The expert choice for spray foam roof restoration:
Durable waterproofing with PURelastik liquid plastic and fleece.
Old foam roofs from the 1990s are facing a major challenge today: After more than 30 years without intensive maintenance, the structural integrity is severely compromised. At that time, a classic UV coating was used as surface protection. However, this UV protection chalks over time and should have been renewed every 5 years as part of regular maintenance.
If this maintenance was neglected, the foam has been exposed to UV radiation and the elements for years. The results are deep cracks, embrittlement, and moisture damage.
Chalked UV protection layer as the root cause of moisture penetration.
Typical damage profile after 30 years without maintenance: Once the original UV protective coating has completely chalked, it loses its bonding strength and remains on the roof as a loose, powdery film. This leaves the old foam exposed and unprotected. UV radiation destroys the cell structure, leading to massive weathering, embrittlement, and deep cracks. These cracks allow moisture to penetrate the roof structure unhindered – making urgent renovation with our fleece-reinforced liquid plastic system essential.
The Problem: Why neglected foam roofs fail after 30 years
Yes, in most cases, an aged foam roof can be saved through professional restoration, provided that the bond between the foam and the substrate is still intact. The decision between restoration or a complete tear-off depends primarily on a precise on-site damage analysis.
The Inspection Process: On-Roof Assessment
A sound damage analysis is conducted in three standardized steps:
-
Visual Inspection: Checking for cracks, blisters, mechanical damage, and UV degradation.
-
Moisture Measurement: Non-destructive testing methods locate deep-seated water pockets within the polyurethane (PU) foam.
-
Adhesion Testing: Testing the remaining bond strength between the foam and the substrate.
Damage Analysis: Can your foam roof still be saved?
The Solution: The FLK PURelastik system in a 3-step application
1. Preparation and Deep Cleaning of the Old Foam:
A long-lasting restoration of old foam requires the perfect substrate. Before applying PURelastik liquid plastic and fleece, we remove moss, algae, and deep-seated dirt from every pore.
Our professional roof cleaning creates the optimal adhesive bridge on the old PUR foam. Only on an absolutely clean surface can the liquid-plastic-fleece system bond seamlessly with the roof. The result for your building: an extremely tear-resistant, UV-resistant, permanently elastic, and 100% waterproof seal.
2. Full-Surface Fleece Reinforcement for Maximum Crack Bridging:
The heart of the restoration system is the fleece-reinforced intermediate layer. In this step, the single-component liquid plastic PURelastik is applied, and a special technical reinforcement fleece is immediately embedded—completely free of wrinkles and bubbles. For this initial base coat, a material quantity of approximately 2.0 - 2.5 kg/m² is applied. The fleece is worked into the liquid mass until it is completely saturated. This reinforcement reliably absorbs future thermal movements of the roof and provides a permanently elastic bridge for even deep cracks in the old foam.
3. Seamless Finish for Permanent UV Protection:
After the fleece is fully embedded, the final top coat follows the next day. With an additional layer of PURelastik (consumption: approx. 1.0 kg/m²), the reinforcement fleece is completely coated and sealed. This achieves a professional total consumption of approximately 3.0 kg/m² of PURelastik, guaranteeing a long-lasting and seamless protective membrane. This light gray finish reflects solar radiation, permanently protects the insulation material from new chalking, and makes future maintenance coatings every five years completely unnecessary.
Is your foam roof getting old or leaking?
In this video, we show you the process of a professional old foam roof restoration! While old PU foam roofs provide excellent insulation, decades of exposure and the loss of UV protection make them brittle. Join us on the construction site as we explain how to efficiently refurbish and seal old foam, protecting it for the next 20+ years – without the need for UV coating renewal.
