Cohen Foods in Granite City, Illinois, utilized American WeatherStar’s Foam-Gard™ Roof Restoration System to restore and protect two separate roof areas totaling 28,000 square feet. With each roof requiring a different preparation approach, the project incorporated spray polyurethane foam insulation and a protective acrylic coating system to provide a seamless, weather-resistant roofing solution.
Restoring Two Separate Roof Areas
The Cohen facility featured two roof sections totaling approximately 28,000 square feet. Although both areas would receive the Foam-Gard™ System, their existing conditions required different approaches to preparation.
The larger, 16,000-square-foot roof had an existing spray polyurethane foam surface that could be prepared for restoration. The second, 12,000-square-foot section required a tear-off and the installation of a recovery board before the new roofing system could be applied.
American WeatherStar’s Foam-Gard™ System was selected to provide a continuous, insulated roofing membrane across both areas. The system combines spray polyurethane foam with protective elastomeric coatings to deliver long-term waterproofing and weather resistance.
Preparing and Installing the Foam-Gard™ System
An American WeatherStar Approved Contractor began by preparing each roof section according to its existing conditions. The 16,000-square-foot SPF roof was scarified to prepare the surface for the new system, while the 12,000-square-foot section underwent a tear-off followed by the installation of a recovery board.
Following preparation, Acrylic Bonding Primer 905 was applied to promote adhesion. Everest Evercell 30 spray polyurethane foam, with a density of 3.0 pounds per cubic foot, was then installed to create a continuous insulation layer.
The SPF was applied in a tapered configuration, transitioning from approximately 2 inches at the high points to 1 inch at the low areas. This approach allowed the roofing system to incorporate slope while providing a seamless layer of insulation.
Once the foam application was complete, High-Build Acrylic 212 was applied as both the base coat and top coat. These protective coating layers provided a durable, weather-resistant finish designed to shield the underlying SPF from UV exposure and environmental conditions.
28,000 Square Feet of Long-Term Roof Protection
The completed Foam-Gard™ System provided Cohen with 28,000 square feet of restored roofing, combining the insulating properties of spray polyurethane foam with the protection of a seamless acrylic coating system.
By addressing the different conditions of each roof section, the project established a consistent roofing system across both areas without requiring the same preparation approach throughout.
The completed project received a 10-year American WeatherStar Roof Coating & Foam Material Warranty, providing long-term protection for the installed roofing system.
Looking to restore an aging commercial roof? Discover how American WeatherStar’s Foam-Gard™ System can provide lasting waterproofing and insulation for your facility.
