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The Roofing Professionals

Manth-Brownell, Inc. – Reroofing an existing Built-Up Roof

Manth-Brownell 1Client

Manth-Brownell, Inc.
Kirkville, NY

Existing Roof

Smooth-Surfaced Built-Up Roof System


Being one of the largest turned parts companies in North America, Manth-Brownell’s 128,000 square foot complex houses millions of dollars of computerized machining equipment.  This high-tech equipment was at increased risk due to more frequent roof leaks, especially at tie-ins to numerous buildings constructed over the years.  Furthermore, a decision was made to remove the fiberglass batt insulation on the underside of the roof deck, leaving the roof structure inadequately insulated.


Seamless Spray-Applied Polyurethane Foam (SPF) Roofing System.


After evaluating various single-ply and spray-applied systems, management selected a seamless spray-applied polyurethane/silicone system to be installed by S. D. Carruthers.  Particularly appealing was the seamless, self-flashing feature of the SPF system in dealing with difficult tie-in details, which would have been problematic with alternative systems. Other benefits included the superior insulating properties of the closed-cell polyurethane foam and the ability to custom taper the foam insulation during application for improved drainage.

Application of the new SPF system included the following:

  • Removal and replacement of isolated areas of wet insulation.
  • Cutting and fastening of blisters in the built-up roof membrane and securing of loose felts.
  • Priming the built-up membrane to assure proper adhesion.
  • Spray-applying two layers of seamless polyurethane foam insulation, with a minimum compressive strength of 40 PSI.
  • Field tapering of the foam insulation for improved drainage.
  • Spray-applying two layers of silicone protective membrane coating.
  • Applying ceramic granules into the top coating layer, providing increased durability and a non-skid surface.
  • Providing a full-system labor and materials warranty, with manufacturer’s follow-up inspection program.

Results & Owners Comments

Management was extremely pleased with the project’s outcome offering the following comments:

Manth-Brownell, Inc.
April 17, 2014

“We were really impressed how much the foam insulation expanded, sealing all the gaps and cracks where we have interconnected buildings.  Already it’s cooler in our sorting and stock area due to the new insulation.  Also, not having to remove the old roof, coupled with the efficiency of Carruthers’ crew, resulted in minimal disruption, and we were able to conduct business as usual.”

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