"This part of the USA experiences hurricanes and tornadoes, along with extremely hot and humid temperatures," says Ralph.  "These factors strongly influenced my designing a 'whole building system.'  I wanted a completely airtight, maintenance-free home with exceptional structural integrity, cost-efficient energy sources and pleasing aesthetics."

Energy efficient
The walls are 6 in/15.24 cm thick insulated concrete forms (ICFs) that are steel reinforced.  Vertical steel reinforcing rods placed 2 ft/.61 m apart tie the walls to the 3,400 sqft/316 sq m concrete slab and footer foundation.  Every 2ft/.61 m steel anchor plates are positioned into the top of the walls with 5/8 in/1.59 cm J-bolts. These secure the steel roof trusses to the walls.  The exterior surface of the ICFs is coated with synthetic stucco, which further stops air filtration and heat loss.

There are no soffits or vents.  An air-to-air energy recovery ventilator exchanges the interior and exterior air, recapturing up to 83 percent of the house's heat from the expelled air, transferring it to the incoming new air.  An air cleaner maintains air quality and controls airborne dust particles.  Special in-floor water heating zones were installed prior to pouring the slab.

"The roof is an important integral feature of the 'whole building system.'  Using the POLYSET® tile roofing system, the insulation moved from the top of the rooms to the top of the house.  With this system, we could eliminate the traditional roof decking and waterproofing membrane.  So we saved building costs, while adding to our insulation and structural needs.  This roof can withstand winds in excess of 200 mph," says Ralph.

Innovative technologies
Both the POLYSET tile roofing system and the formulated polyurethane adhesive are patented by Polyfoam Products, Inc. to attach roofing tiles.  It utilizes a JEFFCAT® amine catalyst with RUBINATE® M isocyanate from Huntsman Polyurethanes.  "We work extensively with Huntsman Polyurethanes in our development of innovative foam technologies,"says Pat Murray, vice president of Polyfoam Products.

POLYSET tile roofing system was developed in response to the damages inflicted by Hurricane Andrew on South Florida in 1992.  The destruction included widespread failure of the tile attachment methods used at that time.  The POLYSET tile roofing system is designed to withstand Category 5 hurricane winds.  Its wind uplift resistance is 50-100 percent greater than with nails or screws.

On the Stork house, 53,000lbs/24,040 kg of 17 in/43.18 cm long overlapping concrete tiles are positioned on steel battens.  These are attached every 14 in/35.56 cm to the steel truss.  Six inches (15.24 cm) of POLYSET foam adhesive are sprayed onto the underside of the exposed tiles and battens.  When the material cured, the tiles and steel battens became permanently locked together in a waterproof impermeable barrier.  POLYSET foam adhesive reaches 90 percent strength within two hours.

According to Dave Faulkner, Polyfoam Products' marketing development manager:  "This is an unusual application method.  Typically POLYSET foam adhesive is applied onto roof decking in patties, and then the tiles are put in place.  Essentially, the polyurethane adhesive replaces traditional attachment methods utilizing mortar, nails, screws and clips for installing tiles onto the roof decking."

Triple duty
The POLYSET foam adhesive provides a lightweight, resilient, impact-resistant support under the tiles,  allowing contractors to walk on the roof almost immediately.  Also, if flying debris breaks a tile, it remains affixed to the roof, so it doesn't become an airborne missile.

"With the POLYSET foam adhesive I'm getting value for my money, because it does triple duty," says Ralph.  "The top of the house is now one solid piece of construction.  There's no opportunity for roof leaks caused by mechanical fasteners puncturing the waterproofing membrane.  The roof significantly contributes to our home's R-40 insulation value, substantially reducing heating and air conditioning costs.  The attic is usable, airconditioned space."

In addition to the POLYSET adhesive, the company markets the foam dispensing equipment and trains certified applicators.  The roofing system is widely used in Florida, the Caribbean, and Puerto Rico.  Commercial use is expanding in Mexico, Okinawa, Guam and Hawaii, with start-up efforts in Japan.  The company also manufactures foam systems for packaging, rigid molding, flotation, and specialty uses.

Ralph Stork, Homeowner, USA
Phone +1 843 626 9123
Fax +1 843 626 9123

Pat Murray, Polyfoam Products, Inc.,Headquarters, USA
Phone +1 281 350 8888
Fax +1 281 516 3074

Dave Faulkner, Polyfoam Products, Inc.,Roofing Division, USA
Phone +1 954 578 1559
Fax +1 954 578 1042
www.polyfoam.cc

MAR 2003