturer guidelines.

What to Do: Leak on a Roof with Ballasted Rocks on Top?

Tue, 19 Jul 2022 17:44:27 GMT

What to Do: Leak on a Roof with Ballasted Rocks on Top?

Ballasted roofs — where gravel or stone covers a single-ply membrane — are among the most difficult roofing systems to diagnose and repair when leaks develop. Here's what to do.

Why Ballasted Roofs Are Hard to Fix

The gravel hides the membrane surface completely, making visual leak detection nearly impossible. Water can enter through a breach anywhere beneath the ballast, travel laterally along the membrane, and exit the ceiling 20–30 feet from the actual entry point. Traditional spot repair requires removing gravel from a large area, locating the breach, patching it, and re-spreading gravel — a labor-intensive process with no guarantee of finding all breaches.

Step 1: Infrared Scan

An infrared scan performed at dusk can identify wet insulation beneath the ballast by detecting heat signatures. This helps narrow the search area before any gravel is moved.

Step 2: Core Samples

Once wet areas are identified, core samples confirm moisture levels in the insulation below and help determine whether restoration or replacement is viable.

The Spray Foam Solution

For ballasted roofs at end of life, spray foam restoration after gravel removal is often the best solution. The gravel is hydro-vacuumed, the existing membrane substrate is inspected, wet insulation is replaced, and foam is applied creating a completely new seamless surface. This eliminates every existing breach simultaneously — no hunting required.

What Is the Cheapest Commercial Roofing System?

Tue, 12 Jul 2022 19:22:17 GMT

What Is the Cheapest Commercial Roofing System?

When budget is the primary constraint, understanding your options helps you make the best decision for your situation. Here's how commercial roofing systems compare on cost.

Cheapest Upfront: Coating Restoration

Silicone coating systems applied over existing roofing are typically the least expensive option — ranging from $2.00–$4.50 per square foot. For roofs that qualify (under 25% wet insulation, membrane in acceptable condition), this is the cheapest path to a renewed warranty and restored waterproofing.

Mid-Range: Spray Foam Restoration

Spray foam plus silicone coating runs $4.00–$8.00 per square foot — more expensive than coating-only systems, but it provides slope correction, insulation improvement, and seamless waterproofing that coating alone can't deliver.

Most Expensive: Full Replacement

Complete tear-off and installation of a new single-ply or built-up system costs $7.00–$14.00+ per square foot. This is the most expensive option and should only be chosen when restoration is genuinely not viable.

The Warning About "Cheap" Bids

The cheapest bid is rarely the cheapest outcome. Contractors who skip wet insulation removal, use inferior materials, or don't address underlying drainage issues will produce a system that fails prematurely — costing far more than a properly done job from the start.

The True Cheapest Option

Over a 40-year ownership period, a properly installed renewable coating system — maintained and recoated on schedule — is almost certainly the cheapest total cost of ownership available for any commercial roof.

What Is a Self-flashing Roof and What Are Its Benefits?

Fri, 17 Jun 2022 13:42:52 GMT

What Is a Self-flashing Roof and What Are Its Benefits?

A self-flashing roof is one where the roofing membrane itself handles all waterproofing transitions — eliminating the need for separate metal or bituminous flashing at walls, penetrations, and edges.

Traditional Flashing vs. Self-Flashing

Traditional roofing systems require separate flashing components at every roof termination: counterflashing at parapet walls, pipe boots around penetrations, metal edge flashing at perimeters, and transition strips where roof levels change. Each of these is a potential failure point that requires its own installation, inspection, and maintenance.

Spray Foam: The Ultimate Self-Flashing System

Spray polyurethane foam is inherently self-flashing. Because it's fluid-applied and adheres to any surface, foam flows over and around all transitions, penetrations, and terminations in a single continuous application. There are no separate flashing components to install, inspect, or fail. The foam itself is the flashing — seamlessly integrated into the roofing surface.

Benefits of Self-Flashing

Fewer failure points: eliminating separate flashing components removes dozens of potential leak sources. Simplified installation: no custom cutting or fitting of flashing at complex transitions. Lower maintenance: fewer components means fewer things to inspect and repair over the roof's life. Better performance around complex geometries: foam handles irregular penetrations and unusual roof profiles that traditional flashing struggles with.

Silicone Coating Systems

Silicone coating systems are also largely self-flashing when properly installed — the coating extends continuously over prepared transitions and penetrations. Reinforced fabric tape provides additional strength at critical junctions.

Not Eligible for a Roof Coating System? – Here's What To Do

Wed, 08 Jun 2022 18:28:45 GMT

Not Eligible for a Roof Coating System? – Here's What To Do

A roof coating system is the ideal solution for many commercial roofs — but not all qualify. Here's what to do when your roof doesn't meet the eligibility requirements.

Why Roofs Fail to Qualify

The most common disqualifying conditions are: wet insulation exceeding 25% of the roof area, membrane delamination or structural failure, deck rot or structural compromise, and building code restrictions on adding roof layers.

Option 1: Partial Restoration

If only certain sections of the roof are disqualified (e.g., a localized area with high moisture), it may be possible to perform a full tear-off and replacement in those sections while restoring the remainder with a coating system. This hybrid approach can be significantly less expensive than replacing the entire roof.

Option 2: Spray Foam After Wet Insulation Removal

Even roofs with significant wet insulation may qualify for spray foam restoration once the wet areas are removed and replaced. Foam can then be applied over the repaired substrate. This approach works when the underlying deck is sound.

Option 3: Full Replacement

When the roof truly cannot be restored — deck failure, excessive moisture, or code requirements — a full tear-off and replacement is necessary. In this case, the decision shifts to which replacement system offers the best long-term value: spray foam (for maximum insulation and renewability), TPO (for cost-effective new construction), or other options based on your specific building needs.

Get an Independent Assessment

If one contractor tells you replacement is the only option, get a second opinion from a contractor who offers both restoration and replacement. You want an honest assessment, not a recommendation driven by what system the contractor prefers to sell.

What Is a Buyback Period for a Commercial Roof?

Tue, 31 May 2022 19:18:17 GMT

What Is a Buyback Period for a Commercial Roof?

The buyback period is the time it takes for a roofing investment to "pay for itself" through energy savings and avoided costs. It's a useful tool for evaluating whether a more expensive system justifies its additional upfront cost.

How the Buyback Period Is Calculated

Buyback period = Additional upfront cost ÷ Annual savings. For example: if spray foam costs $20,000 more than a coating-only system but reduces annual energy costs by $5,000, the buyback period is 4 years. After 4 years, the additional investment has fully paid for itself in energy savings alone.

What Contributes to Savings

Energy savings from improved insulation (primarily spray foam), reduced leak repair costs from a seamless system, avoided interior damage costs, and potentially lower insurance premiums all contribute to the savings calculation.

Real-World Example

Oakview Elementary School chose spray foam over a coating-only system because the R-value improvement was expected to generate significant annual HVAC savings. For a school that runs heating and cooling year-round, the insulation improvement had a meaningful buyback period that justified the additional investment.

Using Buyback Period in Decisions

If you're evaluating whether to invest in spray foam insulation vs. a simpler coating, calculate the expected buyback period based on your building's energy usage. If the buyback period is shorter than the warranty period, the investment is clearly justified. Ask your contractor for help estimating energy savings based on your current vs. projected R-value.

Why Put Coating on a Roof Instead of a Replacement?

Tue, 17 May 2022 13:33:10 GMT

Why Put Coating on a Roof Instead of a Replacement?

When a commercial roof starts failing, building owners face a choice: coat it or replace it. For the majority of roofs in acceptable condition, coating wins on nearly every dimension. Here's why.

Cost: Coating Costs 50–70% Less

A silicone coating system runs $2–$5 per square foot. Full replacement runs $7–$14 per square foot. On a 50,000 sq ft roof, that's the difference between $100,000–$250,000 and $350,000–$700,000. The savings are enormous even at the lower end of both ranges.

No Disruption

Coating goes over the existing roof — no tear-off, no exposure to weather during installation, no disposal trucks, no noise. Business operations continue normally throughout. Replacement creates days or weeks of disruption with real cost implications for operating businesses.

Renewable Warranty

A coating system can be recoated at the end of its warranty period for a fraction of the original cost, renewing coverage indefinitely. Replacement just starts another 20-year cycle before the next replacement.

Environmental Impact

Coating generates virtually no landfill waste. Replacement contributes thousands of pounds of old roofing material to landfills. For building owners with sustainability goals, coating is the clear choice.

When Replacement Is Still Necessary

Coating isn't always an option. When wet insulation exceeds 25% of the roof area or the deck is structurally compromised, replacement is required. But for most aging commercial roofs in otherwise acceptable condition, coating is the smarter financial and practical choice.

The Best Roof for a School

Tue, 10 May 2022 15:29:44 GMT

The Best Roof for a School

Schools have unique roofing requirements that make certain systems far more practical than others. Here's what works best for educational facilities.

The Constraints Schools Face

School roofing projects typically must be completed during summer break — a narrow 8–10 week window. Budgets are often tight and require board approval. And schools are typically owned long-term by the district, making lifecycle cost more important than upfront savings.

Why Spray Foam Excels for Schools

Spray foam is frequently the best choice for school roofs for several reasons. First, it avoids tear-off — which means faster installation (critical for summer-only windows) and no risk of weather exposure during the project. Second, it adds significant insulation value, reducing HVAC costs year-round for buildings that run climate control year-round. Third, the renewable warranty means the district gets decades of coverage without another full replacement project.

Real Examples

Heskett Middle School's 104,000 sq ft BUR restoration was completed in 37 days — well within a summer break window — saving an estimated $1M over replacement. Oakview Elementary chose foam specifically for the R-value improvement and avoided a full tear-off. Normandy High School's 97,100 sq ft recoat was completed during summer break including the school's unique domed structures.

Silicone Coating for Newer Schools

For schools with TPO or single-ply roofs approaching warranty expiration, a silicone restoration membrane is the most cost-effective path to a new warranty — again, completable within a summer window without disrupting the school year.

Why Is a Spray Foam Roof So Expensive?

Mon, 02 May 2022 18:59:19 GMT

Why Is a Spray Foam Roof So Expensive?

Spray foam roofing costs $4–$8 per square foot — more than a basic coating-only system and comparable to single-ply replacement. Here's exactly what drives the cost and why it's often worth it.

Material Costs Are High

High-quality closed-cell spray polyurethane foam is an expensive material. The two-component chemical system, when mixed at the correct ratio and applied at the required density, costs significantly more per square foot than commodity roofing products. Approximately 60% of a foam roofing project cost is materials — which means your investment goes into a product working on your roof for 10–20+ years, not into labor that disappears when the crew leaves.

Specialized Equipment Required

Spray foam application requires professional-grade plural component spray equipment — proportioners that heat and precisely mix the two components in correct ratios. This equipment costs tens of thousands of dollars and requires regular maintenance and calibration. Only trained, manufacturer-approved applicators are qualified to operate it correctly.

Skilled Labor

Spray foam application is a skilled trade. Improper application ratio, temperature, or technique results in off-ratio foam that doesn't perform as intended. Contractors must complete extensive training and maintain manufacturer certifications.

Why It's Still Good Value

Despite higher upfront cost, spray foam's renewable warranty, energy savings from R-6.5 per inch insulation, and seamless leak prevention often deliver a lower total cost of ownership than less expensive systems that require full replacement cycles every 20 years.

The Purpose of Roofing Granules on a Flat Roof

Mon, 25 Apr 2022 18:03:46 GMT

The Purpose of Roofing Granules on a Flat Roof

Granules serve several important functions on commercial flat roofs. Here's where they're used and why they matter.

UV Protection on Modified Bitumen

Granulated modified bitumen roofing uses embedded mineral granules as the primary UV protection layer for the bitumen membrane beneath. Without granules, the bitumen would degrade rapidly from sun exposure. The granules also provide some impact resistance and improve the aesthetic appearance of the surface.

Foot Traffic Protection on Coating Systems

On silicone and acrylic coating systems, broadcast granules are applied into the wet coating at designated foot traffic areas — around HVAC units, near roof hatches, and along service paths. The granules become embedded in the cured coating, creating a textured surface that improves traction and reduces abrasion from foot traffic. This protects the coating from wear in high-traffic zones while allowing the smooth, reflective coating to remain in low-traffic areas.

Walkway Pads

Pre-fabricated granule-surfaced walkway pads are another option for high foot traffic areas. These pads are installed over the existing roofing system and provide a designated path for maintenance personnel.

Granules on Spray Foam Roofs

For spray foam roofs in high foot traffic areas, granules are broadcast into the topcoat while it's still wet — creating a textured, slip-resistant surface. This is typically done around HVAC units and rooftop access points where regular maintenance foot traffic occurs.

TPO Roof at the End of Its Life? Here's What to Do

Mon, 18 Apr 2022 17:27:36 GMT

TPO Roof at the End of Its Life? Here's What to Do

Your TPO roof is at or approaching the end of its warranty. The contractor who installed it is recommending replacement. Before you sign anything, here's what you should know.

Get an Independent Inspection First

Before accepting any recommendation, get a professional inspection with core samples from a contractor who offers both restoration and replacement. The installing contractor has an incentive to recommend replacement — that's the higher-dollar job. An independent assessment gives you unbiased data.

Check the Moisture Level

The key question is: how much of the insulation beneath your TPO is wet? If it's under 25%, restoration is almost certainly viable. If it's over 25%, replacement becomes more cost-effective. Core samples and an infrared scan will give you this data precisely.

The Restoration Option

If your roof qualifies, a silicone restoration membrane (SRM) can be applied over the existing TPO — sealing all failing seams, creating a completely new waterproof surface, and issuing a new 10–20-year manufacturer's warranty at $2.50–$4.50 per square foot. Compare that to replacement at $7–$12 per square foot.

If Replacement Is Truly Necessary

If moisture levels disqualify restoration, consider what replacement system to install. Spray foam is worth evaluating — it provides the renewable warranty that prevents you from facing this same decision again in 20 years.

How to Repair Tiny Holes in Your Commercial Roof?

Mon, 11 Apr 2022 19:42:30 GMT

How to Repair Tiny Holes in Your Commercial Roof?

Tiny holes in commercial roofing membranes — from fasteners, foot traffic, hail, or equipment installation — are among the most common sources of leaks. Here's the right way to address them.

Why Small Holes Are a Big Problem

A pinhole in a roofing membrane allows water infiltration that can travel laterally through insulation for feet before appearing as an interior leak. Left unaddressed, a tiny hole can saturate insulation, cause mold growth, and eventually compromise the structural deck below. Small problems become expensive problems when ignored.

Standard Repair: Patch and Seal

For isolated holes in TPO, EPDM, or modified bitumen systems, the standard repair involves: cleaning the area thoroughly, applying a compatible primer, placing a reinforced patch of the same membrane material over the hole with appropriate overlap, and heat-welding or adhering the patch per manufacturer specifications. The patch must extend at least 3 inches in all directions from the hole.

Coating System Repairs

For roofs with existing coating systems, small holes can be repaired by cleaning the area, applying compatible sealant, and recoating the patch area to match the surrounding coating. This restores the seamless surface.

Spray Foam for Multiple Small Holes

When a roof has many small holes distributed across a large area — common on aging metal roofs with fastener corrosion — individual patching becomes impractical. A silicone coating restoration system addresses all holes simultaneously in a single application, which is far more cost-effective than individual repairs on a roof with widespread issues.

Spray Foam Over Metal Roofing: Cost, Benefits and Installation

Tue, 05 Apr 2022 12:56:36 GMT

Spray Foam Over Metal Roofing: Cost, Benefits & Installation

Quick answer: Spray foam roofing costs $5-$10 per square foot. The #1 benefit for metal roofs is that spray foam covers every seam and fastener and provides an enormous R-value increase. It’s fluid-applied, comes out of a spray gun as a liquid, then forms into a foam.

This article covers:

- What is spray foam roofing?

- How much does it cost?

- Why choose spray foam over other systems?

- What issues could arise from installing spray foam?

- What are some Northeast Ohio projects of spray foam over metal

What is spray foam roofing?

Spray foam roofing is a commercial roofing system that gets sprayed onto a roof as a liquid, which then turns into a foam after it comes in contact with the roofing surface.

Two coats of coating are installed over it for UV protection. Granules are embedded into the topcoat of coating for added strength.

Metal roofing owners choose spray foam because it covers every potential leak point, including all seams, fasteners, and penetrations.

It also prevents the complete tear-off and provides the owner with a 10-20-year, renewable and transferable warranty.

How much does it cost to install spray foam over an existing metal roof?

The cost to spray foam over a metal roof is usually in the $5-$10 per square foot.

Variables that influence price include the distance from the contractor, how much foam they want/need, the length of the warranty, and the condition of the existing metal roof.

There are some extremes that can be well past that mark.

For example, on one recent project, the space between the ribs was very deep.

It was cost-effective to insert wood panels in-between each rib, and then spray over everything, as opposed to spraying an incredible amount of foam inside each rib to ensure water flows correctly.

The same roof needed all new custom-fabricated, flanged gutters.

That roof was about $20 per square foot.

Why choose spray foam over other options?

There are really only four options available:

1) Install spray foam

2) Install coating system

3) Flute-fill and TPO

4) Complete tear-off and replacement

Metal roof owners/managers choose spray foam because coating the roof (the least expensive option) is not an option.

The roof may be too rusty or in too poor of shape to coat, so spray foam is the next best option.

Some people choose spray foam because the current roof has no insulation and foam offers the best R-value of any commercial roofing insulation available.

Spray foam has an R-value of 6.5 per inch.

Owners rarely choose flute-fill and TPO because it’s very expensive.

Some people like TPO for whatever reason, and that’s the reason they go that route.

I’m not sure what the price is for a complete tear-off and replacement, but it’s likely north of $15 per square foot. It’s a lot more when you throw in business/operation disruptions.

Metal roof owners choose spray foam because it’s fluid-applied. It covers up all the seams and fasteners that are the usual culprits of metal roofing leaks.

And it comes with a renewable and transferable 10-20-year warranty.

What issues could arise from installing spray foam roofing?

The only issue that can happen is with the contractor.

- Can they install a good spray foam roof?

- Do they know the science of foam, and how much experience do they have?

If you choose a bad contractor, they could install bad foam; it blisters, they don’t take care of it, lawyers are involved, and you go down that road.

There’s absolutely nothing wrong with the system; it’s just making sure it’s installed correctly.

This article goes into depth on the red flags of a commercial roofing contractor and how to ensure you don’t choose a bad one.

Three local projects of spray foam over an existing metal roof:

People's Services - Marvo

Akron, Ohio

Installed May 2025

123,000 square feet

Ontario Mechanical

Ontario, Ohio

Installed October 2025

45,900 square feet

Facultatieve Technologies Medina, Ohio

Installed August 2024

15,120 square feet

How To Convince Your Board To Go With a Spray Foam Roof?

Tue, 29 Mar 2022 14:56:11 GMT

How To Convince Your Board To Go With a Spray Foam Roof?

If you're a facilities manager or property owner who's already convinced spray foam is the right choice, getting board or committee approval can be the hardest part. Here's how to build the case.

Lead With the Cost Comparison

Boards respond to numbers. Present a direct cost comparison: spray foam restoration at $4–$8/sq ft vs. full replacement at $8–$14/sq ft. For a 100,000 sq ft roof, that's potentially $400,000 vs. $1,000,000. Then show the lifecycle picture: spray foam is renewable (recoat at $1–$2/sq ft every 20 years), while replacement cycles repeat at full cost.

Address the "Is Foam Real?" Skepticism

Many board members have never heard of spray foam roofing. Come prepared with: West Roofing Systems' 45+ year track record, project examples (Heskett Middle School saving $1M, MTD's 384,000 sq ft robotic installation, Normandy High School's dome project), and manufacturer warranty documentation.

Highlight Minimal Disruption

For occupied facilities, the no-tear-off advantage resonates strongly. Present the operational continuity benefits: no weather exposure risk, no business interruption, faster completion than replacement.

Present Independent Core Sample Data

Board decisions should be based on facts, not contractor recommendations. Commission an independent inspection with core samples before the board meeting. Presenting objective moisture data showing the roof qualifies for restoration — rather than a contractor's recommendation — dramatically strengthens your case.

What's the Purpose of a Coverboard in Commercial Roofing?

Tue, 15 Mar 2022 13:53:07 GMT

What's the Purpose of a Coverboard in Commercial Roofing?

A coverboard is a rigid board layer installed between the insulation and the roofing membrane in some commercial roofing systems. Here's when it's used and why.

What a Coverboard Does

Coverboards serve several functions: they provide a smooth, stable substrate for membrane installation over irregular insulation surfaces, add compressive strength to resist foot traffic loads on the insulation below, improve fire resistance in some assemblies, and create a thermal break in certain system designs.

When Coverboards Are Required

Single-ply membranes (TPO, EPDM) installed over soft polyiso or other flexible insulation typically require a coverboard to prevent the membrane from telegraphing insulation board edges and joints over time. Some manufacturers also require coverboards for warranty compliance in specific assembly configurations.

When Coverboards Can Be Avoided

Spray foam roofing is a significant advantage here: because foam is fluid-applied and adheres directly to the existing substrate in a monolithic bond, no coverboard is needed. The foam itself provides the smooth, continuous surface that sheet membranes require a coverboard to achieve. This eliminates one complete material layer and the associated cost and labor.

Cost Implications

Coverboard material costs typically add $0.50–$1.50 per square foot to a roofing project. On large commercial roofs, this is a meaningful expense that spray foam systems avoid entirely by design.

Pros and Cons to Working at a Spray Foam Roofing Company

Mon, 28 Feb 2022 18:20:58 GMT

Pros and Cons to Working at a Spray Foam Roofing Company

Spray foam roofing is a specialized trade with a different profile from general commercial roofing. Here's an honest look at what it's like to work in this field.

The Pros

Specialized skills command better pay. Spray foam applicators who master the technical requirements of foam application earn more than general roofing labor because the skill set is harder to find and develop. The work is varied — foam projects range from small commercial buildings to 384,000 sq ft industrial facilities, and the problems solved are genuinely interesting and complex. There is growing market demand for restoration systems as more building owners choose cost-effective renewal over replacement. And the renewable nature of foam roofing means long-term relationships with building owners who return every 10–20 years.

The Cons

The learning curve is steep. Spray foam application requires extensive training, equipment calibration knowledge, and understanding of chemical ratios, ambient conditions, and substrate requirements. Mistakes result in off-ratio foam that performs poorly. Overspray is a real concern on windy days — additional precautions are required that add time to installations. The work is physically demanding and requires working in all weather conditions within acceptable temperature and humidity ranges for foam application.

Is It a Good Career?

For motivated tradespeople who enjoy technical challenge and take pride in specialized skills, spray foam roofing offers strong career prospects in a growing market segment. Companies like West Roofing Systems that have been in business since 1979 offer stability and the opportunity to build a career in a field with genuine expertise value.

How to Cost-Effectively Repair a Flat Gravel Roof

Mon, 21 Feb 2022 20:45:52 GMT

How to Cost-Effectively Repair a Flat Gravel Roof

Flat gravel built-up roofs (BUR) are among the most durable commercial roofing systems when properly maintained — but when they develop problems, the gravel complicates both diagnosis and repair. Here's the most cost-effective approach.

The Challenge with Gravel BUR Repairs

Gravel hides the membrane surface, making leak detection difficult. Traditional spot repairs require removing gravel from a large area, locating and patching the breach, then re-spreading gravel. This is labor-intensive and rarely finds all leaks in aging systems where multiple failure points exist.

Option 1: Targeted Spot Repairs

For newer BUR systems with isolated failures, targeted spot repair makes sense. Hydro-vacuum the gravel in the problem area, locate and patch the membrane breach, and replace the gravel. Cost-effective for truly isolated problems in otherwise sound systems.

Option 2: Full Spray Foam Restoration (Best for Aging BUR)

For older BUR roofs with widespread wear, spray foam restoration is typically the most cost-effective solution. After hydro-vacuuming the gravel, wet insulation is replaced, and foam is applied directly to the BUR substrate. This addresses every existing leak point simultaneously, adds insulation, and comes with a new 10–20-year warranty — at roughly half the cost of full BUR replacement.

When Full Replacement Is Required

If the BUR substrate itself has delaminated significantly or wet insulation exceeds 25% of the total area, full tear-off and replacement may be the only viable option.

5 Things to Consider About Your HOA's Choice of Roofing System

Tue, 08 Feb 2022 20:42:25 GMT

5 Things to Consider About Your HOA's Choice of Roofing System

HOA roofing decisions are high-stakes — they affect every resident's daily life during installation and every owner's financial investment in the property. Here are 5 critical considerations.

1. Disruption to Residents

Roofing work on occupied buildings requires minimizing disruption. Full tear-off projects create noise, debris, and the risk of weather exposure for units below. Restoration systems that go over existing roofing — spray foam or silicone coating — are significantly less disruptive and allow residents to remain in their units during installation.

2. HOA Reserve Fund Impact

Major roof replacements are one of the largest capital expenditures an HOA faces. A restoration at 50–70% less cost than replacement preserves reserve funds for other needs. The renewable nature of coating systems also makes long-term financial planning more predictable.

3. Getting Independent Assessment

HOA boards should not rely solely on a single contractor's recommendation. Commission independent core sample testing to determine actual moisture levels before accepting any proposal for replacement.

4. Warranty and Liability

HOAs need to ensure any new roofing system comes with a manufacturer's warranty (not just a contractor warranty) that remains valid regardless of which contractor performs future work. Manufacturer warranties provide the strongest protection.

5. Contractor Qualifications

Verify that any contractor working on HOA roofs is manufacturer-approved, properly insured, and has verifiable experience on similar multi-unit projects. HOA projects have higher liability stakes than single-building commercial work.

How To Get 10 More Years Out of an Old, Metal Roof?

Thu, 27 Jan 2022 14:31:07 GMT

How To Get 10 More Years Out of an Old, Metal Roof?

Your metal roof is showing its age — rust spots, leaking fasteners, failing seams — but the structure beneath is still solid. You're not ready for a full replacement. Here's how to get another 10–20 years.

Assess the Current Condition

Before any restoration, get a professional assessment. Check for: panel structural integrity (not just surface rust), fastener condition, seam separation extent, and any areas of significant deterioration. If the metal panels are structurally sound, restoration is almost certainly viable and far less expensive than replacement.

Surface Preparation

The key to a successful metal roof restoration is thorough preparation: power washing to remove dirt and loose rust, mechanical treatment of heavy rust areas, application of rust-inhibiting primer where needed, and sealing all fasteners and seams with reinforced fabric tape and compatible sealant.

Silicone Coating Application

After preparation, a full silicone coating is applied at the required mil thickness for a 10 or 20-year manufacturer's warranty. The coating adheres to the prepared metal surface, seals every remaining fastener and seam under a continuous waterproof membrane, and provides high solar reflectance that reduces roof surface temperature and cooling costs.

The Result

A properly prepared and coated metal roof gets a new 10–20-year warranty at $2.50–$5.00 per square foot — compared to metal roof replacement at $8–$15+ per square foot. For most older metal roofs in adequate structural condition, this is the clear financial choice.

How to Repair a Torch Down Roof: Best Options Explained

Fri, 21 Jan 2022 20:01:43 GMT

How to Repair a Torch Down Roof: Best Options Explained

Torch down roofing (modified bitumen) is common on commercial and low-slope residential buildings. When it develops leaks or shows age, here are your best repair options.

Understanding Torch Down Failure Modes

Modified bitumen roofs most commonly fail at: laps and seams where torch welding has separated or never fully bonded, granule loss exposing the bitumen to UV degradation, blistering from trapped moisture below the membrane, and flashing failures at penetrations and transitions.

Option 1: Torch Repair of Failed Seams

For isolated seam failures on otherwise sound systems, a qualified roofer can re-torch failed laps and re-seal problem areas. This is the lowest-cost short-term repair but doesn't address overall membrane aging.

Option 2: Silicone Coating Over Modified Bitumen

A silicone coating system can be applied directly over granulated modified bitumen roofing. The coating fills in granule gaps, seals all laps and transitions, and creates a new continuous waterproof surface with a 10–20-year renewable warranty. This is the most cost-effective long-term option for granulated mod-bit roofs in acceptable condition.

Option 3: Spray Foam Restoration

For smooth modified bitumen roofs or those with significant blistering, spray foam applied over the existing membrane provides superior adhesion and creates a completely seamless new surface. Foam also adds insulation value and corrects any drainage issues.

Option 4: Full Replacement

Required when the membrane has extensive delamination or wet insulation exceeds 25% of the roof area.

How To Save Money and Extend the Life of Your Commercial EPDM Roof

Mon, 10 Jan 2022 17:45:45 GMT

How To Save Money and Extend the Life of Your Commercial EPDM Roof

EPDM (rubber) roofing is among the most durable commercial membrane systems — but even the best systems age. Here's how to save money and extend your EPDM roof's life significantly.

Annual Inspections and Maintenance

The most cost-effective way to extend EPDM roof life is regular maintenance. Semi-annual inspections catch seam separations, flashing issues, and membrane cracks before they become active leaks. Drain cleaning, minor seam re-bonding, and prompt flashing repairs cost very little compared to the water damage they prevent.

Silicone Coating Over EPDM

When your EPDM roof is aging — seams losing adhesion, membrane surface oxidizing — a silicone restoration membrane applied over the existing EPDM is the most cost-effective path to extended life. The coating seals every seam and weak point under a new seamless surface and comes with a new 10–20-year manufacturer's warranty. Cost: $2.50–$4.50 per sq ft vs. $7–$12 per sq ft for replacement.

The Wet Insulation Check

Before investing in a coating restoration, core samples should confirm that wet insulation is below 25% of the total area. This is the critical qualifying criterion — coating over wet insulation leads to blistering and system failure.

Spray Foam for EPDM Roofs with Drainage Issues

For EPDM roofs with ponding water problems, spray foam restoration corrects drainage slope while providing waterproofing and insulation — capabilities a coating alone can't deliver.

The Best Repair Option for a Gravel Built-up Roof

Wed, 05 Jan 2022 13:53:40 GMT

The Best Repair Option for a Gravel Built-up Roof

Gravel built-up roofs (BUR) are among the most durable commercial systems, but when they age, their restoration requires a specific approach. Here's the best repair option.

Why Traditional Repairs Fail on Gravel BUR

The gravel layer makes leak detection difficult and individual repairs impractical on aging systems. Water can enter through a breach anywhere beneath the ballast and travel significant distances before appearing as an interior leak. Spot repairs rarely find all breaches.

The Best Option: Spray Foam After Gravel Removal

For aging gravel BUR roofs, spray foam restoration after hydro-vacuuming is consistently the best value. The process: hydro-vacuum gravel ($0.50–$1.00/sq ft), replace wet insulation, apply spray foam directly to the BUR substrate, and finish with a silicone topcoat. Total cost: $4–$7/sq ft with a new 10–20-year warranty.

Why This Works So Well

The existing BUR substrate — once gravel is removed — provides an ideal bonding surface for foam. The foam fills every crack, seam, and potential breach simultaneously, creating a completely new seamless surface. Every existing failure point is eliminated in a single application.

Compared to Alternatives

Full BUR replacement: $8–$14/sq ft. TPO over cover board: similar or higher cost, plus introduces new seams. Spot repairs: address individual failures but not system-wide aging. For most gravel BUR roofs, foam restoration delivers the best performance at the lowest long-term cost.

The Two Biggest Fears in Commercial Roofing

Mon, 27 Dec 2021 15:39:56 GMT

The Two Biggest Fears in Commercial Roofing

After decades in commercial roofing, West Roofing Systems has heard the same two fears repeatedly from building owners facing roofing decisions. Here's what they are and how to overcome them.

Fear 1: Choosing the Wrong Contractor

This fear is well-founded. Commercial roofing is a large investment, and the wrong contractor can result in system failure, warranty issues, or — worst case — interior damage from a failed installation. The solution: verify manufacturer approval (call the manufacturer directly), check verifiable project references, confirm proper insurance, and insist on a detailed written proposal specifying materials, thickness, and warranty terms. A reputable contractor welcomes scrutiny.

Fear 2: Making the Wrong System Choice

Building owners worry about committing to the wrong system and paying the price for years. The solution here is data. Commission an independent inspection with core samples before accepting any recommendation. With objective moisture data in hand, the system choice becomes clear — restoration if moisture is below 25%, replacement if above. The data removes the guesswork.

The Common Thread

Both fears are addressed the same way: with transparent information. The right contractor provides honest data, honest recommendations, and complete transparency about what they're installing and why. If a contractor resists core sampling, can't provide manufacturer references, or pressures you to decide quickly, those are red flags worth taking seriously.

How To Fix a TPO Roof That's Too Reflective?

Mon, 20 Dec 2021 15:17:44 GMT

How To Fix a TPO Roof That's Too Reflective?

White TPO membranes are highly reflective by design — that's a feature for energy efficiency. But in some installations, the reflectivity creates problems: glare for neighboring buildings, heat reflection onto adjacent HVAC units, or local ordinance issues. Here's what can be done.

Why High Reflectivity Is Usually Good

White TPO typically achieves solar reflectance of 70–80%, keeping roof surface temperatures low and reducing cooling loads. This is generally desirable and is often required by energy codes in warm climates. Most "too reflective" concerns are aesthetic or neighbor-relations issues rather than performance problems.

Option 1: Apply a Coating With Lower Reflectance

A coating in a gray or tan color can be applied over the white TPO, reducing overall reflectance while still maintaining better performance than a dark roof. This approach preserves the waterproofing benefit while moderating the visual impact.

Option 2: Granule Application

Broadcast granules can be applied into a coating layer to reduce reflectance and create a matte surface. This is commonly done in areas where glare is a specific concern.

Option 3: Parapet Walls or Screening

For rooftop glare issues affecting neighboring buildings, physical screening or parapet wall extensions can block sightlines without changing the roof surface itself.

Important Note

Before altering the reflectance of a warranted TPO system, consult with the manufacturer. Some modifications may affect warranty validity. Work with a manufacturer-approved contractor for any coating applied over an existing warranted membrane.

What Is the Process, Warranty, and Cost of Silicone Roof Coating Systems?

Mon, 13 Dec 2021 15:24:08 GMT

What Is the Process, Warranty, and Cost of Silicone Roof Coating Systems?

Silicone roof coating systems are one of the most widely applicable and cost-effective commercial roofing restoration solutions. Here's a complete overview.

The Installation Process

1. Inspection with core samples to verify roof eligibility and identify wet insulation areas. 2. Wet insulation removal and replacement. 3. Power washing to remove all dirt and contaminants. 4. Seam and flashing repairs using reinforced fabric tape and compatible sealant. 5. Primer application (where required by substrate or manufacturer). 6. Silicone coating application at the required mil thickness for the chosen warranty. 7. Quality inspection and mil thickness verification.

Warranty Options

Manufacturer warranties are available in 10, 15, and 20-year terms, determined by coating thickness applied. 10-year warranty: typically 20 mils. 15-year warranty: typically 25 mils. 20-year warranty: typically 30 mils. At the end of the warranty period, a recoat renews coverage for another cycle.

Typical Costs

Silicone coating over TPO or EPDM: $2.00–$4.50/sq ft. Silicone coating over metal: $2.50–$5.00/sq ft. Factors affecting cost include roof size, wet insulation extent, required coating thickness, and roof complexity.

