Roofing Systems

Spray polyurethane foam roofing systems are constructed by spraying a two-component liquid that forms the base of the adhered roof system. The mixed liquid expands 30 times its original volume in a matter of seconds, forming a rigid foam plastic that chemically bonds to the surface to which it is sprayed. The closed cell structure of the foam provides the waterproofing, but must be protected by coatings or other coverings to prevent UV surface degradation. SPF can be installed in various thicknesses to provide slope to drain or meet a specified R-value.

Life Expectancy:
Life expectancy depends on the original application and long term maintenance of the system. It is currently estimated at approximately 30 years to indefinite depending on upkeep, as the SPF changes very little with age. Semi-annual inspections and inspections after events such as hails storms, tornadoes, and hurricanes are recommended to insure longevity of the system. Re-coating at regularly scheduled intervals extend the life of system and is require to achieve full life cycle.

Why We Use SPF on Roofs:

SPF roofs can last indefinitely and hold their insulation value forever. They withstand extraordinary weather events – which is why SPF was chosen for the new roof on the Norfolk Scope Arena.  This roofing system excels when:

• Additional insulation is required
• Critical operations inside cannot be interrupted by leaks
• The roof substrate has numerous penetrations
• Roof deck is an unusual configuration
• Roof is in a wind-prone area
• Lightweight materials are required
• Slope must be added to provide positive drainage

SPF on Roofs:

• Can be applied rapidly with little or no disruption to the facilities.
• Requires fewer people to apply, reducing the likelihood of accidents.
• Eliminates the need for multiple levels of roofing required by conventional systems.
• Conforms to all roof shapes and types.
• Can be applied directly over most commercial construction materials.
• Produces energy savings of 30% compared to alternative roofing systems.
• Self-flashing and seamless – therefore no leaks.
• Is highly chemical resistant.
• Requires minimal upkeep to remain under warranty.
• Lasts forever if properly maintained.

Cost:
Varies widely depending on numerous a number of factors including: thickness, types and thickness of coating and covering, degree of substrate penetration, and availability.  When compared to other roofing systems having the same R-value, slope considerations and warranty, SPF roofs are usually more economical.  When the life cycle costs of all roofing systems are compared, SPF is the most economical choice by a very wide margin.

Warranties:
Numerous warranties are available from RPC Industries, Inc. and our vendors depending on the need and desires of the end user.  We offer coating warranties to full system 20-year warranties including unlimited wind uplift and hail coverage up to 3 inches.  New penetrations in the roofing system are easily installed and become a part of the warranted roofing system.

Carlisle’s FleeceBACK Fully Adhered Roofing System features a patented impact resistant, low-rise, two component, insulating polyurethane adhesive. Flexible FAST Adhesive is applied using state-of-the-art heated proportioning pumps delivering both components to a mixing spray gun for distribution onto the surface.  Within 15 minutes Flexible FAST Adhesive cures to form a tenacious, mechanical bond between the substrate and FleeceBACK membrane.  Flexible FAST Adhesive is considered one of the best insulation adhesives on the market resulting in a non-intrusive system application.

Fleece adds toughness and durability:

• External fleece reinforcement creates a very thick 100-, 115- and 145-mil EPDM sheet and 100-, 115- and 135-mil TPO sheet
• Choice of Sure-Seal (black) or Sure-White (white) EPDM
• Choice of Sure-Weld in white or tan TPO
• FleeceBACK 100 offers 40% greater puncture resistance than 60-mil EPDM and 180% greater tear resistance
• Greater puncture resistance than Modified Bitumen
• 67% fewer seams than Modified Bitumen
• Passes FM’s severe hail test

EPDM excels in a wide range of temperatures and conditions and demonstrates superior UV and weather resistance as well as sheet flexibility and high elongation. EPDM membranes are available in several thicknesses, with or without polyester scrim reinforcement, and can be installed in ballasted, mechanically fastened or adhered applications.  With wide widths and fewer seams, EPDM systems improve efficiency during installation. EPDM offers a quick, clean, inexpensive solution. 

What are Thermoset Membranes?
Thermoset membranes are vulcanized, or chemically cross-linked. In this process, curatives or sulfur are added to rubberized materials which makes them more durable through crosslink chains. These materials are much less gummy than thermoplastics yet have superior mechanical assets. Thermoset membranes come in five distinct subtypes, but the most common is EPDM – comprised mainly of propylene and ethylene and comes primarily in 7.5 – 50 foot wide sheets which are 45-60 mils in thickness. Liquid adhesives or tapes are normally used to seal the seaming of EPDM membranes, and the colors are white or black.

