Roofing an RoofingRepairs
About half of low slope (or flat) roofs in the Midwest are done using a single-ply roofing technique. This is due in part to the relatively minimal equipment cost and experience required by the contractor, as well as the relatively low material cost — on most sheet systems the cost of the sheet is only 25% of the total bid.
The most common application is over tar or tar-and-gravel roof systems as they wear out, although single-plys are often installed over other single-ply roofs as they deteriorate.
Sometimes single ply systems are installed over metal roofs, but we don’t recommend this application. To make it work, board must be screwed or glued down to fill the flute, insulation board installed over that, and finally installing the single-ply sheet on top. Thousands of new holes have just been made with only a thin layer of material keeping water out.
There are a variety of chemistries for single-ply materials.
EPDM
In layman’s terms EPDM is called a “rubber” roof because it is usually made of black vulcanized rubber — like the old car or bicycle inner tubes. These systems are designed to work in one of three ways.
The first is to lay insulation board on top of the roof deck with the sheet placed directly on top of the insulation board and then held down by what is called ballasted material (usually river rock) weighing up to 8-12 pounds per square foot depending on code.
The second application involves mechanically fastening the insulation board to the rubber sheet with screws and plates at least every two feet (depending on wind uplift ratings) in addition to the screws that are holding down the sheet itself.
The third system is called fully adhered or glued in place. In this application the insulation board is usually mechanically fastened and the EPDM sheet adhered with slow rise foam or other adhesives.
While there are cost advantages to EPDM, there is also a significant downside.
First, these systems can shrink as much as 5-7% per year. This causes pulling on the edges of the building which in turn causes termination bars, parapet walls and side walls to be pulled out, seams to be pulled apart, and vent pipes pulled over among other problems.
Second, we often see screws back out of the roof deck and poke their heads up through the sheet itself, making holes through which water can seep. Third is the problem of weather cracking caused by huge temperature fluctuations which can make the sheet brittle after several years. Fourth is wind damage, especially prevalent on ballasted roofs.
Lastly, the seams of EPDM are sealed with a water-soluble glue that can cause seam failure over time.
PVC
CONS These sheet systems are typically white or tan in color and are usually fabric scrim reinforced to make them stronger than EPDM. However, in our experience, the typical chemical makeup of these systems can cause them to brittle with age. These systems are usually mechanically fastened, and although they don’t shrink, they can have many of the same problems as EPDM: screws back out making holes, and wind damage is not uncommon.
PRO'S On the positive side, the PVC sheet is usually white, which reflects rather than absorbs the sun’s energy & new chemical additives have made them much less brittle. The seams are heat welded, rather than glued, which results in a significantly stronger seam & much less problems.
TPO
Thermoplastic Olefin (TPO) is a relative newcomer to the single-ply market. TPO was designed to replace EPDM at the low end of the market because PVC’s are typically higher in cost then an EPDM roof. Overall performance for TPO is generally in between EPDM and PVC. TPO's are popular because of pricing, but have yet to prove their durability over long extended periods of time like some of the other systems.
Hypalon
These are proven to be the best of the sheet systems on the market today, because Hypalon cures on the roof and does not become weak and brittle like other single-plys. It can be held down using ballast, mechanically fastened, fully adhered, or held in place with negative air pressure, although mechanically fastened is by far the most popular. This sheet is also heat-welded at the seams. Hypalon sheets are very chemically resistant and are the roof-of-choice in cases where chemicals may be deposited. However, as with all single ply systems, once it has a hole in it, water is free to migrate anywhere.
Spray Polyurethane Foam
Spray Polyurethane Foam (SPF) is applied using a special spray gun that mixes two chemicals as they exit the barrel, causing a chemical reaction that produces the end product. Foam is usually applied in thicknesses from one inch to several inches. Polyurethane foam is a plastic and is waterproof after it is applied, however, it needs protection in the form of a top-coat or layer of rock to help it resist the UV rays in sunlight and keep it from deteriorating.
SPF can be made as soft as a pillow or so hard that you can drive a nail into it. Foam used for roofing is soft enough to be able to move with the expansion and contraction of the roof but hard enough to withstand foot traffic, impact, wind and weather. Foam is flexible and can go over different substrates with ease.
As a roofing material, SPF is difficult to beat if good quality coatings are used and properly applied. If, on the other hand, substandard equipment is used and the ratio between the chemicals is incorrect, it can cause bubbles in the foam. The same problem can occur from applying roofing over a wet substrate. Conklin roofing contractors apply SPF to a depth of no less than 1 inches, One inch is recommended by the Society of the Plastics Industry (SPI). Some contractors will skimp and only apply a half-inch or less, only to have the roof blister & fail prematurely.
