Exciting Times for Washington Roofing & Insulation

There is so much going on this year and we want to continue to share exciting updates with everyone. Washington Roofing & Insulation was awarded the job to work with almost a dozen Casey's General Stores in the state of Missouri and will be working with them for several months. We also recently finished a Digester Lid Dome in Lubbock, Texas with SPF and elastomeric roof coating.

We are in the process of working with a 30,000 square foot building in Lenexa, Kansas which will entail using GacoFlex S-20 Silicone Coatings from GACO Western over an existing EPDM roof. Exciting times in the roofing industry.

In addition, we ran across this case study from the Honeywell Report which shows how well closed cell polyurethane foam saves on utilities. Yes, we work in commercial construction and the report is based on residential case studies, but it is a great example of how SPF can be a major player in energy efficiency.

Midwest Commercial Roofing Company Named after Town in Kansas

When you start a business, one of the first things people ask you is, "How did you come up with the name?" We get asked that a lot, especially now, where the name doesn't correspond to anything people can put their finger on immediately.

Washington Roofing & Insulation, part of Washington Companies, Inc., is not named after the state, nor a famous person like George or Denzel, and it doesn't represent our political affiliations in any way.

It was named because Chuck Carpenter, owner, started the company 35 years ago in the small town of Washington, Kansas. Located in north-central Kansas off of Hwy 56, Washington is 20 minutes south of the Nebraska line and 50 miles north of Manhattan. It is home to around 1100 people.

Now our main office is located in Great Bend, Kansas with offices in Claremore, Oklahoma and Kansas City. We provide commercial roofing solutions with SPF foam roofing, elastomeric roof coatings and total building insulation with air barrier systems and products. We service the entire midwest, from Iowa, Missouri, Oklahoma and Texas, and have installed millions of square feet of roofing.

So people do squint their eyes at us and ponder how we got our name, and it makes us smile. In the end it never matters, because no matter which political party you belong to, the bottom line is that when we're finished, your roof won't leak.  

~ GO FORTH AND VOTE! ~

Highly Trained and Certified Staff to Install High Pressured SPF Insulation

Spray Polyurethane Foam (SPF) insulation can either be open-cell or closed-cell foam. The open-cell foam has tiny cells that are not completely closed (thus the name "open" cell). This allows air to fill up the open spaces inside the material, making the foam weaker and softer to the touch.

Closed-cell foam, on the other hand, is made up of cells completely closed and packed together. They are filled with a gas that forces the foam to rise and expand which makes it a greater insulator.

Closed-cell foam has a greater R value, is stronger and it has a better resistance to the leakage of air and water vapor. The higher the density the foam, the heavier, or stronger it becomes.

For mid-size jobs in homes, there are low pressure (< 250 pounds per inch) two-component kits for SPF projects. These are used to insulate small areas by SPF foam contractors who use special personal protective equipment.

One of the spray rigs used in Washington Roofing's projects.

Commercial applications and other large renovations use two-component, high pressure systems (800-1600 psi) with 55-gallon drums and a spray rig. This product is applied by contractors who have had special training and use specialized personal protective equipment, including respirators.

Washington Roofing & Insulation uses BASF Closed Cell Spray Foam and the staff is trained and certified for SPF commercial projects. For more information, visit our website or contact us at 800.383.3062

An Energy Conservation Idea for Building Owners

We have always been interested in energy conservation, which is one of the things that got us started with Spray Polyurethane Foam Roofing in the first place over 35 years ago. Though out the years we were naturally led to maximizing an owner's investment through quality products and installation for the entire building "envelope," which then started to include Polyurethane Foam Air Barrier and Fluid Applied Air Barrier services.

For building owners and our clients it all boils down to this: decreasing your energy consumption and increase profits while protecting the health of the occupants.

As there are many ways for to accomplish this, we found an article interesting in the Commercial Construction & Renovation July/August 2012 issue which talked about ways to reduce building HVAC costs with site-recovered energy by using Energy Recovery Wheel Technology, or Enthalpy Wheels.

According to the article, enthalpy wheels "transfer energy by rotating between outdoor air and exhaust air streams to transfer heat and moisture from one airstream to another." It retrieves the wasted energy in building exhaust air and recycles it and allows the building to increase outdoor air levels without making your HVAC unit work harder.

It also helps enable building owners to participate in energy programs. Energy recovery wheels are available from most HVAC OEMs and distributors.

