- Highest R-value per inch of any commercial roofing insulation (R-6.5 per ASHRAE 90.1)
- Closed-cell foam eliminates thermal bridging at fasteners, seams, and penetrations, a primary failure mode in mechanically-attached single-ply systems
- Continuous insulation envelope exceeds IECC and ASHRAE prescriptive requirements without additional rigid board
SPFA, Oak Ridge National Laboratory (ORNL)
- Field data from IECC Climate Zone 5A buildings shows 15–30% reduction in annual HVAC energy costs after SPF application (ORNL Roof Savings Calculator methodology)
- Ford Motor Co. Sheldon Road plant (Plymouth Twp., MI): annual energy costs reduced from $876K to $412K post-SPF installation, per plant engineer M.M. Forester
- Combined air-sealing + insulation effect outperforms rigid-board-over-membrane assemblies at equivalent R-value
ORNL Roof Savings Calculator, Ford Motor Co.
- Closed-cell SPF typically absorbs <2% moisture by volume when tested per ASTM D2842 (ASTM C1029 max: 5%), eliminating wet-insulation R-value degradation
- Adhered application adds measurable uplift resistance; NIST TN 1476 (2006) documented SPF roofs intact after Hurricane Katrina while mechanically fastened systems failed
- No fastener penetrations means no corrosion points, no back-out, no progressive membrane fatigue
SPFA, NIST TN 1476
- Silicone coatings maintain flexibility and adhesion through 10,000+ hours accelerated UV weathering (ASTM G154)
- No chalking, cracking, or hardening. Remains elastic across -40°F to 300°F service range
- Sherwin-Williams Uniflex silicone applied at 20–25 mil DFT; renewable topcoat extends system life indefinitely
ASTM G154, Sherwin-Williams Uniflex TDS
- No tear-off required. SPF is spray-applied directly over existing substrate, eliminating demolition cost and landfill waste
- 30-year lifecycle cost is significantly lower than TPO or EPDM tear-off/replace cycles due to eliminated tear-off and reduced maintenance intervals
- Recoatable every 15–20 years at a fraction of original install cost, resetting warranty and extending roof life
NRCA, SPFA
- Initial solar reflectance ≥0.80 / 3-year aged reflectance ≥0.70 (CRRC product-rated values)
- Qualifies for ENERGY STAR® roof products program and contributes to LEED v4 Heat Island Reduction credit
- Reduces roof surface temperature by up to 60°F vs. dark membranes, lowering cooling load and extending HVAC equipment life
CRRC, ENERGY STAR, USGBC
REAL-WORLD CASE STUDIES
Documented SPF Performance Across Building Types, Climates, and Ownership Scenarios
LANDMARK INSTALLATIONS
Post-Katrina SPF Rebuild
After Hurricane Katrina destroyed the Superdome's EPDM membrane in 2005, SPF was selected as the replacement roofing system during the facility's restoration. NIST TN 1476 separately documented that SPF roofs on other Gulf Coast buildings survived Katrina intact while mechanically fastened systems failed.
NIST TN 1476; IRC Project Profile
3.5M SF
Largest documented SPF roof installation in the world. GreenSeal 3.0 closed-cell SPF was applied across the entire roof while Tesla simultaneously installed robotic manufacturing equipment below, with daily roof penetration relocations to maintain watertight integrity throughout construction.
RoofersCoffeeShop Project Profile
Complex Geometry
SPF was selected over the original PVC membrane specification due to the structure's complex curved geometry. Spray application eliminated an estimated 80 semi-loads of rigid insulation and 20-25% material waste inherent in fitting sheet goods to compound curves.
CoatingsPro Magazine; SprayFoam Magazine
OWNERSHIP & ROI
53% Energy Reduction
The ~900,000 SF facility was reroofed with SPF starting in 1989. Plant engineer M.M. Forester documented annual energy bills dropping from $876,000 to approximately $412,000, a 53% reduction in total energy costs.
Ford Motor Co. plant engineer testimonial
FEATURED STUDY
Beginning in 1980, Gerald Scott, P.E. in the Texas A&M Physical Plant began specifying SPF roofing after built-up roofs were failing in as few as 5 years. Scott monitored energy consumption across 27 campus buildings over a 4-year period (1980–1984), documenting that energy savings alone recovered the full cost of the SPF roof system in an average of 4.5 years. Today, TAMU has over 7 million square feet of SPF roofing on campus. Many of the original installations from the early 1980s remain in service with periodic silicone recoats. Texas A&M continues to specify SPF + silicone as its standard roofing system.
“From the time of their construction, and throughout the life of the roof, built-up roofs were major maintenance and repair items. The experience that Texas A&M University Physical Plant has gained since 1974 indicates that no major problem, and very few minor ones, exist in the polyurethane roof systems.”
Sam Cohen, Texas A&M University Physical Plant Department
Source: Sam Cohen, 'A Comparison of Built-Up and Foam Roofing Systems,' Texas A&M Physical Plant Dept.; SPFA documentation