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The Spray Foam Roofing Guide: Everything You Should Know

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

 

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

Sections:

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

Top 3 Flat Roofs

Know which flat roofs perform best in Tucson's climate

Top 3 Pitched Roofs

Know which sloped roofs perform best in Tucson

Roof Ventilation

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

Roof Warranties

Factory and Workmanship warranties explained in depth

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What is Spray Polyurethane Foam?

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


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

The Spray Foam Roofing Essentials

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

 

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

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Spray Foam Roof-Over Installation:

  1. Existing Substrate

  2. Substrate Primer

  3. Spray Polyurethane Foam

  4. /5. Reflective Roof Coatings

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UV Performance

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

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

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

Pros of Spray Foam Roofing

Thermal Resistance

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

Strength & Durability

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

Longevity

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

Seamless & Self Flashing

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

Quick Installation

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

Renewable and Sustainable

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

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

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

  • Quality of material

  • Roof ventilation

  • Quality of the Install

  • Maintenance habits

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

20-30 Years

  • Architectural Shingles

  • Tile roof w/ Premium Underlayment​

  • Built-Up Roof w/ premium roof coating

  • ​TPO Roof 

10-15 Years

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

  • ​Tile roofing FELT underlayment 

35+ Years

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

  • Premium Shingles

  • ​TPO Roof w/ thicker mil

15-20 Years

  • 3-Tab Shingles (disc.)

  • Mod-Bit Granulated Roof system

  • Spray foam roof w/ premium coating

  • Exposed fastener Metal Roof 

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When do I know I need a new roof?

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

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

Signs that your roof is on it's last breath

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

Shingle Roof

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

Built-Up Roof w/ Elastomeric Coating

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

Built-Up Roof w/ Silicone Coating

Your spray foam has huge blisters, unevenness that traps water, and/or is completely exposed and drying up.

Spray Foam Roof w/ Coating

Fasteners are failing / falling, rust, and buckling

Corrugated / Ribbed Metal Panels

The underlayment beneath the tiles is the most vital component. The only way it's condition is to have an experienced roofing contractor inspect your tile roof's underlayment.

Tile Roof

*Blown off tiles are not signs that you need all new tiles*

Concrete/Clay tiles them are designed to last 50+ years. They are natural materials w/ no watertightness warranty. 

Did you know?

When should I replace my roof?

A reputable contractor should advise you to look into replacing your roof when you've reached about 80% of its lifespan. This is because our dry heat affects all building components and tends to accelerate your roof's lifespan.

For the new roof, you may want to look into a Cool Series material or something more flexible than you had before. Flexible & reflective roofs perform best in Tucson's climate.

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It pays to be proactive

Interior leaks should be treated as a high importance matter for the sake of your health. Trapped moisture eventually grows into mold and this can spread, the longer you wait to fix your roof. 

Roofs should be inspected at least twice per year to ensure that nothing is affecting the system from keeping 100% of moisture out. Keep in mind, materials can't do their job if they are not properly maintained.

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Not even the toughest of roofs can survive a really bad monsoon storm.

If a recent storm has affected your area, it is likely that your entire roof system may have been affected. You should not rely on what your eyes can see from the ground. If your neighbors are chirping about it, you should likely get your roof checked, too.

Storm damages are covered by your insurance provider

If you have homeowner's insurance, your roof likely covered by your policy provider. You must act fast because they may hold you accountable for lack of damage mitigation.

 

If your roof blew off, make sure to:

  1. Mitigate / Control the Damage. Tarps and sandbags are ideal for this.

  2. File A Claim

  3. Meet w/ Your Adjuster

  4. Do your research on local roofers

  5. Collect Insurance Funds

  6. Hire a Roofing Contractor

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Have you seen roofers in your neighborhood lately?

If you have homeowner's insurance, your roof likely covered by your policy provider. You must act fast because they may hold you accountable for lack of damage mitigation.

