Spray Polyurethane Foam Manufacturers List & Website Directory

By Roof Online Staff • Last updated April 24, 2024

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Spray polyurethane foam roof as a gray silicone coating is being applied. — Spray polyurethane foam roof as a gray silicone coating is being applied (image courtesy American WeatherStar)

Spray Polyurethane Foam Introduction

Spray (or sprayed) polyurethane foam is commonly referred to as “SPF”. It is an insulation, roofing, and air barrier material that is applied as a liquid spray which rapidly expands to form a solid, yellowish foam. It’s composed of two primary chemicals that react immediately when mixed together during the application process: a polyol resin and an isocyanate. When sprayed onto a surface using (very) specialized equipment, these chemicals produce a layer of extremely well-adhered polyurethane foam.

Types of Spray Polyurethane Foam

Closed-cell SPF: This form of SPF is denser and more compact, with a closed-cell structure that provides one of the highest available building insulation R-values (a measure of thermal resistance), which means it’s one of the best insulation materials you can get. Depending on the specific product, closed-cell SPF has a recognized R-value of up to R-7.1 per inch. It is also water-resistant (and even waterproof at higher densities) and will add some structural strength to walls, ceilings, or roofs where it is applied. Closed-cell SPF is the type you want for any exterior applications.
Open-cell SPF: Lighter and less dense than closed-cell foam, open-cell SPF is soft and spongy. Although it has a lower R-value (R-3.7 to R-4.0) compared to closed-cell foam, it is still a good insulation material. It is more effective as a sound barrier than open-cell foam, and it is far more permeable to moisture, which can help with detecting and locating leaks. Open-cell SPF should only be used for interior applications.

Key Points

Energy Efficiency: SPF is an extremely effective insulation; by significantly reducing heat transfer, it helps to lower heating and cooling costs.
Air Sealing: It can completely and comprehensively seal gaps and cracks in the building envelope, preventing heat loss and drafts.
Moisture Barrier: As a monolithic barrier, closed-cell foam keeps out water and water vapor and reduces the risk of mold and mildew.
Installation: Although spray polyurethane foam should only be installed by someone with the proper equipment and specialized training, it can be easily applied to almost any substrate without much prep and without regard to surface irregularities.

Other things to consider:

Installation: It must be installed by properly-trained professionals because of the hazardous chemicals involved, as well as the need for specialized and rather expensive equipment to apply the foam safely and effectively. Respirators are worn during application to avoid breathing in fumes or particles.
Cost: SPF is more expensive than more common insulation materials like fiberglass or foam board insulation, and SPF application is not normally a DIY operation.
Health and Safety: During application, spray polyurethane foam emits volatile organic compounds (VOCs) and other harmful substances that need to be properly managed with adequate ventilation and protective gear. During outdoor application, loose strands of SPF may blow away in the wind and stick to nearby cars.

Use of SPF on Roofs

Although it can be used for new construction, spray polyurethane roofs are typically installed as recovery roof systems, that is, an SPF roof will be installed over an existing roof that has reached the end of its service life. SPF can be installed over existing built-up, EPDM, TPO, metal, modified bitumen, and other types of roofing. SPF is even used on old residential tile roofs sometimes.

Spray polyurethane foam (with an appropriate surface coating) functions as both a weatherproofing membrane and the code-required thermal roof insulation. It also seals air leaks and can serve as a vapor barrier. SPF is sprayed directly onto the substrate and then expands to form a continuous, monolithic membrane that covers the entire roof. Spray foam is normally installed at a minimum thickness of 1.5 to 2 inches, but an SPF membrane can be much, much thicker where R-value considerations call for it. Separate flashing components at roof penetrations are generally unnecessary, as the SPF itself can be applied at these transition points.

Spray polyurethane foam is often applied over existing roofs in order to avoid the expense of removing and replacing them. But an SPF roof itself is an interesting case when it comes time for replacement. By grinding off the coating and scarifying the surface of an existing SPF roof, new SPF can be applied over the old SPF, a new warranty can be issued, and the resulting roof will not be considered a new roof, but rather a renovation of an existing roof. This means you can sort of do an end run around code requirements that say you can only install two roofs on a building before removal down to the roof deck is mandatory.

Coatings on SPF Roof Applications

Spray polyurethane foam is highly susceptible to UV degradation. SPF roofs must be coated (or at least thoroughly primed) soon after installation, as the foam will begin to break down due to ultraviolet rays within three days of exposure. After the SPF has been applied, the surface is typically primed immediately and then later coated with a long-lasting protective roof coating to shield it from ultraviolet light, mechanical damage, and moisture. Common coatings include:

Acrylic coatings: These water-based roof coatings are the cheapest coatings and typically don’t last as long as other types. These do provide good protection against UV radiation, but will need to be touched up periodically over the life of the roof.
Silicone coatings: These are the best coatings for an SPF roof, but also usually the most expensive. Known for their superior weather and UV resistance, silicone coatings perform well in extreme weather conditions and are often used in areas with high rainfall or on roofs that are known to experience areas of ponding water.
Polyurethane coatings: These coatings are highly resistant to abrasion and foot traffic, making them good for roofs with a lot of rooftop equipment that need to be accessed frequently.

Important Considerations Before Purchasing SPF

R-value Requirements: Check that the product will result in a foam that is dense enough to meet your desired R-value.
Local Codes: Check your local codes to see whether there are any local amendments that restrict the use of spray foam. You can also see what the insulation R-value requirements in your area and figure out how thick your SPF application will need to be.
Health and Safety: Installation involves chemicals that can be quite hazardous. Proper safety gear, installation equipment, and installation by trained and certified professionals are strongly advised.
Ventilation: Adequate ventilation is necessary during and right after application in order to allow the chemical fumes to dissipate harmlessly.

Importance of a Reputable SPF Manufacturer

Choosing a reputable manufacturer is very important:

Quality of Material: The components of spray polyurethane foam are chemical compounds that must be precisely and carefully formulated. This means production standards must be very high, and must be carefully followed. You want a manufacturer who you can trust to follow production quality standards and procedures.
Technical Support: Reputable manufacturers will have competent technical departments who can provide any necessary technical support, from product selection to application advice.
Compliance with Standards: Reputable manufacturers will ensure that their products meet industry standards, regulations, and code requirements. This is important for both long-term performance and regulatory compliance.

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If you are a reputable and qualified spray polyurethane foam manufacturer and feel that we’ve overlooked your company, feel free to contact us to ask to be added to this list.

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