Flint Hills Discovery Center Project Complete

The Flint Hills Discovery Center project is complete.

We are proud to pass along the announcement that the grand opening for the Flint Hills Discovery Center in Manhattan, Kansas is right on schedule for this April. The Center broke ground in July 2010 with a mission to "celebrate, explore and care for the flint hills."

Back in November we had posted how Washington Roofing and Insulation (WRI) was working with Split Rock Studios out of Minneapolis to create a cave at the center for people to walk into and see exhibits. This was done by spraying polyurethane foam inside the structure and then the creative people at Split Rock made the "cave like" appearance by cutting into the foam and adding the vines. WRI finished the project by spraying polyurethane foam inside the walls of the cave and then using Flame Seal TB on top of the foam to create the thermal barrier needed to meet fire requirements. WRI also sprayed foam on the walls of the center.

Inside the cave during construction.

Moriah Carpenter, project estimator for the company, said that this was one of the more unique projects WRI had ever done.

"What is done behind the scenes makes a big difference," she said. "It will really help them with their energy efficiency. It was exciting to be a part of it and watch it all come together."

The Center is hosting a Contractor's Grand Opening on April 7th and then will be open to the general public shortly after that. 

"McCownGorden worked hard to get this open on time," Moriah said. "They did a fantastic job."

Inside the cave with exhibits.

Another shot of the cave's interior with exhibits.

Note: Photos compliments of the Flint Hills Discovery Center construction page

The Importance of the Climate Zone Map

In order to provide the insulation material for your building, the BASF educates contractors to reference the the U.S. Department of Energy's climate zone map. The map breaks the United States up into two main areas: dry and moist, and further breaks it down into eight zones.

Each zone has specific requirements for how spray polyurethane foam should be applied. To spare you with all the technical jargon, SPF is applied differently from one zone to the next, depending upon climates.

"Both open-cell and closed-cell spray foam are air impermeable and can help to reduce energy losses and avoid condensation by increasing the airtightness of the enclosure if the enclosure is properly designed and the spray foam is properly installed. Open-cell foam is vapor permeable so care must be taken in colder climates to minimize the risk of vapor diffusion wetting of the exterior sheathing. Hybrid applications, known as “flashand- batt” or “flash-and-fill” or “combo systems” consist of spray foam against the exterior sheathing covered with a layer of fibrous insulation. Spraying foam directly against exterior foam insulation is also possible as a hybrid approach but care must be given during the foam application process." Spray Foam Guide, Building Science Corporation 2011.

As a performance-based mid-western spray polyurethane roofing and air barrier company we take understanding the reasons behind the different applications very seriously. We are committed to providing our clients with nothing less than an exception final product so continual staff education in SPF design and installation is a priority.

Why Choose Spray Foam?

Our friends at the Spray Foam Coalition provided us with a 2-page document that lists the benefits of choosing spray polyurethane foam (SPF) for your insulation and air sealing barrier needs on walls, roofs and other surfaces. You can download the document from our website or keep reading for the summarized version.

Spray Foam is Energy Efficient
As much as 40% of a building's energy is lost due to air infiltration, gaps, holes and air leaks. Spray foam closes gaps that lets air escape and can reduce utility bills. It also helps your HVAC unit as it maintains an optimal climate in your building, keeping it from working as hard. In fact, a HVAC unit can be downsized by as much as 35% when a building is SPF insulated.

When SPF is applied to the roof of a building, it can provide cool roof performance when topped with a protective, reflective coating. "Cool roofs" are designed to maintain a lower temperature than traditional roofs.

Common air leaks found in most buildings.
Source: 2011 American Chemistry Council, Inc.

Buildings can be sealed with SPF.
Source: 2011 American Chemistry Council, Inc.

Closed-Cell Spray Foam Can Improve Building Strength and Durability
A SPF roofing system is known to have effective lifespans that can exceed 30 years. A professionally applied SPF can create a strong bond to protect the roof and eliminate water seepage through weak spots. It increases a building's resistance to wind uplift, "gluing" the overall building together.

SPF insulation is highly resistant to floodwater damage. It also prevents moisture and condensation throughout the building, helping prevent mold and mildew. When closed-cell is applied in the cavities of walls it increases durability of the wall system because of its ability to conform and adhere to the surface.

Source: Spray Foam Coalition

Up On the Roof Top

We have been "up on the roof top" now for over 35 years and have never been mistaken for Ol' St. Nick, albeit we would find it to be a complimentary identity mishap. The jolly man himself may have a bigger service area and a larger target audience but our mid-western clientele is pretty extensive with places in Texas, Oklahoma, Texas, Iowa and of course, Kansas.

