While Phenolic Foam exhibited excellent insulating characteristics it did have one major drawback. When moisture is introduced in to the foam through leaks or condensation, an acidic discharge takes place that can erode metal roof decks.

damage caused by PFRI

Damage from Phenolic Foam Roof Insulation can be difficult to diagnose from inside the building. Damage is caused from the top down. By the time the rust actually penetrates the deck in an area it is likely significant damage has occurred throughout the building. Rust oftentimes goes undetected because it can occur randomly right next to like-new decking.

This area of deteriorated decking was hidden by a drop ceiling and went completely undetected for years until portions of the drop ceiling fell-in.

Years of leaking at the perimeter of this building lead to complete disintegration of the metal deck. It is critical that PFRI be kept dry to prevent accelerated damage.

For a more scientific analysis of how PFRI can deteriorate metal decks,
click here (2.46MB, requires Adobe Acrobat Reader).