When It Makes the Most Sense

Silicone coating is ideal for: TPO or EPDM roofs with less than 25% wet insulation, metal roofs with no structural damage, modified bitumen roofs in acceptable condition, and any roof where the goal is renewed warranty coverage at minimum cost and disruption.

What's the Most Affordable Commercial Roofing System?

Tue, 30 Nov 2021 13:56:44 GMT

What's the Most Affordable Commercial Roofing System?

Affordability means different things depending on your time horizon. Here's a breakdown of which systems are most affordable upfront and over time.

Most Affordable Upfront: Silicone Coating Restoration

For roofs that qualify (under 25% wet insulation), a silicone coating system at $2.00–$4.50/sq ft is the least expensive option that still delivers meaningful warranty protection and waterproofing performance. No other system delivers a new 10–20-year manufacturer's warranty at this cost.

Most Affordable Over 40 Years: Renewable Coating Systems

A silicone or spray foam system recoated on schedule ($1–$2/sq ft every 20 years) costs dramatically less than replacement cycles (full TPO at $7–$12/sq ft every 20 years) over a 40-year building lifecycle. The renewable nature of coating systems makes them the most affordable option for long-term building ownership.

The "Affordable" Trap

The cheapest bid on any roofing project is almost never the cheapest outcome. Contractors who skip wet insulation removal, use substandard materials, or omit proper preparation deliver systems that fail early — creating costs that far exceed any initial savings. True affordability means getting the job done right at a fair price.

The Bottom Line

If your roof qualifies for restoration: silicone coating is the most affordable path to renewed protection. If you need foam for slope correction or insulation: foam restoration is still more affordable than replacement. If replacement is unavoidable: choose a system with a renewable warranty to avoid the replacement cycle repeating in 20 years.

How To Get a Commercial Roof With an R-25 and 20-Year Warranty

Wed, 10 Nov 2021 16:43:35 GMT

How To Get a Commercial Roof With an R-25 and 20-Year Warranty

R-25 insulation value with a 20-year renewable manufacturer's warranty — this combination is achievable with spray polyurethane foam roofing. Here's how.

Why R-25?

R-25 is a meaningful insulation threshold for commercial buildings. In cold climates (ASHRAE Zone 5+), it exceeds minimum energy code requirements for new construction. For existing buildings, upgrading to R-25 from a low baseline can generate substantial annual HVAC savings that contribute to a compelling buyback period.

Achieving R-25 with Spray Foam

Spray polyurethane foam provides R-6.5 per inch of thickness. To achieve R-25, approximately 3.85 inches of foam is required. In practice, contractors typically apply 4 inches to achieve R-26, providing a comfortable margin above the target.

The 20-Year Warranty

A 20-year manufacturer's warranty requires applying the silicone topcoat at the specified thickness — typically 30 mils minimum. The foam thickness and topcoat thickness together qualify the system for the 20-year warranty term from approved manufacturers.

Cost Estimate

At 4 inches of foam plus a 20-year warranty topcoat, total installed cost runs approximately $7–$10 per square foot depending on roof size and conditions. This is comparable to TPO replacement — but with R-26 insulation value, a seamless waterproof surface, and a renewable warranty that TPO can't offer.

What Roofs Qualify

Any commercial roof with adequate structural capacity for the additional load and less than 25% wet insulation in the existing system can qualify. A professional inspection is the first step.

Roof Seams Coming Apart on Flat Roof: What to Do?

Wed, 03 Nov 2021 12:47:34 GMT

Roof Seams Coming Apart on Flat Roof: What to Do?

Failing seams are the #1 cause of commercial roof leaks — and they're inevitable on aging TPO and EPDM systems. Here's what to do when you notice seams coming apart.

Why Seams Fail

Daily thermal cycling causes commercial roofing membranes to expand and contract. Over years, this stress gradually weakens heat-welded or adhesive seam bonds. Seams that were perfectly sound when installed eventually lose adhesion — creating microscopic openings that allow water infiltration.

Immediate Action: Stop Active Leaks

If seams are actively leaking, apply compatible lap sealant or caulk as an emergency measure to stop water infiltration until a proper repair or restoration can be planned. This buys time but isn't a permanent solution.

Option 1: Seam Repairs

For isolated failed seams on an otherwise sound membrane, targeted seam repairs make sense. A qualified contractor cleans the failed seam area, applies compatible primer, and either re-welds (TPO) or re-bonds with EPDM primer and adhesive. This is cost-effective for truly isolated failures.

Option 2: Silicone Coating Restoration

When seam failures are widespread across an aging membrane, individual repairs become impractical. A silicone coating restoration seals every seam on the entire roof simultaneously under a continuous new membrane — solving the problem permanently with a new 10–20-year warranty. This is the most cost-effective solution for roofs with systemic seam deterioration.

Should I Choose Spray Foam Roofing or Silicone Roof Coatings?

Tue, 26 Oct 2021 17:34:24 GMT

Should I Choose Spray Foam Roofing or Silicone Roof Coatings?

Both spray foam and silicone coating systems are excellent long-term roofing solutions — but they're best suited to different situations. Here's how to choose.

Choose Silicone Coating When:

Your existing membrane (TPO, EPDM, metal) is in acceptable condition with no significant drainage issues. You need the most cost-effective path to a new warranty. You don't need added insulation value. The roof is structurally flat with adequate drainage to existing outlets. Silicone coating at $2–$5/sq ft is ideal for sealing aging membranes and restoring warranty coverage at minimum cost.

Choose Spray Foam When:

Your roof has ponding water or inadequate drainage slope that needs correction. You're dealing with a gravel built-up roof that needs full restoration after gravel removal. You need to add significant insulation value (R-6.5 per inch). You have a roof with many penetrations that foam can seal more efficiently than a sheet system. Your building has complex geometry that foam can handle without custom fabrication. Spray foam at $4–$8/sq ft is the right choice when slope correction, insulation, or complex substrates are involved.

When Both Are Options

On a structurally sound TPO or EPDM roof with no drainage issues and less than 25% wet insulation, both systems work. Silicone coating is less expensive. Spray foam adds insulation. The right choice depends on whether the insulation investment is justified by your building's energy usage and ownership timeline.

What Is the Process, Warranty, and Cost of Spray Foam Roofing?

Mon, 18 Oct 2021 20:03:51 GMT

What Is the Process, Warranty, and Cost of Spray Foam Roofing?

Spray polyurethane foam roofing is one of the most versatile and long-lasting commercial roofing systems available. Here's a complete overview.

The Installation Process

1. Inspection with core samples to verify eligibility and moisture levels. 2. Wet insulation removal and replacement. 3. Surface preparation: cleaning, priming (where required), and sealing penetrations. 4. Foam application at specified thickness using plural-component spray equipment. 5. Thickness verification with depth probes. 6. Silicone or acrylic topcoat application at required mils. 7. Final inspection by manufacturer-approved inspector for warranty issuance.

Warranty Options

Manufacturer warranties: 10, 15, or 20 years depending on foam and topcoat thickness. At warranty end, a recoat of the topcoat renews coverage — the foam itself remains in place indefinitely. This renewable cycle is what makes spray foam uniquely cost-effective over long building ownership periods.

Typical Costs

1.5–2 inch foam plus silicone topcoat (10-year warranty): $4–$6/sq ft. 3–4 inch foam plus silicone topcoat (20-year warranty): $6–$10/sq ft. Factors include foam thickness, roof size, wet insulation extent, and substrate complexity.

When It Makes the Most Sense

Spray foam is ideal for: gravel BUR roofs after gravel removal, any roof with ponding water or drainage issues, roofs needing significant insulation improvement, buildings with complex penetrations, and any situation where a seamless surface is critical to long-term performance.

Can Spray Foam Be Installed If Vents and HVAC Equipment Are Present?

Tue, 12 Oct 2021 15:55:34 GMT

Can Spray Foam Be Installed If Vents and HVAC Equipment Are Present?

Yes — and in fact, spray foam handles rooftop vents and HVAC equipment better than any other roofing system. Here's why.

The Challenge with Penetrations

Every penetration through a roofing membrane is a potential leak point. Traditional systems require custom-cut boots, flanges, and flashing at each penetration — creating seams and attachment points that can fail over time. Roofs with many HVAC units, exhaust vents, and pipes are particularly challenging for sheet membrane systems.

How Spray Foam Handles Penetrations

Spray foam is fluid-applied and conforms to any shape. Around a pipe, vent, or HVAC curb, foam flows into every gap and crevice, creating a continuous seamless seal from the roof surface up and around the penetration. No custom cutting, no separate boot, no attachment seams. The penetration is simply sealed in one continuous application with the rest of the roof.

HVAC Equipment Curbs

HVAC units sit on curbs above the roof surface. Foam can be applied around the base of the curb, sealing the transition from roof to curb completely — one of the most common leak sources on commercial roofs. This transition is handled in the same pass as the rest of the roof installation.

Equipment Clearance

HVAC units are typically raised on curbs well above the foam application area. Contractors work around equipment during installation, and service access to units is fully maintained after foam is applied. Foam doesn't interfere with HVAC operation or service.

What to Do If Commercial Roof Leaks Are Difficult to Track and Fix

Wed, 06 Oct 2021 17:12:08 GMT

What to Do If Commercial Roof Leaks Are Difficult to Track and Fix

Few things are more frustrating than a commercial roof that keeps leaking despite repeated repairs. Here's why this happens and how to solve it permanently.

Why Chronic Leaks Are Hard to Fix

Water doesn't travel straight down. It enters the roof through a breach, flows laterally through insulation or along the membrane, and exits the ceiling far from the actual entry point. Repairing the apparent leak location often doesn't fix the actual source — leading to the same leak appearing again, or new leaks appearing elsewhere.

Step 1: Get an Infrared Scan

An infrared thermal scan performed at dusk identifies wet insulation across the entire roof — not just around the apparent interior leak location. This gives you a complete picture of where water has infiltrated the roofing system, pointing you toward the actual entry zone rather than the exit point.

Step 2: Core Samples

Core samples in the wet areas identified by the IR scan confirm moisture depth and condition. This data determines whether targeted repairs are viable or whether the roof needs a broader restoration.

The Permanent Solution: Spray Foam Restoration

For roofs with chronic, hard-to-locate leaks, spray foam restoration eliminates the problem entirely. Rather than hunting for and repairing individual breaches one at a time, foam creates a completely new seamless surface over the entire roof — eliminating every existing entry point simultaneously. No more chasing leaks.

Silicone Roof Systems and Existing Metal Roofs (Costs, Durability, Benefits)

Mon, 27 Sep 2021 19:40:26 GMT

Silicone Roof Systems and Existing Metal Roofs (Costs, Durability, Benefits)

Silicone coating systems are among the best solutions for aging commercial metal roofs — addressing leaking fasteners, seam failures, and rust simultaneously in one seamless application.

Costs

Silicone coating only over metal: $2.50–$5.00/sq ft. Spray foam plus silicone (for insulation): $4.00–$8.00/sq ft. Full metal replacement: $8–$15+/sq ft. Restoration at 30–60% of replacement cost makes compelling financial sense for structurally sound metal roofs.

Durability

High-solids silicone is 95% solids content, UV-resistant (doesn't chalk or degrade in sunlight), and remains flexible across extreme temperature swings — critical for metal roofs that expand and contract daily. With a renewable warranty system, properly maintained silicone-coated metal roofs can last indefinitely.

Key Benefits

Seals all fasteners and seams simultaneously, eliminates active leaks, reflects solar heat to reduce cooling costs, provides 10–20-year renewable warranty, requires no tear-off, and is typically completable in days. For most aging metal roofs in adequate structural condition, silicone restoration is the clear financial and performance winner.

What Can Go Wrong with a Spray Foam Roof?

Tue, 21 Sep 2021 18:17:06 GMT

What Can Go Wrong with a Spray Foam Roof?

Spray foam roofing installed by a qualified, manufacturer-approved contractor is one of the best commercial roofing systems available. But there are specific failure modes to understand.

Off-Ratio Foam

Spray foam is a two-component system mixed in precise ratios. If equipment is improperly calibrated or components are applied at incorrect temperatures, the foam cures "off-ratio" — resulting in soft, friable foam that doesn't achieve proper density, R-value, or adhesion. This is the most serious quality issue and why manufacturer-approved applicators with proper equipment are essential.

Topcoat Applied Too Thin

If the silicone or acrylic topcoat is applied below the required mil thickness, it wears away faster than the warranty design period, exposing foam to UV damage prematurely. Thickness verification with probes during installation and third-party inspection at completion protects against this.

Wet Insulation Not Removed

Coating or foaming over wet insulation leads to blistering, poor adhesion, and continued leaks. This is non-negotiable — wet insulation must be identified and removed before any restoration.

Missed Recoat Window

If the recoat schedule isn't followed when the warranty expires, the topcoat can wear away and expose foam to UV degradation. Once significant exposure occurs, sections may need replacement before the roof can be recoated.

How to Avoid All of These

Work only with manufacturer-approved contractors, insist on core sampling before restoration, verify mil thickness during application, and follow the recoat schedule. A well-installed foam roof with proper maintenance avoids all of these issues.

How Durable Is Spray Foam Roofing and How Long Will It Last?

Tue, 14 Sep 2021 15:32:38 GMT

How Durable Is Spray Foam Roofing and How Long Will It Last?

Properly installed and maintained spray foam roofing is one of the most durable commercial systems available — with a theoretical lifespan that has no limit. Here's what the data shows.

Real-World Longevity: 45+ Years

West Roofing Systems has been installing spray foam roofs since 1979. Many of those original installations are still performing today — over 45 years later — because the foam substrate was properly maintained and recoated on schedule. No other commercial roofing system has a documented track record of this length with continuous performance.

What Determines How Long It Lasts

The foam itself doesn't degrade — it's the topcoat that wears. How long a spray foam roof lasts depends primarily on: whether the recoat schedule is followed, the quality of the original installation (correct ratio, density, and thickness), and whether mechanical damage is repaired promptly. A foam roof that is recoated on schedule can theoretically last forever.

Physical Durability

Closed-cell spray foam has compressive strength of 25–60 PSI — supporting significant foot traffic and equipment loads. Wind uplift resistance is exceptional due to the full-surface adhesion with no vulnerable seam edges. Hail impact is absorbed and distributed by the cellular foam structure rather than causing punctures.

The Bottom Line

With proper installation by a manufacturer-approved contractor and adherence to the recoat schedule, spray foam roofing is the last commercial roof a building should ever need.

How Does a Spray Foam Roof Get Installed?

Fri, 03 Sep 2021 13:43:56 GMT

How Does a Spray Foam Roof Get Installed?

Spray foam roofing installation is a precise, multi-step process. Here's exactly what happens from start to finish.

Step 1: Inspection and Assessment

A qualified contractor performs a thorough inspection with core samples to assess moisture levels in the existing insulation and determine roof eligibility. An infrared scan may be used on larger roofs.

Step 2: Wet Insulation Removal

Any areas with saturated insulation are cut out and replaced with dry insulation to match the surrounding level. This is non-negotiable for system performance and warranty compliance.

Step 3: Surface Preparation

The existing roof surface is power-washed to remove all dirt, debris, and contaminants. Primer is applied where required by the substrate type and manufacturer specifications.

Step 4: Foam Application

A two-man crew operates plural-component spray equipment. Component A (isocyanate) and Component B (polyol resin) are heated separately and mixed at the spray gun tip, reacting and expanding into rigid closed-cell foam. The foam is applied in multiple lifts to achieve the specified thickness, with depth probes used throughout to verify consistent coverage.

Step 5: Topcoat Application

Within the manufacturer's specified window after foam application, the protective topcoat — typically silicone — is spray-applied at the required mil thickness for the chosen warranty. Granules are broadcast into wet coating at designated foot traffic areas.

Step 6: Inspection and Warranty

A manufacturer representative or third-party inspector verifies thickness, coverage, and quality. The manufacturer then issues the warranty documentation.

What is a Good Alternative to Polyiso Board Insulation?

Thu, 26 Aug 2021 15:33:53 GMT

What is a Good Alternative to Polyiso Board Insulation?

Polyiso (polyisocyanurate) board insulation is commonly specified in commercial roofing — but it has known limitations. Here are the best alternatives and when to consider them.

Polyiso Limitations

Polyiso's R-value degrades significantly in cold temperatures. Its nominal R-6.5 per inch can drop to R-4.5 or lower at temperatures below 20°F — a significant performance gap in cold climates. Additionally, polyiso can absorb moisture if exposed, reducing performance over time.

EPS (Expanded Polystyrene)

EPS provides consistent R-4 per inch across temperature ranges, doesn't absorb moisture, and maintains performance in cold climates better than polyiso. It's commonly used as an alternative in cold-climate applications where polyiso's thermal drift is a concern.

XPS (Extruded Polystyrene)

XPS provides R-5 per inch with excellent moisture resistance and consistent performance across temperatures. It's a premium option that maintains performance better than polyiso in cold conditions.

Spray Polyurethane Foam: The Best Alternative

Spray foam provides R-6.5 per inch consistently across temperature ranges, doesn't require a separate cover board, bonds directly to the substrate without mechanical fasteners, and eliminates the seams and thermal bridging at board joints that rigid insulation systems introduce. For roofing applications where insulation performance and simplicity matter, spray foam outperforms board insulation on every dimension.

Stay With Existing Spray Foam Roof or Go with TPO? (Pros and Cons)

Tue, 03 Aug 2021 18:26:10 GMT

Stay With Existing Spray Foam Roof or Go with TPO? (Pros and Cons)

If your spray foam roof is aging and needs attention, you may wonder whether to recoat it or switch to a different system like TPO. Here's a direct comparison.

Option 1: Recoat the Existing Spray Foam

If the foam substrate is still in good condition — no significant UV degradation, no major mechanical damage — a recoat is almost always the best choice. Cost: $1–$2/sq ft for the topcoat renewal, plus any spot repairs needed. You get a new 10–20-year manufacturer's warranty and preserve all the insulation value and seamlessness already in the system. This is the clear financial winner in almost every case.

Option 2: Tear Off Foam and Install TPO

This would require full tear-off of the existing foam system (a significant expense), new insulation, and TPO installation at $7–$12/sq ft total. You lose all existing insulation value, get a seamed system, and restart a 20-year replacement cycle. This option rarely makes financial sense unless the foam has been severely degraded from extended UV exposure without recoating.

The Exception: When Switching Makes Sense

If the foam has been severely degraded — years of UV exposure without topcoat protection — significant sections may need complete replacement regardless. In this rare scenario, evaluate whether a full tear-off vs. partial foam replacement plus recoat makes more economic sense on a case-by-case basis.

The Bottom Line

Stay with the foam and recoat. It's almost always the right financial decision.

Cost-Effective Repair for Modified Bitumen Roof

Wed, 28 Jul 2021 12:53:04 GMT

Cost-Effective Repair for Modified Bitumen Roof

Modified bitumen (mod-bit) roofing is a workhorse in commercial construction, but like all systems it ages and eventually needs attention. Here are the most cost-effective repair approaches.

Understanding Mod-Bit Failure

Modified bitumen roofs most commonly fail at seams and laps, through granule loss exposing underlying bitumen to UV, at flashing transitions, and through blistering from trapped moisture. Understanding the failure mode guides the repair approach.

Most Cost-Effective: Silicone Coating Over Granulated Mod-Bit

For granulated modified bitumen roofs in acceptable condition (under 25% wet insulation, adequate adhesion), a silicone coating system applied over the existing surface is the most cost-effective restoration option. The coating fills granule gaps, seals all laps and transitions, and creates a continuous waterproof surface with a 10–20-year warranty at $2.50–$4.50/sq ft — compared to $8–$12/sq ft for replacement.

For Smooth Mod-Bit or Extensive Blistering: Spray Foam

Smooth mod-bit surfaces or those with extensive blistering are better candidates for spray foam restoration. Foam bonds over the existing surface, corrects any drainage issues, and creates a completely seamless surface regardless of the underlying membrane condition.

Targeted Repairs for Isolated Issues

For systems in otherwise good condition with specific problem areas — failed seam, flashing separation — targeted torch repairs or sealant application addressed to the specific failure can extend system life cost-effectively.

What Is the Effective Useful Life of a Commercial Spray Foam Roof?

Wed, 21 Jul 2021 17:48:15 GMT

What Is the Effective Useful Life of a Commercial Spray Foam Roof?

The effective useful life of a spray foam roof is fundamentally different from every other commercial roofing system — because it has no theoretical end.

The Foam Substrate Is Permanent

Closed-cell spray polyurethane foam, once properly installed and protected by a topcoat, doesn't degrade on its own. It doesn't rot, compress, or lose structural integrity over time. West Roofing Systems' earliest installations from 1979 still have intact foam substrates 45+ years later.

What Determines Useful Life

The useful life of the system is determined by the topcoat, not the foam. Each topcoat application is warranted for 10–20 years depending on thickness. When the warranty expires, a fresh topcoat renews the warranty. This cycle can repeat indefinitely — there is no point at which the entire system needs replacement, only periodic topcoat renewal.

Comparison to Other Systems

TPO: 15–25-year useful life before replacement is typically needed. EPDM: 20–30 years. Modified bitumen: 15–25 years. Spray foam with recoating: indefinite. The renewable nature of foam roofing is what makes it uniquely valuable for long-term building ownership.

The Key Condition

Indefinite useful life depends on following the recoat schedule. A missed recoat window that allows foam UV degradation can shorten useful life significantly. The maintenance commitment is simple — recoat every 10–20 years — but it must be honored to achieve the system's full potential.

Spray Foam Roofing for Existing Roofs: A Beginner's Guide

Fri, 09 Jul 2021 12:49:55 GMT

Spray Foam Roofing for Existing Roofs: A Beginner's Guide

If you're new to spray foam roofing and wondering if it's right for your building, this guide covers everything you need to know.

What Is Spray Foam Roofing?

Spray polyurethane foam (SPF) is a two-component liquid system that's sprayed onto an existing roof surface. The components react and expand into a rigid, closed-cell foam that bonds directly to the substrate. A protective silicone or acrylic topcoat is then applied to protect the foam from UV radiation.

Can It Go Over My Existing Roof?

In most cases, yes. Spray foam can be applied over TPO, EPDM, metal, gravel BUR (after gravel removal), and modified bitumen systems — without tearing off the existing roof. The requirement is that the existing substrate has less than 25% wet insulation and the membrane is in acceptable condition.

What Does It Do?

Spray foam simultaneously: creates a seamless waterproof surface (eliminating seams — the #1 cause of leaks), adds insulation (R-6.5 per inch), can correct slope and drainage issues, and comes with a 10–20-year renewable manufacturer's warranty.

How Much Does It Cost?

Typically $4–$8 per square foot for foam plus silicone topcoat, depending on thickness and roof conditions. This is significantly less than full roof replacement at $7–$14 per square foot.

How Long Does It Last?

With proper maintenance and periodic recoating, a spray foam roof can last indefinitely. West Roofing Systems has installations from 1979 still performing today.

What's the First Step?

A professional inspection with core samples to assess moisture levels and determine eligibility. Contact West Roofing Systems for an honest, no-pressure assessment.

How to Avoid a Complete Tear-off for a Commercial Roof?

Thu, 01 Jul 2021 17:38:52 GMT

How to Avoid a Complete Tear-off for a Commercial Roof?

A full tear-off is the most expensive and disruptive commercial roofing option. In many cases, it's completely avoidable. Here's what determines whether you can skip it.

The 25% Rule

The most important factor: if wet insulation comprises less than 25% of the total roof area, tear-off can almost always be avoided. The wet sections are cut out and replaced, and a restoration system is applied over the rest. Above 25%, tear-off becomes more cost-effective.

Core Samples Are Essential

You can't know whether tear-off is necessary without testing. Visual inspection of the roof surface tells you almost nothing about insulation moisture. Core samples and/or an infrared scan are the only reliable way to determine whether restoration is viable.

Systems That Avoid Tear-Off

Both silicone coating systems and spray foam restoration go over the existing roof — no tear-off required. Silicone is applied over existing membranes (TPO, EPDM, metal, mod-bit). Spray foam is applied over BUR after gravel removal, or directly over most other membrane types.

What Tear-Off Does Cost You

Beyond the direct cost ($1–$3/sq ft just for removal), tear-off exposes your building to weather during the project, generates significant landfill waste, can trigger new construction building codes requiring minimum R-values, and creates disruption for operations below.

The Bottom Line

Don't assume tear-off is necessary before getting core sample data. For most roofs that have been in service less than 25+ years with reasonable maintenance, restoration without tear-off is viable and far more cost-effective.

An Honest Comparison: Single-Ply vs. Metal vs. Spray Polyurethane Foam

Mon, 28 Jun 2021 11:57:26 GMT

An Honest Comparison: Single-Ply vs. Metal vs. Spray Polyurethane Foam

These three systems are among the most common commercial roofing options. Here's an honest comparison across the dimensions that matter most.

Initial Cost

Single-ply (TPO/EPDM): $5–$9/sq ft for new installation. Metal roofing: $8–$15/sq ft for new installation. Spray foam restoration: $4–$8/sq ft over existing roofing. For restoration applications, foam is the most affordable entry point.

Seams

Single-ply: heavily seamed — seams are the #1 cause of leaks and require ongoing inspection. Metal: seamed at panel joints, fasteners are leak points. Spray foam: completely seamless — no seams anywhere on the surface. Winner: foam.

Insulation Value

Single-ply: essentially none (R-0 for the membrane). Metal: essentially none (metal is a heat conductor). Spray foam: R-6.5 per inch — the highest of any roofing material. Winner: foam.

Warranty Renewability

Single-ply: replaced at end of warranty (full cost). Metal: replaced at end of useful life. Spray foam: recoated at end of warranty at $1–$2/sq ft — indefinitely renewable. Winner: foam.

Complexity Handling

Single-ply: requires custom fabrication at penetrations and transitions. Metal: seamed systems require custom flashing everywhere. Spray foam: conforms to any shape, sealing all penetrations and transitions in one application. Winner: foam.

The Bottom Line

For commercial roofing restoration, spray foam wins on seams, insulation, renewability, and complexity handling. Single-ply and metal have their place in new construction where foam isn't the appropriate primary system.

Cost-Effective Solution for Leaking Commercial Metal Roof

Mon, 21 Jun 2021 20:42:08 GMT

Cost-Effective Solution for Leaking Commercial Metal Roof

A leaking commercial metal roof is a common problem — and silicone coating restoration is almost always the most cost-effective solution. Here's why.

Why Metal Roofs Leak

Metal roofs develop leaks primarily from: fastener holes enlarging over time from thermal expansion, seam separations, rust penetrating through panels, and failed flashing at edges and penetrations. Traditional patching repairs one problem at a time but doesn't address the system-wide aging.

The Cost-Effective Solution: Silicone Coating

A silicone coating restoration addresses all of these failure modes simultaneously. After thorough cleaning, rust treatment, and reinforced sealing of all fasteners and seams, a silicone topcoat is applied over the entire roof at the required thickness. The result: a completely seamless waterproof membrane over the entire surface with a 10–20-year renewable warranty.

Cost Comparison

Silicone coating over metal: $2.50–$5.00/sq ft. Metal roof replacement: $8–$15+/sq ft. For a 50,000 sq ft metal roof, that's $125,000–$250,000 vs. $400,000–$750,000. The savings are enormous, and the coating result is actually superior — no seams means no future seam failures.

When Replacement Is Unavoidable

If metal panels have significant structural corrosion or are compromised beyond surface rust, restoration isn't viable. A structural assessment distinguishes surface deterioration (restorable) from structural failure (replacement required).

What Is a Monolithic Roof System?

Mon, 07 Jun 2021 20:04:00 GMT

What Is a Monolithic Roof System?

A monolithic roof system is one that is applied as a single continuous, seamless surface — with no joints, seams, laps, or attachment points anywhere on the roof. Spray polyurethane foam is the defining example of a monolithic roofing system.

Why Seams Are the Enemy

Virtually every commercial roof leak originates at a seam. Whether it's a heat-welded TPO lap, an EPDM splice, a metal panel joint, or a flashing transition — seams are where adhesion fails, where movement occurs, and where water finds entry. A roofing system with no seams eliminates the #1 cause of leaks by design.

How Spray Foam Achieves Monolithic Performance

Spray foam is fluid-applied — it literally flows into and around every penetration, transition, and surface irregularity, creating a continuous bond across the entire roof in one application. There are no joints between sections, no laps to fail, no attachment points. The entire roof surface is one continuous material from edge to edge.

Benefits of Monolithic Systems

Zero seam failure risk — the #1 cause of leaks is eliminated. Self-flashing — transitions, penetrations, and edges are all handled in the same continuous application. Uniform performance — no weak points anywhere on the surface. Lower maintenance costs — no seams to inspect and re-bond over time.

Silicone Coatings as Monolithic Systems

Silicone coating systems applied over existing roofing are also largely monolithic — the coating creates a continuous film over the existing surface, sealing all underlying seams under the new membrane.

What Is Commercial Roof Recovery and Is It a Cost-Effective Option?

Tue, 01 Jun 2021 18:52:16 GMT

What Is Commercial Roof Recovery and Is It a Cost-Effective Option?

Roof recovery refers to installing a new roofing system directly over an existing one — without tearing off the old roof. It's distinct from full replacement and is often more cost-effective when the existing roof meets certain conditions.

How Roof Recovery Works

In a roof recovery, the existing membrane is left in place (after removing any wet insulation sections) and a new system is installed on top. This can mean a new single-ply membrane over an existing BUR, a silicone coating over existing TPO, or spray foam over virtually any existing system.

When Recovery Is Viable

Recovery is viable when: wet insulation is below 25% of the total area, the existing membrane is structurally adhered (not significantly delaminated), building codes permit it (most jurisdictions allow one overlay), and structural capacity accommodates the additional load.

Is It Cost-Effective?

Yes — significantly so. Recovery typically costs 40–70% less than full tear-off and replacement because it eliminates tear-off labor and disposal costs. For a 50,000 sq ft roof, avoiding tear-off alone can save $50,000–$150,000. When combined with coating restoration systems that provide 10–20-year warranties, recovery is almost always the better financial choice for qualifying roofs.

The Most Cost-Effective Recovery Systems

Silicone coating: $2–$5/sq ft, ideal for TPO/EPDM/metal. Spray foam: $4–$8/sq ft, ideal for BUR, complex roofs, or when insulation improvement is needed. Both deliver new manufacturer warranties without requiring the expensive disruption of tear-off.

Built-Up Roof Repair: Options to Fix and Protect Your Roof

Mon, 24 May 2021 19:52:18 GMT

Built-Up Roof Repair: Options to Fix and Protect Your Roof

Built-up roofing (BUR) systems are durable but develop specific problems over time. Here are the best repair and restoration options.

Option 1: Surface Maintenance and Spot Repairs

For younger BUR systems with isolated issues, targeted repairs — sealing cracks with compatible mastic, re-embedding gravel, reinforcing specific failure areas — extend system life at minimal cost. Best for roofs under 15 years old with limited problem areas.

Option 2: Silicone Coating Over Smooth BUR

Smooth BUR (without gravel) can receive a silicone coating directly, sealing the existing surface and providing a new waterproof membrane with a 10–20-year warranty. This is the most cost-effective long-term solution for smooth BUR in acceptable condition at $2.50–$4.50/sq ft.

Option 3: Spray Foam After Gravel Removal

For gravel BUR, the best restoration approach is hydro-vacuuming the gravel, replacing wet insulation, and applying spray foam directly to the BUR substrate. Total cost: $4–$7/sq ft with a new 10–20-year warranty — roughly half the cost of BUR replacement at $8–$14/sq ft.

Option 4: Full Replacement

When the BUR substrate has delaminated significantly or wet insulation exceeds 25%, full replacement is required. Choose a system with a renewable warranty to avoid repeating the decision in 20 years.

What's the Best Solution for a Leaking Single-Ply Roof?

Mon, 17 May 2021 13:40:25 GMT

What's the Best Solution for a Leaking Single-Ply Roof?

Single-ply roofs (TPO and EPDM) leak almost exclusively at seams. The best solution depends on whether failures are isolated or widespread.

For Isolated Failures: Targeted Repair

If only a few seams have failed on an otherwise sound membrane, re-welding (TPO) or re-bonding (EPDM) the specific failed seam areas addresses isolated failures cost-effectively.

For Aging Membranes with Widespread Issues: Silicone Coating

When a single-ply roof is 10–20+ years old with widespread seam deterioration, individual repairs become impractical. A silicone restoration membrane applied over the entire roof seals every seam simultaneously under a new continuous waterproof surface — with a new 10–20-year warranty at $2.50–$4.50/sq ft vs. $7–$12/sq ft for replacement.

The Critical Pre-Condition: Core Samples

Before any restoration, core samples must confirm wet insulation is below 25% of the total area. Coating over wet insulation causes blistering and system failure — this step is non-negotiable.

If Restoration Isn't Viable

If the membrane has failed completely, choose a replacement system with a renewable warranty — spray foam or silicone coating system — to avoid facing the same decision in 20 years.

What Happens If There's a Tear in a TPO Roof?

Thu, 13 May 2021 20:38:31 GMT

What Happens If There's a Tear in a TPO Roof?

A tear in a TPO membrane is an active leak point that needs prompt attention. Here's what to do and what your options are.

What Causes TPO Tears

TPO membrane tears most commonly result from: foot traffic damage (equipment installation, maintenance), hail or impact from falling objects, thermal stress at penetrations and transitions, and improper installation leaving sections under-welded. Small tears can also develop at seam edges over time as the membrane becomes more brittle with age.

Immediate Action: Stop the Leak

Apply compatible TPO lap sealant or cover the area with a temporary patch to stop active water infiltration. This is a temporary measure — not a permanent repair.

Permanent Repair: Patch Over Tear

For isolated tears, the permanent repair involves: cleaning the area thoroughly, applying a compatible primer, cutting a TPO patch that extends at least 3 inches beyond the tear in all directions, and heat-welding the patch in place. Done correctly with proper equipment and technique, a welded patch is as strong as the original membrane.

When Restoration Makes More Sense

If your TPO roof is 10+ years old and experiencing multiple tears or widespread seam issues, individual repairs address symptoms but not the underlying aging. A silicone coating restoration seals the entire roof — including all existing tears — under a new continuous membrane with a fresh warranty. This is often more cost-effective than accumulating individual repairs on an aging system.

What Is the R-Value of Silicone Roof Coatings?

Mon, 03 May 2021 19:24:50 GMT

What Is the R-Value of Silicone Roof Coatings?

The R-value of silicone roof coatings is essentially negligible — approximately R-0.02 to R-0.05 per mil of coating. At 20–30 mils, that's essentially R-0. But this doesn't tell the whole energy efficiency story.

R-Value vs. Solar Reflectance

R-value measures resistance to heat flow through a material. Silicone coatings are too thin to provide meaningful thermal resistance. However, energy efficiency isn't only about insulation — it's also about heat gain from solar radiation, which silicone addresses extremely well.

What Silicone Actually Delivers: High Reflectance

High-solids silicone coatings achieve solar reflectance of 85%+ and thermal emittance of 90%+. This means they reflect the majority of solar energy away from the building. A dark, uncoated roof can reach 180°F on a hot summer day. A white silicone-coated roof may stay at 100°F under the same conditions — an 80°F reduction in surface temperature that directly reduces cooling load.