We have met some fantastic people along the way, and they are all pretty satisfied with their polyurethane spray foam roof systems or their air barrier systems for their commercial buildings.  This last year has been quite a ride. We became Air Barrier Association of America (ABAA) accredited to install Air Barrier systems and, along with many others, are currently working with the Beta Theta Pi Fraternity House at the University of Missouri in Columbia, Missouri.

But aside from all of that, we want to wish everyone happy holidays and the best for the 2012 new year. We are looking forward to being "up on the roof top" for many more years to come.

Flame Seal-TB

After taking an intensive training class, Washington Roofing and Insulation is proud to announce our recent certification as a qualified Flame Seal-TB applicator.

Flame Seal-TB is a waterbased, intumescent coating product that has been certified multiple times as both a Thermal and Ignition Barrier when used over a Spray Polyurethane Foam system. With very low toxicity and low VOCs, the coating qualifies for the LEED IEQ4 Credit for Low Emitting Material - Paints and Coatings.

The certification process for a LEVEL ONE applicator includes passing a detailed test and establishing a Quality Assurance and Control process within their organization.

NOAA Forecasters Predict More Activity this Hurricane Season

On August 4, 2011 the National Oceanic and Atmospheric Administration (NOAA) issued an updated forecast for the 2011 Atlantic hurricane season that predicts more storms and hurricanes than was originally thought to occur. Peak hurricane months are between August and October in the Atlantic region and even FEMA has warned residents to get prepared.

You don't have to live in the Atlantic, however, to respect the enormous force of Mother Nature. Midwestern storms can have hurricane-strong gusts and create havoc on trees and building structures. This makes it important to choose the right product and performance-based roofing contractor when considering applications for roof repairs or new roofs.

Many Spray Polyurethane Foam Roofing manufactures have products that carries the Miami-Dade County Notice of Acceptance as protecting the roof in winds up to 150 miles per hour, or a level 5 hurricane, when properly applied over concrete, steel or a smooth surface BUR wood deck. The system creates a monolithic seal over the roof, making it impossible to detach in high winds. When applied by a an accredited roofing professional, Polyurethane Spray Foam Roofing can meet the needs of building owners in the Midwest.

Source: NOAA - http://www.noaanews.noaa.gov/stories2011/20110804_update_atlantichurricaneoutlook.html

Comparing Insulation Products

Out of the dozen positive features compared between spray foam insulation, fiberglass batts, fiberglass loose-fill, wet-sprayed cellulose, blown-in (dry) cellulose and mineral wool, only the spray foam insulation had the most. They include:

• High to Highest R-Value per inch


• No wind washing effect


• Certified air barrier


• Expands to fill hard-to-reach spaces


• Contains no HCFCs or CFCs


• Does not contain formaldehyde


• Won't shrink or settle over time when properly installed


• Will not absorb significant levels of water


• FEMA approved flood-resistant insulation materials


• Will not distort framing when properly installed


• Efficiently reduces sound transmission through walls

The only feature that Spray Foam Insulation does not have that two of the others provide is the ability to inject it into existing wall cavities without major demolition. Spray Foam Insulation is normally done during the initial building process, while adding on to an existing structure or remodeling.

Source: sprayfoam.com, "Insulation Comparison Chart"

It's Not Just About Roofs, Anymore

As building and architecture focuses more on energy efficiency and renewable resources, spray polyurethane foam (SPF) insulation will become more prevalent for the entire building structure.

As opposed to traditional fiberglass insulation, SPF fills every crack and crevice to eliminate airflow in and out of the building, saving on utility bills and extending the life of your HVAC. It also helps keep insects, spiders, dust, pollen and mold down, giving you cleaner, healthier air to breathe.

Metal studs on the interior of a building.
Photo by: Washington Roofing & Insulation

Metal studs after spraying BASF Spraytite as Insulation.
Photo by: Washington Roofing & Insulation

Washington Roofing & Insulation uses SPRAYTITE closed cell SPF with uses ZONE3 zero-ozone-depleting blowing-agent technology and emits no volatile organic compounds (VOCs). It can be used in the following areas of insulation applications:

• Above Rafters
• Between Rafters
• Cavity and Cavity Walls
• Ceilings
• Exteriors
• Floors
• Interiors
• Perimeters
• Roofs