Left and Below: The team needed to mask the facility before applying the foam
in order to protect beams, conduits and factory machinery.
“The existing insulation was falling in various locations,” said Gary
Harvey, General Manager for Wedge Roofing and also a Certified
Green Building Professional. “A draft from ventilation or opening
doors would send particular matter wafting down from the ceiling.”
Obviously, this is not okay in a food-processing area; particularly in
an organic label environment which is hyper-sensitive to FDA and
other food inspector regulations. Wedge Roofing was contracted by
Amyʼs to first remove the existing insulation, and then apply spray
foam to the entire ceiling.
In order to complete the job, the Wedge Roofing team had to mask
and protect literally miles of beams, conduits and factory machinery
(see photos). They then sprayed two inches of Lapolla closed-cell
foam, and on top of that applied Flame Seal Intumescent Coating.
Although the ceiling surface stretches 110,000 square feet - already
a massive undertaking - the job consisted of much more than that.
“We cut and trimmed around beams that totaled to over 19,000
lineal feet. That works out to be 3. 6 miles of hand-cutting and
trimming around all the beams up on the ceiling,” recalled Harvey.
All of this was done 30 feet up in the air on a boom lift.
Extreme precision in masking and trimming wasnʼt the only
significant factor weighing upon the Wedge Roofing team. Because
Amyʼs Kitchen is a 24-hours-a-day, 365-days- a-year operation, they
could only give the project a very slim time frame for completion.
“They could only allow us a 3-week window in order to keep up
with production, so all the work had to be done within 21 days,”
To meet these scheduling demands, Wedge Roofing had between
35 to 45 employees on-site every day of the project. They were able
to complete the job in 20 days, meeting the Amyʼs Kitchen goal with
24 hours to spare.
The spray foam application was
completed in January 2010 and since
then, Amyʼs Kitchen has continued to be
the leading mass producer of natural frozen
foods in the world.
This is not the first time spray foam insulation and protective coatings
have been used for this very application in rooms which must be kept
clean and sanitary, such as in food processing plants. The combination
of SPF and coatings has been proven not only to achieve great cost
savings in energy consumption, but also to meet FDA requirements
and remediate failing traditional systems such as fiberglass and other
potentially hazardous materials.
To learn more about Wedge Roofing, Inc., please visit the companyʼs