Real-World Energy Impact

In warm climates or buildings with significant solar exposure, silicone coatings can reduce cooling costs by 10–20% annually. Over a 20-year warranty period, these savings can meaningfully offset the installation cost.

For R-Value, Add Spray Foam

If actual insulation improvement is the goal, spray polyurethane foam (R-6.5 per inch) combined with a silicone topcoat delivers both high R-value and high reflectance — the complete energy efficiency solution for commercial roofs.

The Best Roof for a Property Management Company

Mon, 26 Apr 2021 15:53:40 GMT

The Best Roof for a Property Management Company

Property management companies face roofing challenges across multiple buildings simultaneously. The best roofing solution is one that minimizes lifecycle cost, reduces management overhead, and keeps tenants satisfied.

The Property Management Perspective

Unlike single-building owners, property managers deal with roofing decisions across portfolios. This creates different priorities: predictable maintenance costs across buildings, minimal tenant disruption, systems that don't require frequent attention, and warranty protection that remains valid regardless of which contractor performs maintenance.

Why Renewable Coating Systems Win for Property Management

Silicone coating and spray foam restoration systems offer three advantages that are specifically valuable to property managers. First, they're completed faster and with less disruption than replacement — keeping tenants happy. Second, renewable warranties with predictable recoat schedules make long-term budgeting straightforward. Third, the cost savings vs. replacement free capital for other portfolio needs.

The Recommended Approach

For any building in the portfolio: commission an independent inspection with core samples to determine if restoration is viable. For eligible roofs, apply the appropriate system (silicone coating for TPO/EPDM/metal, spray foam for BUR or drainage issues). Document all maintenance and warranty information centrally. Schedule recoats proactively rather than reactively.

Long-Term Portfolio Impact

A portfolio-wide approach to renewable roof coatings can transform roofing from an unpredictable emergency expense into a predictable scheduled maintenance item — exactly what property management requires.

Flat Roof Re-Roofing: 3 Options You Should Consider

Fri, 23 Apr 2021 13:01:01 GMT

Flat Roof Re-Roofing: 3 Options You Should Consider

When a flat roof reaches the end of its service life, most building owners think immediately of replacement. But there are three distinct options worth considering — and the least disruptive is often the most cost-effective.

Option 1: Full Tear-Off and Replacement

The most comprehensive option — remove the existing system completely and install a new one. Required when wet insulation exceeds 25%, the deck is compromised, or building codes prohibit another overlay. Cost: $7–$14/sq ft. Most disruptive. Only viable for roof that truly cannot be restored.

Option 2: Coating Restoration (Recover)

Apply a silicone or acrylic coating system over the existing membrane without tear-off. For roofs with less than 25% wet insulation and intact membranes, this provides a new 10–20-year warranty at $2–$5/sq ft — 50–70% less than replacement. Minimal disruption, fastest completion.

Option 3: Spray Foam Restoration

Apply spray polyurethane foam over the existing substrate, creating a completely new seamless surface with slope correction, added insulation, and a renewable warranty. Best for: gravel BUR systems, roofs with drainage issues, or when insulation improvement is a goal. Cost: $4–$8/sq ft.

How to Choose

Get a professional inspection with core samples first. The moisture level in your insulation determines which options are viable. For most flat roofs with reasonable maintenance history, restoration (Option 2 or 3) is both viable and significantly more cost-effective than full replacement.

How to Easily Increase the Slope of Your Commercial Roof?

Mon, 19 Apr 2021 13:37:40 GMT

How to Easily Increase the Slope of Your Commercial Roof?

Flat commercial roofs require adequate slope to drain water properly. When slope is insufficient, ponding water develops — and ponding accelerates membrane wear, adds structural load, and voids most warranties. Here's the easiest way to add slope.

Why Traditional Methods Are Difficult

Traditional slope correction requires: removing the existing membrane, installing tapered insulation boards at varying thicknesses (a precise, labor-intensive process), and re-installing the membrane. This is expensive, time-consuming, and highly disruptive — effectively a full tear-off project.

Spray Foam: The Easy Solution

Spray foam is fluid-applied and can be built up at any thickness in any location. To add slope, the contractor applies more foam in low areas and feathers it toward drains or roof edges — creating positive drainage without any structural work. The foam itself becomes the new roof surface (with topcoat), so no separate membrane installation is required. The entire slope correction happens in the same application as the waterproofing.

Precision Slope Design

Before installation, a spray plan is developed that specifies foam thickness at each point of the roof to achieve the desired drainage pattern. Depth probes verify that specified thicknesses are being achieved throughout application.

Cost-Effective at Any Scale

Because foam application scales efficiently with crew size and equipment, slope correction on large commercial roofs is completed in days to weeks at $4–$8/sq ft total — far less than a structural slope correction combined with a new roofing system.

How Is Spray Foam Roofing Sustainable and Renewable?

Fri, 09 Apr 2021 13:11:01 GMT

How Is Spray Foam Roofing Sustainable and Renewable?

Spray foam roofing stands out from conventional roofing systems on sustainability in several meaningful ways.

Zero Tear-Off Waste

Traditional roof replacements generate thousands of pounds of landfill waste — old TPO, EPDM, or BUR materials that end up in landfills. Spray foam restoration goes over the existing roof with no tear-off, generating essentially zero construction waste. Over a 40-year building lifecycle, this represents a significant reduction in material waste compared to multiple replacement cycles.

Genuinely Renewable

No other roofing system can claim true renewability. At the end of each warranty period, a spray foam roof is renewed with a fresh topcoat — no new materials needed for the substrate, no waste generated, no new manufacturing impact. The foam itself continues indefinitely.

Energy Efficiency

At R-6.5 per inch, spray foam adds the highest insulation value of any roofing material. For buildings with inadequate roof insulation, foam restoration directly reduces heating and cooling energy consumption — lowering carbon footprint for the building's operational life.

High Reflectance Topcoat

The white silicone topcoat achieves 85%+ solar reflectance, reducing urban heat island effect and building cooling loads simultaneously.

Long Service Life Reduces Manufacturing Impact

A properly maintained foam roof that lasts 45+ years requires far fewer manufacturing cycles of replacement materials compared to a TPO or EPDM system replaced every 20–25 years.

4 Reasons Why SPF Roofing Is the Most Cost-Effective Option

Thu, 01 Apr 2021 14:48:05 GMT

4 Reasons Why SPF Roofing Is the Most Cost-Effective Option

Spray polyurethane foam roofing isn't always the cheapest upfront — but across the full lifecycle of a commercial building, it consistently delivers better value than alternatives. Here are the 4 key reasons.

1. No Tear-Off Required

Foam goes over the existing roof, eliminating tear-off labor, disposal costs, and the risk of weather exposure during installation. Tear-off alone adds $1–$3/sq ft to any replacement project. Over multiple replacement cycles, the cumulative savings are substantial.

2. Renewable at Minimal Cost

At warranty end, a recoat at $1–$2/sq ft renews coverage indefinitely. Compare this to TPO replacement at $7–$12/sq ft every 20 years. Over a 40-year period, a foam system renewed twice costs $2–$4/sq ft total in topcoat costs vs. $14–$24/sq ft for two TPO replacement cycles.

3. Energy Savings

R-6.5 per inch is the highest insulation value of any roofing material. For buildings transitioning from low-insulation roofs, HVAC cost reductions can meaningfully contribute to the return on investment — often generating a compelling buyback period of 5–10 years on the insulation premium.

4. Fewer Repairs Over Time

A seamless roof has no seams to fail, inspect, and repair. Traditional seamed systems require ongoing seam inspections and periodic re-welding or re-bonding as adhesion weakens. The elimination of seam maintenance over a 40-year period represents real savings that don't appear in upfront cost comparisons.

6 Ways Spray Foam Roofing is Unique

Fri, 26 Mar 2021 18:37:13 GMT

6 Ways Spray Foam Roofing is Unique

Spray polyurethane foam roofing isn't just another commercial roofing option — it does things no other system can. Here are 6 capabilities that set it apart.

1. Builds Slope Without Structural Work

Spray foam can be applied at varying thicknesses to create positive drainage on a flat or insufficiently-sloped roof. No tear-off, no structural modifications — just foam feathered to the desired slope in one application.

2. Conforms to Any Surface

Domes, curved surfaces, corrugated panels, complex penetration fields — foam conforms to and seals them all in a single application. Sheet membranes require custom fabrication at every irregularity; foam has no such limitation.

3. Self-Flashing

Foam flows up walls, around penetrations, and over transitions in one continuous application — eliminating the need for separate flashing components at every roof termination.

4. Highest R-Value Per Inch

R-6.5 per inch is unmatched by any other roofing material. No other restoration system adds meaningful insulation value in a single application.

5. Genuinely Renewable

No other commercial roofing system can be renewed indefinitely with periodic topcoat application. Every other system eventually requires full replacement.

6. Encapsulation Capability

Foam can encapsulate existing asbestos-containing materials, exposed fasteners, and deteriorated substrates — capabilities that no sheet membrane system can offer.

5 Things to Know About Re-Roofing a Commercial Building

Mon, 22 Mar 2021 14:38:52 GMT

5 Things to Know About Re-Roofing a Commercial Building

Re-roofing a commercial building is one of the largest capital expenditures most building owners face. Here are 5 things you must know before making any decisions.

1. "Re-Roofing" Can Mean Different Things

Re-roofing can mean full tear-off and replacement, roof recovery (installing a new system over the existing one), or restoration with a coating system. These options have dramatically different costs, disruption levels, and performance outcomes. Don't assume "re-roofing" means replacement.

2. Core Samples Determine Your Options

The moisture level in your existing insulation is the single most important factor in determining what approach is viable. You cannot know this without core samples. Any contractor who quotes a system without doing core sampling is making assumptions — not recommendations.

3. The 25% Rule Is the Key Threshold

Less than 25% wet insulation: restoration is almost certainly viable. More than 25%: full replacement becomes more cost-effective. This threshold drives virtually every "restore vs. replace" decision.

4. Restoration Costs 50–70% Less

For qualifying roofs, silicone coating restoration at $2–$5/sq ft or spray foam at $4–$8/sq ft costs dramatically less than replacement at $7–$14/sq ft. This difference is worth investigating before committing to replacement.

5. Manufacturer Warranty vs. Contractor Warranty

Always insist on a manufacturer-backed warranty. Contractor warranties expire when the contractor goes out of business. Manufacturer warranties protect your investment regardless of who performs future work.

Everything Building Owners Must Know About Silicone Roof Coatings

Tue, 16 Mar 2021 14:32:35 GMT

Everything Building Owners Must Know About Silicone Roof Coatings

Silicone roof coatings are one of the most effective and cost-efficient commercial roofing solutions available. Here's a complete guide.

What Are Silicone Roof Coatings?

High-solids silicone coatings are fluid-applied waterproofing membranes containing 90–95% solids content. Applied at 20–30 mils over an existing roofing membrane, they create a seamless, highly reflective waterproof surface that is UV-resistant, flexible, and extremely durable.

What Substrates Can They Go Over?

Silicone coatings can be applied over: TPO, EPDM, metal, modified bitumen, smooth BUR, spray foam, and other commercial membranes in acceptable condition. They require thorough surface preparation and, in some cases, primer to ensure adhesion.

What Warranties Are Available?

10, 15, or 20-year manufacturer warranties based on applied coating thickness. At warranty end, a recoat renews coverage indefinitely.

What Do They Cost?

$2.00–$5.00/sq ft depending on substrate type, roof size, required coating thickness, and prep work needed. This is 50–70% less than full roof replacement.

What Are the Requirements?

Wet insulation must be below 25%, the existing membrane must be in acceptable condition, and installation must be performed by a manufacturer-approved contractor using approved materials.

What Are the Limitations?

Silicone coatings don't add meaningful insulation value (for that, spray foam is needed). They also can't correct slope or drainage issues — those require spray foam.

The Most Cost-Effective Repair Option for Commercial EPDM Roofing

Thu, 11 Mar 2021 20:44:19 GMT

The Most Cost-Effective Repair Option for Commercial EPDM Roofing

EPDM (ethylene propylene diene monomer) rubber roofing is durable and common on commercial buildings — but it develops specific failure modes over time. Here are the most cost-effective repair options.

How EPDM Fails

EPDM roofs most commonly fail at: seam splice adhesive failures (the #1 cause of EPDM leaks), lap sealant deterioration at seam edges, membrane shrinkage causing edge and flashing separation, and punctures from foot traffic or falling objects. The membrane itself can last 20–30+ years; seams are the system's vulnerability.

Most Cost-Effective for Isolated Failures: Seam Repair

For isolated seam failures on an otherwise sound membrane, targeted seam repair — cleaning, priming, and re-bonding with EPDM lap adhesive and cover tape — is the least expensive fix. Best for roofs under 15 years old with limited problem areas.

Most Cost-Effective for Aging EPDM: Silicone Coating

For EPDM roofs 15–25+ years old with widespread seam deterioration, silicone coating restoration is the most cost-effective solution. A silicone membrane applied over the entire EPDM surface seals every seam under a new continuous waterproof layer with a new 10–20-year warranty at $2.50–$4.50/sq ft — far less than replacement at $7–$12/sq ft.

For EPDM with Drainage Problems: Spray Foam

If ponding water is also a problem, spray foam restoration corrects slope while providing waterproofing and insulation — a capability silicone coating alone can't deliver.

Why Commercial Roof Proposals Are Over Budget (What Options Exist)

Mon, 08 Mar 2021 16:46:08 GMT

Why Commercial Roof Proposals Are Over Budget (What Options Exist)

You've received a roofing proposal that's significantly over your budget. Before cutting corners or abandoning the project, understand why the cost is what it is — and what legitimate alternatives exist.

Why Proposals Come In Over Budget

Commercial roofing proposals often exceed expectations for legitimate reasons: the scope of wet insulation removal required, the size of the project, premium material costs for manufacturer-warranted systems, travel costs for qualified contractors, and thorough preparation requirements. These costs are real and cutting them leads to system failures.

Option 1: Verify Whether Restoration Is Viable

If the proposal is for full replacement, get an independent inspection with core samples. If wet insulation is below 25%, a coating restoration at 50–70% less cost may be viable — and you may not need the replacement at all.

Option 2: Reduce Warranty Tier

If restoration is being proposed with a 20-year warranty, asking for a 10-year warranty option reduces material cost (less coating thickness required). The work quality is identical — only the coverage period changes.

Option 3: Phase the Project

For large roofs, some contractors can phase work across budget cycles — completing the most critical sections in year one and the remainder in subsequent years.

What Not to Do

Don't accept a proposal that skips wet insulation removal to reduce cost. This is the most common shortcut that leads to system failure. Any savings from skipping this step will cost far more in remediation within a few years.

Water Damage on TPO Roof (What You Should Do Immediately)

Mon, 01 Mar 2021 12:55:56 GMT

Water Damage on TPO Roof (What You Should Do Immediately)

Active water infiltration from a TPO roof requires immediate action to minimize interior damage. Here's what to do right now and what comes next.

Immediate Steps

First, protect interior contents — move equipment, cover inventory, and place buckets or containment to limit interior water damage. Document the damage with photos for insurance purposes. Then apply compatible TPO lap sealant or a temporary patch to the apparent leak area on the roof to stop active infiltration. This buys time for a proper assessment.

Get a Professional Inspection Quickly

Once the immediate emergency is contained, schedule a professional roof inspection as soon as possible. The inspection should include: locating all breach points (not just the apparent ones), core sampling to assess wet insulation extent, and documentation of damage for insurance if applicable.

Why You Shouldn't Wait

Every day water sits in insulation, the damage expands. Wet insulation compresses, creating low spots that cause more ponding. Mold can begin developing within 24–48 hours in saturated insulation. What starts as a restorable leak situation can become a full replacement scenario if left unaddressed.

Long-Term Solutions

If moisture is below 25% after inspection: silicone coating restoration ($2.50–$4.50/sq ft) is the most cost-effective solution. If above 25%: full replacement may be necessary. Either way, acting quickly limits how much wet insulation must be replaced and keeps restoration viable.

How Silicone Coatings React to Thermal Movements of a Metal Roof

Mon, 22 Feb 2021 16:00:28 GMT

How Silicone Coatings React to Thermal Movements of a Metal Roof

Metal roofs experience significant thermal expansion and contraction — often 1/4 inch or more per 10 feet of panel length for every 100°F temperature change. This movement is one of the primary reasons metal roofs develop leaks over time. Silicone coatings handle it exceptionally well.

Why Thermal Movement Causes Metal Roof Leaks

Traditional metal roof sealants are rigid or semi-rigid — they work when new but crack and lose adhesion as they repeatedly cycle through expansion and contraction. Once sealant at fasteners or seams fails, water finds entry. This is why patching metal roofs is a losing battle; the same thermal forces that broke the original sealant will break the patch.

Silicone's Flexibility Advantage

High-solids silicone coatings maintain flexibility across temperature ranges from -80°F to 300°F+. They elongate significantly under stress and return to their original form without cracking or delaminating. A properly applied silicone coating over metal accommodates the full range of thermal movement without failure — the coating moves with the metal rather than fighting it.

Why Silicone Outperforms Other Coatings on Metal

Acrylic coatings harden over time, reducing flexibility. Butyl and asphalt-based sealants have limited temperature range and poor UV resistance. Silicone maintains its flexibility and UV resistance throughout its 20-year warranty period — making it the preferred coating for metal roof applications in all climates.

How to Avoid a Disastrous Spray Foam Roof Installation

Fri, 05 Feb 2021 15:54:23 GMT

How to Avoid a Disastrous Spray Foam Roof Installation

Spray foam roofing installed correctly is one of the best commercial systems available. Installed poorly, it can fail quickly and expensively. Here's how to protect yourself.

The Risks of Poor Foam Installation

Off-ratio foam — caused by improper equipment calibration or incorrect component temperatures — cures soft and friable, with poor adhesion and inadequate R-value. Topcoat applied too thin wears through prematurely, exposing foam to UV. Wet insulation not removed causes blistering and adhesion failure. These mistakes are difficult and expensive to correct after the fact.

How to Vet a Contractor

Always verify manufacturer approval — call the manufacturer directly and confirm the contractor is approved to purchase materials and issue warranties. Ask for verifiable references on similar projects you can call. Confirm the contractor has plural-component equipment capable of proper ratio control and temperature management. Insist on a written proposal specifying materials, thickness, and warranty terms.

Insist on Third-Party Inspection

For warranted systems, insist on a third-party inspection at project completion. Most reputable manufacturers send a representative or require a certified inspector to verify thickness and quality before issuing the warranty. This is your protection against substandard installation.

Red Flags During Installation

Foam that looks bubbly, discolored, or soft is off-ratio. Application in wind without proper overspray protection. Topcoat applied immediately without sufficient foam cure time. Inadequate surface preparation. Any of these should prompt immediate stoppage and discussion with the contractor.

How Do Silicone Roof Coatings Work?

Thu, 14 Jan 2021 14:41:41 GMT

How Do Silicone Roof Coatings Work?

Silicone roof coatings work through a combination of chemistry and physical properties that make them uniquely effective for commercial roofing. Here's the explanation.

The Chemistry: High Solids Content

High-solids silicone coatings contain 90–95% active silicone solids. When applied to a roof surface, the solvent or water carrier evaporates, leaving behind a thick film of pure silicone — typically 20–30 mils. Because so little is lost to evaporation, the applied wet film closely matches the final dry film thickness. This is why silicone delivers exceptional coverage without multiple coats.

How Adhesion Works

Silicone bonds to prepared roofing substrates through a combination of mechanical adhesion (interlocking with surface irregularities) and chemical bonding. Primer is used on some substrates (particularly smooth TPO and certain metals) to improve chemical bonding and ensure long-term adhesion.

UV Resistance: Why Silicone Doesn't Chalk

Unlike acrylic or polyurethane coatings, silicone's Si-O-Si (silicon-oxygen) backbone is more stable than the carbon-carbon bonds that UV radiation degrades. This is why silicone doesn't chalk, yellow, or lose flexibility with prolonged UV exposure — it maintains its performance characteristics for the full warranty period.

Waterproofing Mechanism

The cured silicone film is hydrophobic — water beads and runs off rather than being absorbed. The seamless, pinhole-free film prevents water infiltration even under standing water conditions, which is why silicone coatings are specifically approved for use on roofs with ponding water concerns.

Does Spray Foam Stop Roof Leaks?

Mon, 11 Jan 2021 14:21:42 GMT

Does Spray Foam Stop Roof Leaks?

Yes — spray polyurethane foam stops roof leaks, and it does so more comprehensively than any other system. Here's why.

Why Traditional Repairs Often Fail

Most commercial roof leaks originate at seams, and individual seam repairs address one leak at a time. But an aging roof with one leaking seam often has dozens more on the verge of failure. Repairing individual breaches is a recurring battle — as soon as one is fixed, another appears. This is the fundamental limitation of patch-and-repair approaches on aging membranes.

How Spray Foam Stops Leaks Permanently

Spray foam doesn't repair individual leaks — it eliminates all existing leak points simultaneously. Applied over the entire roof, foam bonds to every surface and creates a completely seamless, continuous waterproof membrane. Every existing seam, fastener, crack, and penetration is sealed in one application. There are literally no entry points left for water.

The Seamless Advantage

Because foam has no seams of its own, it also eliminates the future leak risk that comes with seamed systems. A foam-restored roof doesn't develop new seam failures because there are no seams to fail. This is a fundamental performance advantage over any sheet membrane system.

What Foam Can't Fix

Spray foam won't fix leaks caused by structural problems — failed decking, compromised parapet walls, or improperly flashed roof penetrations above the roofline. And it can't be applied over wet insulation, which must be removed first. Within those parameters, foam is the most comprehensive leak-stopping solution available.

How Does Spray Foam Roofing Work?

Mon, 04 Jan 2021 20:53:45 GMT

How Does Spray Foam Roofing Work?

Spray polyurethane foam roofing works through a two-component chemical reaction that creates a rigid, closed-cell foam bonded directly to the roof surface. Here's exactly how it works.

The Two Components

SPF roofing uses two liquid chemicals: Component A (isocyanate) and Component B (polyol resin blend). These are stored separately in heated drums on the spray rig. When mixed, they react exothermically and expand to approximately 30 times their original volume within seconds.

The Spray Process

A plural-component proportioner heats both components to specified temperatures and pumps them in precise ratio (typically 1:1 by volume) to a spray gun. The components mix at the gun tip and are sprayed onto the roof surface. Within seconds of application, the liquid mixture reacts, expands, and begins curing into rigid foam.

Adhesion to the Substrate

As the foam expands and cures, it bonds chemically and mechanically to the substrate. This bond forms at the molecular level — no separate adhesive is needed. The result is a continuous, monolithic layer that is fully adhered across its entire surface.

The Topcoat

Within the manufacturer's specified window after foam application (typically hours), a protective silicone or acrylic topcoat is applied over the foam. This topcoat provides UV resistance (protecting the foam from degradation), weatherproofing, and the reflective surface that gives foam roofs their energy efficiency.

What R-Value Can You Expect from Spray Foam Roofing?

Mon, 28 Dec 2020 15:51:46 GMT

What R-Value Can You Expect from Spray Foam Roofing?

Spray polyurethane foam provides R-6.5 per inch — the highest R-value per inch of any roofing insulation available. Here's what that means in practice.

R-Value by Thickness

1 inch = R-6.5. 1.5 inches = R-9.75. 2 inches = R-13. 3 inches = R-19.5. 4 inches = R-26. These values are consistent across temperature ranges, unlike polyiso board which loses R-value significantly in cold weather.

Comparison to Other Roofing Insulation

Polyiso board: R-6 per inch (nominal), but drops to R-4–4.5 in cold climates. EPS board: R-4 per inch consistently. XPS board: R-5 per inch consistently. Spray foam: R-6.5 per inch, consistent across temperatures. Foam provides the best insulation performance in all conditions.

What R-Value Does Your Building Need?

ASHRAE Zone 5 (Ohio, Pennsylvania, etc.) requires R-30 for new construction roofs. To achieve R-30 with spray foam, approximately 4.6 inches are needed. Many foam restoration projects apply 2–4 inches, achieving R-13 to R-26 — still far superior to the near-zero insulation value of most existing single-ply membranes.

Energy Savings Impact

The energy savings from improved roof insulation depend on climate, building use, and existing insulation levels. Buildings transitioning from poorly insulated or uninsulated roofs typically see the most dramatic HVAC cost reductions — sometimes 20–30% in heating and cooling costs in extreme climates.

Renew or Replace Your Commercial EPDM Roof: A Step-by-Step Guide

Tue, 22 Dec 2020 13:45:55 GMT

Renew or Replace Your Commercial EPDM Roof: A Step-by-Step Guide

If your EPDM roof is aging and causing problems, this step-by-step guide will help you make the right decision.

Step 1: Commission an Independent Inspection

Before accepting any recommendation, commission an independent inspection from a contractor who offers both restoration and replacement. Request core samples at multiple locations and an infrared scan if the roof is large. You need objective moisture data — not a contractor's opinion formed on a visual walkthrough.

Step 2: Determine Wet Insulation Percentage

The core sample data reveals moisture levels in the insulation. If wet insulation is below 25% of the total area: renewal is viable. If above 25%: replacement is more cost-effective. This single data point drives the decision more than anything else.

Step 3: Assess Membrane Condition

If moisture qualifies for renewal, assess the membrane itself. Is it adhered (not significantly delaminated)? Are seams still bonded (even if leaking)? Widespread membrane shrinkage or delamination may prevent restoration even when moisture levels are acceptable.

Step 4: Get Proposals for Both Options

If renewal is viable, get proposals for silicone coating restoration ($2.50–$4.50/sq ft). Get a replacement proposal for comparison. In most qualifying cases, the cost difference is so significant that renewal wins clearly.

Step 5: Choose and Execute

For renewal: verify the contractor is manufacturer-approved, confirm the proposal includes wet insulation removal and replacement, and insist on a manufacturer warranty. For replacement: choose a system with a renewable warranty to avoid repeating this decision in 20 years.

Review of a Spray Foam Roof

Mon, 14 Dec 2020 15:41:24 GMT

Review of a Spray Foam Roof

After decades of spray foam installations, West Roofing Systems has seen how building owners feel about their foam roofs over the long term. Here's an honest review.

What Building Owners Love

The #1 feedback from satisfied foam roof owners: "We haven't had a single leak since installation." The seamless nature of foam eliminates the seam failures that plagued previous systems. Owners who switched from aging TPO or EPDM consistently report dramatically reduced roofing maintenance costs. The renewable warranty — knowing they'll never face another full replacement — is consistently cited as a major relief.

Energy Savings Are Real

Building owners who upgrade from minimal-insulation roofs to foam consistently report meaningful HVAC cost reductions. Schools with year-round climate control, warehouses in extreme climates, and buildings with poor existing insulation see the most dramatic improvements.

What Building Owners Find Challenging

The upfront cost is the most common concern — foam costs more than a basic coating system. The recoat requirement surprises some owners who expected the system to be truly maintenance-free. And finding qualified applicators in some markets requires more vetting than hiring a general roofing contractor.

The Overall Assessment

For building owners who do their homework — verify contractor approval, insist on core sampling, and commit to the recoat schedule — spray foam roofing consistently delivers on its promises. The 45+ year track record at West Roofing Systems speaks for itself.

Is Commercial Roofing Maintenance a Rip-off?

Wed, 25 Nov 2020 13:46:16 GMT

Is Commercial Roofing Maintenance a Rip-off?

This is a fair question. Some roofing maintenance programs don't deliver meaningful value — but legitimate preventive maintenance genuinely protects your roof investment. Here's how to tell the difference.

What Legitimate Maintenance Includes

A real maintenance visit should include: thorough visual inspection of the membrane, seams, flashings, and penetrations; cleaning of all drains and gutters; documentation of any new damage or wear; minor seam and flashing sealant repairs where needed; and a written report with photos. This typically costs $0.02–$0.07/sq ft annually.

The ROI of Real Maintenance

A $500 maintenance visit that catches a developing seam failure prevents it from becoming a $5,000 interior damage event. Kept drains prevent ponding that accelerates coating wear. Documented maintenance records protect warranty claims. The math strongly favors maintenance for roofs under active warranty.

What Suspicious Maintenance Looks Like

A "maintenance visit" that takes 30 minutes for a large roof, produces no written report, makes no repairs, and costs $1,000+ is likely not delivering value. Maintenance programs that primarily generate upsell opportunities rather than genuine roof protection are the source of the "rip-off" reputation.

The Bottom Line

Legitimate preventive maintenance is one of the best ROI investments in building ownership. Verify what the maintenance program includes, insist on written reports, and ensure the contractor is doing actual work — not just collecting a fee.

Can You Install Silicone Coating Over a Roof With Fractured Insulation?

Mon, 02 Nov 2020 21:25:12 GMT

Can You Install Silicone Coating Over a Roof With Fractured Insulation?

Fractured or broken insulation beneath a roofing membrane creates an uneven, unstable substrate. Whether silicone coating can go over it depends on the extent and nature of the damage.

What Causes Insulation Fracturing

Roof insulation boards fracture from: foot traffic compression over time, freeze-thaw cycling in cold climates, moisture intrusion causing the board to degrade, and manufacturing defects. Fractured insulation creates a wavy, uneven surface with potential voids beneath the membrane.

Can Silicone Coat Over It?

If the existing membrane is still adhered to the fractured insulation and the surface is reasonably stable (not heaving or creating sharp protrusions), silicone coating can often be applied successfully. The coating bridges minor surface irregularities and creates a uniform waterproof membrane on top.

When It Can't

If fractured insulation has caused the membrane to delaminate or created tent-like separations between the membrane and substrate, coating isn't viable. The air pockets beneath would cause blistering under the coating. These areas require cut-and-replace repair before coating can proceed.

The Assessment Process

A contractor performs a walk test — areas where the roof feels soft or hollow underfoot indicate delaminated membrane over fractured insulation. Core samples confirm the condition beneath. The rule: if the membrane is adhered, coating is viable. If it's separated, repair is required first.

Silicone Coating Over Gravel Roofs: How It Works & Benefits

Wed, 14 Oct 2020 15:15:21 GMT

Silicone Coating Over Gravel Roofs: How It Works & Benefits

Silicone coating cannot go directly over gravel — the gravel must be removed first. But once removed, the existing BUR substrate is an excellent candidate for either silicone coating or spray foam restoration.

Why Gravel Must Be Removed

Gravel prevents coating adhesion — no liquid coating can bond reliably to a surface covered in loose aggregate. Additionally, gravel holds moisture and organic debris that would contaminate the substrate. Gravel removal is a required first step for any BUR restoration.

The Removal Process

Hydro-vacuuming is the preferred method: high-pressure water loosens the gravel while a vacuum system collects it. Cost: $0.50–$1.00/sq ft. After removal, the existing BUR substrate is revealed — in most cases a smooth, adhered surface that is ideal for coating or foam adhesion.

What Goes On After Removal

For smooth BUR after gravel removal: silicone coating can be applied directly over the substrate, creating a new waterproof membrane with a 10–20-year warranty. For textured or irregular BUR substrates: spray foam is the preferred approach, filling in surface irregularities and creating a level surface for the topcoat.

Benefits of Restoration vs. Replacement

BUR replacement costs $8–$14/sq ft. Gravel removal plus restoration costs $4–$7/sq ft total — roughly half the replacement cost, with equivalent or better waterproofing performance from a seamless restored surface.

How to Locate a Roof Coatings Contractor

Thu, 08 Oct 2020 14:54:00 GMT

How to Locate a Roof Coatings Contractor

Not all roofing contractors are qualified to install manufacturer-warranted coating systems. Here's how to find and vet the right one.

Start With Manufacturer Directories

The most reliable starting point is contacting coating manufacturers directly — companies like Polyglass, GAF, and others maintain directories of approved applicators by region. These contractors have completed the required training and are authorized to purchase materials and issue manufacturer warranties. This filters out unqualified contractors before you even make a call.

Verify Approval Directly

Any contractor claiming manufacturer approval should be verifiable. Call the manufacturer, provide the contractor's name, and confirm they are currently approved. Approvals can lapse — verify current status, not historical status.

Check References on Similar Projects

Ask for references specifically on commercial coating projects similar to yours in scale. Call the references. Ask: Did the crew show up when scheduled? Was the work completed on time and on budget? Have there been any leaks since installation? Would you hire them again?

Insist on Written Proposals

A qualified coating contractor provides a detailed written proposal specifying: the exact products being used (manufacturer and product name), application thickness in mils, warranty terms and duration, scope of surface preparation included, and wet insulation removal procedure.

Red Flag: No Manufacturer Warranty Offered

If a contractor proposes a coating system but only offers a "workmanship warranty" rather than a manufacturer warranty, they are either not manufacturer-approved or are using non-approved products. Insist on a manufacturer-backed warranty as a non-negotiable requirement.

2 Types of Seamless Roofing Systems for Commercial Buildings

Fri, 02 Oct 2020 20:15:24 GMT

2 Types of Seamless Roofing Systems for Commercial Buildings

Seamless commercial roofing systems eliminate the #1 cause of leaks — seam failures. There are two primary types, each suited to different applications.

1. Silicone Coating Systems

A silicone coating system is applied as a liquid directly over the existing roofing membrane, curing to a continuous seamless film. Applied at 20–30 mils over TPO, EPDM, metal, or modified bitumen, it creates a new waterproof surface that seals all underlying seams under a continuous film. Cost: $2–$5/sq ft. Best for: membranes in acceptable condition that primarily need seam sealing and warranty renewal. Limitations: doesn't add insulation or correct slope.

2. Spray Polyurethane Foam (SPF)

Spray foam is applied as a two-component liquid that expands and cures into a rigid, seamless structure that adheres directly to the substrate. Applied at 1.5–4+ inches, it creates an insulating, self-flashing, seamless waterproof surface. Cost: $4–$8/sq ft. Best for: roofs needing slope correction, insulation improvement, BUR restoration after gravel removal, or any situation where the substrate has complex geometry or drainage issues.

Key Differences

Silicone is thinner, lower cost, and goes over existing membranes. Spray foam is thicker, adds insulation, and handles slope and drainage issues. Both eliminate seams entirely and come with renewable 10–20-year manufacturer warranties.

How to Choose

If your roof is flat with adequate drainage and primarily needs waterproofing: silicone. If you need slope correction, insulation, or are dealing with a BUR after gravel removal: spray foam.

3 Different Types of Roofing Companies

Mon, 21 Sep 2020 18:30:25 GMT

3 Different Types of Roofing Companies

When shopping for a commercial roofing contractor, understanding the three types of companies helps you find the right fit for your project.

Type 1: General Commercial Roofing Contractors

These contractors install and replace standard commercial roofing systems — TPO, EPDM, modified bitumen, metal. They typically focus on new construction and full replacements. They may or may not offer coating restoration systems. If replacement is genuinely necessary, a qualified general commercial contractor is appropriate. Be cautious of contractors in this category who recommend replacement without thoroughly exploring restoration alternatives.

Type 2: Spray Foam Roofing Specialists

These contractors specialize in spray polyurethane foam application. They have the specialized equipment, training, and manufacturer approvals required for quality foam work. They typically also apply silicone coating systems. For restoration projects involving foam, this category of contractor is the most qualified. West Roofing Systems is a specialized spray foam and coating contractor with over 45 years in the field.

