According
to the Department of Energy’s Commercial Buildings Energy Consumption
Survey, there were 5.9 million commercial buildings in the United States
in 2018, covering 97 billion square feet of floor space. That year,
they consumed 6.8 quadrillion British thermal units of energy,
translating to $141 billion spent on electricity and natural gas. With
stringent energy-related regulations on the horizon, big corporations
are seeking innovative and cost-effective solutions to reduce their
carbon footprint.

One of the principal challenges for large
facilities is maintaining optimal internal temperatures, especially when
the building design and materials exacerbate heat retention. A Fortune
500 big box store recently chose NanoTech Materials, Inc., to apply its
Cool Roof Coat to a 180,000-square-foot retail facility with a 30-foot
ceiling and a trapezoidal metal roof to maximize energy efficiency. Here
are the highlights of what they found.

The Challenge

The
retail facility, a single-story building with expansive square footage,
faced substantial thermal management issues. The building’s trapezoidal
metal roof, which had never been coated, contributed to high internal
temperatures. During initial baseline scans, the surface temperature of
the uncoated roof reached a scorching 149 degrees Fahrenheit, while the
ceiling temperature underneath the batt insulation was recorded at
112.28 degrees Fahrenheit (44.6 degrees Celsius). These conditions were
measured with an ambient outside temperature of 90 degrees Fahrenheit.

Such
high internal temperatures meant that the store’s HVAC system was under
constant strain, working tirelessly to bring the internal temperature
down from 112 degrees Fahrenheit to a more comfortable 70 degrees
Fahrenheit for ground-level customers and employees. Excessive heat
increases energy consumption and operational costs and poses potential
risks to product integrity and customer comfort.

In addition, the
HVAC system was the single most significant contributor to the
facility’s Scope 2 carbon footprint. The parent company had recently
pledged an aggressive Net Zero strategy to shareholders and knew that a
dramatic reduction in energy use across its owned buildings portfolio
was the fastest way to achieve this. As such, regional facility managers
were under intense pressure to reduce their locations’ overall energy
use.

The Solution

In
search of a solution to address thermal challenges and reduce the
workload on the building’s HVAC, the company decided to implement a cool
roof coat solution, a high-performance reflective roof coating designed
to reduce heat absorption and improve energy efficiency. In searching
for vendors that could be a good fit, the company was introduced to
NanoTech Materials’ new advanced formulation, which promised significant
reductions in surface temperatures. The goal was trifold: alleviate the
burden on the HVAC system, significantly reduce the building’s Scope 2
CO₂ footprint, and ultimately impact the company’s bottom line.

The Technology

The
NanoTech Materials Cool Roof Coat leverages the company’s proprietary
technology, the Insulative Ceramic Particle (ICP), which is integrated
into building materials and coatings for heat control. This innovation
goes far beyond traditional reflective coatings by significantly
reducing heat transfer through the thickness of the coating. Instead of
simply reflecting heat away, the coating creates a physical barrier that
stops the heat through low thermal conductivity. The technology is
based on the energy band theory, a departure from low-mass technologies
(aerogels) or reactive chemistry (intumescent).

The coating
incorporates ICP, an acrylic coating that significantly reduces heat
transfer by increasing the heat resistance of the materials it applies
to. It reflects sunlight within the visible light spectrum, emits solar
radiation from the UV and infrared spectrum, and increases the
material’s heat resistance, lowering indoor temperatures by 25-45
degrees Fahrenheit and significantly reducing the carbon emissions of
the building. Conventional roofing materials often lack the necessary
thermal insulation, resulting in higher energy usage for air
conditioning, increased utility costs, and elevated greenhouse gas
emissions. Reflective coatings designed to reduce heat absorption lose
effectiveness over time due to dirt accumulation and environmental wear.
The company projects the material can generate energy savings from 20%
up to 50%, far surpassing the typical 15% savings of traditional
reflective coatings.

Its ability to withstand harsh environments
also ensures long-term performance and reliability. The coating is UV
resistant, waterproof, and maintains no-crack flexibility. It also
protects against hail up to 2 inches in diameter. The product can be
easily applied using spray-on or roll-on methods and does not contain reportable
volatile organic compounds.

Implementation

The
application was meticulously planned and executed to ensure no
disruption to store operations. The coating process involved several
steps. The roof surface was thoroughly cleaned to remove debris, dust,
and any existing contaminants. This step was crucial for ensuring proper
adhesion of the coating. The coating was applied evenly across the
entire 180,000-square-foot roof using advanced spray equipment. Two
coating layers were applied to achieve the desired thickness and
uniformity.

Quality control checks were conducted throughout the
application process to ensure the coating was applied correctly and
consistently. This included verifying the thickness of the coating and
inspecting for any missed spots or inconsistencies.

The coating
comes with a 20-year NDL warranty, is walkable in 90 minutes, and is
rain-safe within eight hours. It can be applied in temperatures ranging
from 41 to 200 degrees Fahrenheit and has a mechanical bond cure.

Results

The
impact was immediately apparent. Post-application scans revealed a
dramatic reduction in temperatures. The internal ceiling temperature
dropped to a much more manageable 73 degrees Fahrenheit, starkly
contrasting to the previous 112 degrees Fahrenheit. This significant
decrease in internal temperature had several key benefits. The HVAC
system no longer had to work as hard to maintain indoor temperatures,
leading to a 49% reduction in the cooling component of HVAC use. This
not only lowered energy consumption but also extended the lifespan of
the HVAC equipment. Lowering the HVAC load decreased electricity bills,
providing a quick return on investment for the coating application.

The store also minimized its carbon footprint by reducing energy consumption, contributing to its sustainability goals.

Industry Impact

In
the evolving landscape of commercial building management, introducing
this technology presents significant opportunities for roofing
contractors. By incorporating advanced cool roof technologies,
contractors can diversify their services, leading to higher-value
projects and increased revenue potential. Expertise in these
technologies provides a competitive edge, meeting commercial clients’
growing energy efficiency and sustainability demands.

Contractors
can foster long-term client relationships by addressing ongoing
challenges like energy costs and carbon footprint reduction, resulting
in repeat business and referrals. Cool roof solutions help clients meet
stringent energy regulations and enhance project value through
significant energy savings and improved building performance.

Integrating
advanced roofing solutions into services positions contractors as
trusted advisors opens up new avenues of revenue, and drives client
satisfaction.

Conclusion

Applying
NanoTech Materials Cool Roof Coat to the 180,000-square-foot retail
facility demonstrates the transformative potential of advanced roofing
solutions for improving thermal efficiency and reducing operational
costs. This project highlights the significant benefits of proactive
thermal management and innovative roofing technologies, providing a
sustainable solution that aligns with the store’s environmental
objectives.

The success of this project underscores the
importance of addressing thermal challenges from the top down,
showcasing the value of energy-efficient roofing solutions. For roofing
contractors, it illustrates the growing opportunities in the commercial
sector for advanced, sustainable technologies, positioning them as
essential partners in creating more cost-effective commercial buildings.