Many thermoset roofs are either ballasted or fully adhered, although some larger commercial applications may prefer the optional mechanical attachments. When you generally hear someone discussing ‘rubber roofs’, they are usually talking about EPDM roofing materials.

Why It Works Well
Commercial building owners who wish to apply roofing materials for longevity would prefer the thermoset membranes due to their stronger manufacturing qualities over other single-ply membranes. This material also works perfectly in all climates, is great for flat roofs, and doesn’t easily wear down. In cold-weather climates, black thermoset membranes will absorb heat, whereas in warmer climates, white membranes are recommend to reflect this heat load. Finally, this material is cost-effective in accordance with how long it will last the building owner.

Would This Material Work For My Commercial Building?
Deciding on the proper long-term roofing system depends on various factors: climate, visual appeal, warming/heating properties, building characteristics, and so on. RPC Industries, Inc. can inspect your roof in relevance to various factors and make several recommendations to you. Thermoset membranes do possess many great characteristics, with durability leading the way. For deeper insight into comparing your current roof with the potential of thermoset membrane materials being applied, contact us today.

Thermoplastic single-ply membrane roofing systems are often used on commercial roofs and have some distinct qualities. We’ll talk about what this material is, why it works well for commercial structures and why you should consider this type of roofing material.

The material differs from thermosets (EPDM) in the fact there is no chemical cross-linking.  It is distinguished solely for its repetitious ability to be cooled and reheated.  The seams of this material are typically heat welded with either solvents or hot air. 

Types of thermoplastic membranes:

• PVC, or polyvinyl chloride, are calendared, extruded or spread coated while being reinforced with scrim, polyester or distinct glass fiber mats. They range in sizes, usually 6-12 feet wide and 45-90 mils thick. Gray and white are the most common PVC membrane colors. It provides excellent weathering characteristics, high tensile strength and long-term flexibility. It also exhibits excellent resistance to harsh chemicals and industrial pollutants.
• PVC Alloys such as Tripolymer Alloys, Nitrile Alloys, Ethylene Interpolymer or Copolymer Alloys make up the compounded thermoplastics, commonly known as PVC Alloy.
• TPO, or Thermoplastic Olefin, are similarly calendared to PVC yet are lamination-based in manufacturing. Two different polymers, polypropylene and ethylene propylene, are forged into sheets with polymer added to backing. They are flame-retardant, UV absorbent and are stronger than most other Thermoplastic membranes. It is designed for use in mechanically fastened and adhered roofing applications in new, re-roof and re-cover roof constructions.
• Chlorinated Polyethylene
• Polyolefin

PVC and TPO are the most commonly used thermoplastic membranes due to their material qualities, although some applications will use the latter two.

Why It Works Well
Many hot and dry climates favor this material because of extreme concentration of ultraviolet rays constantly beaming down on the roof. Whereas tar-based roofs can radiate heat inwards since it lacks UV-blocking properties, Thermoplastic membranes generally carry much stronger UV protection which reflect the UV rays back up.

Would This Material Work For My Commercial Roof?
General practice is to apply thermoplastic sheets to flat roofing structures since they’re not particularly flexible on ridged roofs. If your industrial, commercial, retail or institutional roofing system is flat and needs something that will block the sun’s damaging rays along with having cost-effectiveness in mind, this material would work perfectly for you. RPC personnel are experts in thermoplastic roofing materials and can suggest the correct application on a per-client basis.

There are three general types of metal roof systems used for steep-slope applications: Architectural, Structural, and Metal Shingle Panels. Architectural metal panel roof systems are “water shedding” and intended for use on steep slope roofs. Structural metal panel roof systems are installed over a large variety of substrates.  Solid roof sheathing, or decking, is required for architectural metal panel roof systems.

Steep Slope roof systems are typically composed of individual components as an assembly typically consists of three primary parts:

• Roof Deck – the structural substrate
• Underlayment – sheet material installed between the roof deck and roof system providing temporary roof protection until the roof covering is installed and provides a secondary weatherproofing barrier. (felt or paper)
• Roof Covering – The roof covering is the external metal water shedding material.

Because architectural metal panel roof systems typically are designed to be used on steep slopes that will shed water rapidly over the metal panels’ surface, the seams typically are not watertight. Many architectural metal roof systems are well suited for use on roof slopes of 3 inches per foot (14 degrees) or greater.

