Closed-Cell SPF Insulation Creates a Better Atmosphere Inside Future Restaurant

BONNERDALE, AR – August 16, 2013 – Robert Freeman, building owner and restauranteur, is in the process of opening Sawmill Roadhouse, a destination for Arkansas barbecue and live music. As he prepared the building for the restaurant's grand opening, he decided he wanted the best possible insulation so that his guests were comfortable. Additionally, he wanted an insulating material that was waterproof so that he was able to keep the metal building's existing sprinkler system that was fixed to the roof trusses, so that, in the event of the sprinklers going off, he wouldn't have to worry about replacing the insulation later due to molding issues. Closed-cell SPF insulation was the solution to the owner's decision.

Freeman brought in SprayDay Coating Solutions (SDCS) for the job, which consisted of applying spray polyurethane foam the underside of the metal building's curved roof. SDCS' Ben Riley affirmed that SPF insulation was the best option in order to accomplish the owner's demands.

"Spray foam insulation provided the building a high R-value that blown or batt insulation could not match, solid structural integrity, and a waterproof barrier that eliminated any possible leaks or molding of the sprinkler system in case it was ever to go off," Riley said.

Prior to the application, the SDCS crew masked all windows, doors, electrical outlets, and plumbing fixtures of the building with plastic. The crew also covered the floor, the wooden exterior walls, and masked off all sprinkler heads and cooler systems from the roof. According to Riley, the exterior walls were not part of the application because they had batt insulation installed in them and were covered with drywall previously. He explained that the owner decided not to do a tear-out to apply SPF on the exterior walls because it would have proved more expensive. The crew wore jumpsuits, respirators, and fresh air hoods. They used scaffolding to get to the rafters and to the apex of the curved roof, which was 20-feet high from the building's floor.

The crew applied two inches of FOAM-LOK 2000, a 2 lb. closed-cell spray polyurethane foam made by Lapolla, on the underside of the roof. Nearly six sets of foam were used on the SPF insulation project, which comprised a spray area of 10,680 square feet.

With one rig equipped with a Graco Reactor E-30 proportioner and a Graco Fusion spray gun, SDCS' five-man crew was able to complete the project in seven days. Riley said it was necessary to have five people on the project. Crewmembers had to disassemble a section of the scaffolding and move it over to the next roof rafter to set it back up to apply SPF to a different section of the roof's underside.

Riley was satisfied with his crew's work and noted that they were able to meet their client's needs.

"Because closed-cell SPF is waterproof, the owner won't have any leaking issues from the attic and from the sprinkler system because the spray foam is seamless and it won't mold, sag, or disintegrate," said Riley. "We strengthened the integrity of the building and created a monolithic seal."

Riley added that Freeman will notice a substantial difference when it comes to energy expenditures and that the cost of the SPF application will be paid on energy savings alone over time. Freeman plans to install a ceiling system to cover the SPF insulation and prevent the foam from being exposed, a phase that is already underway. Freeman was happy with end result of the project, said that SPF application solved his sprinkler issue.

"It was the only option that made sense," said Freeman. "When I learned that closed-cell SPF was waterproof, well, that was the magic word."

Freeman pointed out that screws hold the metal roof in place and that, over time, the screws could work themselves out and give way to leaks. He said that even if leakage were to occur through any resulting gaps and cause the plywood decking to rot, closed-cell SPF insulation would protect anything from seeping through as it grips to the substrate.

"The structural integrity of SPF insulation tied all of that together," said Freeman. "If I was going to have any leak problems, it would be around the roof curves that support the heating areas and the SPF insulation sealed them."

According to Freeman, Sawmill Roadhouse is set to open in late September.

About SprayDay Coating Solutions, LLC: Serving Arkansas and surrounding areas, SprayDay Coating Solutions has 15 years of experience in SPF. Through commercial and residential projects of both spray room insulation and roofing, SprayDay Coating Solutions generated a large base of satisfied customers. They utilize SPF made my Gaco Western, Lapolla, and NCFI. For more information on SprayDay Coating Solutions, please refer to the contact information and link provided below.