Spray Foam Roofing Revitalizes Iconic Hobie Surf Shop
Seamless SPF system solves ponding issues and extends roof life for historic California building with improved drainage, durability and sustainability.
Key Takeaways
- Spray polyurethane foam (SPF) roofing creates a seamless, fully adhered system that improves drainage and eliminates ponding on low-slope roofs.
- SPF can be customized in thickness to correct uneven surfaces, combining insulation, slope and waterproofing in one application.
- Retrofit SPF systems reduce tear-off costs, minimize disruption and extend roof lifespan through recoating and sustainable performance.
Most commercial buildings have low-slope roofs, making maintenance easier, and creating valuable rooftop real estate for equipment and energy upgrades. Low-slope roof systems are designed with a slight incline of ¼” - ½” per foot to encourage the flow of water towards a drainage system. However, as water accumulates it finds a weak spot to penetrate into permeable materials or seams that aren’t well-sealed. As water accumulates, it deteriorates most traditional roofing materials: adhesives in single-ply roof systems lose their grip; steel equipment supports are corroded; oil solvent components of roofing asphalts seep into the water, leaving the remaining membrane brittle, cracked and leaking as the pond grows, accelerating the roof’s aging. Ponding also adds more weight onto the roof and, unfortunately, remains until the water evaporates.
Fortunately, a spray polyurethane foam (SPF) roofing system builds resilience into the structure. The seamless, fully adhered, insulated membrane combines slope, insulation, and waterproofing in one field-applied system, becoming the evolution of the modern roof.
This virtually maintenance-free system includes a solar reflective coating with embedded granules that increases the roof’s surface durability and helps meet California’s stringent building requirements.
Photo: General Coatings Manufacturing Corp.
A New Roof: Hobie Surf Shop in Dana Point, California
The Hobie Surf Shop is a historic spot where Hobie Alter started shaping boards, offering surf gear, and apparel. Described as a man of great imagination, Alter started out shaping surfboards in his family’s Laguna Beach summer home for friends and ended up shaping a culture. The first store opened in 1954 and two blocks away is the current location. As Alter told Longboard Magazine, “My Laguna run totaled 99 boards. Number 100 came with the purchase of the Dana Point shop.”
The 5,000 square-foot building is now owned by a retail developer who knew the low-slope roof was having challenges and reached out to a general contractor. Since the original roof was foam, California-based Vision Roof Services was brought in to trim the old roof and apply a new foam and acrylic system.
Since the roof was not level, installing a seamless spray foam roof system filled in uneven areas, ensuring a natural slope that directs water to the drain and mitigates ponding. Because spray foam is applied directly to the roof surface rather than being prefabricated and then put on the roof, it can be installed thicker in some areas and thinner in others. This allows for filling in the known ponding areas and rain to flow to the channels and drain more effectively.
First the crew used a scarfer to trim the old foam, allowing them to then apply General Coatings Manufacturing Corporation’s Ultra Thane 230 2.7, a one-inch foam, and then add Flex 1000, a 33-mil acrylic protective coating, on top of the fully adhered SPF roofing. Every inch of SPF Roofing is engineered for performance; the insulation, slope correction, adhesion, and weatherproofing work together as one resilient system.
“Because the California sun is relentless on roofs and to meet the state’s rigorous sustainability requirements, we knew that GCMC’s SFP and acrylic products would be the ideal choice for this project,” said Mike Zapata, director of sales Vision Roof Services.
Since the roof was not level, California-based contractor Vision Roof Services trimmed the old foam, which allowed them to apply GCMC’s Ultra Thane 230 2.7 to fill in uneven areas.
Photo: General Coatings Manufacturing Corp.
Easy Application, Maintenance, and Long Life
The spray primer, foam and roof coating as a retrofit system was installed with minimal interruption to the Hobie Surf Shop because the contractor didn’t need to tear off of the existing roof, saving the building owner time and money. Additionally, this virtually maintenance-free system includes a solar reflective coating with embedded granules that increases the roof’s surface durability. California building requirements can be challenging, however, the spray foam roofing system is actually renewable because it can be recoated with additional roof coating as the system comes to its surface life in 10-20 years. It’s the only roofing system that is designed to be sustainable and to last the lifespan of the building.
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