Type 3: Coating-Only Contractors

Some contractors specialize exclusively in liquid-applied coating systems (silicone, acrylic) without offering spray foam. For roofs that qualify for coating restoration only, these contractors can be appropriate. Verify manufacturer approval and experience with your specific substrate type.

Who to Choose

For restoration projects: seek a Type 2 or Type 3 specialist who is manufacturer-approved. For replacement: a qualified Type 1 contractor. Get at least two quotes from different contractor types and compare both the proposed solution and the cost — not just the number.

3 Reasons Why Nobody Knows About Spray Foam Roofing

Thu, 10 Sep 2020 15:14:57 GMT

3 Reasons Why Nobody Knows About Spray Foam Roofing

Spray polyurethane foam roofing has been in commercial use since 1979, yet many building owners have never heard of it. Here are the 3 main reasons.

1. It's Not Sold by Most Roofing Contractors

The vast majority of commercial roofing contractors install sheet membranes — TPO, EPDM, modified bitumen. These are familiar systems with established supply chains, and they're what most contractors know how to install. Spray foam requires specialized equipment, training, and manufacturer approval that most general roofing contractors don't have. So most building owners never hear about it because their usual contractors don't offer it.

2. It Competes with Higher-Dollar Work

A spray foam restoration at $4–$8/sq ft directly competes with a full replacement at $7–$14/sq ft. For contractors who prefer the higher-dollar replacement job, there's no incentive to mention the restoration alternative. This financial dynamic keeps many building owners unaware that a more cost-effective option exists.

3. Limited Marketing vs. Big Manufacturers

TPO and EPDM are products of large manufacturers with significant marketing budgets. They actively promote their products and train general contractors. Spray foam roofing, while superior in many applications, is supplied by a smaller set of specialized manufacturers who market primarily to approved applicators rather than directly to building owners.

Why This Is Changing

As building owners do more online research, compare options independently, and prioritize long-term value over lowest upfront cost, spray foam is gaining recognition. The sustainable advantages — zero waste, renewable warranty, energy savings — also resonate with modern building ownership priorities.

The Easiest Way to Extend the Life of Your Commercial Roof

Mon, 10 Aug 2020 19:52:24 GMT

The Easiest Way to Extend the Life of Your Commercial Roof

If you want to maximize your commercial roof's life at minimum cost, there's one approach that consistently outperforms all others: preventive maintenance plus timely coating restoration.

Step 1: Annual Inspections

The single most impactful action is regular inspection — catching developing issues before they become expensive problems. A twice-annual inspection that identifies and repairs minor seam separations, flashing issues, and drain blockages costs very little and prevents the moisture infiltration that cuts roofing system life short.

Step 2: Coat Before the Warranty Expires

The most common and costly mistake building owners make is waiting until after the warranty expires — by which point seam failures are active and moisture infiltration has begun. A silicone coating restoration performed while the roof is still in acceptable condition (under 25% wet insulation) is dramatically less expensive than one performed after the roof has deteriorated further.

Step 3: Follow the Recoat Schedule

For foam roofs already under a coating warranty, following the recoat schedule at warranty end is the most cost-effective way to maintain the system. Missing the recoat window leads to UV foam degradation that requires more expensive remediation before a fresh topcoat can be applied.

The Math

A well-maintained commercial roof that receives timely coating restoration when eligible can last 40+ years at dramatically lower lifecycle cost than a roof that cycles through full replacements every 20 years. Maintenance and timely restoration are the two most powerful tools a building owner has.

Can You Spray Foam Over an Existing Leaky Roof?

Thu, 06 Aug 2020 13:43:18 GMT

Can You Spray Foam Over an Existing Leaky Roof?

Yes — spray foam can be applied over an existing leaky roof, and in many cases it's the most permanent solution available. But two conditions must be met first.

Condition 1: Wet Insulation Must Be Removed

This is non-negotiable. Any insulation beneath the membrane that has been saturated with water must be removed and replaced with dry insulation before foam can be applied. Foaming over wet insulation causes blistering, poor adhesion, and continued leaks. The wet areas are identified through core samples and/or infrared scanning, then cut out and replaced before foam application proceeds.

Condition 2: The Substrate Must Be Structurally Sound

The existing roof substrate — whether it's TPO, EPDM, metal, or BUR — must be structurally intact enough to support foam adhesion. Extensive delamination or structural failure of the substrate may prevent foam from bonding properly. A professional assessment determines substrate condition.

What Happens When Both Conditions Are Met

Once wet insulation is replaced and the substrate is confirmed sound, spray foam is applied over the entire existing roof. The foam bonds to every surface, fills every crack and seam, and creates a completely seamless waterproof membrane in a single application — permanently sealing every existing leak point simultaneously.

Why This Is Better Than Repairs

Repairing individual leaks on an aging roof is a recurring battle. Foam restoration addresses every failure point at once, eliminating both existing leaks and future seam failure risk. For roofs with chronic, hard-to-locate leaks, foam restoration is often the definitive solution.

5 Problems With Single-Ply Roofing Systems

Thu, 30 Jul 2020 17:21:49 GMT

5 Problems With Single-Ply Roofing Systems

TPO and EPDM single-ply membranes are among the most common commercial roofing systems installed today. They're cost-effective and perform well when new — but here are 5 problems building owners frequently encounter.

1. Seam Failure Is Inevitable

Every single-ply system relies on seams — heat-welded (TPO) or adhesive-bonded (EPDM). Daily thermal cycling gradually stresses these seams, and over 10–20 years, seam adhesion fails. Since seams are the #1 cause of commercial roof leaks, aging single-ply systems eventually leak at predictable locations.

2. No Insulation Value Added

Single-ply membranes provide essentially no insulation value (R-0 for the membrane itself). A building with inadequate roof insulation before TPO installation will have the same insulation problem after installation.

3. End-of-Warranty = Full Replacement

Unlike spray foam systems, single-ply warranties cannot be renewed with a simple recoat. At end of warranty, the system typically requires full tear-off and replacement — another $7–$12/sq ft investment.

4. Susceptible to Wind Uplift at Edges

Mechanically fastened single-ply systems have attachment points that create thermal bridging and potential wind uplift vulnerabilities at the fastener locations and perimeter edges.

5. Difficult to Seal Complex Penetrations

Every HVAC unit, pipe, and skylight penetration requires custom-fabricated boots and terminations — each a potential failure point. On roofs with many penetrations, the seam count multiplies accordingly.

How Is a Spray Foam Roof Renewable?

Mon, 27 Jul 2020 13:33:30 GMT

How Is a Spray Foam Roof Renewable?

Spray foam roofing is described as renewable — but what does that actually mean in practice? Here's the complete explanation.

What "Renewable" Means

A renewable roofing system is one that can be brought back to warranted condition without removing the existing system. For spray foam, this means: at the end of the warranty period, the foam substrate remains in place and only the topcoat is renewed — providing a new manufacturer's warranty without any tear-off, replacement materials, or new foam installation.

The Renewal Process

When a spray foam roof warranty expires, the renewal process is: power-wash the surface to remove dirt and biological growth, inspect the foam and topcoat condition, perform any spot repairs needed, apply a fresh layer of silicone or acrylic topcoat at the required mil thickness for the new warranty period. The manufacturer then issues a new 10–20-year warranty.

The Cost of Renewal

Topcoat renewal costs approximately $1–$2/sq ft — a fraction of the original installation cost and a small fraction of what any other system's "renewal" (full replacement) would cost.

Infinite Renewability

This process can repeat indefinitely — there is no theoretical limit to how many times a spray foam roof can be renewed. The foam substrate, once properly installed, is permanent. Only the protective topcoat needs periodic renewal. This is what makes spray foam fundamentally different from every other commercial roofing system.

The Lifecycle Cost Implication

Over a 40-year period: two topcoat renewals at $1–$2/sq ft each = $2–$4/sq ft total. Two TPO replacement cycles at $7–$12/sq ft each = $14–$24/sq ft total. The difference is extraordinary.

Single-Ply vs Spray Foam: Which Roof Costs Less?

Wed, 22 Jul 2020 17:02:56 GMT

Single-Ply vs Spray Foam: Which Roof Costs Less?

Upfront: single-ply may be less expensive. Over time: spray foam almost always costs less. Here's the complete picture.

Upfront Cost Comparison

New TPO installation: $5–$9/sq ft. New EPDM installation: $5–$8/sq ft. Spray foam restoration over existing roof: $4–$8/sq ft. For restoration projects, spray foam is often comparable to or less than single-ply replacement upfront — while also preserving the existing substrate and avoiding tear-off costs.

20-Year Cost

At year 20: Single-ply typically requires full replacement again ($7–$12/sq ft). Spray foam: recoat at $1–$2/sq ft. For a 50,000 sq ft roof over 20 years, that difference is $350,000–$600,000 vs. $50,000–$100,000 in ongoing costs.

40-Year Cost

Two full single-ply replacement cycles: $14–$24/sq ft cumulative. Two spray foam topcoat renewals: $2–$4/sq ft cumulative. The 40-year cost difference for a medium commercial roof can easily exceed $500,000 in favor of foam.

Energy Savings

Spray foam adds R-6.5 per inch — single-ply adds R-0. For buildings with inadequate roof insulation, the energy savings from foam can generate a compelling payback period of 5–10 years on the insulation premium, making foam cheaper even on a short time horizon in some applications.

How Fast Can a Spray Foam Roof Be Completed?

Mon, 20 Jul 2020 14:55:48 GMT

How Fast Can a Spray Foam Roof Be Completed?

Spray foam roofing is one of the fastest commercial roofing systems to install. Here's what determines completion speed.

Production Rates

A standard two-person spray foam crew with professional equipment typically applies 3,000–7,000 sq ft of foam per day depending on roof complexity, ambient conditions, and required foam thickness. Adding a second crew or using robotic equipment can double or triple this rate — West Roofing Systems' MTD facility project applied 384,000 sq ft in 52 days using robotic application (approximately 7,384 sq ft/day).

Topcoat Application

Silicone topcoat application typically follows foam at a rate of 10,000–20,000+ sq ft per day depending on crew size and equipment. For most commercial projects, topcoat is the faster phase.

What Slows Projects Down

Weather is the primary constraint. Spray foam requires: ambient temperature above 40°F (and rising), relative humidity below 85%, and wind speeds low enough to prevent overspray (typically under 15–20 mph). Wet insulation removal and replacement adds time proportional to the affected area.

Compared to Single-Ply Replacement

Foam restoration is significantly faster than single-ply replacement because there's no tear-off phase — the slowest, most weather-sensitive part of any replacement project. For a 50,000 sq ft roof, foam restoration typically completes in 1–2 weeks. Full replacement with tear-off often takes 3–5 weeks or longer.

Spray Foam Scarfing: What It Is and Why It Matters

Fri, 17 Jul 2020 13:07:54 GMT

Spray Foam Scarfing: What It Is and Why It Matters

Scarfing is a quality control process unique to spray polyurethane foam roofing. Understanding it helps building owners verify they're getting a quality installation.

What Is Scarfing?

After spray foam is applied and cured, scarfing involves cutting or grinding the foam surface to remove the outer "skin" layer — the outermost 1/8 to 1/4 inch of foam that formed when the foam was in contact with air during curing. This outer layer has a different cell structure than the interior foam and can affect topcoat adhesion if not removed in some applications.

Why Scarfing Is Performed

The outer skin of spray foam is typically glossy and less porous than the foam interior. Some coating systems require scarfing to ensure proper mechanical adhesion of the topcoat to the foam. When the surface has been contaminated by dew, rain, or extended cure time, scarfing removes the compromised surface and exposes fresh foam for topcoat bonding.

When Scarfing Is Required

Not all foam installations require scarfing — it depends on the specific foam product, topcoat system, and application conditions. Manufacturer specifications define when scarfing is required. A qualified contractor follows manufacturer guidelines and performs scarfing when specified.

What It Reveals About Installation Quality

A contractor who understands and properly performs scarfing when required demonstrates adherence to manufacturer specifications. This attention to detail is a positive indicator of overall installation quality.

Can a Spray Foam Roof Get Holes or Punctures?

Wed, 15 Jul 2020 12:59:39 GMT

Can a Spray Foam Roof Get Holes or Punctures?

Yes — spray foam roofs can be punctured by mechanical damage. But they're more resistant than you might expect, and repairs are straightforward when they occur.

How Durable Is Spray Foam?

Closed-cell spray foam has compressive strength of 25–60 PSI — it can support significant weight without permanent deformation. Normal foot traffic doesn't damage it. However, sharp tools, falling objects, or concentrated impact forces can puncture through the foam and topcoat.

Common Puncture Sources

The most common sources of mechanical damage on foam roofs are: HVAC equipment installation or removal (tools dropped on the roof), foot traffic in non-walk-pad areas over time, hail (though foam absorbs impact well, severe hail can penetrate the topcoat), and construction activity on the roof for other trades.

How Serious Is a Puncture?

A topcoat puncture that doesn't penetrate into the foam is a minor concern — the silicone remains essentially waterproof even with surface damage. A puncture that exposes foam requires timely repair to prevent UV degradation of the exposed foam. Neither is an emergency, but both should be addressed during the next inspection.

How Easy Are Repairs?

Foam roof repairs are simple and inexpensive. Clean the area, apply compatible sealant or patch coating over the damaged area, and the repair is complete. Most repairs take minutes and cost very little. This is significantly simpler than repairing punctures in sheet membrane systems, which often require heat welding and precise technique.

Spray Foam Roofing 101: 6 Basics You Need to Know

Thu, 25 Jun 2020 08:53:25 GMT

Spray Foam Roofing 101: 6 Basics You Need to Know

If you're encountering spray foam roofing for the first time, here are the 6 fundamental things you need to understand.

1. It Goes Over Existing Roofs

Spray foam is applied directly over most existing commercial roofing systems without tear-off. This alone makes it significantly less expensive and disruptive than replacement.

2. It Always Needs a Protective Topcoat

Foam degrades rapidly when exposed to UV radiation. Every foam roof requires a silicone or acrylic topcoat applied immediately after the foam to protect it.

3. It Provides Real Insulation

At R-6.5 per inch, spray foam provides the highest insulation value of any roofing material — significantly improving building energy efficiency.

4. It Creates a Seamless Surface

Unlike sheet membranes, foam creates a monolithic, seamless surface with no joints, laps, or attachment points that can fail and leak.

5. The Warranty Is Renewable

At warranty end (10–20 years), a fresh topcoat renews the warranty without removing the foam. This renewable cycle can continue indefinitely.

6. Contractor Quality Is Critical

Spray foam installation requires specialized equipment and training. Only manufacturer-approved applicators should be used. A poorly installed foam roof is difficult and expensive to correct. Verify manufacturer approval before hiring any contractor.

The Best Roof for a Cold Storage Facility

Tue, 16 Jun 2020 14:42:48 GMT

The Best Roof for a Cold Storage Facility

Cold storage facilities present extreme roofing challenges that most standard roofing systems handle poorly. Here's what works best.

The Challenges

Cold storage roofs face: extreme temperature differentials between interior and exterior (creating significant thermal stress), condensation risk at roof penetrations and transitions, very high insulation requirements to maintain temperature-controlled environments, and the catastrophic cost of any moisture infiltration that compromises insulation value.

Why Spray Foam Is Ideal

Spray foam addresses cold storage challenges better than any other roofing system. Closed-cell foam is both an excellent insulator AND a vapor barrier — the combination that cold storage roofs require. Applied at 3–4 inches, foam provides R-19 to R-26 in a single installation. As a seamless system, it eliminates every condensation-prone transition and penetration in one application. And its flexibility across temperature extremes means it handles the significant thermal cycling cold storage roofs experience without cracking or delaminating.

Vapor Barrier Significance

Standard roofing systems require a separate vapor barrier installation to prevent moisture infiltration in cold storage applications. Closed-cell foam provides vapor barrier performance as part of the roofing system — eliminating a separate installation step and its associated seams and failure points.

Cost Justification

For cold storage, the energy cost savings from high-performance insulation typically justify the foam premium within a few years. Failed roof insulation in a cold storage facility creates both energy and product spoilage costs that dwarf any roof investment.

The Dangers of Off-Ratio Spray Foam for Commercial Roofing

Fri, 12 Jun 2020 14:25:49 GMT

The Dangers of Off-Ratio Spray Foam for Commercial Roofing

Off-ratio foam is the most serious quality problem in spray foam roofing. Here's what it means, why it's dangerous, and how to prevent it.

What Is Off-Ratio Foam?

Spray polyurethane foam is a two-component system that must be mixed in precise ratios (typically 1:1 by volume) for the chemical reaction to proceed correctly. When the mixing ratio deviates — due to equipment malfunction, improper calibration, temperature problems, or operator error — the resulting foam is "off-ratio." Off-ratio foam doesn't cure to proper density or strength.

What Off-Ratio Foam Looks Like

Off-ratio foam typically appears: softer and more friable than properly-cured foam, discolored (may appear orange, brown, or unusual color instead of cream/yellow), with a rough or irregular surface texture, and with poor adhesion to the substrate. It may also be brittle or crumble when touched.

The Performance Consequences

Off-ratio foam: doesn't achieve proper compressive strength (poor foot traffic resistance), has inadequate adhesion to the substrate (may delaminate), doesn't achieve design R-value, and provides poor topcoat adhesion. In severe cases, off-ratio foam may need to be completely removed and re-installed — a very expensive remediation.

How to Protect Yourself

Only use manufacturer-approved contractors with properly maintained, calibrated equipment. Insist on third-party inspection at project completion. If foam looks wrong during installation — unusual color, texture, or softness — stop the project and have the foam tested before proceeding.

Spray Foam Roofs: How Thick Should They Really Be?

Mon, 01 Jun 2020 18:57:03 GMT

Spray Foam Roofs: How Thick Should They Really Be?

Spray foam thickness affects R-value, warranty options, structural performance, and cost. Here's how to think about the right thickness for your application.

Minimum Thickness

For waterproofing and warranty purposes, most manufacturers require a minimum of 1.5 inches of closed-cell foam. Below this threshold, the foam system typically doesn't qualify for a manufacturer warranty. At 1.5 inches, foam provides approximately R-10 and meets minimum performance requirements.

Standard Restoration Thickness: 1.5–2 Inches

The most common commercial restoration application is 1.5–2 inches of foam, providing R-10 to R-13 and qualifying for a 10–20-year warranty depending on topcoat thickness. This is the most cost-effective entry point for foam restoration.

When More Thickness Makes Sense

3–4 inches makes sense when: significant insulation improvement is the primary goal, the building is in a cold climate and approaching new construction R-value requirements, cold storage or extreme climate control is required, or slope correction requires additional thickness in low areas.

Slope Correction Thickness

In areas requiring slope correction, foam may be applied at 3–6+ inches in the lowest points, tapering to the minimum thickness at high points. The designer specifies thickness profiles to achieve the desired drainage pattern.

The Cost-Thickness Relationship

Each additional inch of foam adds approximately $1.00–$1.50/sq ft to project cost. The insulation improvement per inch (R-6.5) needs to justify this premium based on your building's energy usage and climate.

What R-Value Do You Need for a Commercial Roof? (Complete Guide)

Wed, 27 May 2020 13:28:06 GMT

What R-Value Do You Need for a Commercial Roof? (Complete Guide)

Roof R-value requirements depend on your climate zone, building type, and whether you're doing new construction or a restoration. Here's a complete guide.

ASHRAE Climate Zones

The US is divided into climate zones (1–8) by ASHRAE, with higher numbers indicating colder climates. R-value requirements increase with zone number. Ohio, Pennsylvania, and similar mid-Atlantic/Midwest states fall in Zone 5, which requires R-30 for new commercial roof construction.

New Construction vs. Restoration

New construction triggers building code compliance, which may require minimum R-values. Restoration (coating over existing roofing) typically does not trigger new construction codes in most jurisdictions — meaning a restoration project avoids the minimum R-value requirements that a tear-off would trigger.

Existing Building Insulation Assessment

If your existing commercial roof has inadequate insulation (common in buildings with older roofing systems), foam restoration can significantly improve R-value. At 2 inches, foam adds R-13 — a meaningful improvement over the near-zero value of most membrane-only systems.

Optimal vs. Minimum

Code compliance establishes minimum R-values, but optimal R-value for energy efficiency may be higher. For buildings with high HVAC costs, calculating the energy savings from additional foam thickness vs. the installation cost premium helps identify the optimal investment point.

Getting it Right

Work with a qualified spray foam contractor who understands both code requirements and energy optimization. The right thickness for your building depends on climate, building use, existing insulation, and ownership timeline goals.

Spray Foam Roofing for Apartment Complexes: Pros and Cons

Mon, 18 May 2020 14:01:11 GMT

Spray Foam Roofing for Apartment Complexes: Pros and Cons

Apartment complexes present specific roofing challenges — occupied units below, multiple roofs, HOA or ownership dynamics, and the need to minimize disruption to residents. Here's an honest assessment of spray foam for this application.

The Pros

Minimal disruption to residents: No tear-off means no weather exposure risk for units below, no significant noise from demolition, and faster completion. Energy savings for residents: improved insulation reduces heating and cooling costs for the units below — a benefit that can be passed on or retained as improved property value. Seamless waterproofing: eliminates the seam failures that are the #1 cause of leaks and water damage complaints in apartment buildings. Renewable warranty: eliminates the large capital expenditure of periodic full replacement — predictable smaller recoat costs instead.

The Cons

Overspray concern: On wind-prone days, foam application can create overspray risk for resident vehicles or adjacent property. Professional crews manage this with screening and scheduling, but it requires communication with residents. Odor during application: Foam does have a chemical odor during application. It dissipates quickly but can temporarily affect occupied units on upper floors if windows are open.

The Bottom Line for Apartment Complexes

For apartment complexes with flat roofs, spray foam restoration is often the best option — particularly when multiple roof sections need attention simultaneously. The combination of minimal disruption, energy improvement, and renewable warranty makes it well-suited to the multi-unit residential context.

4 Ways a Cool Roof Benefits an Industrial Building

Fri, 15 May 2020 20:09:47 GMT

4 Ways a Cool Roof Benefits an Industrial Building

A "cool roof" is one with high solar reflectance — it reflects sunlight rather than absorbing it. For industrial buildings with large flat roof areas, the benefits are substantial.

1. Reduced Cooling Costs

Industrial buildings typically have large, poorly insulated roof areas exposed to direct sun. A conventional dark roof can reach 180°F on a hot day, transferring significant heat load into the building interior. A cool roof (85%+ solar reflectance) may stay at 90–100°F under the same conditions — dramatically reducing HVAC load and cooling costs. For a large industrial building, this can translate to thousands of dollars in annual energy savings.

2. Extended Equipment Life

Lower roof surface temperatures reduce thermal stress on roofing materials, HVAC equipment, and any exposed mechanical systems on the roof. Equipment that runs less hard and experiences less thermal cycling lasts longer.

3. Improved Worker Comfort

In industrial buildings where workers operate near or under the roof, lower ceiling temperatures from reduced heat transfer directly improve comfort and productivity — particularly in facilities without full air conditioning.

4. Energy Code Compliance

Many jurisdictions now require minimum solar reflectance values for commercial and industrial roofs. High-solids silicone coatings (85%+ reflectance) easily meet these requirements, often satisfying compliance obligations while simultaneously restoring an aging roof under a new warranty.

What Commercial Roof Types Can Spray Foam Be Installed Over?

Wed, 13 May 2020 12:11:33 GMT

What Commercial Roof Types Can Spray Foam Be Installed Over?

Spray foam is compatible with a remarkably wide range of commercial roofing substrates. Here's a complete list of what it can go over and what to watch out for.

TPO and PVC

Spray foam bonds well to TPO and PVC after thorough cleaning and priming. Some manufacturers require specific primers for these substrates. Verify manufacturer specifications for the specific foam and topcoat combination being used.

EPDM (Rubber)

Foam adheres to EPDM membranes with proper preparation and primer. EPDM's smooth surface typically requires primer for adequate chemical adhesion.

Metal Roofing

Metal is one of the best substrates for foam — foam bonds chemically to metal and mechanically fills corrugations, fastener holes, and seams. Rust treatment and primer may be required for heavily oxidized metal.

Gravel Built-Up Roof (BUR)

Foam can go over BUR — but gravel must be removed first via hydro-vacuuming. The existing BUR substrate after gravel removal provides an excellent bonding surface.

Modified Bitumen

Both smooth and granulated modified bitumen can receive foam, though the specific preparation requirements vary. Smooth mod-bit is generally a better substrate than granulated.

Existing Spray Foam

New foam can be applied over existing foam — this is how recoat projects work when topcoat replacement alone isn't sufficient.

What Foam Cannot Go Over

Surfaces with more than 25% wet insulation beneath them require wet insulation removal before foam is applied. Severely delaminated membranes may not provide adequate adhesion. These situations require targeted repair before foam installation.

Good vs Bad Spray Foam Roofing Contractors: 5 Differences

Fri, 08 May 2020 20:22:42 GMT

Good vs Bad Spray Foam Roofing Contractors: 5 Differences

The quality of a spray foam installation depends almost entirely on the contractor. Here are 5 specific differences between good and bad contractors.

1. Manufacturer Approval

Good: Manufacturer-approved, verifiable by calling the manufacturer directly, uses approved products, can issue manufacturer warranties. Bad: Not manufacturer-approved, offers only contractor warranties that expire with the business, may use non-approved products.

2. Equipment Quality

Good: Professional plural-component proportioning equipment, properly maintained and calibrated, capable of precise ratio and temperature control. Bad: Undersized, poorly maintained equipment unable to maintain proper mixing ratios — a primary cause of off-ratio foam.

3. Core Sampling Before Work

Good: Performs core samples before any proposal to verify wet insulation levels, provides objective data before recommending a solution. Bad: Makes recommendations based on visual inspection only, may skip this step entirely to save time.

4. Wet Insulation Handling

Good: Explicitly addresses wet insulation in the proposal, includes removal and replacement as a line item, won't foam over wet areas. Bad: Doesn't mention wet insulation, may coat or foam over wet areas to reduce cost — leading to blistering and system failure.

5. Third-Party Inspection

Good: Welcomes and facilitates third-party inspection at project completion for warranty issuance. Bad: Resistant to independent inspection, unable to provide manufacturer warranty documentation.

Why Spray Foam Roofs Need 2 Layers of Coating

Wed, 06 May 2020 10:50:23 GMT

Why Spray Foam Roofs Need 2 Layers of Coating

Most spray foam roofing systems require two separate coat applications to achieve required mil thickness and warranty compliance. Here's why.

The Mil Thickness Requirement

Manufacturer warranties specify minimum coating thickness — typically 20 mils for a 10-year warranty or 30 mils for a 20-year warranty. A single coat of silicone typically delivers 10–15 mils wet film, which cures to approximately 10 mils dry film depending on the specific product. Two coats are needed to reach the required dry film thickness for most warranty tiers.

Why Not One Thick Coat?

Applying one very thick coat doesn't work the same way as two thinner coats. An overly thick single application can: trap solvents that cause blistering as they evaporate, cure unevenly, and result in inconsistent film thickness. Manufacturer specifications define the maximum recommended application rate per coat — and two coats staying within that spec is more reliable than one oversized coat.

The Two-Coat Process

Coat 1 is applied at the specified application rate and allowed to cure. Coat 2 is applied after Coat 1 has cured sufficiently. The total dry film thickness of both coats combined determines the warranty tier. Third-party inspectors verify total mil thickness before issuing the warranty.

Granule Broadcast

On foam roofs with foot traffic areas, granules are typically broadcast into the wet second coat — becoming embedded in the cured film to provide traction and additional wear resistance.

How Does an Infrared Inspection Work on a Commercial Roof?

Fri, 01 May 2020 16:27:52 GMT

How Does an Infrared Inspection Work on a Commercial Roof?

Infrared (thermal) scanning is one of the most valuable diagnostic tools for commercial roofing. Here's how it works and why it matters.

The Physics Behind It

Water has a much higher heat capacity than dry insulation. During the day, the entire roof absorbs solar heat. After sunset, dry insulation cools quickly while areas containing moisture retain heat longer. An infrared camera detects these temperature differences — wet areas appear as warm spots on the thermal image while surrounding dry areas appear cooler.

When to Perform the Scan

Infrared scans must be performed at dusk (1–2 hours after sunset) on a clear day following several hours of sunshine. The contrast between wet and dry areas is greatest in this window. Cloudy days, recent rain, or wind can reduce the temperature differential and compromise scan accuracy.

What the Scan Reveals

The infrared scan maps wet insulation locations across the entire roof — not just where leaks are visible inside. This gives a complete picture of moisture infiltration that core samples alone might miss, particularly on large roofs where comprehensive core sampling isn't practical.

Limitations

Infrared scanning identifies wet insulation by temperature differential — but it doesn't distinguish between slightly damp and fully saturated insulation. Core samples are still needed to confirm moisture extent and severity in areas identified by the scan. The combination of infrared mapping plus targeted core samples provides the most complete picture of roof condition.

Emergency Roof Leaks: Why Spray Foam Is the Quickest Solution

Thu, 30 Apr 2020 20:38:55 GMT

Emergency Roof Leaks: Why Spray Foam Is the Quickest Solution

An active commercial roof leak requires immediate action — and for many situations, spray foam provides the fastest path from emergency to permanent solution.

The Emergency Response

First priority: stop active water infiltration. Apply compatible lap sealant, temporary patches, or tarping to stop the immediate leak while a permanent solution is planned. Document damage for insurance purposes.

Why Foam Is Often the Fastest Permanent Fix

Traditional permanent repairs require locating every breach (difficult on seamed systems where water travels), patching individual failures, and hoping no others develop. For roofs with multiple leaks or widespread seam failures, this cycle can repeat indefinitely. Spray foam eliminates this by covering the entire roof in one application — every existing breach sealed simultaneously.

Speed Advantages of Foam Restoration

No tear-off means foam can begin as soon as dry insulation is confirmed and weather conditions permit. Application rates of 3,000–7,000 sq ft/day mean even large commercial roofs can be completed in days. No seam welding cure times or adhesive set times — foam is a single-pass application. For buildings that genuinely cannot tolerate continued leaks, foam's speed from "roof not fixed" to "roof fixed permanently" is often its most compelling advantage.

The One Caveat

Wet insulation from the leak must be identified and replaced before foam is applied. Acting quickly after a leak event minimizes wet insulation extent — another reason not to delay after discovering a leak.

What Are the Restrictions for a Spray Foam Roofing Installation?

Thu, 23 Apr 2020 17:49:12 GMT

What Are the Restrictions for a Spray Foam Roofing Installation?

Spray foam roofing has specific installation restrictions that qualified contractors follow to ensure proper curing and performance. Here's what they are.

Temperature Restrictions

Ambient temperature must be above 40°F and rising at the time of application. Cold temperatures slow the chemical reaction and can result in off-ratio foam. Application in very hot conditions (above 90°F) can also affect performance — work is typically scheduled for morning hours in extreme heat.

Humidity Restrictions

Relative humidity must generally be below 85% at the time of application. High humidity affects the foam reaction and can result in blistering or poor surface quality. Dew point must also be considered — if the substrate temperature is near the dew point, condensation on the surface will compromise adhesion.

Wind Restrictions

Wind is the most operationally challenging restriction. Foam overspray is a real concern — lightweight foam droplets can travel significant distances in wind and deposit on vehicles, windows, and adjacent property. Most contractors restrict application to wind speeds below 15–20 mph, using wind screens and scheduling around calm weather windows.

Substrate Restrictions

The substrate must be clean, dry, and free of frost, dew, or standing water at the time of application. Wet insulation beneath the membrane must be removed. Delaminated membrane sections require repair before foam can be applied over them.

Why These Restrictions Matter

A qualified contractor monitors all of these conditions and won't apply foam when they're not met — even if it means delaying the project. Cutting corners on application conditions is a primary cause of off-ratio foam and system failures.

Common Spray Foam Roofing Warranty Questions (Answered)

Wed, 22 Apr 2020 12:58:09 GMT

Common Spray Foam Roofing Warranty Questions (Answered)

Spray foam roofing warranties work differently from other commercial systems. Here are the most common questions answered directly.

Who issues the warranty — the contractor or manufacturer?

Both typically provide coverage. The manufacturer issues a warranty covering materials and system performance. The contractor may provide a separate workmanship warranty. Manufacturer warranties are more valuable — they remain valid even if the installing contractor goes out of business.

What does the warranty cover?

Manufacturer warranties cover waterproofing performance of the system when installed according to specifications. They typically cover material defects and system failure due to normal service conditions. They generally don't cover damage from intentional acts, unusual mechanical damage, or failure to maintain the recoat schedule.

What are the warranty terms — 10, 15, or 20 years?

The warranty term is determined by topcoat thickness applied: typically 20 mils for 10 years, 25 mils for 15 years, and 30+ mils for 20 years. You choose the warranty term by specifying the coating thickness in the project scope.

How is the warranty renewed?

At warranty end, inspect and clean the roof, perform any spot repairs, apply fresh topcoat at the required mil thickness, and the manufacturer issues a new warranty. The foam substrate remains in place indefinitely.

Does the warranty require maintenance?

Yes — most manufacturer warranties require documented semi-annual inspections and prompt repair of any mechanical damage. Failure to maintain the roof per warranty requirements can void coverage. Keep maintenance records throughout the warranty period.

What Is a Temporary Roof Repair? (Cost & Process)

Mon, 20 Apr 2020 18:53:23 GMT

What Is a Temporary Roof Repair? (Cost & Process)

A temporary roof repair stops active water infiltration while a permanent solution is planned and scheduled. Here's what it involves and what to expect.

What Temporary Repairs Include

Temporary repairs vary by situation but typically include: applying compatible lap sealant or mastic over failed seams or cracks, installing reinforced fabric patches over punctures or tears, applying tarps or temporary waterproofing membrane over large problem areas, and clearing blocked drains causing ponding. The goal is to stop active leaks — not to provide long-term performance.

Cost of Temporary Repairs

Simple sealant applications: $200–$800. Larger temporary patches: $500–$2,500. Emergency tarping on a large roof: $1,000–$5,000+. These costs are often covered by building insurance when the leak was caused by a covered event (hail, storm damage, etc.). Document the damage before temporary repairs for insurance purposes.

Limitations

Temporary repairs are not permanent solutions. Sealants crack and lose adhesion. Patches can fail at edges. Tarps blow off in wind. A temporary repair that stops today's leak doesn't address underlying system aging — additional leaks typically appear elsewhere as the system continues to deteriorate.

The Transition to Permanent Solution

Schedule a professional inspection with core samples as soon as possible after a temporary repair. The moisture data will determine whether restoration or replacement is the right permanent solution — and acting quickly limits how much wet insulation must be replaced.

Spray Foam Roofing vs Spray Foam Insulation: 4 Differences

Tue, 07 Apr 2020 19:52:47 GMT

Spray Foam Roofing vs Spray Foam Insulation: 4 Differences

Both are spray polyurethane foam, but roofing SPF and insulation SPF are different products designed for different applications. Here are the 4 key differences.

1. Density and Compressive Strength

Roofing SPF: 2.8–3.0 lb/cu ft density, 25–60 PSI compressive strength — designed to support foot traffic, equipment loads, and weather. Insulation SPF (interior walls/attics): 0.5–2.0 lb/cu ft density, lower compressive strength — designed for insulation performance in protected environments, not outdoor exposure.

