For several years, this 30,000 square foot modified bitumen roof at Rolls Royce Naval Marine in Pascagoula, MS had been a problem. The roof had already been leaking well before the hurricanes did even further damage. When Hurricane Katrina hit in 2005 Rolls Royce had several contractors make attempts at repairs but were never able to completely waterproof the building.
When it came time to completely restore the roof in late 2008, Rolls Royce realized that they had an existing PUF roof on another building that had been installed almost ten years ago and had survived the same hurricanes the Mod Bit roof did not. Like many building owners and facility managers do, Rolls Royce began their foam roofing research at www.sprayfoam.com which led them to Finishing Solutions, LLC, a foam applicator in Pelham AL.
When Jason Forrester of Finishing Solutions first surveyed the roof in late Summer of 2008, he realized that the existing Mod Bit roof had to be torn off. It was completely saturated. Once the job began, Forrester determined that not only did the roofing substrate and insulation have to be torn off, but the existing metal deck was completely rusted to a point where the foam system he had specified could not be installed. Rolls Royce agreed to let him tear the entire metal deck system off and come back with new 22 gauge metal deck, 1/2” dens deck, and 2” of 3LB Polyurethane Foam & Coating System.
The project took up to 22 people at times. Worker safety was critical so everyone on the job was completely tied off with appropriate safety lanyards. The tear off took 35 dumpsters to cart all the material away.
After installing the Dens Deck, Finishing Solutions sprayed 2” of NCFI 3 LB foam. The job had originally specified 30 mills of acrylic coating, but it was December at the time of installation and the weather was cold with a chance of rain evident and possible every day. Forrester also came to the conclusion that this 1950’s building with drainage to the center did not properly move water through its drainage system quick enough for an acrylic system to be successful.
He chose instead to apply two coats of American Weatherstar’s Urethane 520, a single component moisture cure urethane designed for low slope roofs that may not drain well and great for application in humid conditions which are prevalent in Southern Mississippi.
The project has since turned out great and Rolls Royce now has a new water-tight SPF Roof that will withstand wind conditions much higher than the best Modified Bitumen Roof can handle. The new foam roof and reflective coating system will also lower temperatures in a building that gets very hot during the southern summer months as well.