Metal Panel Roof Systems for Low-Slope Applications

Metal panel systems for low slope applications are the preferred metal roof covering for commercial, institutional and industrial buildings. Generally used in roof pitches ranging from ¼:12 to 3:12. The systems consists of interlocking panels commonly called standing seam roofing that run vertically along the roof surface. Varying in weight form 40-135 lbs, it is the lightest roofing product and easiest to install. The system itself places fewer demands on a building’s structural support system. Some require machine seaming during installation to ensure a watertight seal. A seaming tool is simply rolled along the panels to crimp the panel seams together.

There are two types of metal paneling typically used: structural and non-structural (architectural). However structural is the most commonly used for its water barrier characteristics. Structural attaches directly to purlins or lathe boards and does not require any sort of solid support beneath it. Because of their interlocking and active fastening systems metal roof panels are designed to meet the requirements of ASTM E1592, UL580, UL1897 and other severe wind and uplift tests (winds up to 140 mph). No denting should occur on 26 gauge or thicker steel applied over a solid backing. Softer metals may be susceptible to denting. When on the roof it is recommended that you wear soft soled shoes for both traction and protection of the finish.

RPC Industries, Inc. uses advanced coating materials with state-of-the-art application technology and equipment to provide coating solutions to meet all of your material protection and maintenance needs. Our portfolio of coatings provide UV-resistance, waterproofing, and protection from impact, abrasion, and corrosion. Our coatings are recommended for use on multiple materials including polyurethane foam, wood, concrete, metal, plastics, and all other existing conventional roofs.  We provide coatings for every application from Energy Star certified reflective roof coatings to custom colored coating systems. 

Metal Roof Restoration:
Metal roof restoration is an excellent service we offer to building owners. Common throughout the Southeast, metal buildings (and metal roofs in particular) comprise the majority of industrial buildings. They are good buildings but often have their fair share of problems as they age. Here is why:

• A metal roof in Virginia that is only ten years old will have gone through at least 3,650 expansion and contraction cycles as they warm during the day and cool at night. That number could be far higher if you factor in midday rain showers that instantly cool the metal, only to expand again when the sun comes out. Regularly, we record temperatures of 140+ degrees on metal roofs.
• This relentless cycle of expanding and shrinking metal causes fasteners to back out and panel seams to break their seals, both creating leaks.
• Ridge vents start to leak as heat and UV radiation break down foam rubber bellow that was originally installed to keep rain out.
• Skylights begin to deteriorate the moment they are installed. Normally comprised of fiberglass, they are a constant source of leaks.

Our Solution:

• After we pressure wash the roof with 3,600 psi water, we hand tighten or replace each and every fastener. Each fastener then is treated with a butter-grade Silicone roofing membrane. Imagine a dollop of cookie dough on each fastener.
• Next, we apply an epoxy primer to the metal roof to kill any corrosion and provide a superior bond for our membrane.
• On most metal roofs we apply sprayed-in-place polyurethane foam to penetrations, the ridge, and side (rake) areas of metal roofs. This extra step is extremely effective in bridging gaps and sealing the most common leak-prone areas.
• Finally, we apply Silicone roof membrane to the entire roof. Available in bright white with 88% reflective index, this instantly levels out the temperature swings that cause so many problems. As important as thermal reduction, your roof is now waterproofed by one of the most durable roof coatings ever made.
• All of our restoration jobs are backed by our manufacturer partner’s 10 year system warranty. It’s the best in the business and covers labor and materials for 10 years.

Built-Up Roof (Tar and Gravel) Restoration:
Our proven solution to restore an old tar and gravel roofing system will end your constant problems. Ponding water and UV radiation combine to break down the asphalt and imbedded fiberglass plies that make up the base of the system causing the issues that all BUR owners experience. Our coating systems protects against these known shortfalls and extends the life of the roof.

Modified Bitumen Roof Restoration:
Modified Bitumen, or rolled roofing, is our third most-seen style of roofing. Most manufacturers claim their modified will last 12-15 years but our experience is that by year 7, or earlier, modified is showing significant signs of decay. However, the service life of rolled roofing can often be extended by eliminating the disastrous effects of the sun and making it waterproof. Here is how it is done:

• Pressure wash the roof and perform any needed repairs to the modified roof surface (seams and penetrations are of particular concern)
• Apply primer to the roof surface
• Apply silicone roof membrane (the dynamics of water flow and heat transfer instantly change with the application of the coating)