2. UV Stability

Roofing SPF: formulated to maintain structural integrity during the brief window before topcoat is applied. Still degrades with extended UV exposure — hence the required topcoat. Interior insulation SPF: never exposed to UV — UV stability is not a design criterion.

3. Moisture Resistance

Roofing SPF (closed-cell): water-resistant, low water vapor permeance — serves as both insulation and vapor barrier. Interior open-cell SPF: absorbs moisture, high vapor permeance — not appropriate for exterior or roofing applications.

4. Application Requirements

Roofing SPF: requires professional plural-component spray equipment, manufacturer-approved applicators, third-party inspection, and topcoat application immediately after foam. Interior insulation SPF: simpler application, no topcoat required, different equipment specifications.

The Key Takeaway

Never allow interior insulation foam to be substituted for roofing-grade SPF. They are not interchangeable — interior foam applied to a roofing application will fail. Always verify that your contractor is using roofing-grade, manufacturer-approved materials.

The Best Roof for a Climate-Controlled Building

Wed, 25 Mar 2020 14:20:02 GMT

The Best Roof for a Climate-Controlled Building

Climate-controlled buildings — whether cold storage, pharmaceutical manufacturing, data centers, or precision manufacturing — have roofing requirements that go beyond simple waterproofing. Here's what works best.

The Requirements

Climate-controlled buildings need: high R-value to minimize heat transfer, vapor barrier performance to prevent condensation, seamless waterproofing to prevent any moisture infiltration, and thermal stability across extreme temperature differentials.

Why Spray Foam Excels

Closed-cell spray foam is the only commercial roofing system that simultaneously addresses all four requirements in a single application. R-6.5 per inch delivers excellent insulation value. The closed-cell structure provides vapor barrier performance without a separate installation. The seamless application eliminates every condensation-prone transition and penetration. And foam maintains flexibility and adhesion across extreme temperature swings.

The Alternative: Separate Systems

Traditional approaches for climate-controlled buildings layer multiple systems: rigid board insulation + separate vapor barrier + membrane roofing. Each layer adds cost, creates more seams, and introduces more potential failure points. Spray foam achieves the same or better performance in one application with fewer failure points.

Cost Justification

For climate-controlled buildings, the energy cost implications of poor roof insulation are severe. Failed roof performance in a cold storage or precision manufacturing facility creates direct product or process losses that dwarf any roof investment. The premium for high-performance foam roofing pays back quickly in these applications.

Spray Foam Roofing and Asbestos: Everything You Need to Know

Tue, 24 Mar 2020 20:23:02 GMT

Spray Foam Roofing and Asbestos: Everything You Need to Know

Many older commercial buildings have asbestos-containing roofing materials — particularly buildings constructed before the 1980s. Here's how spray foam relates to this situation.

Common Asbestos-Containing Roofing Materials

Asbestos was used in various roofing products including: transite panels (corrugated cement-asbestos panels), certain modified bitumen products, some flat roof flashings, and roofing mastics and adhesives. A licensed asbestos inspector can identify whether your roof contains asbestos-containing materials (ACMs).

Can Spray Foam Go Over Asbestos-Containing Roofing?

In many cases, yes — and this is a significant advantage of spray foam. Rather than disturbing ACMs through tear-off (which would require costly regulated abatement), foam can be applied directly over intact, non-friable ACMs, encapsulating them in place. The Jabala Military Base project in West Roofing's history involved exactly this scenario — foam was applied over transite panels containing asbestos, encapsulating the material without abatement.

When Encapsulation Is Appropriate

Encapsulation is appropriate when the ACMs are in good condition (not friable — meaning they don't crumble easily) and can be physically covered without disturbing them. When ACMs are deteriorated or must be physically disturbed, licensed abatement is required before any work proceeds.

Regulatory Compliance

Always consult with a licensed asbestos inspector before any roofing work on a building suspected of containing ACMs. Regulations vary by jurisdiction. Your roofing contractor should be aware of the applicable requirements.

The Complete Guide to Silicone Roof Coatings: Costs, Installation, Benefits

Thu, 05 Mar 2020 13:24:00 GMT

The Complete Guide to Silicone Roof Coatings: Costs, Installation, Benefits

Silicone roof coatings are one of the most effective commercial roofing restoration solutions available. This complete guide covers everything you need to know.

What Are Silicone Roof Coatings?

High-solids silicone coatings are fluid-applied waterproofing systems containing 90–95% silicone solids. Applied at 20–30 mils over existing commercial roofing, they create a seamless, highly UV-resistant waterproof film. The Si-O-Si backbone makes silicone uniquely resistant to UV degradation — it doesn't chalk, yellow, or become brittle with age.

Installation Process

Core sampling → wet insulation removal → power washing → seam/flashing repairs → primer (where required) → first coat → second coat → granule broadcast at foot traffic areas → inspection and warranty issuance. Typical completion: 1–5 days for most commercial roofs.

Costs

Over TPO/EPDM: $2.00–$4.50/sq ft. Over metal: $2.50–$5.00/sq ft. 10-year warranty: ~$2.00–$3.50/sq ft. 20-year warranty: ~$3.00–$5.00/sq ft. Full replacement comparison: $7.00–$14.00/sq ft.

Key Benefits

Seamless waterproofing (no seams to fail), 85%+ solar reflectance (cool roof), 10–20-year renewable manufacturer's warranty, 50–70% less cost than replacement, zero tear-off waste, minimal disruption to operations, works over TPO/EPDM/metal/mod-bit.

Limitations

Doesn't add R-value. Doesn't correct drainage slope. Requires substrate in acceptable condition (under 25% wet insulation). Manufacturer-approved applicator required.

3 Reasons Spray Foam Roofing Won't Work for Your Building

Mon, 02 Mar 2020 20:59:35 GMT

3 Reasons Spray Foam Roofing Won't Work for Your Building

Spray foam roofing is one of the best commercial roofing systems available — but it's not right for every building. Here are 3 situations where it's genuinely not the right choice.

1. Wet Insulation Exceeds 25%

When moisture has infiltrated more than 25% of the roof's insulation, the wet sections must be removed and replaced. At high percentages, this becomes so labor-intensive that a full tear-off and replacement is more cost-effective. Foam restoration works best when wet insulation is limited — extensive moisture damage is a genuine disqualifier.

2. Structural Deck Failure

Spray foam addresses roofing system problems — it doesn't fix structural problems beneath the roofing system. If the roof deck has rotted, corroded, or structurally failed, the underlying deck must be repaired or replaced before any roofing system (foam or otherwise) can be installed. Foam on a compromised deck will fail along with the deck.

3. Building Codes Require Full Replacement

Some jurisdictions require full tear-off when the existing roof has reached maximum allowed layer count (typically two layers). If a building already has the maximum permitted roofing layers and code requires tear-off before any new system, foam restoration may not be code-compliant without tear-off. Check local codes before assuming restoration is permissible.

The Honest Assessment

West Roofing Systems is committed to honest recommendations — if foam isn't the right solution for your building, we'll tell you and explain why. A professional inspection with core samples will reveal whether any of these disqualifiers apply to your specific situation.

Can You Install Spray Foam on a Sloped Roof?

Mon, 24 Feb 2020 21:21:59 GMT

Can You Install Spray Foam on a Sloped Roof?

Yes — spray foam can be installed on sloped roofs, and it has been used successfully on steep-slope applications including domes, curved surfaces, and metal panel systems with significant pitch. Here's what you need to know.

Low-Slope vs. Steep-Slope Applications

Low-slope commercial roofs (up to 2:12 pitch) are the primary market for spray foam roofing — this is where the seamless waterproofing and drainage correction benefits are most needed. Steep-slope applications (above 2:12) are less common but entirely feasible with proper foam formulation and technique.

Foam Formulation for Sloped Surfaces

Standard spray foam can sag or run on steep surfaces before it sets. Specialized "steep-slope" foam formulations have faster reaction times and higher initial viscosity that prevent sagging during application. These formulations are applied in thinner lifts to manage the cure dynamics on angled surfaces.

Real-World Examples

The Normandy High School project involved spray foam application on school domes — significantly curved, non-flat surfaces. The Jabala Military Base involved steep-slope transite panels. Steep-slope applications require contractor experience with these specific geometries and foam formulations.

When It Makes Sense on Sloped Roofs

Spray foam on sloped roofs makes most sense when: the substrate has complex geometry (domes, irregular profiles), the surface has many penetrations that sheet membranes can't easily address, the substrate contains asbestos that needs encapsulation, or the system requires weatherproofing without affecting the roof's appearance.

6 Installation Mistakes Spray Foam Roofing Contractors Make

Thu, 20 Feb 2020 15:51:10 GMT

6 Installation Mistakes Spray Foam Roofing Contractors Make

Spray foam roofing is unforgiving of mistakes — improper installation leads to system failure that's expensive to correct. Here are the 6 most common errors.

1. Skipping Core Samples

Applying foam over wet insulation causes blistering and adhesion failure. Any contractor who skips core sampling is gambling with your roof — and you pay for the consequences.

2. Off-Ratio Application

Equipment not properly calibrated or components not at the correct temperature produce off-ratio foam — soft, friable, with inadequate adhesion and R-value. This is the most costly mistake to correct.

3. Applying Foam in Poor Conditions

Foam applied when temperature is too cold, humidity too high, or wind too strong produces inferior foam quality. A contractor who prioritizes schedule over weather conditions creates system failures.

4. Insufficient Topcoat Thickness

Applying topcoat below the specified mil thickness produces a warranty that isn't truly supported — the coating will wear through before the warranty period ends. Mil thickness verification is essential.

5. Inadequate Surface Preparation

Dirty, oily, or damp substrates compromise foam adhesion. Power washing, degreasing, and ensuring the substrate is completely dry before application is non-negotiable.

6. Missing the Topcoat Window

Foam must receive its protective topcoat within the manufacturer's specified window after application. Foam exposed to UV beyond this window may require scarfing or surface treatment before topcoat can be applied — adding cost and time.

How Much Does a Spray Foam Roof Recoat Cost

Mon, 17 Feb 2020 16:57:18 GMT

How Much Does a Spray Foam Roof Recoat Cost

A spray foam roof recoat is the maintenance step that renews your warranty and keeps the foam substrate protected indefinitely. Here's what it costs and what's included.

Typical Recoat Cost

A spray foam roof recoat typically costs $1.00–$2.50 per square foot, depending on: the condition of the existing topcoat (minor repairs add cost), required topcoat thickness (20 mils for 10-year vs. 30 mils for 20-year warranty), roof size (larger roofs cost less per square foot), and travel distance for the contractor.

What's Included in a Recoat

A complete recoat project includes: inspection of the foam and existing topcoat, any necessary spot repairs, power washing to remove dirt and biological growth, primer application (where required), fresh topcoat at the specified mil thickness, granule broadcast at foot traffic areas, and manufacturer warranty issuance upon completion.

Recoat vs. Original Installation Cost

The original spray foam plus topcoat installation typically costs $4–$8/sq ft. A recoat at $1–$2.50/sq ft represents roughly 25–50% of the original installation cost — to renew the warranty for another full 10–20-year cycle. This is why spray foam's total lifecycle cost is so compelling.

When to Schedule

Recoats should be scheduled proactively before the warranty expires — not reactively after the topcoat has worn through. Contact your contractor 6–12 months before warranty expiration to schedule inspection and plan the recoat.

The Dangers of Installing Spray Foam Over Wet Insulation

Thu, 13 Feb 2020 16:21:25 GMT

The Dangers of Installing Spray Foam Over Wet Insulation

Installing spray foam over wet insulation is one of the most serious and costly mistakes in commercial roofing. Here's exactly what happens and why it's absolutely non-negotiable to remove wet insulation first.

What Happens Physically

When foam is applied over wet insulation, the moisture beneath the membrane heats up during the foam's exothermic reaction and converts to steam. This steam has nowhere to go and creates pressure pockets — blisters — beneath and within the foam. These blisters compromise adhesion, create weak spots in the waterproofing layer, and can rupture over time, leaving exposed areas.

The Performance Consequences

Foam applied over wet insulation: doesn't adhere properly to the substrate in wet areas, develops blisters that can grow and rupture over time, fails to achieve uniform R-value across the roof, allows continued moisture movement beneath the new system, and can actually accelerate insulation degradation by trapping moisture that can't escape.

Why Some Contractors Skip This Step

Wet insulation removal adds cost and time. Core sampling costs money. Some contractors skip these steps to win the bid with a lower price — knowingly or unknowingly setting up a system for failure. The building owner pays for this shortcut when the roof fails prematurely.

The Non-Negotiable Standard

Core samples before any restoration. All wet insulation removed and replaced before foam application. Third-party inspection to verify. Any contractor who doesn't follow this standard should not be hired for spray foam roofing.

6 Questions (and Answers) About Damages on a Spray Foam Roof

Mon, 10 Feb 2020 14:05:59 GMT

6 Questions (and Answers) About Damages on a Spray Foam Roof

Spray foam roofs can be damaged — here are 6 common damage scenarios and what to do about each.

Q1: What if HVAC equipment installation damages the foam?

A: Clean the damaged area, apply compatible sealant or patch coating to restore the waterproof surface, and verify no foam is exposed. Schedule proper repair before the next inspection.

Q2: What if hail damages the topcoat?

A: Inspect for actual foam penetration. If only the topcoat is damaged, apply compatible coating over the damaged areas. If foam is exposed, repair immediately to prevent UV degradation.

Q3: What if a contractor working on the roof punctures through the foam?

A: Identify the full extent of damage. If the puncture goes through to the substrate below, it creates a potential leak path — repair with compatible sealant or foam patching material promptly.

Q4: What if overspray from nearby construction gets on the foam?

A: Most contaminants can be cleaned or removed from cured foam without compromising the system. Contact your coating manufacturer for compatible cleaning recommendations.

Q5: What if blisters appear in the foam?

A: Blisters indicate wet insulation beneath the foam — the most serious issue. Investigate the source of moisture, remove the blistered foam section, replace wet insulation, and re-foam the area.

Q6: What if the topcoat is wearing through in spots before the warranty expires?

A: This is a warranty claim. Contact the manufacturer directly. Early topcoat wear may indicate insufficient initial application thickness — document with mil gauge measurements before contacting the manufacturer.

Can You Install a Spray Foam Roof Over TPO?

Thu, 06 Feb 2020 14:57:22 GMT

Can You Install a Spray Foam Roof Over TPO?

Yes — spray foam can be installed over existing TPO roofing, and it's an effective restoration approach when certain conditions are met. Here's what's involved.

When Foam Over TPO Makes Sense

Foam over TPO is most appropriate when: the TPO roof has drainage issues that need slope correction, significant insulation improvement is needed, the roof has complex penetrations that foam handles more efficiently than silicone coating, or when the building owner wants the long-term renewability of foam over the shorter lifecycle of silicone alone.

Preparation Requirements

Before foam is applied over TPO: core samples confirm wet insulation is below 25%, wet sections are removed and replaced, the TPO surface is thoroughly cleaned, primer is applied (TPO typically requires primer for adequate foam adhesion), and any seam failures are addressed.

Adhesion Considerations

TPO's smooth surface requires specific primers to ensure proper chemical and mechanical bonding with spray foam. Using manufacturer-approved primers for the specific foam/substrate combination is essential. Unapproved combinations may have inadequate adhesion that leads to delamination.

vs. Silicone Coating Over TPO

For most aging TPO roofs without drainage issues and with adequate existing insulation, silicone coating restoration is more cost-effective than spray foam. Foam over TPO makes most sense when the additional capabilities of foam (slope correction, insulation, complex geometry) are needed beyond what coating alone provides.

How Is an Elastomeric Roof Coating System Maintained?

Fri, 31 Jan 2020 16:48:19 GMT

How Is an Elastomeric Roof Coating System Maintained?

Elastomeric roof coating systems (silicone and acrylic) are low-maintenance but not zero-maintenance. Here's the complete maintenance protocol.

Semi-Annual Inspections

Inspect twice yearly — spring and fall. Walk the entire roof and check: coating surface for wear, cracking, or mechanical damage; seam and flashing conditions; penetration seals; drainage outlet cleanliness; and any areas showing unusual wear patterns. Document findings with photos.

Drain and Gutter Cleaning

Clean all roof drains, scuppers, and gutters at each inspection. Clogged drains cause ponding water that accelerates coating wear, particularly in areas without proper slope. This is the single most impactful maintenance task for extending coating life.

Repair of Mechanical Damage

Any mechanical damage to the coating — cuts, punctures, or abrasion — should be repaired promptly by cleaning the area and applying compatible patch coating. Small repairs are simple and inexpensive; delayed repairs can allow water infiltration.

Maintenance Documentation

Most manufacturer warranties require documented maintenance records. Keep a maintenance log with dates, findings, repairs made, and photos. This documentation protects warranty claims and demonstrates proper stewardship of the system.

Proactive Recoat Planning

Monitor coating thickness during inspections using mil gauges as the warranty approaches expiration. Plan the recoat 6–12 months before warranty end to ensure weather windows and contractor scheduling availability.

What is an Elastomeric Coating? Benefits, Uses & Warranties

Mon, 27 Jan 2020 19:53:15 GMT

What is an Elastomeric Coating? Benefits, Uses & Warranties

Elastomeric coatings are the category of fluid-applied roofing systems that includes silicone, acrylic, and polyurethane coatings. Here's what they are and why they matter.

What "Elastomeric" Means

Elastomeric refers to materials that exhibit elastic properties — they can stretch and return to their original form without permanent deformation. For roofing coatings, this means the material can accommodate thermal expansion and contraction of the substrate without cracking or losing adhesion. This flexibility is what makes elastomeric coatings effective on roofs that experience significant temperature cycling.

Types of Elastomeric Coatings

Silicone: highest UV resistance, maintains flexibility long-term, ideal for metal roofs and ponding water situations. Acrylic: water-based, lower initial cost, best in dry climates without ponding water. Polyurethane: excellent abrasion resistance, good for high foot traffic areas.

Key Benefits

Seamless waterproofing when applied correctly, high solar reflectance (cool roof), flexibility across temperature extremes, renewable warranty system, applicable over most existing commercial roofing substrates.

Warranty Availability

Manufacturer warranties of 10–20 years are available for properly applied elastomeric coating systems from approved applicators. The warranty tier is determined by coating thickness applied. At warranty end, recoating renews coverage indefinitely — making elastomeric systems the only truly renewable commercial roofing option.

What Happens During a Commercial Roof Inspection?

Fri, 10 Jan 2020 13:08:22 GMT

What Happens During a Commercial Roof Inspection?

A professional commercial roof inspection is the essential first step before any roofing decision. Here's what a thorough inspection actually involves.

Visual Membrane Assessment

The inspector walks the entire roof surface documenting: membrane condition (cracking, blistering, delamination), seam adhesion status, flashing condition at all penetrations and edges, surface granule loss or oxidation, drainage patterns and ponding areas, and any visible punctures or mechanical damage. Photos document findings at each problem area.

Core Samples

Core samples are the most critical part of any pre-restoration inspection. The inspector removes small plugs (typically 4–6 inch diameter) from multiple locations across the roof — including areas that appear sound as well as areas with visible problems. Each core reveals the condition of the membrane, insulation, and any moisture present beneath the surface. Core locations are typically patched after sampling.

Infrared Scan (for Larger Roofs)

On roofs over approximately 20,000 sq ft, an infrared scan performed at dusk maps wet insulation locations across the entire roof efficiently. This helps determine the overall extent of moisture infiltration and guides where core samples should be taken.

Drain and Drainage Assessment

The inspector checks all drains and scuppers for blockage, assesses slope and drainage patterns, and identifies any areas of chronic ponding.

Written Report

A professional inspection concludes with a written report including: photos of all findings, core sample results, moisture extent estimate, and a clear recommendation with supporting data. This report is the basis for your roofing decision.

Spray Foam Roof in Florida? 5 Things to Consider Before Installing

Fri, 03 Jan 2020 20:36:59 GMT

Spray Foam Roof in Florida? 5 Things to Consider Before Installing

Florida's climate — intense UV, high humidity, hurricane exposure, and year-round heat — creates specific considerations for spray foam roofing. Here are the 5 most important factors.

1. UV Intensity

Florida receives among the highest UV radiation levels in the continental US. This means topcoats wear faster than in northern climates — the recoat interval may be shorter than the full 20-year warranty period. High-quality silicone topcoats with proven UV stability are essential. Inspect coating thickness annually and recoat proactively.

2. High Humidity Application Conditions

Florida's year-round humidity requires careful scheduling of foam application. Dew point management is critical — work should be scheduled for periods when substrate temperature is at least 5°F above dew point. This often means morning application windows.

3. Wind and Hurricane Resistance

Spray foam's fully-adhered, seamless surface provides excellent wind uplift resistance compared to mechanically fastened or partially adhered membranes. For hurricane-prone areas, foam's monolithic bond is a significant performance advantage over seamed systems.

4. Ponding Water from Intense Rainfall

Florida's heavy rainfall events can overwhelm inadequate drainage on flat roofs. Silicone coatings are specifically approved for use in ponding water conditions — an advantage for Florida's intense rain events. Foam can also correct drainage slope to minimize ponding.

5. Contractor Availability

Qualified manufacturer-approved spray foam applicators are less common in some Florida markets than in industrial states. Take extra care to verify manufacturer approval and references — the tight application windows and climate demands make contractor quality even more critical in Florida.

4 Lies Roofing Contractors Tell Building Owners

Fri, 27 Dec 2019 14:10:22 GMT

4 Lies Roofing Contractors Tell Building Owners

Most commercial roofing contractors are honest professionals. But the industry has specific misleading claims that appear repeatedly. Here are 4 to watch for.

Lie 1: "Your roof definitely needs to be replaced."

The Truth: Full replacement is the most expensive option, and it's not always necessary. Any contractor recommending replacement without performing core samples first is making an assumption, not a recommendation. Get core sample data before accepting any replacement recommendation — in most cases, restoration is viable and costs 50–70% less.

Lie 2: "Our warranty is as good as the manufacturer's."

The Truth: A contractor warranty is only as good as the contractor's continued business existence. Manufacturer warranties remain valid regardless of contractor status and are backed by large manufacturers. Always insist on manufacturer-backed warranty documentation.

Lie 3: "Removing wet insulation isn't necessary — it'll dry out."

The Truth: Wet insulation beneath a roofing membrane doesn't dry out — it stays wet and causes ongoing problems including mold, compression, and coating failure. This claim is used to reduce installation cost at the building owner's long-term expense.

Lie 4: "You need the most expensive system for the best results."

The Truth: The most expensive system isn't always the best choice for your specific situation. A silicone coating restoration that perfectly addresses your roof's needs outperforms an unnecessary foam installation. Honest contractors recommend the system that's right for your building — not the most profitable job for them.

What Warranties Come with a Spray Foam Roof?

Tue, 24 Dec 2019 15:53:01 GMT

What Warranties Come with a Spray Foam Roof?

Spray foam roofing comes with several layers of warranty protection. Here's what each covers and what to look for.

Manufacturer System Warranty

The most important warranty — issued by the foam and coating manufacturer after a third-party inspection verifies proper installation. Available in 10, 15, or 20-year terms based on coating thickness. Covers waterproofing performance of the system. Remains valid regardless of which contractor performs future work. This is the warranty you should always insist on.

Contractor Workmanship Warranty

Issued by the installing contractor, covering installation errors or defects in workmanship. Typically 1–5 years. Only as valuable as the contractor's continued existence — less protection than the manufacturer warranty.

Material Warranty

Some foam and coating manufacturers provide separate material warranties covering defects in the manufactured product itself. This is distinct from the system warranty and is typically part of the manufacturer's standard product offering.

What Warranties Don't Cover

All warranties have exclusions: damage from negligence or intentional acts, failure to maintain the system per warranty requirements (documented inspections, prompt repairs), structural failures unrelated to the roofing system, and in some cases ponding water if drainage was inadequate at installation.

Renewable Warranty

The unique feature of spray foam warranties: at expiration, a recoat renews the warranty for another full cycle. No other commercial roofing system offers this. The renewable warranty is what makes foam roofing the best long-term investment for commercial building owners.

How to Stop a Roof Leak on a Shingle Roof?

Tue, 17 Dec 2019 21:29:13 GMT

How to Stop a Roof Leak on a Shingle Roof?

While spray foam and silicone coatings are primarily applied to flat and low-slope commercial roofs, shingle roofs on commercial buildings do develop leaks. Here's how to address them.

Identifying the Source

Shingle roof leaks typically originate at: flashing failures around chimneys, vents, and skylights; cracked or missing shingles; deteriorated ridge caps; and ice dam damage (in cold climates). Water often travels down the roof deck before appearing as an interior leak, making the entry point hard to identify from below.

Immediate Repairs

For isolated failures: replace cracked or missing shingles, re-seal flashing with compatible roofing sealant, apply temporary patch to damaged areas, and clear any ice or debris. These repairs address immediate leaks but don't address overall shingle aging.

When Spray Foam Is an Option

Spray foam is occasionally used on steep-slope shingle roofs for encapsulation — particularly on historic buildings where appearance must be maintained or where unusual penetrations make sheet membrane solutions impractical. Specialized steep-slope foam formulations and techniques are required.

When Replacement Is the Answer

Shingles that have reached end of life — widespread granule loss, curling, brittleness — typically require full replacement. The key question is whether the decking beneath is still sound. Inspect for rotted decking before any restoration or replacement work begins.

Can I Restore My Roofing System with Silicone Coating?

Mon, 02 Dec 2019 19:23:54 GMT

Can I Restore My Roofing System with Silicone Coating?

Silicone coating restoration is available for most common commercial roofing substrates — but not all roofs qualify. Here's how to determine if your roof is a candidate.

Substrates That Qualify

Silicone coating can be applied over: TPO, EPDM, PVC, metal, modified bitumen, smooth BUR, and existing spray foam. Each substrate requires specific preparation and potentially primer, but all are viable candidates when the underlying conditions are met.

The Eligibility Requirements

Three conditions must be met: the existing membrane must be in acceptable condition (not extensively delaminated or structurally failed), wet insulation must be below 25% of the total roof area, and the work must be performed by a manufacturer-approved contractor using approved materials.

How to Know If You Qualify

The only reliable way to determine eligibility is a professional inspection with core samples. Visual inspection alone cannot tell you the moisture level beneath the membrane — and that moisture level is the critical factor. Any contractor who assesses eligibility without core samples is making assumptions.

What to Expect

If your roof qualifies: core sampling → wet insulation removal → power washing → repairs → primer (if needed) → two coats of silicone → granule broadcast at foot traffic areas → manufacturer warranty issuance. Typical cost: $2–$5/sq ft. Typical completion: 1–5 days depending on roof size.

What If You Don't Qualify?

If wet insulation exceeds 25% or the membrane has failed, silicone coating over the entire roof may not be viable. Options include partial restoration (coating the eligible areas, replacing failed sections) or full replacement with a system that offers renewable warranty coverage.

The First Step to Take When You Notice a Roof Leak

Fri, 22 Nov 2019 14:15:15 GMT

The First Step to Take When You Notice a Roof Leak

Discovering a commercial roof leak demands immediate, systematic action. Here's the right sequence — and why it matters.

Step 1: Protect Interior Contents

Before anything else: protect what's inside. Move equipment, cover inventory, place buckets under active drips, and document the leak and any interior damage with photos. If the building has insurance, this documentation supports claims. Acting fast here prevents expensive interior damage from compounding.

Step 2: Apply a Temporary Fix on the Roof

Get on the roof as soon as safely possible and apply compatible lap sealant, temporary patch material, or tarps over the apparent breach area. You may not find the exact entry point on a first pass — water travels laterally — but covering the most likely area helps. This buys time for a proper assessment.

Step 3: Schedule a Professional Inspection Promptly

Don't wait. Every day water sits in insulation, the moisture spreads — converting what might be a restorable situation into one that requires more extensive (and expensive) remediation. Schedule a professional inspection with core samples within 1–2 weeks of discovering the leak.

Step 4: Get Data Before Making Decisions

Do not accept any restoration or replacement recommendation without core sample data. The inspection will tell you the moisture extent and determine whether restoration or replacement is the right path. Making a major roofing decision based on visual assessment alone is a mistake.

Step 5: Act on the Inspection Results

With objective data in hand, choose the right solution — restoration if moisture is below 25%, replacement if above — and move forward with a qualified contractor.

What Is the Best Roofing System Against Penetrations?

Mon, 18 Nov 2019 20:37:54 GMT

What Is the Best Roofing System Against Penetrations?

Every pipe, HVAC unit, vent, and skylight that penetrates a commercial roof creates a potential leak point. The more penetrations, the more critical the roofing system's ability to seal them reliably.

Why Penetrations Are Challenging for Sheet Membranes

Traditional single-ply systems (TPO, EPDM) require custom-fabricated boots, pipe flashings, and termination bars at each penetration. Each custom component is a seam — and seams fail over time. A roof with 50 HVAC units has hundreds of penetration-related seam points, each requiring periodic inspection and maintenance.

Why Spray Foam Is the Best Solution for Penetrations

Spray foam is fluid-applied and conforms to any surface. Around a pipe, foam flows into every gap and crevice, creating a continuous seamless seal from the roof field up and around the penetration. No custom boot, no separate flashing, no attachment seam. The penetration is sealed in the same application pass as the rest of the roof — zero additional failure points created.

Real-World Validation

West Roofing's Jabala Military Base project involved applying foam over a roof with thousands of exposed bolt penetrations — sealed in a single application. Maryland Court had HVAC penetrations every few feet — foam handled them all simultaneously. The Chardon, Ohio project featured a roof with dozens of penetrations across multiple levels — foam treated them as no different from the flat roof field.

The Bottom Line

For roofs with many penetrations, spray foam is the clear winner. It reduces penetration-related leak risk from "many failure points" to zero by eliminating separate flashing components entirely.

The Greatest Weakness of a Spray Polyurethane Foam Roof

Thu, 07 Nov 2019 13:19:11 GMT

The Greatest Weakness of a Spray Polyurethane Foam Roof

Spray foam roofing has remarkable capabilities — seamless waterproofing, slope correction, high insulation value, and indefinite renewability. But it has one significant weakness that building owners must understand.

The Critical Weakness: UV Vulnerability

Spray polyurethane foam degrades rapidly when exposed to UV radiation. Without a protective topcoat, foam breaks down within days to weeks depending on UV intensity — losing structural integrity, waterproofing capability, and R-value. This UV sensitivity is the system's fundamental vulnerability.

Why This Matters in Practice

The foam is never actually exposed during a properly managed installation — the topcoat is applied within the manufacturer's specified window. But this vulnerability becomes a real problem when: the recoat schedule is missed (topcoat wears away, exposing foam), mechanical damage punctures the topcoat and goes unrepaired, or an unqualified contractor applies topcoat outside the allowable window after foam application.

How Serious Is It?

A foam roof with exposed foam left uncorrected for weeks can suffer surface degradation that requires scarfing or partial foam replacement before recoating — significantly adding to the remediation cost compared to a simple recoat. Extended neglect can render sections of foam non-restorable.

How to Eliminate This Weakness

Three practices completely protect against this vulnerability: use only manufacturer-approved contractors who apply topcoat within specified windows, inspect the roof semi-annually for topcoat wear and mechanical damage, and follow the recoat schedule proactively before the warranty expires. With these practices in place, the foam's UV weakness is fully managed and the system performs indefinitely.

The 7 Advantages of a Spray Foam Roofing System

Mon, 04 Nov 2019 13:52:39 GMT

The 7 Advantages of a Spray Foam Roofing System

Here are the 7 specific advantages that make spray foam roofing uniquely valuable for commercial buildings.

1. Seamless Waterproofing

No seams. No laps. No attachment points. Zero seam-related leak risk — the #1 cause of commercial roof failures is eliminated by design.

2. Slope Correction

Foam can be applied at varying thicknesses to build positive drainage on flat or insufficiently sloped roofs — no structural modifications required.

3. Highest Insulation Value Per Inch

R-6.5 per inch is the best available in any roofing material, directly reducing HVAC costs.

4. Self-Flashing

Foam flows up walls, around penetrations, and over all transitions in a single application — no separate flashing components, no additional failure points.

5. Universal Substrate Compatibility

Foam adheres to TPO, EPDM, metal, BUR, modified bitumen, concrete, and corrugated panels — the most universally compatible restoration system available.

6. Renewable Warranty

The only commercial roofing system with a genuinely renewable warranty. A recoat at $1–$2/sq ft renews coverage for another 10–20 years, indefinitely.

7. Zero Tear-Off Waste

Applied over existing roofing, foam generates no landfill waste — a significant sustainability advantage over replacement systems that contribute thousands of pounds of material to landfills each cycle.

How Long Do Elastomeric Roof Coatings Last? (Lifespan & Renewal)

Fri, 01 Nov 2019 13:04:03 GMT

How Long Do Elastomeric Roof Coatings Last? (Lifespan & Renewal)

Elastomeric roof coatings have a defined warranty period — but with proper renewal, their effective lifespan is unlimited. Here's how it works.

Warranty Period vs. Actual Lifespan

A manufacturer warranty of 10, 15, or 20 years defines the period during which the coating performs to its specified standard. It does not mean the coating fails at that point — it means that's when renewal is required to maintain warranty coverage. A coating that reaches its warranty period in good condition can simply be recoated to start a new cycle.

What Determines Coating Lifespan

Actual coating lifespan depends on: climate (UV intensity, rainfall, temperature extremes), applied thickness (thicker = longer life), coating quality (silicone outperforms acrylic in most climates), maintenance (semi-annual inspections and prompt repairs), and whether ponding water is present (accelerates wear in areas without adequate drainage).

Silicone vs. Acrylic Longevity

Silicone coatings typically outperform acrylic in longevity due to silicone's unique UV resistance. Acrylic coatings can chalk and harden over time, losing flexibility. Silicone maintains its flexibility and UV resistance throughout its warranty period and beyond.

The Renewal Process

When the warranty expires: inspect and clean, perform spot repairs, apply fresh topcoat at required thickness, receive new warranty. This cycle can repeat indefinitely — there is theoretically no end to how long a properly maintained elastomeric coating system can last on a building.

How Does Spray Foam Roofing Perform in Colder Climates?

Fri, 25 Oct 2019 12:24:00 GMT

How Does Spray Foam Roofing Perform in Colder Climates?

Cold climates present challenges that test commercial roofing systems — and spray foam handles them exceptionally well. Here's a breakdown by challenge.

Freeze-Thaw Cycling

Foam's flexibility across extreme temperature ranges (-80°F to 300°F+) means it accommodates freeze-thaw cycling without cracking or delaminating. Traditional seamed systems fail at seams as freeze-thaw cycling stresses adhesion bonds over time. Foam's seamless, fully-adhered surface has no vulnerable points where freeze-thaw stress concentrates.

Snow and Ice Loads

Closed-cell spray foam has compressive strength of 25–60 PSI, easily handling the structural loads from snow accumulation. The seamless waterproof surface also prevents ice dam infiltration — a common problem on seamed systems where melt water finds seam pathways.

Insulation Performance in Cold Climates

Unlike polyiso board insulation (which loses R-value significantly in cold), spray foam maintains its R-6.5 per inch across all temperature ranges. This consistent performance is particularly valuable in cold climates where insulation effectiveness during the coldest periods matters most for energy costs.