Among the advantages to SPF is that it creates a continuous seamless membrane, with every square inch fully adhered to the roof deck. Thus, if a puncture is created in the coating layer it will not create a leak. In fact, if a hole is made clear through to the roof deck, a leak still may not occur, because foam is fully adhered. Yet if the same hole were formed in a single-ply roof, the water can spread throughout the roof deck, finding any number of holes caused by screws holding down the sheet system.
SPF roofs are also referred to as a renewable roof system because even if the roof has gone too long without attention, bad areas can be cut out and reformed and settled areas can be filled in with more foam.
The big saving In SPF roofs, however, comes from energy efficiency. Each inch of foam roof has an R-value of around 7, and the roof surface is white which helps reflect sunlight and make the roof cooler. Most SPF systems pay back the cost of the roof, in energy savings alone, in just a few years.
In addition, years down the road, the cost to re-roof over SPF will be substantially less expensive than roofing over other systems.
Coating on Existing Metal Roofs
Metal roofs wear out over time because of a number of things happening to them which then lets water in to the building. The neoprene washers wear out and the holes around the screws become oblong due to the expansion and contraction of the metal. The mastic that is put between the sheets gets hard and cracks. Skylights and seals around penetrations are also a common cause of failures.
The system that I use to correct the above problems is called the MR-system. This system is very simple to understand. The roof is power washed; screws are tightened and in some cases added. Patches are added to bad sections of rusted out tin or breaks in the tin. Over the metal which is just rusty an inhibitor primer is applied. In some cases this primer is applied to the entire roof. Fabric and coating is then applied to the vertical and horizontal seams and also around the penetration and skylights. Screws are then treated with a fastener-grade caulking and finally the entire roof is usually sprayed with a white coating. This white final coat makes the entire roof seamless and the complete system makes the roof waterproof.
Cons- Some contractors use cheap coatings which will not last on the roof. Some coatings get brittle with age, turn chalky, or get hard. Some manufactures try to cut corners buy not using tape on the seams. Therefore, due to product or application errors the coating can’t stand the amount of stretch required and cracks appear on the seams which cause system failure.
Pros- This system does not add any additional holes in the roof. It is less costly 1/3 to ½, than other alternative roof systems (single ply, new metal roof, foam). This system is light weight and makes the roof white which in turn makes the interior of the building 10-15 degrees cooler by going from a silver roof to a white roof color. The MR-system stops leaks! This may sound funny but I roofed some new metal roofs which were under construction, before they were even completed, the roofs were already leaking. The MR system solved their problems. A new metal roof doesn’t come with a “leak free” warranty. If one reads the fine print of the warranty, most of the time that they’re not getting what they think they’re getting. With our MR-system you can get a 10-year “leak free” warranty on material and workmanship. The MR-system also doesn’t interrupt the work of the building being roofed. The roof system can be written off in one year on taxes as “maintenance and repair” not depreciate out like a new metal roof, single ply, or a foam roof needs to be.
Metal over Metal or over BUR–
This is where a new metal roof is placed over an old metal roof or BUR called (retrofit) or the old metal roof is torn off and a new one put in its place. This is fairly self-explanatory. There is, however, some misconception about this process. When I first started roofing over 10 years ago the types of roofs on which that I applied the MR-coating system where about 20-30 years old. In the last several years the age of the metal roofs that I have been doing has decreased to 10 years to not even yet finished. Yes, you read correctly not even finished.
Today material and labor in constructing buildings is not of the same standard as buildings put up 20-30 years ago. The only way that I can explain this is that the average age of construction crew workers today is in their mid 20s and early 30s and so the experience is not there. Also, the major of today’s workers are in it for a paycheck and don’t have the pride of workmanship that their fathers did. Another problem is that all the screws today are put in by electric drills, which may not be set property and screws may be over tightened.
All of this put together makes for less then quality work. Don’t get me wrong, there are still good roofs put on by good crews but I don’t think you can assume a leak free roof every time. Finally, the roof may come with a 20-year warranty on the building but read the fine print. This is not for a leak free roof. They will come out for about a year and put caulk on seams, etc. to show effort to stop leaks until you finally get tired of calling or they say their obligation is up.Don
,
t throw your roof away!
Let us show you how to SAVE it.
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Reasonable Repair Rates
Green Roof Certified Co.
(419) 270-6163
BlissfieldMaintenance@yahoo.com
• Building Maintenance
• Roof Repairs
• Sheet Metal
• Foam Insulation
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