 

If your roof blew off, make sure to:

  1. Mitigate / Control the Damage. Tarps and sandbags are ideal for this.

  2. File A Claim

  3. Meet w/ Your Adjuster

  4. Do your research on local roofers

  5. Collect Insurance Funds

  6. Hire a Roofing Contractor

Pitched Roof Components

Universal Roof Components

Roof Decking

This is the roof substrate (sheathing). The most common decking types in Tucson are: OSB, CDX, CCX, Plank boarding and tongue/groove. This is the structural component that attaches to your home's trusses.

Ice & Water Barrier

This barrier adds an extra layer of protection to your roof's most sensitive areas. Things like transitions, valleys, and pitch breaks should all get this material.

Roof Flashings

Cricket

This structural component diverts water away from walls and other vertical changes on your roof. These are most common on chimneys and flat roofs with parapet walls.

These are typically made of metal and are roofing components designed to shield joints and other components from water intrusion. Examples are: drip edge, valley, Z-bar, & counter flashings.

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Flat Roof Components

Underlayment

This is the vapor barrier that goes directly above your decking to provide additional protection to your roof system. This is the main component for waterproofing tile roof systems

Pipe Boots

These terminate the round tubes that stick out of your roof. A metal/rubber boot protects this vertical joint from leaking.

Ridge Cap

This is the trim piece of roof material installed where two slopes meet to form the "ridge/hip".

Roof Vents

These vents allow fresh air to regulate the temperature of your crawl/attic space. Usually "T-Tops", Static Vents, Mechanical Vents, Ridge Vent, etc.

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Long lasting roof replacement solutions for all types of roofs in Tucson

ABRC is dedicated to providing clients with unrivaled service, backed by our extensive knowledge of all roofing systems. Tucson is a diverse architectural community, meaning no two roofs are the same. Each roof system has its own weak points and installation techniques. Our team works together to deliver quality so high, very few can offer.

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America's Best Roofing Company is Tucson's most trusted roofer because our team works tirelessly to deliver peace of mind to all of our clients. 

Tearing off the old shingle roof on a church in Tucson, AZ: new lifetime shingles installed by ABRC: Tucson roofing pros.
Get financed for your new roof system with ABRC's quick pre-approval process. Tucson roofing companies: ABRC.

Fix your roof now, pay overtime.

Finance your roof repairs, roof replacement, or roof restoration with one of ABRC's lending partners. Get a freaky fast pre-approval and your funds would be available for you to use same day. 

Get financed for your new roof system with ABRC's quick pre-approval process. Tucson roofing companies: ABRC.
Get financed for your new roof system with ABRC's quick pre-approval process. Tucson roofing companies: ABRC.
Get financed for your new roof system with ABRC's quick pre-approval process. Tucson roofing companies: ABRC.

Frequently asked questions

Appropriate Roofing Substrates

Foam roofing insulation is a highly adaptive material, suitable for a range of commercial roofing substrates which include:

  • Built-up roofing (BUR)

  • Modified bitumen roofing (mod-bit)

  • EPDM (over coverboard)

  • PVC / TPO (over coverboard)

  • Metal Roof

  • Concrete

  • Plywood / OSB decking

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Roofers installing a spray foam roof.

Cons of Spray Foam Roofing

Costs

It's hard to find a good spray foam roofing contractor in Tucson. Hiring a reputable contractor that will stand by their work will come at a luxury.

UV Exposure

SPF roof systems are not designed to withstand much exposure to the elements. Spray foam roofs rely heavily on the elastomeric or acrylic roof coating to reflect UV rays and protect the roof from system failure.

Low Hail Impact Rating

Though spray foam roofs are solid, Tucson hail storms tend to impact the coating due to the density of the foam roof material when compared to other flat roof options. To offset this issue, you can add granules to your reflective roof coating.

Impact from a hail storm on a spray foam roof in Green Valley, AZ.

Impact from a hail storm on a spray foam roof in Green Valley, AZ.

Roof granules in spray foam roof coating on a  roof in Tucson, AZ..

Roof granules in spray foam roof coating on a  roof in Tucson, AZ.

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