Installation Restrictions in Cold Climates

Foam cannot be applied when ambient temperature is below 40°F — a genuine seasonal constraint in cold climates. Work must be scheduled for appropriate weather windows, typically spring through fall. This is the primary cold-climate limitation for foam installation (not performance).

The Verdict

Spray foam is an excellent choice for cold climates — its insulation value, seamless waterproofing, and freeze-thaw resistance make it arguably better suited to cold climates than to warm ones.

Spray Foam Roofing: How Much Does It Weigh and Why It Matters

Mon, 21 Oct 2019 20:18:04 GMT

Spray Foam Roofing: How Much Does It Weigh and Why It Matters

Spray foam adds weight to a commercial roof structure. Here's exactly how much and what building owners need to consider.

Weight of Spray Foam

Closed-cell spray foam used in roofing applications weighs approximately 2.8–3.0 lbs per cubic foot. At 1.5 inches thickness: approximately 0.35 lbs/sq ft. At 2 inches: approximately 0.5 lbs/sq ft. At 3 inches: approximately 0.75 lbs/sq ft. The silicone topcoat adds approximately 0.05–0.1 lbs/sq ft at 20–30 mils.

Comparison to Other Roofing Materials

For perspective: TPO membrane alone weighs approximately 0.1–0.3 lbs/sq ft. Standing water (1 inch depth) weighs approximately 5 lbs/sq ft. Gravel BUR weighs 5–15 lbs/sq ft. Spray foam at typical restoration thickness (1.5–2 inches) is lighter than gravel ballast and comparable to or slightly heavier than sheet membranes alone.

When Weight Is a Concern

Most commercial structures have adequate capacity for foam restoration at standard thicknesses. Weight becomes a concern when: the structure is already carrying maximum design loads, very thick foam applications are planned (4+ inches), or the building has known structural weaknesses. For buildings with concerns, a structural engineer can calculate available capacity before specifying foam thickness.

The Practical Reality

For the vast majority of commercial buildings, the weight of a standard foam restoration (1.5–3 inches) is not a structural concern. The weight of foam is far less than the ponding water problems that foam's slope correction eliminates.

Energy Savings and Spray Polyurethane Foam Roofs

Thu, 03 Oct 2019 20:44:35 GMT

Energy Savings and Spray Polyurethane Foam Roofs

Spray foam roofing delivers energy savings through two mechanisms: insulation (R-value) and solar reflectance. Here's how each works and what to expect.

Insulation Savings

At R-6.5 per inch, spray foam provides the highest roof insulation value available. For buildings transitioning from minimal or zero roof insulation to 2–4 inches of foam, HVAC cost reductions can be substantial — potentially 15–30% of heating and cooling costs in extreme climates. The exact savings depend on existing insulation level, climate zone, building HVAC system efficiency, and foam thickness applied.

Solar Reflectance Savings

The white silicone topcoat achieves 85%+ solar reflectance. In warm climates or for buildings with significant sun exposure, this can reduce cooling load by an additional 10–20%. A roof surface that stays 80°F cooler on a hot day transfers dramatically less heat to the building interior.

Combined Effect

For buildings with poor existing insulation in hot or cold climates, the combination of foam insulation plus reflective topcoat can transform roof-related energy performance. Case studies consistently show meaningful HVAC cost reductions — particularly for schools, warehouses, and large commercial facilities that run climate control year-round.

Calculating Your Savings

The most accurate way to estimate savings is to calculate the delta between your current roof R-value and the proposed foam R-value, then apply that difference to your heating/cooling degree days and HVAC system efficiency. A qualified foam contractor can help with this calculation for your specific building.

Can Spray Foam Be Installed over a Commercial Metal Roof?

Wed, 02 Oct 2019 15:34:35 GMT

Can Spray Foam Be Installed over a Commercial Metal Roof?

Yes — and metal is actually one of the best substrates for spray foam. Here's why it works so well and what the process involves.

Why Metal Is an Ideal Substrate

Metal provides a rigid, stable substrate for foam adhesion. The foam bonds chemically and mechanically to the metal surface, filling corrugations, sealing fastener holes, and encapsulating seams in a single application. Unlike sheet membranes that must be custom-cut and fitted around metal profiles, foam conforms to any surface automatically.

What Foam Fixes on Metal Roofs

Every common metal roof problem simultaneously: leaking fasteners sealed by foam flowing into and around each hole, seam separations filled and sealed, rust encapsulated where it can't spread, corrugations filled creating a flat surface for uniform topcoat application, and the bare metal's near-zero R-value transformed into meaningful insulation.

Preparation Requirements

Before foam application: power wash and degrease the metal surface, treat rust areas with rust-inhibiting primer, apply appropriate foam adhesion primer (most metals require primer for proper chemical bonding), and address any severely corroded areas that require mechanical reinforcement.

Cost Comparison

Spray foam plus silicone over metal: $4–$8/sq ft. Full metal roof replacement: $8–$15+/sq ft. For most metal roofs with sound structural panels, foam restoration at half the cost delivers superior waterproofing performance (seamless vs. seamed) and added insulation value.

Can Spray Foam Be Installed Directly over a Cover Board?

Mon, 30 Sep 2019 18:39:59 GMT

Can Spray Foam Be Installed Directly over a Cover Board?

Yes — spray foam can be applied directly over cover boards in commercial roofing assemblies. Here's what you need to know.

What Is a Cover Board?

A cover board is a rigid board layer (typically gypsum, wood fiber, or polyiso) installed between the insulation and the roofing membrane in some commercial roofing assemblies. It provides a smooth, stable substrate for membrane installation and improves compressive strength.

Foam Over Cover Board: How It Works

Spray foam adheres directly to cover board surfaces with appropriate preparation. Gypsum cover boards typically require primer for adequate foam adhesion. Wood fiber boards bond well to foam with minimal preparation. Polyiso cover boards adhere well, particularly when the surface is clean and free of release agents.

When This Scenario Arises

This application typically comes up during restoration projects where the existing roofing assembly (membrane + cover board + insulation) is to be retained and foam applied over the top. As long as the cover board is sound and adhered, foam can bond over it effectively.

The Advantage of Foam Over Cover Board

When foam is applied over an existing cover board assembly, the foam adds insulation value while creating a seamless waterproof surface — achieving in one step what traditional systems require multiple layers to accomplish.

Manufacturer Specification Check

Always verify manufacturer specifications for the specific foam product and cover board combination. Some combinations require specific primers or preparation protocols to ensure long-term adhesion. Use only manufacturer-approved products and applicators.

Roofing: Silicone Restoration Membrane vs Spray Polyurethane Foam

Fri, 27 Sep 2019 17:49:28 GMT

Roofing: Silicone Restoration Membrane vs Spray Polyurethane Foam

SRM (silicone restoration membrane) and SPF (spray polyurethane foam) are both excellent restoration systems with renewable warranties. Here's how to choose between them.

What They Share

Both systems: create seamless waterproof surfaces, eliminate seam-related leak risk, come with 10–20-year renewable manufacturer warranties, avoid tear-off, require wet insulation removal before application, and are applied by manufacturer-approved applicators.

Key Differences

SRM is thinner (20–30 mils) and applied over the existing membrane as a liquid coating. SPF is thicker (1.5–4+ inches), expands from liquid, and becomes a rigid insulating structural layer. SRM adds no insulation; SPF adds R-6.5 per inch. SRM cannot correct slope or drainage issues; SPF can. SRM costs $2–$5/sq ft; SPF costs $4–$8/sq ft.

Choose SRM When:

The roof has adequate drainage and slope, existing insulation is acceptable, waterproofing and warranty renewal are the primary goals, and cost minimization is a priority.

Choose SPF When:

Slope correction or ponding water is an issue, significant insulation improvement is needed, the substrate is BUR (after gravel removal) or an unusual surface, complex penetrations favor foam's self-flashing capability, or long-term renewable system economics are the priority.

When Both Work

For qualifying TPO or EPDM roofs with good drainage and adequate existing insulation, either system works. SRM is more cost-effective; SPF adds insulation value. The right choice depends on whether the insulation premium justifies the higher cost for your specific building.

How Does an SRM Roofing Solution Restore a Rubber Roof?

Wed, 25 Sep 2019 15:08:48 GMT

How Does an SRM Roofing Solution Restore a Rubber Roof?

A silicone restoration membrane (SRM) transforms an aging, leaking EPDM rubber roof into a freshly warranted system at a fraction of replacement cost. Here's exactly how it works.

Step 1: Core Sample Assessment

Before any work begins, core samples confirm wet insulation levels. For restoration to proceed, wet insulation must be below 25% of the total area. Wet sections are identified, cut out, and replaced with dry insulation.

Step 2: Surface Preparation

The EPDM surface is power-washed to remove all dirt, chalk, and contaminants. EPDM's smooth surface typically requires primer application to ensure proper chemical bonding with the silicone coating. The primer is applied and allowed to cure per manufacturer specifications.

Step 3: Seam and Flashing Repairs

Failed seams and flashing are addressed before the coating — reinforced fabric tape embedded in compatible sealant strengthens existing seam locations before the coating seals over them.

Step 4: SRM Application

The silicone coating is spray-applied in two coats over the entire EPDM surface. Each coat is allowed to cure before the next is applied. The two coats together achieve the required mil thickness for the chosen warranty tier (typically 20 mils for 10 years, 30+ mils for 20 years).

Step 5: Warranty Issuance

A third-party inspector verifies thickness and coverage. The manufacturer issues a new warranty — the rubber roof is now protected by a continuous silicone membrane with a fresh 10–20-year manufacturer warranty, at $2.50–$4.50/sq ft vs. $7–$12/sq ft for replacement.

Roofing: Silicone Restoration Membrane vs Complete Tear-Off and Replacement

Wed, 18 Sep 2019 13:46:00 GMT

Roofing: Silicone Restoration Membrane vs Complete Tear-Off and Replacement

This is the most common decision in commercial roofing — and the data strongly favors restoration for qualifying roofs. Here's the complete comparison.

Cost

SRM restoration: $2.00–$4.50/sq ft. Full replacement: $7.00–$14.00/sq ft. On a 50,000 sq ft roof: $100,000–$225,000 vs. $350,000–$700,000. Restoration saves 50–70% — a dramatic difference that justifies a thorough inspection before any replacement is considered.

Disruption

SRM: no tear-off, no weather exposure, completed in days, operations continue normally. Replacement: tear-off exposes building to weather, generates significant debris and noise, may take weeks, can disrupt operations significantly.

Performance

SRM creates a new seamless surface over the existing membrane — better waterproofing than the aging seamed system it covers. Replacement creates a new seamed system that will face the same aging process. SRM is actually superior waterproofing.

Warranty

Both provide 10–20-year manufacturer warranties. SRM warranties are renewable; replacement warranties end the cycle that starts again. SRM's renewable warranty is a long-term advantage.

Environmental Impact

SRM: zero landfill waste. Replacement: thousands of pounds of material per project. Sustainability goals strongly favor restoration.

When Replacement Is Necessary

When wet insulation exceeds 25%, the deck is compromised, or code requires tear-off. For all other qualifying roofs, SRM wins on every dimension.

How Does Spray Foam Perform in High Wind Situations?

Wed, 04 Sep 2019 15:40:30 GMT

How Does Spray Foam Perform in High Wind Situations?

Wind uplift is one of the most destructive forces on commercial roofing. Here's how spray foam performs — and why it outperforms seamed alternatives.

How Wind Damages Roofing Systems

Wind creates uplift pressure — particularly at roof edges, corners, and perimeter areas. On seamed systems, this pressure can get under membrane edges and seam laps, progressively peeling the membrane from the substrate. Once a membrane edge lifts, wind loads dramatically increase and rapid failure can occur.

Why Spray Foam Excels in Wind

Spray foam's fully-adhered, seamless surface has no vulnerable edges or seam points for wind to get under. The foam bonds across its entire surface area — there is no perimeter edge where uplift can initiate. The monolithic bond requires wind pressure to peel the entire system off simultaneously, which requires forces far exceeding any realistic wind event.

The Numbers

Closed-cell spray foam systems regularly achieve wind uplift resistance of FM 1-90, 1-120, or higher in testing. These ratings indicate resistance to 90–120+ mph wind-equivalent uplift pressure — exceeding requirements for most hurricane-prone regions.

Real-World Validation

West Roofing Systems' project at Peppertree II Condos in Boca Raton, Florida — in a region with significant hurricane exposure — used spray foam specifically for its superior wind performance characteristics compared to alternative membrane systems.

How Long Does a Spray Foam Roofing Job Take?

Tue, 03 Sep 2019 17:43:45 GMT

How Long Does a Spray Foam Roofing Job Take?

One of the most practical questions building owners ask. Here's a realistic timeline breakdown for commercial spray foam projects.

Pre-Installation Phase

Core sampling and inspection: 1–2 days. Wet insulation removal and replacement: 1–5 days depending on extent. Total pre-installation: 2–7 days. Note: wet insulation removal is often the most time-variable phase — small amounts complete quickly, larger extents take longer.

Foam Application

A standard two-person crew applies 3,000–7,000 sq ft of foam per day. For typical commercial roofs: 10,000 sq ft = 1.5–3 days. 50,000 sq ft = 7–17 days. 100,000 sq ft = 14–33 days. Larger crews or robotic equipment significantly increase daily production rates.

Topcoat Application

Topcoat application is faster than foam — a crew can typically cover 10,000–20,000 sq ft per day. Most commercial roofs require 1–3 days for complete topcoat application.

Total Project Duration

Small commercial roof (10,000 sq ft): 5–10 days total. Medium commercial roof (50,000 sq ft): 2–4 weeks total. Large facility (100,000+ sq ft): 4–8+ weeks total depending on crew size.

Compared to Replacement

Foam restoration is typically completed in 50–70% of the time required for full tear-off and replacement — because there's no tear-off phase, which is typically the slowest and most weather-sensitive part of any replacement project.

How Long Does a Spray Foam Roof Last?

Wed, 28 Aug 2019 14:36:59 GMT

How Long Does a Spray Foam Roof Last?

The honest answer: indefinitely — if properly installed and maintained. Here's what the data shows.

The 45+ Year Track Record

West Roofing Systems has been installing spray foam roofs since 1979. Many of those original installations are still performing today, 45+ years later, because the foam substrate was properly protected and recoated on schedule. No other commercial roofing system has this documented longevity.

Why Foam Can Last Indefinitely

The foam substrate doesn't degrade on its own — closed-cell polyurethane foam maintains its structural integrity indefinitely when protected from UV exposure. The protective topcoat is the component that requires periodic renewal. At warranty end (10–20 years), a recoat renews the topcoat without replacing the foam. This cycle can repeat indefinitely.

What Determines Practical Lifespan

The recoat schedule is the critical factor. A foam roof maintained on schedule lasts indefinitely. Missing the recoat window by years allows UV degradation that can require more than a simple recoat to fix. The maintenance commitment is straightforward but must be honored.

Comparison to Other Systems

TPO: 15–25 years before replacement. EPDM: 20–30 years before replacement. Modified bitumen: 15–25 years. Spray foam with recoating: indefinite — it's the only commercial roofing system where "how long does it last" can honestly be answered with "potentially forever."

The Spray Foam Curing Process: Everything You Need to Know

Mon, 26 Aug 2019 15:28:17 GMT

The Spray Foam Curing Process: Everything You Need to Know

Understanding the spray foam curing process helps building owners know what to expect during installation and why certain quality protocols matter.

Immediate Reaction

When the two foam components mix at the gun tip, they immediately begin an exothermic (heat-releasing) chemical reaction. The mixture expands to approximately 30 times its original volume within seconds. The foam begins hardening almost immediately — most foam reaches a tack-free surface within 10–30 seconds of application.

Full Cure Timeline

While foam reaches tack-free surface quickly, full cure to maximum density and properties takes longer. Most closed-cell roofing foam achieves approximately 90% of its final properties within 24 hours. Full cure to final density, compressive strength, and R-value typically takes 24–72 hours depending on foam formulation, temperature, and humidity.

The Critical Topcoat Window

Manufacturers specify a window during which topcoat must be applied after foam — typically 24 hours to 30 days. Applying too soon (before adequate cure) can trap off-gassing that causes topcoat blistering. Waiting too long allows UV exposure to begin degrading the foam surface. A qualified contractor applies topcoat within the specified window consistently.

Temperature and Humidity Effects

Cold temperatures slow the reaction and cure process — foam applied near minimum temperature may require longer before topcoat can be applied. High humidity can accelerate certain reactions and affect surface quality. Qualified contractors monitor conditions and adjust application parameters accordingly.

Hail vs SPF – Will a Spray Foam Roof Hold Up?

Tue, 20 Aug 2019 14:37:01 GMT

Hail vs SPF – Will a Spray Foam Roof Hold Up?

Hail is a significant concern for commercial roofing. Here's how spray polyurethane foam performs under hail impact.

Why Foam Is More Hail-Resistant Than Sheet Membranes

Sheet membranes (TPO, EPDM, modified bitumen) are relatively thin and can be punctured by large hail. The underlying insulation boards don't absorb impact — the impact force is transferred through the membrane to the hard board beneath, concentrating stress at the impact point. Spray foam is different: its cellular structure absorbs and distributes impact energy rather than concentrating it. The foam "gives" slightly under impact and recovers, distributing the force across a larger area.

What Happens During Hail Impact on Foam

Small to moderate hail (under 1 inch): typically causes no damage to the foam or topcoat. Moderate hail (1–2 inches): may cause surface indentation in the topcoat without penetrating to the foam. Large hail (2+ inches): can penetrate the topcoat and potentially damage the foam surface — requiring repair.

Repairing Hail Damage

Topcoat-only damage: apply compatible coating over the damaged areas. Foam surface damage: clean, apply compatible sealant or new foam, recoat. Most hail damage is cosmetic or minor — the repairability of foam roofs is one of their practical advantages over sheet membranes where hail punctures can be more serious.

Insurance Considerations

Hail damage to commercial roofs is a common insurance claim. Document hail events and inspect for damage promptly. Minor damage that goes unrepaired can lead to larger issues over time.

Which Roofing System Performs Best Against Hail?

Fri, 16 Aug 2019 14:12:43 GMT

Which Roofing System Performs Best Against Hail?

Not all commercial roofing systems handle hail equally. Here's a comparison of common systems by hail resistance.

Spray Polyurethane Foam: Best Overall

Foam's cellular structure absorbs and distributes impact energy — the best hail resistance of any commercial system. When hail damages a foam roof, repairs are straightforward: clean and apply compatible sealant or coating. Foam roofs also self-seal small penetrations if the topcoat remains intact around the impact point.

Modified Bitumen: Good

Granulated modified bitumen has reasonable hail resistance — the granules provide a protective surface layer that absorbs some impact energy. Smooth modified bitumen is more vulnerable to puncture than granulated versions.

Metal Roofing: Moderate

Metal panels dent under hail but rarely puncture — denting doesn't necessarily compromise waterproofing unless it damages seams or fasteners. However, large hail can cause significant cosmetic damage to metal panels.

TPO and EPDM: Vulnerable

Single-ply membranes are relatively thin and can be punctured by large hail. The seams are particularly vulnerable — hail impact near existing seams can cause delamination. Post-hail inspection and repair is critical for single-ply systems.

The Bottom Line

For hail-prone regions, spray foam's combination of impact absorption, seamless surface, and easy repairability makes it the most resilient commercial roofing option. A silicone-coated foam roof that receives hail damage can typically be repaired without compromising the overall system.

7 Questions (And Answers) About Birds Pecking Spray Foam Roofs

Wed, 31 Jul 2019 19:59:34 GMT

7 Questions (And Answers) About Birds Pecking Spray Foam Roofs

Bird pecking is a documented phenomenon on spray foam roofs in certain regions. Here are 7 common questions answered directly.

Q1: Why do birds peck foam roofs?

A: Birds — particularly woodpeckers and starlings — peck foam roofs searching for insects or nesting material. Foam's cellular structure resembles wood in some ways, which can attract woodpeckers. UV-degraded foam (exposed topcoat worn away) is particularly attractive to birds as the degraded surface resembles bark.

Q2: How serious is bird damage?

A: If birds peck through the topcoat into the foam, they create holes that expose foam to UV radiation. Small holes can expand over time. In severe cases, bird damage has required significant remediation.

Q3: Where is this most common?

A: Primarily in the southwestern US, particularly Arizona, where woodpecker populations are high and foam roofs are common. Less common in other regions.

Q4: Does topcoat prevent bird damage?

A: A well-maintained, adequate-thickness topcoat provides better protection than worn topcoat. Granulated topcoats are more resistant to bird pecking than smooth coatings.

Q5: How is bird damage repaired?

A: Clean the damaged area, apply new foam to fill any voids, sand smooth, and recoat. Repairs are straightforward but should be done promptly.

Q6: Can bird damage be prevented?

A: Bird deterrent systems, granulated topcoats, and maintained topcoat thickness all help. Some contractors apply pepper or citrus additives to topcoats as deterrents.

Q7: Should I choose a different roofing system because of birds?

A: In most regions, bird pecking is not a significant concern. In high-risk areas, preventive measures are more practical than choosing a different roofing system.

Can You Walk on a Foam Roof? 6 Questions (+ Answers)

Mon, 22 Jul 2019 15:56:00 GMT

Can You Walk on a Foam Roof? 6 Questions (+ Answers)

Yes — you can walk on a properly installed spray foam roof. Here are 6 specific questions about foot traffic answered.

Q1: Is foam strong enough to walk on?

A: Yes. Closed-cell spray foam has compressive strength of 25–60 PSI — easily supporting the weight of people and maintenance equipment without permanent deformation.

Q2: Will foot traffic damage the coating?

A: Over time, concentrated foot traffic in specific areas can wear the topcoat. This is why high-traffic areas (around HVAC units, access hatches) should have granule-embedded coatings or walk pad installations.

Q3: What are walk pads?

A: Pre-fabricated granule-surfaced pads installed over the roofing system in designated foot traffic paths. They protect the topcoat and foam from wear and provide improved traction.

Q4: Are foam roofs slippery?

A: Smooth silicone topcoats can be slippery when wet. In foot traffic areas, granules are broadcast into the wet coating to create a textured, slip-resistant surface.

Q5: Can heavy equipment be placed on foam roofs?

A: Yes, with appropriate protection. HVAC units and mechanical equipment are typically placed on curbs or pads that distribute load. Consult with your contractor before placing any new heavy equipment on an existing foam roof.

Q6: How often should people walk on a foam roof?

A: Regular foot traffic for HVAC maintenance is fine with proper walk pads and granule surfaces. The semi-annual inspection walks by a roofing contractor are standard. Unnecessary foot traffic should be minimized to protect the topcoat.

The 3 Best Qualities of a School Roofing Contractor

Thu, 11 Jul 2019 12:16:46 GMT

The 3 Best Qualities of a School Roofing Contractor

School roofing projects are different from standard commercial work. Here are the 3 qualities that matter most when selecting a contractor for an educational facility.

1. Experience with School-Specific Constraints

School roofing projects must often be completed within specific windows — summer break being the most critical. A contractor who regularly works on school facilities understands how to plan projects for completion before the school year starts, how to coordinate with district administration and facilities personnel, and how to manage scheduling within a tight timeline. References from completed school projects are essential verification.

2. Manufacturer Approval for Warranted Systems

Schools typically need manufacturer-backed warranties rather than contractor-only warranties — for board accountability, ongoing coverage, and independent quality verification. Any roofing contractor for a school project should be able to provide manufacturer warranty documentation and verify their approval status upon request. This is non-negotiable for institutional projects.

3. Safety Program and Insurance

School facilities have heightened safety requirements — particularly during occupied periods and adjacent to student areas. The roofing contractor should have a documented safety program, OSHA compliance record, appropriate liability and workers' compensation insurance, and experience managing roofing work safely near occupied spaces. Request safety documentation along with the proposal.

TPO vs SPF: Which Roof Is Better for Your School?

Mon, 08 Jul 2019 12:47:02 GMT

TPO vs SPF: Which Roof Is Better for Your School?

School districts frequently evaluate TPO and spray foam as roofing options. Here's an honest comparison across the factors that matter most for educational facilities.

Cost

TPO installation: $5–$9/sq ft. SPF restoration over existing roofing: $4–$8/sq ft. For new construction or full replacement, costs are comparable. For restoration of existing roofs, foam is often less expensive. Over a 40-year school ownership horizon, foam's renewable warranty ($1–$2/sq ft recoat cycles) vs. TPO's replacement cycles ($7–$12/sq ft) creates enormous lifecycle cost difference.

Timeline

Both systems can typically be completed within a summer break window for most school roof sizes. Foam restoration is generally faster (no tear-off) and has fewer weather dependencies than TPO installation. For schools with tight summer windows, foam's speed advantage is meaningful.

Insulation Value

TPO adds essentially no insulation. Foam adds R-6.5 per inch. For schools with aging, poorly insulated roofs, foam's insulation improvement translates to direct HVAC savings — important for school districts managing operating budgets.

Long-Term Commitment

TPO requires full replacement every 20–25 years. Foam requires recoating every 10–20 years at a fraction of the cost. A school district planning 40+ years of building ownership gets dramatically better value from foam's renewable warranty structure.

The Recommendation

For schools with aging BUR or single-ply roofs under 25% wet insulation: foam restoration is almost always the better choice. For new construction where foam overlay isn't applicable: get quotes for both and compare lifecycle costs, not just upfront cost.

3 Problems That Can Happen During a School Roof Repair

Tue, 02 Jul 2019 13:21:10 GMT

3 Problems That Can Happen During a School Roof Repair

School roof repairs are time-sensitive and operationally complex. Here are the 3 most common problems that arise and how to prevent them.

Problem 1: Running Out of Summer Break Time

School roofing projects must often be completed before students and staff return in August or September. Projects that run over schedule due to unexpected wet insulation extent, weather delays, or poor contractor planning can create situations where work continues into the school year — disruptive and sometimes impossible to manage safely. Prevention: hire experienced school roofing contractors, schedule inspections and planning early, build schedule buffer, and confirm weather windows with the contractor before start date.

Problem 2: Discovering More Wet Insulation Than Expected

Core samples provide an estimate of wet insulation, but the actual extent sometimes exceeds the estimate once work begins. This can affect both cost and timeline. Prevention: take comprehensive core samples across the entire roof — not just at obvious problem areas — before finalizing the project proposal. Have a pre-agreed protocol for handling unexpected wet insulation findings during work.

Problem 3: Contractor Unable to Meet Warranty Requirements

Sometimes a contractor wins a school roofing bid but isn't actually manufacturer-approved for the warranted system they proposed. The district discovers this when they try to get warranty documentation. Prevention: verify manufacturer approval BEFORE awarding the contract. Call the manufacturer directly and confirm the contractor's current approval status and any limitations.

The Best Way to Clean Your Spray Polyurethane Foam Roof

Mon, 01 Jul 2019 13:40:05 GMT

The Best Way to Clean Your Spray Polyurethane Foam Roof

Regular cleaning is part of proper spray foam roof maintenance. Here's how to do it correctly without damaging the system.

Why Cleaning Matters

Dirt, debris, biological growth (algae, mold), and organic material accumulate on the roof surface over time. Heavy dirt loading on topcoats can reduce solar reflectance — affecting energy efficiency. Biological growth can accelerate coating wear. And documented cleaning is typically required for warranty compliance.

The Standard Method: Power Washing

Low-pressure power washing is the most effective cleaning method for foam roofs. Use water pressure in the 1,000–1,500 PSI range. Higher pressures can damage the coating surface — avoid using industrial-grade equipment set to maximum pressure. Use a wide-angle spray tip (25–40°) and keep the nozzle at least 12 inches from the surface. Rinse with clean water after washing.

Cleaning Agents

For routine cleaning, plain water is often sufficient. For biological growth (algae, mildew), a diluted bleach solution (1 part bleach to 10 parts water) or commercial roof cleaner can be used. Always check with your coating manufacturer before applying any chemical cleaner — some products can affect silicone coating adhesion or appearance.

When to Clean

Clean during semi-annual inspections or when visually dirty. Clean before applying fresh topcoat during the recoat process — the inspection typically identifies cleaning needs. Avoid cleaning in direct sunlight on hot days — the cleaning solution can dry too quickly on hot surfaces.

How Much Will a New Roof for a School Cost?

Mon, 24 Jun 2019 19:15:44 GMT

How Much Will a New Roof for a School Cost?

School roof costs vary significantly based on roof size, condition, and the system chosen. Here's a realistic breakdown to help districts budget accurately.

Full Replacement Cost Range

TPO replacement: $5–$9/sq ft. Modified bitumen replacement: $6–$10/sq ft. Spray foam over existing roofing: $4–$8/sq ft. For a typical 50,000 sq ft school roof, full replacement costs $250,000–$500,000 depending on system and conditions. Foam restoration of the same roof: $200,000–$400,000.

What Drives the Cost Higher

Wet insulation extent is the biggest variable — every square foot of wet insulation requiring removal and replacement adds $0.50–$2.00/sq ft to project cost. Roof complexity (many penetrations, multiple levels, difficult access) adds labor cost. Larger warranty tier (20-year vs. 10-year) adds coating material cost. Travel distance for the contractor adds mobilization cost.

Why Restoration Is Typically Better Value

For most school roofs under 25% wet insulation, restoration at $4–$8/sq ft delivers the same or better waterproofing performance vs. replacement at $7–$12/sq ft. Over a 40-year school ownership horizon, the lifecycle cost difference is enormous — foam's renewable recoat cycles vs. periodic full replacements.

How to Get Accurate Budgets

Commission professional inspections with core samples from 2–3 qualified contractors. Get detailed proposals specifying materials, warranty terms, and wet insulation handling. Compare total lifecycle costs, not just upfront numbers. For board presentations, presenting a 20-year cost comparison is more compelling than upfront cost alone.

How Thermal Imaging is Used for Roof Inspections

Tue, 02 Apr 2019 13:00:06 GMT

How Thermal Imaging is Used for Roof Inspections

Thermal imaging transforms commercial roof inspections by revealing wet insulation that's completely invisible to the naked eye. Here's a complete explanation of how it works and when it's most valuable.

The Science Behind Thermal Imaging

Water has a much higher heat capacity than dry insulation — it absorbs more heat during the day and releases it more slowly after sunset. An infrared camera detects this temperature difference. Areas with wet insulation appear as warm spots on the thermal image during the post-sunset cooling period, while dry areas appear cooler.

Optimal Scanning Conditions

Scans must be performed at dusk — 1–2 hours after sunset — following a full day of sunshine. The roof needs to have absorbed significant solar heat during the day for the wet/dry temperature differential to be detectable. Cloudy days, recent rain, and high winds reduce the differential and compromise accuracy.

What the Scan Reveals

The infrared scan creates a complete map of wet insulation locations across the entire roof. This is dramatically more comprehensive than core sampling alone — on a 100,000 sq ft roof, taking enough core samples to comprehensively map moisture isn't practical. The IR scan gives a full picture efficiently.

Limitations and Follow-Up

Thermal imaging identifies wet insulation locations but doesn't quantify moisture severity. Core samples are still needed to confirm wet areas and measure moisture extent. The combination — IR scan for comprehensive mapping plus targeted core samples for verification — provides the most complete pre-restoration assessment available.

What's the Cost of a Commercial Spray Foam Roofing System?

Tue, 12 Mar 2019 08:00:38 GMT

What's the Cost of a Commercial Spray Foam Roofing System?

Commercial spray foam roofing costs vary based on several factors. Here's a complete breakdown to help building owners budget accurately.

Base Cost Range

1.5-inch foam plus 10-year warranty topcoat: $4.00–$6.00/sq ft. 2-inch foam plus 10-year warranty topcoat: $5.00–$7.00/sq ft. 3-inch foam plus 20-year warranty topcoat: $6.50–$9.00/sq ft. 4-inch foam plus 20-year warranty topcoat: $8.00–$11.00/sq ft.

What Adds to Base Cost

Wet insulation removal and replacement: $0.50–$2.00/sq ft per affected area. Gravel removal on BUR roofs: $0.50–$1.00/sq ft. Primer on specialty substrates: $0.25–$0.50/sq ft. Slope correction areas requiring extra foam thickness: $1.00–$1.50/sq ft per additional inch. Roof complexity (many penetrations, difficult access): 10–25% premium.

What Reduces Cost

Larger roofs cost less per sq ft — economies of scale in mobilization and material delivery. Summer or off-peak scheduling may offer better contractor availability and pricing. Choosing a 10-year vs. 20-year warranty saves $1.00–$2.00/sq ft in topcoat material.

Total Project Examples

20,000 sq ft metal roof, 2-inch foam, 20-year warranty, minimal wet insulation: approximately $120,000–$160,000. 50,000 sq ft BUR restoration after gravel removal, 2-inch foam, 10-year warranty: approximately $250,000–$350,000.

Spray Foam Roofing and Solar Panels: The Ultimate Match

Mon, 18 Feb 2019 20:53:25 GMT

Spray Foam Roofing and Solar Panels: The Ultimate Match

Spray foam roofing and solar panels are one of the most compatible pairings in commercial building sustainability. Here's why they work so well together.

No Penetrations Needed

Traditional solar installations on commercial roofs require mechanical fasteners that penetrate the roofing membrane — each penetration is a potential leak point. Solar panel racking systems on spray foam roofs typically use ballasted (non-penetrating) mounting systems, or foam can be applied around any required penetrations to maintain seamless waterproofing.

Foam's Self-Flashing Advantage

If any solar mounting hardware does require roof attachment, spray foam can be applied directly around the mounting bases, creating a continuous seamless seal between the hardware and the roof surface. No separate flashing components needed.

Thermal Synergy

Spray foam's high insulation value (R-6.5/inch) reduces heat transfer through the roof — keeping the building interior cooler and reducing the HVAC load that solar panels are helping to offset. The combination of foam insulation and solar generation creates compounding energy savings.

Reflective Topcoat and Panel Efficiency

The white silicone topcoat's high solar reflectance keeps the roof surface cooler — which actually benefits solar panel efficiency. Solar panels perform best at lower temperatures; a reflective roof surface under the panels contributes to this.

Renewable Warranty Alignment

Solar panel warranties typically run 20–25 years. Foam's 20-year renewable warranty aligns well with solar panel lifecycle — the roof protection and the energy generation investment mature on similar timescales.

West Roofing Systems, Inc. Takes Home Two Industry Awards During Spray Polyurethane Foam Alliance Convention

Fri, 08 Feb 2019 17:21:05 GMT

West Roofing Systems, Inc. Takes Home Two Industry Awards During Spray Polyurethane Foam Alliance Convention

West Roofing Systems, Inc. was honored with two prestigious awards at the Spray Polyurethane Foam Alliance (SPFA) Convention — recognition that reflects our commitment to quality, safety, and professionalism in commercial spray foam roofing.

About the SPFA

The Spray Polyurethane Foam Alliance is the primary trade association for the spray polyurethane foam industry. The SPFA sets quality standards, provides education and training, and recognizes companies that demonstrate excellence in installation practices, safety, and industry contribution.

What These Awards Mean

Industry recognition from the SPFA reflects adherence to the highest standards in foam roofing installation — the same standards that protect West Roofing Systems' customers by ensuring their roofing projects are completed to manufacturer specifications with manufacturer-backed warranty coverage.

