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Flat Roofing Sprayed Polyurethane Foam.

spray coating a industrial flat roof technical team have been asked to visit a large flat corrugated steel cladded roof and the business owners were have problem with condensation underneath.

There were three separate issues going on with this roof, all of which compounded the issue rooted in the failure to ensure in the first place that the roof was properly waterproofed.

To start with, the roof wasn’t watertight, so there were leaks whenever it rained. Secondly, there was no insulation installed underneath the roof. This lack of insulation caused condensation to occur inside the building.

Because of these issues, we had to come up with a different system than we would normally use.

The team had planned on waterproofing the metal roof using a closed cell foam insulation and the pure  polyurea coating. also recognized that condensation problem stemmed from the fact that the existing coating was cooling the roof of the building, which wouldn’t be a problem if the building had insulation.

However, without insulation, when temperatures dropped overnight and then warmed up during the day, condensation developed on the ceiling of the building.  In other words, it would “rain” inside the building every day. proposed that their cold cell insulation foam be applied to the entire roof and this would show the owners exactly how the spray foam would insulate the building and eliminate condensation.. Even though applying closed cell insulation foam would add to the cost of the job, it would be worth every penny.

Flat Roofing Sprayed Polyuret
Flat Roofing Sprayed Polyurethane Foam

The roof was power-hosed and all loose dirt and contamination was completely removed. The roof was then allowed to dry and the closed cell insulation foam was applied and straight away the ULXT 6613, 100-percent solids pure polyurea, was applied over the foam. The roof was also fitted with various types of mushroom roof vents allow any water and moisture to evaporate or gas off.

This roof is now leak-free, the building is properly insulated, and it is no longer any condensation problem in the inside. The building is now conserving energy and saving money. Sprayed Polyurethane Foam and Polyurea roofing is a probably the best of all the flat roofing options available in today’s market. It has a plethora of benefits associated with it and very few drawbacks. spray foam and polyurea roofing is a roofing system that is spray applied directly to the existing roof surface; it cannot be a standalone system, the foam provides the watertight bond to the roof substrate and the polyurea will provide a waterproof, seamless jointless roofing membrane that will endure the toughest of weather and adverse conditions. Specially formulated chemicals are mixed together in a unique spray gun. This mixing turns the liquid to foam, which then expands to many times its original size.

The advantages of foam are its ease of application, its versatility, its insulating capabilities and its strength. Foam is very easy to apply once you are a trained applicator. It takes some skill and knowledge of the product, but after learning that and practicing it is like riding a bike. It can also adhere to many different surfaces and can be sprayed in different thicknesses to improve roof drainage.

Ultimate Linings Sprayed Polyurethane Foam and Polyurea roofing
After foam and polyurea is a great insulator, thanks to the tight bond of the molecules and its seamless application. Finally, foam and polyurea roofs are extremely strong, capable of withstanding tornadoes and hurricanes that bring other roofing systems down. If you don’t use spray applied coatings, we believe foam and polyurea best flat roofing system available today.


If you are looking to replace your roof or just learning to be prepared in the future, we hope this was a valuable resource for you. If you have any other flat roofing options that you have questions about that we didn’t cover, get in touch with us and we will tell you all we know.