A Retirement Community Gets an SPF
Roof Made to Last

By: Jessica A. Baris 
 

Giant, green oak trees growing across 33 acres of land bring peace and shade to the residents of The Estates at Carpenters in Lakeland, FL. In the 1800s, the acres were owned by the Carpenters Union, and it was a place for carpenters with no family to retire. They farmed the property and were self-sustaining, enjoying life near the big Lake Gibson. Today, in 2010, the property is now dedicated to giving care to over 500 retired senior adults.

The Estates keeps its 130,000+-square-foot facility in top-notch shape, so when the aged roof began to leak, it was time to contact someone to get it back into tip-top shape.

Leaky Roof Calls for Spray Foam

David Tidwell of Tidwells’ Urethane Foam Service, Inc., got a call from John Robare, Director of Operations, and Jeff Knight, Maintenance Director, to discuss the benefits of using a spray polyurethane foam (SPF) roof system to fix the leaking roof.

“The problem was that the existing ballasted single-ply was bridging away from the parapet, resulting in leaks that couldn’t be found,” says Tidwell. “The obvious choice for this job was going to be the polyurethane foam roof system. The urethane foam was going to be 100% fully adhered to the deck. The benefits of using urethane are that you have a monolithic surface, from front to rear and side to side, with added insulation and waterproofing.”


When it came to deciding on foam, Tidwell didn’t flinch.

“NCFI provides exceptional engineering and technical support,” he said. “They truly supply the end user with a single, reliable support resource for their foam in place operations.”

Tidwell chose the EnduraRock Roofing System for its “forgiving nature” when difficult tasks are performed at roof level. The gravel never wears out, so future maintenance costs are very low, Tidwell said.

Robare and Knight decided to move forward with the plan. Specifications were developed and approved, and the contract was drawn.

Crew of Five Gets to Work

Before Tidwell’s five-man crew arrived, RK Hydro-Vac, a roof preparation company, had already removed the gravel from the roof. Things were off to a smooth start.

The specification called for total removal of the existing ballasted single-ply. “On a typical day, we would find our feet on the roof by 8 a.m., rolling off the existing ballasted membrane and the polystyrene insulation and stock piling it at the edge for recycling,” Tidwell said.

To dispose of the debris, Tidwell’s crew had to lift the material over a seven-foot parapet wall and then lower it four stories down to the ground. This was the toughest part of the job.

“Debris removal and staging were the most awkward parts of the job due to the mansard height and width,” Tidwell says. “Even when trash chutes are used, debris can kill when falling four stories. I am constantly worried about employees’ safety. You can’t monkey around with that. Set-up has to be right the first time.”

Once the concrete substrate was exposed, some crew members replaced the parapet wood while others continued to prep the concrete by brooming and priming, getting it cleaned up and ready for foam.

After Lunch: Foam Time

The crew put on their Tyvek suits, Survivair respirators, and protective gloves to get ready for foam application. Using a Graco Reactor E-30 with a 310-foot hose and GX spray guns, the crew applied an average of three inches of NCFI’s 10-011 2.8-pound closed-cell foam on the roof deck and 1.5 inches on the plywood walls. The buildings varied between 16 and 20,000 square feet, and they required 17 to 24 sets of foam each.

“The foam application usually included two drain sections, or 1,500 and 2,500 square feet a day with completed thickness and detailing,” says Tidwell. “During the spray process, we were careful to include our drainage pitches so we would have positive water flow to the interior roof drains. At the same time, we applied urethane to the seven-foot walls so they would be monolithic with the roof area.”

Tidwell said that the crew also “insulated the main AC supply and return lines so the owners wouldn’t have to replace exterior ducting at this time.”

When it was time to apply coating, Tidwell said his team “began as soon as possible to prevent sunburn of our foam.”  The crew applied four gallons per square foot of L&L 300 Mastic coating around roof penetrations and on the seven-foot vertical wall areas. A Graco 30:1 Bulldog Pump with a 300-foot hose helped get the job done.

To finish it off, Tidwell called in Hodge Crane of Lakeland, FL, and flew the gravel to the roof.

“That Roof Will Not Blow Off” – An SPF Roof Made to Last

The entire project was accomplished over five years, and the latest project of 40,000 square feet was completed between August and December of 2009. Robare and Knight were satisfied with the result.

“We started with one building, and they’ve done about six for us. We’re real pleased,” says Jeff Knight. “The foam roofing is great. I’ve had people call me for references. His crew did a really good job.”

“I’m proud to say I had nothing but compliments,” says Tidwell. “That roof will not blow off.”

Perhaps spray foam has been around for a few decades, but chivalry has been around a lot longer, and it makes just as good an impression as a spray foam job well done.

“One day I turned around and saw one of my crewmen helping a retired woman carry in her groceries. He sure made us look good!” Tidwell laughed.

“I’m proud of the guys,” Tidwell said of his team. “Some retirees said to me, ‘You got good guys here.’ And that means something to a roofer.”

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