45+ Years of Excellence

West Roofing Systems has been installing spray polyurethane foam roofing systems since 1979 — making us one of the most experienced SPF roofing contractors in the country. These awards recognize decades of consistent quality and the expertise our crew brings to every project, from small commercial buildings to 384,000 sq ft industrial facilities.

What This Means for Building Owners

When you choose West Roofing Systems for your commercial roofing project, you're working with an award-winning contractor with manufacturer approval, a documented safety record, and the industry recognition to back our claims. Our track record speaks for itself.

How to Restore a Commercial Metal Roof

Mon, 14 Jan 2019 14:00:53 GMT

How to Restore a Commercial Metal Roof

Commercial metal roof restoration delivers excellent performance at a fraction of replacement cost. Here's the complete process.

Step 1: Assessment

Inspect the metal panels for structural integrity — not just surface rust. Panels with significant corrosion through the metal or structural compromise require replacement sections. Panels with surface rust and aging fasteners are excellent restoration candidates. Also check for panel deformation, seam separation, and flashing failures.

Step 2: Surface Preparation

Power wash the entire metal surface to remove dirt, loose rust, bird droppings, and any loose coatings. Mechanically treat any heavy rust areas to stable rust. Apply rust-inhibiting primer to all treated areas and as a base coat on severely weathered metal.

Step 3: Fastener and Seam Treatment

Apply reinforced fabric tape embedded in compatible sealant over all exposed fasteners, seam locations, and ridgeline transitions. This creates a reinforced base layer at all historical failure points before the coating is applied over them.

Step 4: Flashing and Transition Treatment

Address all roof-to-wall transitions, ridge caps, and edge conditions with compatible sealant and reinforced fabric tape. These transitions are critical — a coating over the main roof field that fails at edge transitions will still leak.

Step 5: Coating Application

Apply silicone coating in two coats at the required mil thickness for the chosen warranty. The coating covers the entire roof surface — all prepared fasteners, seams, and transitions — under a continuous seamless membrane.

Step 6: Warranty Issuance

Third-party inspection verifies mil thickness and coverage. Manufacturer issues 10–20-year warranty. Total cost: $2.50–$5.00/sq ft vs. $8–$15+/sq ft for replacement.

Types of Roof Insulation Boards

Tue, 04 Dec 2018 14:00:31 GMT

Types of Roof Insulation Boards

Commercial roofing assemblies use various types of insulation boards. Understanding each type helps building owners evaluate roofing system options and performance claims.

Polyisocyanurate (Polyiso)

The most widely used commercial roofing insulation. Nominal R-value: R-6.5 per inch. Key limitation: R-value degrades significantly in cold temperatures (can drop to R-4 or lower below 20°F). Cost-effective and widely available. Most common in TPO and EPDM roofing assemblies.

Expanded Polystyrene (EPS)

R-value: R-4 per inch, consistent across temperature ranges. Doesn't absorb moisture significantly. Better cold-climate performance than polyiso. Used when consistent R-value across temperature ranges is important.

Extruded Polystyrene (XPS)

R-value: R-5 per inch, consistent across temperature ranges. Excellent moisture resistance. Premium cost vs. EPS or polyiso. Best where moisture exposure is a concern.

Mineral Wool (Rock Wool)

R-value: R-4 per inch. Fire-resistant, does not contribute to flame spread. Used in applications requiring fire resistance. Heavier than foam boards.

Spray Polyurethane Foam: The Superior Alternative

Spray foam (R-6.5/inch, consistent across temperatures) outperforms all board insulation options in several ways: no seams at board joints (eliminating thermal bridging), no separate coverboard required, directly bonds to substrate, and simultaneously provides insulation AND waterproofing. For most commercial roofing restoration applications, spray foam delivers better performance than any board insulation system.

Spray Foam and Termites: What You Need To Know

Mon, 12 Nov 2018 13:52:28 GMT

Spray Foam and Termites: What You Need To Know

One of the most common concerns about spray foam is termites. Here are the facts that commercial building owners need to understand.

Does Spray Foam Attract Termites?

No — spray polyurethane foam does not attract termites and is not a food source for them. Termites eat cellulose-based materials (wood, paper, some plant matter). Foam is a synthetic polymer with no nutritional value to termites.

Can Termites Damage Foam?

Yes, under certain circumstances. Subterranean termites can tunnel through spray foam when it's used in wall cavities or foundation applications — not because they eat the foam, but because they're burrowing through it to reach wood. They create tunnels but don't consume the foam.

Roofing Applications: Lower Risk

For roofing applications specifically, termite concern is much lower than for foundation or wall cavity applications. Roofing foam is applied to the exterior surface, is exposed to UV (via topcoat), and is far from the soil where subterranean termite colonies originate. Roofing foam that's protected by a proper topcoat is not a significant termite target.

Practical Risk Assessment

For commercial buildings in termite-prone regions: the primary termite risk is always to structural wood components, not to foam roofing. Standard termite prevention and treatment programs address wood-based structural risks — foam roofing doesn't significantly change the termite risk profile of a commercial building.

Can Your Roof Be Repaired in The Winter?

Mon, 05 Nov 2018 13:53:02 GMT

Can Your Roof Be Repaired in The Winter?

Winter roof repairs require understanding what's possible in cold temperatures and what limitations exist. Here's a practical guide.

What Can Be Done in Winter

Emergency temporary repairs: applying compatible sealant or lap sealant over active leaks can be done in most weather conditions. These stop active infiltration until permanent repairs can be scheduled. Inspections: roof inspections and core sampling can be performed in any season — winter inspections after leaks appear are important for planning spring repairs.

What Cannot Be Done in Winter

Spray foam application requires ambient temperature above 40°F and rising — cold weather prevents proper foam reaction and curing. Silicone coating application similarly requires minimum temperatures. Heat-welded TPO seam repairs require controlled temperatures for proper bonding. Most permanent restoration or replacement work should wait for spring conditions.

Emergency Winter Protocols

For active leaks in winter: apply temporary sealant to stop infiltration, document the damage for insurance, and schedule a professional inspection as soon as safely accessible. If the building uses heat and ice dams are forming, roof raking to remove snow load and break ice dam formation can prevent additional water infiltration.

Planning for Spring

Use winter downtime productively: get professional inspections and proposals, commission core samples (can be done in winter), get board or ownership approval for restoration budgets, and schedule contractors before spring — the best contractors book up quickly once weather permits.

Closed Cell vs. Open Cell Spray Foam

Thu, 18 Oct 2018 13:28:44 GMT

Closed Cell vs. Open Cell Spray Foam

These are two fundamentally different materials with different properties and applications. For commercial roofing, only one is appropriate.

Closed-Cell Spray Foam

Density: 2.8–3.0 lb/cu ft. R-value: 6.5 per inch. Cell structure: closed cells that are impermeable to air and water. Properties: rigid, strong (25–60 PSI compressive strength), waterproof, acts as vapor barrier, UV-sensitive (requires topcoat). Applications: roofing, foundation walls, cold storage, any application requiring structural strength and moisture resistance.

Open-Cell Spray Foam

Density: 0.5–0.8 lb/cu ft. R-value: 3.5–4 per inch. Cell structure: open, interconnected cells that allow air and moisture to pass through. Properties: soft, flexible, low strength, absorbs moisture, allows vapor diffusion. Applications: interior sound dampening, attic insulation in certain climate zones, interior air sealing. NOT appropriate for roofing or exterior applications.

Why the Distinction Matters for Roofing

Open-cell foam would be catastrophic on a commercial roof — it absorbs water, provides minimal structural support, has inadequate R-value, and would soak up moisture from any leak rather than resisting it. Any contractor proposing open-cell foam for a roofing application should be disqualified immediately. Only manufacturer-approved, roofing-grade closed-cell SPF is appropriate for commercial roofing.

What is Single-Ply Membrane Roofing?

Tue, 16 Oct 2018 13:00:27 GMT

What is Single-Ply Membrane Roofing?

Single-ply membrane roofing refers to commercial roofing systems using a single layer of flexible membrane material installed over insulation. The two most common types are TPO (thermoplastic polyolefin) and EPDM (ethylene propylene diene monomer, or rubber roofing).

How It Works

Single-ply membranes come in rolls that are unrolled across the roof surface, positioned, and joined at overlapping seams. TPO seams are heat-welded together. EPDM seams use adhesive bonding. The membrane is either mechanically fastened to the roof deck, fully adhered with adhesive, or ballasted (held down with gravel or pavers).

Key Characteristics

Single-ply systems are cost-effective for new construction, widely available, and offer good initial performance. The primary limitation is seam dependence — every seam is a potential failure point that requires monitoring and periodic maintenance. At end of warranty (10–25 years), single-ply systems typically require full replacement rather than simple renewal.

When Restoration Makes More Sense

For aging single-ply roofs with less than 25% wet insulation, a silicone restoration membrane (SRM) applied over the existing system is often more cost-effective than replacement. The SRM seals all existing seams under a continuous new membrane with a new 10–20-year warranty at 50–70% less cost than replacement.

What Voids a Commercial Roof Warranty?

Thu, 11 Oct 2018 14:00:37 GMT

What Voids a Commercial Roof Warranty?

Commercial roof warranties provide valuable protection — but they have specific exclusions. Here's what can void your coverage and how to avoid it.

Failure to Maintain

Most manufacturer warranties require documented semi-annual inspections and prompt repair of mechanical damage. Failure to maintain the roof per the warranty requirements — and failing to document that maintenance — is one of the most common ways warranties are voided. Keep maintenance logs with dates, findings, and repairs made.

Unauthorized Modifications

Installing new HVAC units, antennas, solar panels, or other rooftop equipment without notifying and potentially involving the roofing contractor can void warranty coverage for the areas affected. Always consult with your roofing contractor before any work on the roof surface.

Using Non-Approved Repair Materials

Applying incompatible sealants, coatings, or repair materials over a warranted system can void coverage. Always use manufacturer-approved materials for any repairs to a warranted system.

Non-Approved Contractors

Having non-manufacturer-approved contractors perform repairs on a warranted system can void coverage. Any repair work should be performed by or with the blessing of a manufacturer-approved applicator.

Missing the Recoat Window (Foam Roofs)

For spray foam systems, missing the recoat schedule window and allowing significant UV degradation of the foam substrate can void warranty coverage and require more extensive remediation before a new warranty can be issued.

Acts Beyond Coverage

Damage from intentional acts, unusually severe weather events beyond design parameters, or building structural failures are typically excluded from roofing warranties regardless of maintenance.

Scheduling a Roof Project: What to Consider

Tue, 02 Oct 2018 12:00:55 GMT

Scheduling a Roof Project: What to Consider

Optimal commercial roof project scheduling balances weather, contractor availability, building operations, and budget timing. Here are the key factors.

Weather Windows

Spray foam requires temperatures above 40°F and rising, relative humidity below 85%, and wind below 15–20 mph. In northern climates, this creates seasonal constraints — spring through fall for foam. Silicone coatings have similar requirements. Winter projects are possible in warm climates but challenging in cold ones. Build weather contingency into schedules.

Building Operations

Schedule roofing work during periods of minimal building impact. Schools: summer break is the critical window. Occupied office buildings: schedule work to minimize noise during business hours if possible. Cold storage facilities: plan for installation during warmer months when temperature differentials are manageable. Retail: avoid holiday seasons when disruption would be most costly.

Contractor Availability

The best roofing contractors book up quickly, especially for summer work. Reaching out 3–6 months before your desired start date for inspections, proposals, and scheduling is not too early. Last-minute scheduling often means accepting less desirable contractor options or delayed project starts.

Procurement Lead Times

Roofing materials sometimes have lead times, particularly for large projects. Confirm material availability with your contractor before finalizing the start date.

Inspection and Planning First

The inspection, core sampling, and proposal process should happen well before the desired project start — ideally 60–90 days prior. This ensures all data is in hand, board approvals are secured, and contractors are confirmed before the weather window opens.

3 Unique Ways to Use Spray Foam for Your Commercial Building

Fri, 07 Sep 2018 13:00:33 GMT

3 Unique Ways to Use Spray Foam for Your Commercial Building

Spray foam's unique properties make it valuable beyond standard roofing applications. Here are 3 less common but highly effective uses.

1. Wall Coating and Restoration

Just as spray foam and silicone coatings restore commercial roofs, similar systems can restore commercial exterior walls. West Roofing Systems completed a wall restoration project at Paisley Farms in Willoughby, Ohio where a high-solids silicone wall coating replaced traditional paint. The result: a 10-year warranted surface with 10x the durability and far less maintenance than conventional paint. For commercial buildings with deteriorating exterior block or concrete walls, this application provides exceptional long-term value.

2. Encapsulation of Problematic Materials

Spray foam's ability to encapsulate existing materials — including asbestos-containing transite panels and exposed mechanical fasteners — allows building owners to address problematic substrates without costly abatement or demolition. The foam creates a continuous, sealed barrier over the existing material, eliminating exposure risk while simultaneously waterproofing and insulating.

3. Slope Correction and Drainage Improvement

Beyond waterproofing, foam's ability to be applied at varying thicknesses makes it uniquely suited to correcting chronic drainage problems. Building owners with persistent ponding water issues — caused by compressed insulation, building settling, or original construction deficiencies — can have foam applied to create positive slope toward drains without any structural modifications.

Elastomeric Commercial Roof Coatings: Types and Applications

Thu, 30 Aug 2018 12:33:20 GMT

Elastomeric Commercial Roof Coatings: Types and Applications

Elastomeric roof coatings encompass several product chemistries, each with distinct properties. Here's a breakdown of the main types and their best applications.

Silicone Coatings

The premium option for commercial roofing. Properties: 90–95% solids, excellent UV resistance (doesn't chalk or harden), flexible across extreme temperature ranges, hydrophobic (water beads off), ponding water resistant. Best for: metal roofs, ponding water areas, high-UV climates, any application where long-term flexibility matters. Cost: $2.50–$5.00/sq ft applied.

Acrylic Coatings

Water-based, lower initial cost. Properties: 55–65% solids (more material lost to evaporation), good UV resistance initially but can chalk over time, may require more frequent recoating in wet climates. Best for: dry climates with adequate drainage, temporary or budget-constrained applications. Not recommended for areas with standing water. Cost: $1.50–$3.50/sq ft applied.

Polyurethane Coatings

Best abrasion resistance. Aromatic polyurethane: excellent durability but UV-sensitive (requires aliphatic topcoat). Aliphatic polyurethane: UV-stable, color-stable, excellent for high foot traffic areas. Best for: roofs requiring high wear resistance, walkway coatings. Cost: $2.00–$4.50/sq ft applied.

The Best Choice for Most Commercial Applications

For most commercial roofing restoration projects, high-solids silicone is the preferred elastomeric coating due to its UV stability, flexibility, ponding water resistance, and long-term performance consistency. The higher upfront cost is offset by superior longevity and fewer recoat cycles.

Aromatic vs Aliphatic Urethane Roof Coatings

Thu, 23 Aug 2018 12:00:18 GMT

Aromatic vs Aliphatic Urethane Roof Coatings

Polyurethane roof coatings come in two distinct chemistries that perform very differently under UV exposure. Understanding the difference is critical for proper application.

Aromatic Polyurethane

Aromatic polyurethane coatings are based on aromatic isocyanates (MDI or TDI). They provide excellent toughness, abrasion resistance, and adhesion. However, they are NOT UV-stable — aromatic coatings yellow, chalk, and degrade rapidly when exposed to direct sunlight. They must always be topcoated with a UV-stable aliphatic coating or used in non-UV-exposed applications.

Aliphatic Polyurethane

Aliphatic polyurethane coatings use aliphatic isocyanates (HDI or IPDI). They maintain color stability and clarity under UV exposure — they don't yellow or chalk. More expensive than aromatic but critical for any application with direct UV exposure. Used as topcoats over aromatic base coats or as standalone finish coats where color and appearance matter.

Typical System Design

For commercial roofing applications requiring urethane: aromatic urethane base coat for adhesion and build, followed by aliphatic urethane topcoat for UV protection and color stability. This two-coat system combines the cost effectiveness and toughness of aromatic chemistry with the UV stability of aliphatic chemistry.

Silicone vs. Urethane for Roofing

For most commercial roofing restoration projects, silicone coatings are preferred over urethane systems due to simpler application, better ponding water resistance, and no need for dual-chemistry systems. Polyurethane is most valuable where abrasion resistance or color stability in specific colors is a primary requirement.

My Commercial Roof Warranty Expired: What Do I Do?

Thu, 16 Aug 2018 21:10:26 GMT

My Commercial Roof Warranty Expired: What Do I Do?

Your commercial roof warranty has expired. Here's your roadmap for determining the right next step.

Step 1: Don't Panic — Expired ≠ Failed

A warranty expiring doesn't mean your roof has failed. Many roofs that reach warranty expiration are still in serviceable condition and qualify for restoration. The warranty period defines coverage duration, not roof lifespan.

Step 2: Commission an Independent Inspection

Get a professional inspection with core samples from a contractor who offers both restoration and replacement options. You need objective data — not a sales recommendation — before making any decisions. Core samples reveal wet insulation percentage, which determines whether restoration or replacement makes more sense.

Step 3: Evaluate Your Options

If wet insulation is below 25%: coating restoration ($2–$5/sq ft for silicone, $4–$8/sq ft for foam) is almost certainly more cost-effective than replacement. A new 10–20-year manufacturer warranty is achievable at a fraction of replacement cost. If wet insulation exceeds 25%: full replacement may be necessary. Choose a system with a renewable warranty to avoid facing this same situation in 20 years.

Step 4: Act — Don't Delay

Every season that passes with an expired warranty and unaddressed issues allows moisture to infiltrate and expand. What qualifies for restoration today may require replacement next year. Acting within 1–2 seasons of warranty expiration typically preserves the most cost-effective options.

What is R-Value and Why is it Important for Commercial Roofing?

Thu, 26 Jul 2018 14:02:34 GMT

What is R-Value and Why is it Important for Commercial Roofing?

R-value is the single most important metric for evaluating roofing insulation performance. Here's what it means and why it matters for your building's energy costs.

What R-Value Measures

R-value measures resistance to heat flow through a material. Higher R-value = more resistance to heat transfer = better insulation. R-value is additive — two layers of R-10 insulation provide R-20 total.

Why It Matters for Commercial Roofs

The roof is one of the largest exposed surfaces on a commercial building and one of the most significant heat transfer pathways. A building with inadequate roof insulation pays for it in HVAC costs every day — heat escapes through the roof in winter, solar heat enters through the roof in summer. Both directions cost money to counteract.

R-Value by Common Roofing Materials

TPO/EPDM membrane alone: R-0. Polyiso board insulation: R-6.5/inch nominal (degrades in cold). EPS board: R-4/inch. XPS board: R-5/inch. Spray polyurethane foam: R-6.5/inch, consistent across temperature ranges.

Why Spray Foam Has the R-Value Advantage

Spray foam provides the highest R-value of any roofing insulation at R-6.5/inch — and unlike polyiso board, it maintains this value in cold weather. For a 2-inch foam application, you achieve R-13 immediately. For buildings transitioning from minimal insulation, this improvement can significantly reduce annual HVAC costs.

Commercial Roof Maintenance: Costs, Benefits, and Why It Matters

Tue, 24 Jul 2018 15:28:15 GMT

Commercial Roof Maintenance: Costs, Benefits, and Why It Matters

Preventive roof maintenance is one of the best investments in commercial building ownership. Here's the complete picture of costs, benefits, and what's included.

What Maintenance Includes

A complete maintenance visit covers: thorough visual inspection of membrane, seams, and flashings; drain and gutter cleaning; minor seam sealant repairs; penetration seal inspection and touch-up; documentation with photos and written report; and recommendations for any needed repairs.

Maintenance Costs

Typical cost: $0.02–$0.07/sq ft per year depending on roof size and complexity. For a 50,000 sq ft roof: $1,000–$3,500 annually. This is less than 1% of the roof's replacement cost per year — making it one of the most cost-effective maintenance investments available.

Concrete Benefits

Early leak detection prevents interior damage that typically costs 10–100x more than the maintenance that would have caught it. Documented maintenance protects warranty claims — most manufacturer warranties require it. Maintained roofs last longer — studies consistently show maintained roofs outlive unmaintained ones by 25–50%. Small problems caught early (seam repair, flashing sealant) cost hundreds of dollars; the same problems left unaddressed for a season cost thousands.

The Simple Math

A $2,000 annual maintenance program that extends a roof's life by 5 years on a 50,000 sq ft building saves approximately $350,000–$500,000 in deferred replacement cost. The ROI is overwhelming.

How to Use Silicone for Roof Repairs

Tue, 29 May 2018 13:00:15 GMT

How to Use Silicone for Roof Repairs

Silicone sealants are among the most versatile and effective materials for commercial roof repairs. Here's how to use them correctly for common repair scenarios.

When to Use Silicone Sealant

Silicone is appropriate for: sealing small gaps and cracks in membranes, reinforcing flashing transitions, sealing around penetrations and pipe boots, temporary repairs while permanent solutions are planned, and patching isolated seam failures. It's particularly effective because of its flexibility, UV resistance, and long service life.

Surface Preparation is Critical

Silicone won't adhere to dirty, wet, or oily surfaces. Before applying: clean the area thoroughly, remove all dirt and loose material, ensure the surface is completely dry, and degrease if oil contamination is present. On smooth surfaces like TPO, a compatible primer may be needed for adequate adhesion.

Application for Seam Repairs

Apply silicone sealant in a continuous bead along the failed seam. Tool smooth with a wet finger or tool. For more durable repairs, embed a piece of reinforcing fabric (polyester mesh tape) into the wet sealant and apply a second coat over the fabric. Allow to cure fully before exposing to rain (typically 24–48 hours).

Application Around Penetrations

Apply silicone around all sides of the penetration where it meets the membrane surface. Ensure complete coverage with no gaps. For pipe penetrations, apply in a consistent bead all around the base and tool smooth.

Limitations

Silicone repairs are not permanent solutions for aged membranes — they address individual failures but not system-wide aging. When multiple silicone repairs are appearing across a roof in a short period, it's a signal that a comprehensive restoration assessment is needed.

The 6 Most Common Commercial Roofing Systems (Pros and Cons)

Wed, 09 May 2018 16:08:06 GMT

The 6 Most Common Commercial Roofing Systems (Pros and Cons)

Commercial roofing encompasses several distinct system types. Here's an honest breakdown of each.

1. TPO (Thermoplastic Polyolefin)

Pros: cost-effective, reflective, widely available. Cons: seams fail over time, no insulation value, replacement required at end of warranty.

2. EPDM (Rubber Roofing)

Pros: durable, long track record, good in cold climates. Cons: seam-dependent, absorbs heat (dark color), replacement required at end of life.

3. Modified Bitumen (BUR)

Pros: durable, good performance history, granulated surface provides UV protection. Cons: seams/laps prone to failure, heavy, tear-off required at end of life.

4. Metal Roofing

Pros: very long lifespan, fire resistant, recyclable. Cons: seam failures at fasteners and joints, poor insulation value, noisy in rain and hail.

5. Spray Polyurethane Foam (SPF)

Pros: seamless, highest R-value, slope correction, renewable warranty, goes over existing systems. Cons: requires UV protection (topcoat), installation temperature restrictions, must be applied by approved contractors.

6. Silicone Coating System (SRM)

Pros: lowest cost restoration option, seamless over existing system, renewable warranty, minimal disruption. Cons: no insulation value added, can't correct drainage issues, requires qualifying substrate condition.

The Bottom Line

For new construction: TPO/EPDM are common choices. For existing buildings with aging roofs: SRM or SPF restoration delivers the best value for qualifying roofs. Full replacement should be the last resort, not the default recommendation.

Section 179 Tax Deduction for Commercial Buildings

Wed, 02 May 2018 17:41:36 GMT

Section 179 Tax Deduction for Commercial Buildings

Section 179 of the IRS tax code allows businesses to deduct the full cost of qualifying equipment and property improvements in the year of purchase, rather than depreciating them over many years. Commercial roofing projects can qualify for significant tax benefits under this provision.

What Is Section 179?

Section 179 allows businesses to expense (deduct immediately) the cost of qualifying business property rather than capitalizing and depreciating it over time. For commercial roofing, this means a roofing investment that might otherwise be depreciated over 39 years can potentially be deducted in the year the project is completed.

What Qualifies for Commercial Roofing

Qualifying improvements include: roofing systems installed on nonresidential (commercial) property, roofing improvements to existing commercial buildings, and related building systems improvements. The property must be placed in service during the tax year and used for business purposes. Limits and specific requirements change — consult with a tax professional for current-year limits and qualification details.

The Financial Impact

For a business in a 25% tax bracket investing $200,000 in a commercial roof restoration, a full Section 179 deduction could generate $50,000 in immediate tax savings — effectively reducing the net cost of the project to $150,000. This materially improves the economics of roofing investments.

Important Disclaimer

Tax laws change frequently and eligibility depends on individual business circumstances. Always consult with a qualified tax professional or CPA before making roofing investment decisions based on tax considerations.

How to Easily Meet Your Bid Requirements Through Cooperative Purchasing

Mon, 26 Mar 2018 13:00:27 GMT

How to Easily Meet Your Bid Requirements Through Cooperative Purchasing

Public entities — schools, municipalities, government agencies, and institutions — typically must follow competitive bidding requirements for major purchases. Cooperative purchasing programs can significantly simplify this process for commercial roofing projects.

What Is Cooperative Purchasing?

Cooperative purchasing programs (also called cooperative contracts or group purchasing) allow public entities to purchase goods and services through contracts that have already been competitively bid and awarded by another public entity. Rather than running their own full bid process, a school district or municipality can "piggyback" on an existing contract.

How It Works for Roofing

A number of national and regional cooperative purchasing organizations have awarded commercial roofing contracts to qualified contractors. When a school district or public entity needs roofing work, they can utilize these existing contracts rather than conducting a full competitive bid process. The contractor is already pre-approved through a competitive process that meets most state and local procurement requirements.

Benefits for Public Entities

Significant time savings — months of bid preparation and evaluation can be reduced to weeks. Reduced administrative burden. Competitively negotiated pricing is already in place. Contractor has been vetted through a rigorous qualification process. Many states and localities have specific statutes authorizing cooperative purchasing.

Important Note

Cooperative purchasing eligibility varies by state and local procurement law. Always verify that your jurisdiction allows cooperative purchasing and that the specific contract you intend to use meets your requirements before proceeding.

How Much Will a Commercial Roof Cost?

Tue, 06 Mar 2018 13:30:46 GMT

How Much Will a Commercial Roof Cost?

Commercial roof costs vary widely based on system type, roof size, condition, and complexity. Here's a comprehensive breakdown to help building owners budget accurately.

Cost by System Type

Silicone coating restoration: $2.00–$5.00/sq ft. Spray foam restoration: $4.00–$8.00/sq ft. TPO replacement: $5.00–$9.00/sq ft. EPDM replacement: $5.00–$8.00/sq ft. Metal roof restoration: $2.50–$8.00/sq ft. Full BUR replacement: $8.00–$14.00/sq ft.

What Drives Cost Higher

Wet insulation extent (each sq ft requiring removal adds $0.50–$2.00). Roof complexity (many penetrations, multiple levels, difficult access). Warranty tier chosen (20-year costs more than 10-year). Travel distance for contractor. Emergency vs. planned scheduling.

What Drives Cost Lower

Larger roof size (economies of scale). Choosing restoration over replacement. Minimal wet insulation. Simple roof geometry. Off-peak scheduling.

Total Project Examples

25,000 sq ft TPO replacement: $125,000–$225,000. 50,000 sq ft silicone coating restoration: $100,000–$250,000. 100,000 sq ft spray foam restoration (2 inch): $400,000–$800,000.

The Most Important Rule

Get core samples before accepting any cost estimate. The wet insulation extent is the most variable cost factor — and it's impossible to estimate accurately without testing. Any proposal without core sample data is a guess, not a quote.

Spray Foam Roofing Installation: Step-by-Step Process

Mon, 26 Feb 2018 13:00:53 GMT

Spray Foam Roofing Installation: Step-by-Step Process

Spray foam roofing installation is a multi-step process requiring specialized equipment, approved materials, and trained applicators. Here's exactly what happens on a professional installation.

Step 1: Core Sampling and Assessment

Before any work begins, core samples determine the extent of wet insulation and the viability of foam application. This is non-negotiable — applying foam over wet insulation traps moisture and causes blistering and system failure.

Step 2: Wet Insulation Removal

All wet insulation identified by core sampling is removed and replaced with dry material before foam application. The substrate must be completely dry.

Step 3: Surface Preparation

The existing roof surface is power washed and all loose debris, grease, and contamination removed. Mechanical fasteners and existing protrusions are addressed. The surface must be clean and dry before application.

Step 4: Foam Application

Two-component polyurethane foam (A-side isocyanate and B-side polyol) is heated, pressurized, and mixed at the spray gun. Foam is applied in multiple passes to achieve specified thickness (typically 1.5–2 inches minimum, 2–3 inches for insulation goals). Application is paused in wind above 15–20 mph to prevent overspray.

Step 5: Silicone Topcoat Application

Within the window specified by the foam manufacturer (typically 72 hours), silicone coating is applied at specified thickness (20–30 mils) in two coats. Granules broadcast at foot traffic areas before final cure.

Step 6: Inspection and Warranty

Third-party inspector verifies thickness and application quality. Manufacturer issues warranty based on confirmed mil thickness and approved installation records.

Got Brown Spots on Your Ceiling? Causes & Solutions for Commercial Buildings

Mon, 12 Feb 2018 15:30:40 GMT

Got Brown Spots on Your Ceiling? Causes & Solutions for Commercial Buildings

Brown ceiling spots in a commercial building are almost always a sign of water infiltration from above. Here's how to diagnose the cause and find the right solution.

What Causes Brown Ceiling Spots

The most common causes: roof membrane failure allowing water infiltration, failed flashing around HVAC units or penetrations, condensation from inadequate insulation or vapor management, plumbing leaks from systems above the ceiling, and HVAC condensate drain issues. Roof-related leaks are the most common cause in commercial buildings.

Why the Stain Isn't Above the Entry Point

Water rarely drips straight down from the breach point. It enters the roof at one location, travels laterally along the membrane or through insulation, and eventually drips through at a lower point — sometimes 20–30 feet from the actual entry. This is why ceiling stains are poor guides to the leak source.

Proper Diagnosis

Professional inspection with infrared scan and core samples is the only reliable way to locate the actual breach. The IR scan maps moisture in the insulation across the entire roof. Core samples confirm and quantify wet areas. Don't repair ceiling cosmetically without addressing the roof — the problem will return.

The Solution

Once the roof breach is located, the appropriate repair depends on the roof's overall condition. For isolated failures on sound membranes: targeted repair. For widespread deterioration with less than 25% wet insulation: restoration. For extensive moisture damage: replacement. Act promptly — delays allow wet insulation to spread and interior damage to compound.

Preparing Your Commercial Facility for a Holiday Vacation

Mon, 11 Dec 2017 13:20:59 GMT

Preparing Your Commercial Facility for a Holiday Vacation

Extended building closures during holidays create unique roofing risks. Here's what to check before leaving your facility unoccupied.

Clear All Roof Drains

Clogged drains are the single biggest risk during extended closures. A blocked drain during a heavy rain event can create thousands of pounds of hydrostatic pressure on a roof not designed for ponding loads. Check and clear all drains and downspouts before closure.

Inspect Critical Flashing Points

Walk the roof and inspect all penetration flashings, particularly HVAC unit bases, pipe penetrations, and parapet caps. Any questionable sealant should be addressed before the closure — you won't be there to catch interior damage from a fresh leak.

Check Interior Leak Indicators

Before closing, document ceiling condition in any known problem areas. Consider placing buckets or absorbent materials under any areas with previous dripping issues to limit interior damage if a leak occurs while unoccupied.

Set HVAC for Low-Load Operation

Completely shutting off HVAC can cause condensation and humidity issues inside the building. Set heating to a minimum maintenance temperature (typically 50–55°F) rather than complete shutdown in winter.

Designate a Check-in Point

If the closure is extended (more than a week), arrange for someone to briefly inspect the building after any significant weather events — particularly heavy snow or rain. Catching a problem early limits damage.

Spray Polyurethane Foam Overspray: Prevention and Cleanup

Tue, 21 Nov 2017 14:19:43 GMT

Spray Polyurethane Foam Overspray: Prevention and Cleanup

Spray foam overspray is one of the practical challenges unique to SPF roofing. Here's how professional contractors manage it and what building owners should know.

What Is Overspray?

During spray foam application, the expanding foam can form small droplets or strings that become airborne in wind. These can travel significant distances and deposit on vehicles, windows, adjacent property, and equipment. Overspray is a real concern that requires proactive management.

Prevention Methods

Wind monitoring: qualified contractors check wind speed before and during application. Application stops when wind exceeds 15–20 mph. Wind screens: physical barriers erected around the work area block horizontal overspray travel. Custom foam booth skirts: on robotic installations, foam-blocking skirts on equipment contain spray within the work zone. Scheduling: prioritizing application during low-wind periods (often morning).

Protecting Adjacent Property

Contractors should notify building occupants and adjacent property owners before foam installation. Vehicles parked near the building should be moved during application. Covering any sensitive equipment on the roof before work begins is standard practice.

Cleanup

Fresh foam overspray (before cure): remove immediately with acetone or specific SPF solvent. Cured foam overspray: mechanical removal (scraping, grinding) is required. On vehicles: a qualified contractor will pay for detailing if their overspray reaches vehicles. This is why preventing overspray proactively is far preferable to cleanup after the fact.

Why Do I Need a Roof Maintenance Plan if I Have a Warranty?

Mon, 06 Nov 2017 15:00:05 GMT

Why Do I Need a Roof Maintenance Plan if I Have a Warranty?

This is one of the most common misconceptions in commercial roofing. A warranty does not replace maintenance — it requires it. Here's why.

Warranties Require Maintenance

Most manufacturer warranties explicitly state that documented maintenance is required to maintain coverage. The warranty doesn't void the moment maintenance lapses — but if you file a claim and the manufacturer investigates and finds no maintenance records, they may deny coverage citing the maintenance requirement. Read your warranty documents carefully.

What Warranties Don't Cover Without Maintenance

Issues that develop due to lack of maintenance — clogged drains causing ponding, unrepaired mechanical damage that allowed water infiltration, or seam failures that would have been caught during routine inspection — may be denied as "failure to maintain." The warranty covers manufacturing defects and system performance under normal service conditions with proper care.

The Value Maintenance Adds Beyond Warranty Protection

Annual maintenance catches problems when they're inexpensive to fix. A $200 drain cleaning prevents $5,000 in interior damage. A $500 seam repair prevents $50,000 of moisture infiltration. The warranty is your last line of defense — maintenance is your first and most cost-effective defense.

What a Maintenance Plan Should Include

Semi-annual inspections with written report and photos. Drain cleaning. Minor sealant repairs. Documentation of findings. This costs $0.02–$0.07/sq ft annually — one of the best ROI investments in building ownership.

Infrared Roof Surveys: How They Are Performed and Why They Matter

Thu, 02 Nov 2017 09:19:24 GMT

Infrared Roof Surveys: How They Are Performed and Why They Matter

Infrared (IR) roof surveys are the gold standard for detecting moisture in commercial roofing systems without destructive testing. Here's how they work and when to use one.

