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Energy Savings Options :: Foam Roof Insulation
Foam Roof Insulation:
A Recall and Warning If Your Roof Insulation is Made From Phenolic Foam
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Although phenolic foam roof insulation is no longer being manufactured or sold, it was used in many low-slope, built-up roofs (BUR) and single-ply roofing systems that were built during the eighties.
Unfortunately, this type of insulation can cause premature corrosion of metal roofs and metal decks. It's a problem caused by the sulfonic acid used to make the foam insulation.
How the Corrosion Happens
When water is absorbed by the phenolic foam, it dissolves the sulfonic acid, creating a highly acidic compound. This highly corrosive compound will immediately start to break down any type of structural metal deck or metal roof coatings. Once this process starts, the corrosion of the steel progresses steadily.
Unlike other types of plastic foam insulation, phenolic foam roof insulation readily absorbs water and will even shrink excessively. When water saturates the foam, it draws chemicals out of the insulation. That water is very corrosive with a low pH factor. The low pH factor is highly corrosive to the steel components found within many roofs or roof decks.
What if You Have Phenolic Foam Insulation?
If phenolic foam insulation is found within a roofing system, it and all its residue should be removed. In addition, all severely damaged structural steel, like a metal deck, should be replaced with all new materials. Minor corrosion can usually be stopped by removing the rust and applying a coat of quality rust inhibitive epoxy.
High Risk Areas for Phenolic Foam
The high R-factor (good insulating properties) of phenolic foam caused it to be widely specified in commercial construction throughout the '80s. Although phenolic foam was specified nationwide, buildings in the Midwest and Northeast are particularly at risk owing to those regions' cold weather patterns.
Cost of Removing Phenolic Foam
Some of the costs associated with removing phenolic foam and repairing the resulting damage may be covered by the manufacturers responsible for the product.
Kopper's Company, which produced the insulation from 1981 through 1989, has been since taken over by the British-based Beazer East.
Manville Inc., which sold the product from 1989 to 1992 when it was discontinued, has since been purchased by Schuller International, Denver. Both Beazer and Schuller have established special departments to handle phenolic foam roof insulation-related liability claims.
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EnergySavingsOptions.com :: Foam Roof Insulation