How Infrared Detection Works

During the day, the sun heats the roof surface and the insulation beneath it. After sunset, dry insulation releases heat quickly (cools fast) while wet insulation retains heat longer (cools slowly). An infrared camera captures this thermal differential — wet insulation appears as warm (bright) areas while dry insulation appears cool (dark). The survey must be performed at night, typically 1–2 hours after sunset, on a day with significant solar gain.

What the Survey Provides

A complete IR survey maps moisture distribution across the entire roof, identifying: total wet area percentage, location and extent of moisture pockets, drainage patterns, and areas of progressive moisture migration. This data directly determines whether a roof qualifies for coating restoration or requires replacement.

IR Survey vs. Core Sampling

IR survey identifies where to core sample — it doesn't replace core sampling. The survey guides efficient placement of core samples, which then confirm moisture presence and assess insulation condition. Best practice: IR survey first, then targeted core samples at identified anomalies.

When to Commission an IR Survey

Before any restoration or replacement decision on a roof older than 10 years. When multiple leaks are occurring across the roof. When building purchase or sale involves commercial property with aging roofs. The survey cost ($0.01–$0.03/sq ft) pays back many times over in accurate decision-making.

Why Is My Commercial Roof Leaking? 5 Common Causes

Fri, 20 Oct 2017 14:30:32 GMT

Why Is My Commercial Roof Leaking? 5 Common Causes

Understanding the cause of a commercial roof leak is the first step to finding the right solution. Here are the 5 most common causes.

1. Seam Failure

The #1 cause of commercial roof leaks. Heat-welded or adhesive-bonded seams on TPO and EPDM systems fail over time from thermal cycling. Once a seam fails, it's a direct water entry point. If seams are failing across an aging membrane, individual repair is impractical — silicone coating restoration seals all seams simultaneously.

2. Flashing Failure

The second most common cause. Flashing at penetrations (HVAC units, pipes, drains), wall-to-roof transitions, and roof edge terminations are vulnerable to failure. Traditional metal and bituminous flashings crack, separate, and lose adhesion. Annual inspection and prompt re-sealing extends flashing life significantly.

3. Membrane Puncture

Physical damage from foot traffic, equipment installation, hail, or falling objects. Foam roofs handle this better than sheet membranes — repair is simpler and the seamless surface self-isolates damage.

4. Ponding Water

Chronic ponding accelerates membrane deterioration — even systems rated for ponding water eventually wear faster in standing water zones. Addressing drainage inadequacy is the fix, not just patching the leak.

5. Age and UV Degradation

Membranes become brittle and lose elasticity with age, making them more susceptible to cracking and failure under thermal stress. When a roof leaks primarily due to age, restoration (not repair) is usually the most cost-effective solution.

Polyiso vs. XPS vs. EPS: Which Rigid-Foam Insulation Is Best?

Mon, 16 Oct 2017 13:38:37 GMT

Polyiso vs. XPS vs. EPS: Which Rigid-Foam Insulation Is Best?

When building or replacing a commercial roof, choosing the right rigid insulation board matters for performance and long-term energy costs. Here's a direct comparison.

Polyisocyanurate (Polyiso)

R-value: R-6.5/inch nominal — but degrades to R-4 or lower in cold (below 20°F). Most widely used, most cost-effective. Good performance in moderate climates. Susceptible to moisture absorption if exposed. Best for: warm climates or moderate climate zones where cold-temperature R-value degradation isn't a significant concern.

Extruded Polystyrene (XPS)

R-value: R-5/inch, consistent across temperatures. Excellent moisture resistance (closed-cell structure). More expensive than polyiso or EPS. Best for: cold climates where consistent R-value matters, or in moisture-prone environments. Commonly used in below-grade and inverted roof assemblies.

Expanded Polystyrene (EPS)

R-value: R-4/inch, consistent across temperatures. Good moisture resistance. Lower cost than XPS. Best for: cold climates where consistent R-value is needed but XPS budget premium isn't justified. Also used in below-grade applications.

The Spray Foam Alternative

For commercial roofing restoration projects, spray polyurethane foam (R-6.5/inch, consistent across temperatures) outperforms all three board insulation options: no seams at board joints eliminating thermal bridging, no separate cover board required, and it simultaneously provides both insulation and waterproofing. For most commercial restoration applications, foam delivers superior value to any board insulation system.

Polyiso vs. XPS vs. EPS: Rigid-Foam Insulation for Commercial Roofing

Mon, 16 Oct 2017 13:38:37 GMT

Polyiso vs. XPS vs. EPS: Rigid-Foam Insulation for Commercial Roofing

Choosing the right rigid insulation board affects your roof's energy performance and long-term cost. Here's a complete comparison of the three main types.

Polyisocyanurate (Polyiso)

R-value: R-6.5/inch nominal, but performance drops significantly in cold (degrades to R-4 or lower below 20°F). Most widely used, lowest cost per R-value. Good in warm to moderate climates. Susceptible to moisture absorption if exposed. Best for: warm/moderate climates where cold-temperature R-value degradation is not a concern.

Extruded Polystyrene (XPS)

R-value: R-5/inch, consistent across temperature ranges. Excellent moisture resistance (closed-cell structure). More expensive than polyiso or EPS per board foot. Best for: cold climates, below-grade applications, inverted roof assemblies where consistent cold-weather R-value and moisture resistance are needed.

Expanded Polystyrene (EPS)

R-value: R-4/inch, consistent across temperature ranges. Good moisture resistance. Lower cost than XPS. Best for: cold climates needing consistent R-value without XPS premium, tapered insulation applications (custom fabrication).

The Spray Foam Advantage

For commercial roofing restoration, spray polyurethane foam (R-6.5/inch, consistent in cold) outperforms all three board options — it provides both waterproofing and insulation in a seamless layer, eliminating thermal bridging at board joints and the need for a separate cover board. Where insulation improvement is a priority, foam delivers more value than board insulation in most commercial applications.

5 Tar & Gravel Roof Problems and How to Prevent Them

Mon, 11 Sep 2017 15:09:49 GMT

5 Tar & Gravel Roof Problems and How to Prevent Them

Gravel built-up roofing (BUR) systems are durable but develop specific problems. Here are the 5 most common issues and how to address them.

1. Blistering

Air or moisture trapped between plies causes bubbles or blisters to form. Prevention: proper installation with adequate ventilation. Solution: small blisters can be left alone; large or rupturing blisters should be cut, dried, and patched. Widespread blistering indicates a system-wide issue requiring restoration.

2. Alligatoring

The surface asphalt oxidizes and cracks in a pattern resembling alligator skin, indicating advanced UV degradation. Prevention: annual maintenance and prompt repair of granule loss. Solution: coating restoration can seal alligatored surfaces and extend system life.

3. Gravel Erosion

Gravel washes or blows off over time, exposing the underlying felt to UV. Prevention: periodic gravel redistribution or addition. Solution: if significant felt exposure has occurred, restoration or replacement may be needed.

4. Ponding Water

Low spots accumulate water, accelerating deterioration in those areas. Prevention: address drainage at installation. Solution: spray foam after gravel removal can build slope to correct ponding.

5. Membrane Delamination

Plies of the BUR system separate, creating voids for water infiltration. Prevention: proper installation and dry substrate. Solution: if delamination is widespread, full restoration or replacement is required.

Membrane Roof Blisters: How to Prevent & Repair Them Effectively

Wed, 06 Sep 2017 12:00:31 GMT

Membrane Roof Blisters: How to Prevent & Repair Them Effectively

Blistering is a common issue on commercial roofing membranes that can range from cosmetic to serious. Here's what building owners need to know.

What Causes Roof Blisters

Blisters form when air or moisture becomes trapped beneath or within the membrane during installation. Heat from the sun causes trapped gas or moisture to expand, creating a dome-shaped bubble. Common causes: damp substrate at installation, solvent evaporation from adhesives, inadequate bonding during heat welding, and moisture infiltration through breaches that becomes trapped.

Types of Blisters

Interply blisters (between plies of BUR): typically less serious, may be monitored. Membrane-to-substrate blisters: more serious, indicate adhesion failure. Foam blisters (on spray foam systems): most serious — indicate wet insulation beneath the foam.

When Blisters Are Serious

Small, stable blisters that aren't growing may be monitored. Blisters that are large, growing, or rupturing require immediate attention. Ruptured blisters create active leak pathways. Any blister on a spray foam roof indicates wet insulation beneath — investigate immediately.

Repair Approaches

Small, intact blisters: may be left alone with monitoring. Large blisters: cut, allow to dry, fill with compatible material, patch and seal. Widespread blistering: indicates system-level issues requiring comprehensive restoration assessment. Blistered foam sections: remove blistered foam, address wet insulation, re-foam and recoat.

Spray-On Roof Coatings: Benefits, Restoration Options, and Costs

Thu, 31 Aug 2017 12:18:33 GMT

Spray-On Roof Coatings: Benefits, Restoration Options, and Costs

Spray-on roof coatings are one of the most cost-effective ways to extend commercial roof life and issue new warranties on aging systems. Here's a complete overview.

Primary Spray-On Options

Silicone coating: highest performance, UV-stable, ponding water approved, best long-term value. 90–95% solids content means minimal material loss. Acrylic coating: lower cost but lower solids content (55–65%), not suitable for ponding water, requires more frequent recoating. Polyurethane coating: best abrasion resistance, requires aliphatic topcoat for UV stability, used where high foot traffic or impact resistance is needed.

Key Benefits of Spray-On Coatings

Seamless application eliminates the seams that are the primary failure point in sheet membrane systems. No tear-off required — applied directly over most existing substrates. Minimal disruption to building occupants. 10–20-year renewable manufacturer warranties available. Solar reflectance 85%+ reduces cooling costs.

When Coatings Are the Right Solution

Aging TPO, EPDM, metal, or modified bitumen roofs with less than 25% wet insulation are ideal candidates. When replacement cost isn't justified. When a new warranty is needed without the cost and disruption of tear-off.

Cost Comparison

Spray-on silicone coating: $2.00–$5.00/sq ft applied. Full roof replacement: $7.00–$14.00/sq ft. The math is straightforward for qualifying roofs — restoration saves 50–70%.

Pros and Cons of Silicone Roof Coatings (Cost, Warranty, Performance)

Wed, 09 Aug 2017 13:17:21 GMT

Pros and Cons of Silicone Roof Coatings (Cost, Warranty, Performance)

An honest assessment of silicone roof coatings helps building owners make informed decisions. Here are the real pros and cons.

The Pros

Cost: 50–70% less than full replacement at $2–$5/sq ft. Seamless waterproofing: eliminates seam-related leaks entirely. UV stability: doesn't chalk, yellow, or lose flexibility with age. Ponding water resistant: specifically approved for standing water applications. 10–20-year renewable manufacturer warranty. Zero tear-off waste or disruption. Applicable over most commercial substrates. Fast installation — most roofs completed in days.

The Cons

No insulation value: silicone coating adds R-0 — for insulation improvement, spray foam is needed. Cannot correct slope or drainage: ponding water issues require foam or structural correction. Substrate condition dependent: requires less than 25% wet insulation and acceptable membrane adhesion. Requires manufacturer-approved contractor: not all roofing companies can issue manufacturer warranties. Slippery when wet (without granules): smooth silicone surfaces require granule application in foot traffic areas.

When Silicone Is the Right Choice

Aging TPO/EPDM/metal roofs in acceptable condition. When cost minimization is the primary goal. When insulation improvement isn't needed. When ponding water is present (where silicone's specific ponding approval is an advantage).

When It's Not the Right Choice

When wet insulation exceeds 25%. When slope correction is needed. When significant insulation improvement is a goal — use spray foam instead.

Silicone Restoration Membrane: Installation and Performance

Thu, 03 Aug 2017 12:38:58 GMT

Silicone Restoration Membrane: Installation and Performance

The silicone restoration membrane (SRM) transforms aging commercial roofs into freshly warranted systems at a fraction of replacement cost. Here's how it works.

What Is an SRM?

A silicone restoration membrane is a high-solids silicone coating applied at 20–30 mils over an existing commercial roofing membrane (TPO, EPDM, metal, or modified bitumen). It creates a continuous seamless film over the entire existing surface, sealing all seams and issuing a new manufacturer warranty.

Installation Process

Core sampling to verify eligibility → wet insulation removal and replacement → power washing → seam and flashing repairs with reinforced fabric tape → primer application (where required) → two-coat silicone application at required mil thickness → granule broadcast at foot traffic areas → third-party inspection → manufacturer warranty issuance.

Performance Characteristics

Solar reflectance: 85%+ (exceeds most energy code requirements). Thermal emittance: 90%+. Ponding water resistance: approved for standing water applications. UV stability: doesn't chalk, yellow, or lose flexibility over the warranty period. Flexibility: maintains performance from -80°F to 300°F+.

Warranty Options

10, 15, or 20-year manufacturer warranties based on coating thickness. Renewable at warranty end with recoat. Compared to full replacement warranties that require full replacement at expiration — SRM's renewable warranty is a significant long-term advantage.

3 Common Problems & Solutions of Single-Ply Membrane Roofing

Mon, 24 Jul 2017 12:05:13 GMT

3 Common Problems & Solutions of Single-Ply Membrane Roofing

Single-ply membranes (TPO and EPDM) dominate commercial roofing but have predictable failure modes. Here are the three most common problems and how to address them.

Problem 1: Seam Failure

The most common single-ply problem. TPO seams are heat-welded; EPDM seams use adhesive tape. Both fail over time from thermal cycling, UV exposure, and aging. Seam failure creates direct water entry points. Individual seam repair is temporary when the membrane is aging — new failures emerge near repaired areas. Best solution for widespread seam failure on aging membranes: silicone coating restoration, which seals all seams simultaneously under a new manufacturer warranty.

Problem 2: Flashing Failure

Flashings at penetrations, parapets, and walls are the second most common failure point. Traditional metal and membrane-based flashings are particularly vulnerable at corners and transitions. Prevention: annual inspection and proactive re-sealing. Solution: silicone coating with reinforced fabric at all flashing transitions provides a durable, flexible repair.

Problem 3: Membrane Shrinkage

EPDM membranes can shrink over time, particularly when installed adhered (not ballasted). Shrinkage pulls flashings away from walls and parapets, creating gaps. Signs: separation at wall/parapet terminations, horizontal wrinkles across the field. Solution: re-secure and reflash terminations. If widespread shrinkage, coating restoration may be needed to stabilize the system.

Single-Ply Membrane vs Built-Up Roofing: Which is Best for Commercial Buildings?

Tue, 18 Jul 2017 12:33:31 GMT

Single-Ply Membrane vs Built-Up Roofing: Which is Best for Commercial Buildings?

Single-ply membrane and built-up roofing (BUR) are both proven commercial roofing systems. Here's how they compare across the factors that matter most.

Cost

Single-ply (TPO/EPDM): $5–$9/sq ft installed. BUR: $8–$14/sq ft installed. Single-ply is significantly less expensive to install.

Durability and Lifespan

Single-ply: 15–25 years typical lifespan; seam-dependent — seams are the primary failure point. BUR: 20–30+ years if properly maintained; multiple redundant layers provide inherent durability. BUR has a longer track record for longevity.

Maintenance Requirements

Single-ply: regular seam inspection and re-sealing critical. BUR: annual gravel redistribution and crack sealing; gravel protects from UV but can obscure damage. Both require regular professional maintenance to achieve designed lifespan.

Restoration Options

Both can be restored with silicone coating (BUR requires gravel removal first or specialized coating over gravel). Both avoid tear-off cost when eligible for restoration.

The Bottom Line

For new construction on a budget: TPO is the most common choice. For long-term durability investment: BUR or modified bitumen offers longer proven life. For existing roofs approaching end of warranty: both qualify for silicone restoration, making the comparison less relevant for building owners managing existing systems.

Do I Need a Commercial Roof Inspection or Survey?

Mon, 10 Jul 2017 14:58:54 GMT

Do I Need a Commercial Roof Inspection or Survey?

"Inspection" and "survey" are often used interchangeably but describe different services with different scopes and purposes. Here's how to know which one you need.

The Roof Inspection

A standard roof inspection is a visual assessment by a qualified roofing professional. It covers: membrane condition and visible deterioration, seam and flashing integrity, penetration seal condition, drain and gutter condition, visible ponding areas, and any obvious damage. Typical duration: 1–3 hours for most commercial roofs. Cost: $0.005–$0.02/sq ft. Best for: annual maintenance, post-storm damage assessment, pre-purchase review of commercial property.

The Roof Survey

A roof survey includes inspection plus diagnostic testing. Full survey adds: infrared scanning (moisture mapping), core sampling (wet insulation confirmation), slope and drainage analysis, and comprehensive written report with photos. Typical duration: full day plus lab results. Cost: $0.02–$0.05/sq ft. Best for: pre-restoration/replacement decision-making, warranty claims, building purchase due diligence on older roofs.

Which One Do You Need?

Annual checkup or post-storm assessment: inspection. Considering restoration or replacement, multiple leaks appearing, building purchase, or warranty claim: full survey. If your roof is over 15 years old and you haven't had a survey in the last 3 years, schedule one regardless of visible condition. Moisture damage that an inspection can't see may already be limiting your restoration options.

How Much Does Single-Ply Commercial Roofing Really Cost?

Mon, 19 Jun 2017 09:00:28 GMT

How Much Does Single-Ply Commercial Roofing Really Cost?

Single-ply roofing prices quoted online often don't reflect real project costs. Here's an honest breakdown.

Base Cost Ranges

TPO (60-mil): $5.00–$8.00/sq ft installed. TPO (80-mil, premium): $6.50–$9.50/sq ft installed. EPDM (60-mil, fully adhered): $5.50–$8.50/sq ft installed. EPDM (60-mil, ballasted): $4.50–$7.00/sq ft installed. These ranges apply to straightforward commercial roofs with standard complexity.

What Drives Cost Higher

Old roof tear-off: add $1.00–$3.00/sq ft. Multiple tear-off layers: add further $0.50–$1.50/sq ft per layer. Wet insulation removal and replacement: add $1.00–$2.50/sq ft for affected areas. High roof complexity (many penetrations, HVAC units, slopes): 15–30% premium. Emergency or fast-track scheduling: 15–25% premium.

What Drives Cost Lower

Large roof size (economies of scale, particularly over 50,000 sq ft). Single layer tear-off vs. no tear-off. Competitive market with multiple qualified bidders. Off-peak scheduling.

The Alternative Comparison

For a 10–15 year old single-ply roof showing seam wear, silicone coating restoration at $2–$5/sq ft is typically 40–60% less than a new TPO installation — with a comparable manufacturer warranty. Before accepting a replacement proposal on an aging roof, get a restoration assessment first.

Single-Ply Membrane Roofing: TPO vs. EPDM Comparison

Thu, 15 Jun 2017 09:00:08 GMT

Single-Ply Membrane Roofing: TPO vs. EPDM Comparison

TPO (thermoplastic polyolefin) and EPDM (ethylene propylene diene monomer) are the two dominant single-ply membrane systems. Here's how they actually compare.

Heat Reflectivity

TPO: white surface reflects 80%+ of solar radiation — meets Energy Star requirements by default. EPDM: traditionally black/dark gray, absorbs heat. White EPDM available but less common and more expensive. Winner: TPO for reflectivity.

Seam Technology

TPO: heat-welded seams — when done properly, can be stronger than the membrane itself. EPDM: adhesive-tape or liquid adhesive seams — generally less reliable long-term than heat welds. Winner: TPO for seam integrity.

Cold Weather Performance

EPDM: excellent flexibility at low temperatures; long track record in northern climates. TPO: can become brittle in extreme cold, particularly older formulations. Winner: EPDM in harsh cold climates.

Cost

TPO (60-mil, fully adhered): $5.00–$8.00/sq ft. EPDM (60-mil, fully adhered): $5.50–$8.50/sq ft. Ballasted EPDM can be less expensive at $4.50–$7.00/sq ft. Generally comparable; EPDM is slightly more expensive fully adhered.

The Bottom Line

For most commercial applications: TPO is the better performing system due to superior seam technology and built-in reflectivity. EPDM has advantages in cold climates and has a longer performance track record. Both are solid choices for new construction and qualify for silicone coating restoration when they age.

Single-Ply Membrane vs Spray Polyurethane Foam: Which is Best for Your Building?

Tue, 13 Jun 2017 09:00:42 GMT

Single-Ply Membrane vs Spray Polyurethane Foam: Which is Best for Your Building?

Single-ply membrane (TPO/EPDM) and spray polyurethane foam (SPF) are fundamentally different commercial roofing systems. Here's how they compare across the factors building owners care about most.

Seams

Single-ply: seam-dependent system; seams are the primary failure mode. SPF: seamless system; no seams to fail.

Insulation

Single-ply: R-0 from the membrane itself (requires separate insulation board). SPF: R-6.5/inch integrated insulation and waterproofing in one layer.

Slope Correction

Single-ply: cannot correct drainage; requires separate tapered insulation at significant cost. SPF: builds slope naturally during application; ideal for correcting poor drainage at no extra step.

Lifespan and Warranty

Single-ply: 15–25-year warranty; requires full replacement at end of life. SPF: renewable warranty — recoat extends warranty indefinitely; foam itself lasts 50+ years.

Cost

Single-ply (new): $5–$9/sq ft. SPF (new): $4–$8/sq ft at similar warranty duration, with better performance characteristics.

Best Applications

Single-ply: new construction, simple flat roofs, budget-constrained projects. SPF: restoration, buildings with drainage issues, cold climates needing insulation improvement, buildings wanting the lowest long-term lifecycle cost.

Pros and Cons of Single-Ply Membrane Roofing (Cost, Durability, Performance)

Wed, 07 Jun 2017 09:00:30 GMT

Pros and Cons of Single-Ply Membrane Roofing (Cost, Durability, Performance)

Single-ply membrane roofing (TPO and EPDM) dominates commercial roofing for good reasons — but it's not without significant drawbacks. Here's the honest assessment.

The Pros

Cost-effective upfront installation: $5–$9/sq ft is less expensive than many alternatives. Light weight: doesn't add significant structural load. Reflective surface (TPO/white): meets Energy Star and LEED requirements. Flexible installation options: fully adhered, mechanically fastened, or ballasted. Widely available from many qualified contractors. 15–20-year manufacturer warranties standard.

The Cons

Seam-dependent: the system's weakest point is also its most common — seams account for the majority of commercial roof leaks. No insulation value: membrane alone is R-0, requiring separate insulation layers. Replacement required at end of warranty: no renewal option means full tear-off cost every 15–20 years. EPDM absorbs heat (black/gray surface): offsets reflective advantage of white membranes. Vulnerable to ponding: while TPO has some ponding resistance, sustained ponding accelerates wear. Short-term economics mask long-term cost: lifecycle cost is higher than spray foam with renewable warranty.

The Bottom Line

Single-ply is a reasonable new construction choice. For existing single-ply roofs approaching end of warranty, restoration with silicone coating typically delivers better value than repeat replacement.

My Commercial Roof is Leaking: What Can I Do?

Wed, 24 May 2017 13:00:12 GMT

My Commercial Roof is Leaking: What Can I Do?

A commercial roof leak demands prompt action. Here's a practical, step-by-step guide for what to do when your roof is actively leaking.

Immediate Steps (Today)

Protect your interior — move equipment, valuables, and inventory away from the leak area. Place buckets and absorbent materials to limit water damage. Document everything with photos and video for insurance purposes. If water is near electrical panels, lighting, or equipment, shut off power to affected areas and call an electrician before proceeding. Contact a qualified commercial roofing contractor for emergency service.

Emergency Temporary Repairs

A qualified roofing contractor can apply emergency tarping or temporary sealant to stop active water entry. This is not a permanent solution — it's a bridge to allow proper diagnosis and repair. Do not let temporary repairs delay proper assessment.

Proper Diagnosis (Next 1–2 Weeks)

Once active leaking is controlled, commission a proper assessment: roof inspection to identify visible breach points, infrared scan to map moisture extent in insulation, and core samples to confirm wet insulation areas. This data determines whether the roof needs targeted repair, restoration, or replacement.

Long-Term Solution

If your roof is actively leaking: targeted repair if failure is isolated and the overall system is sound; silicone coating restoration if seam failure is widespread but wet insulation is under 25%; full replacement if wet insulation is extensive. Don't let a crisis force you into a rushed replacement decision without proper assessment data.

Spray Polyurethane Foam (SPF) Roofing Contractor Qualifications

Mon, 22 May 2017 13:45:55 GMT

Spray Polyurethane Foam (SPF) Roofing Contractor Qualifications

Spray foam roofing requires specialized equipment, training, and certifications. Hiring an unqualified contractor is one of the most common reasons SPF roofs fail prematurely. Here's what to look for.

Manufacturer Approval

The most important credential: the contractor must be approved by the foam and coating manufacturer whose warranty you intend to receive. Manufacturers maintain lists of approved applicators. If a contractor isn't on the manufacturer's approved applicator list, they cannot issue a manufacturer warranty — regardless of what they claim.

SPFA Certification

The Spray Polyurethane Foam Alliance (SPFA) offers professional certification programs. Certified contractors have demonstrated knowledge of proper installation techniques, safety procedures, and material handling. Not all qualified contractors have SPFA certification, but it's a meaningful credential.

Equipment

Qualified contractors use proportioner equipment capable of maintaining precise 1:1 ratio mixing and temperature control. Ask about their equipment model and age — poorly maintained equipment produces off-ratio foam that fails prematurely.

Questions to Ask

Which manufacturers are you approved by? Can you provide references from commercial SPF projects in the last 2 years? What proportioner equipment do you use? Will you conduct core sampling before proposal? Will the warranty be issued directly from the manufacturer?

Red Flags

Cannot name a specific manufacturer whose warranty they issue. No core sampling in the proposal process. No references for commercial SPF projects. Significantly lower price than other quotes (SPF requires proper material quantities; underbidding means cutting corners).

Spray Foam Roofing vs. Built-Up Roofing: Which is Best?

Wed, 17 May 2017 12:58:15 GMT

Spray Foam Roofing vs. Built-Up Roofing: Which is Best?

Spray polyurethane foam (SPF) and built-up roofing (BUR) are two very different approaches to commercial waterproofing. Here's how they compare.

Seams

BUR: multiple plies bonded with asphalt — laps and seams exist at every ply overlap; they are the most common failure point. SPF: completely seamless monolithic system; there are no seams to fail. Advantage: SPF.

Insulation

BUR: separate insulation board required; R-value depends on board type and thickness. SPF: integrated insulation and waterproofing at R-6.5/inch — highest R-value of any roofing material. Advantage: SPF.

Weight

BUR: heavy — multiple layers of felt and asphalt add significant dead load. SPF: very lightweight — typically less than 1 lb/sq ft for a 2-inch application. Advantage: SPF.

Installation Disruption

BUR: hot asphalt application creates odor and disruption. SPF: odorless after cure, minimal disruption, no hot work. Advantage: SPF.

Longevity and Warranty

BUR: 20–30+ year proven lifespan; requires replacement at end of life. SPF: foam itself lasts 50+ years; warranty renewable indefinitely with recoat. Advantage: SPF for lifecycle.

When BUR Has an Edge

BUR has a longer track record (decades of documented performance data). For heavily trafficked roofs requiring physical durability, multi-layer BUR provides redundancy. But for most commercial roofing decisions today, SPF's advantages are compelling.

Spray Foam Roofing Issues: 7 Problems Every Building Owner Should Know

Tue, 16 May 2017 12:36:02 GMT

Spray Foam Roofing Issues: 7 Problems Every Building Owner Should Know

Spray foam is one of the best commercial roofing systems available — but it has specific failure modes that building owners should understand. Here are the 7 most common problems.

1. Off-Ratio Mixing

Improperly calibrated equipment produces foam with incorrect A:B ratios. Off-ratio foam is brittle, blisters, and fails prematurely. Prevention: hire approved contractors with properly maintained proportioner equipment.

2. Overspray

Wind during application carries foam droplets onto adjacent property and vehicles. Prevention: wind monitoring, wind screens, proper scheduling.

3. Blistering

Blisters form when foam is applied over wet insulation, trapping moisture. Prevention: mandatory core sampling and wet insulation removal before application.

4. UV Degradation Without Topcoat

Uncoated foam degrades rapidly in UV exposure — visibly within weeks. SPF always requires a UV-protective topcoat (typically silicone). Prevention: apply topcoat within the manufacturer-specified window after foam application.

5. Topcoat Erosion

The silicone topcoat wears over time and eventually erodes, exposing foam. Prevention: recoat per manufacturer recommendation (typically every 10–20 years based on warranty tier).

6. Mechanical Damage

Foot traffic from HVAC maintenance, sharp tools or equipment, and hail can puncture foam. Prevention: apply granules in all foot traffic areas; promptly repair any punctures with compatible sealant.

7. Inadequate Slope

If the existing roof has severe drainage problems, foam alone may not create adequate slope without very thick applications. Prevention: assess drainage needs during design phase; may require structural correction in severe cases.

Best Commercial Roofing Contractors in Atlanta: What to Look For

Tue, 02 May 2017 09:00:01 GMT

Best Commercial Roofing Contractors in Atlanta: What to Look For

Choosing a commercial roofing contractor in Atlanta is about more than price. Here are the qualifications and selection criteria that actually matter for getting quality work and valid warranties.

Manufacturer Approval is Non-Negotiable

Any contractor claiming to offer a manufacturer warranty must be on that manufacturer's approved applicator list. This applies to spray foam contractors (Carlisle, Versico, etc.) and coating contractors (Gaco, Tremco, Henry, etc.). Verify directly with the manufacturer before signing a contract.

Commercial-Specific Experience

Residential roofing contractors are not qualified for commercial work. Look for: demonstrated commercial project portfolio with verifiable references, experience with your specific roof type (TPO, EPDM, metal, foam), and OSHA compliance documentation for commercial job sites.

Proper Licensing and Insurance

Georgia requires roofing contractors to hold a valid state license. Verify: contractor's license number with the Georgia Secretary of State, current general liability insurance ($1M+ per occurrence minimum), workers' compensation coverage for all employees. Ask for certificates of insurance; verify they're current.

The Proposal Process Reveals Everything

A qualified contractor will: perform core sampling before finalizing a restoration proposal, provide written scope of work with material specifications, identify specific warranty terms and manufacturer. Any contractor proposing restoration without core samples, or offering a warranty without specifying the manufacturer, is a red flag.

West Roofing Systems

West Roofing Systems is a nationally operating commercial roofing contractor specializing in spray foam and silicone coating restoration systems. Manufacturer-approved. Serving commercial building owners throughout the Southeast and nationwide.

Best Commercial Roofing Contractors in Cleveland, OH

Mon, 17 Apr 2017 12:15:55 GMT

Best Commercial Roofing Contractors in Cleveland, OH

Cleveland's freeze-thaw cycles, lake-effect snow loads, and temperature extremes make commercial roofing contractor selection especially important in Northeast Ohio. Here's what matters.

Cold Climate Experience is Critical

Cleveland's climate creates specific challenges: repeated freeze-thaw cycles stress membrane seams, heavy snow loads stress poorly drained roofs, and temperature extremes require materials rated for wide temperature ranges. Look for contractors with documented commercial experience in Northeast Ohio specifically — not contractors who primarily work in milder climates.

Manufacturer Approval Verification

Always verify directly with the manufacturer that the contractor claiming to offer a warranty is currently on their approved applicator list. This is the single most important credential check.

Ohio Licensing and Insurance Requirements

Ohio roofing contractors must hold appropriate state and local licenses. Verify: current state contractor license, general liability insurance ($1M+ minimum), workers' compensation. Ask for current certificates of insurance before work begins.

System Selection for Cleveland

In Northeast Ohio's cold climate: EPDM has a strong performance track record in freeze-thaw conditions. Spray foam with silicone topcoat handles Cleveland's conditions well and provides excellent insulation value — particularly valuable for reducing heating costs. Polyiso insulation degrades in cold temperatures; XPS or EPS may be preferable for roof assemblies in Cleveland's climate zone.

West Roofing Systems

West Roofing Systems is headquartered in the Cleveland area and has decades of experience with commercial roofing in Northeast Ohio. Specializing in spray foam and silicone restoration systems for commercial buildings throughout the region.

Spray Foam Roofing: Pros and Cons You Need to Know

Thu, 06 Apr 2017 15:55:59 GMT

Spray Foam Roofing: Pros and Cons You Need to Know

Spray polyurethane foam roofing is often described as the best commercial roofing system available. Here's an honest assessment of its real advantages and limitations.

The Pros

Seamless: no seams means no seam failures — the #1 cause of commercial roof leaks is eliminated. Highest R-value: R-6.5/inch provides more insulation per inch than any other commercial roofing material. Self-flashing: foam wraps around penetrations without separate flashing materials. Slope correction: foam builds slope, fixing drainage problems other systems can't address. Renewable warranty: recoat every 10–20 years extends the warranty indefinitely — no tear-off required ever. Lightweight: less than 1 lb/sq ft avoids structural loading concerns. Goes over existing systems: eliminates tear-off cost and landfill waste.

The Cons

Requires approved applicator: not every contractor can install it properly or issue a manufacturer warranty. Overspray risk: wind during application requires management (wind monitoring, screens, scheduling). Topcoat required: foam must have UV-protective silicone coating; topcoat needs periodic recoating. Temperature restrictions: cannot apply in temperatures below 40°F or in precipitation. Requires dry substrate: wet insulation must be removed before application — adds cost when present.

The Bottom Line

For commercial roofing restoration, spray foam offers the most complete combination of waterproofing, insulation, slope correction, and renewable long-term warranty of any system available. The limitations are manageable with qualified contractors and proper planning.

Spray Polyurethane Foam (SPF) Roofing: Installation and Performance

Wed, 29 Mar 2017 12:34:22 GMT

Spray Polyurethane Foam (SPF) Roofing: Installation and Performance

Spray polyurethane foam (SPF) roofing is one of the most technically advanced commercial roofing systems available. Here's a comprehensive overview of how it works and what to expect.

What SPF Roofing Is

Two liquid components — isocyanate (A-side) and polyol (B-side) — are heated, pressurized, and mixed at the spray gun tip. The mixture expands 20–30 times its liquid volume within seconds, creating a rigid closed-cell foam that simultaneously provides insulation and waterproofing. A UV-protective topcoat (typically silicone) is applied over the cured foam to complete the system.

Performance Characteristics

R-value: R-6.5/inch — highest of any roofing insulation. Compressive strength: 25–60 psi depending on foam density. Water absorption: less than 3% by volume (closed-cell structure). Temperature range: -100°F to 250°F+. Wind uplift: excellent — foam adheres directly to substrate. Hail resistance: class 4 (highest) rating achievable with appropriate topcoat and granule specifications.

System Lifespan

The foam itself lasts indefinitely if protected from UV degradation. Silicone topcoat lasts 10–20 years depending on warranty tier. System is renewed by recoating — no tear-off, no replacement. A properly maintained SPF roof has documented lifespans exceeding 50 years with multiple recoat cycles.

Cost and Warranty

New installation: $4–$8/sq ft. 10, 15, or 20-year renewable manufacturer warranties. Lifecycle cost is lower than any system requiring replacement at warranty end. For qualifying existing roofs: spray foam restoration at $4–$8/sq ft vs. full replacement at $7–$14/sq ft.