Introduction
In 2024, West Roofing Systems tackled a 3,712 sq ft roof restoration project at Tubular Steel in Lorain, Ohio. The existing trapezoid metal panel roof presented challenges in aesthetic leveling and insulation. Our solution: strategic substrate installation and spray foam application to deliver a seamless, cost-effective, high-performance roof.
Project Challenges
- The metal roof had deep trapezoidal panels, requiring extra foam to level
- Installing 3″ of foam across the board would have been very expensive
- Desired solution needed to balance aesthetics, cost, and structural safety
- Preventing water infiltration under panel ends and panel gaps
Our Solution
Substrate Preparation & Metal Attachment
- Fastened ¾″ plywood strips (30″ wide) in between each metal panel to serve as a leveling substrate
- This approach reduced the required foam thickness from 3″ down to 1.5″, saving on material and cost
Spray Foam + Coatings
- Applied 1.5″ of spray polyurethane foam (SPF) over the newly prepared surface
- Specified manufacturer: Carlisle for SPF
- Coating manufacturer: Progressive Materials
- Installed a flanged-back gutter system to prevent water backup under panels and sealed panel ends to stop wildlife infiltration.
Project Details
- Project Year: 2024
- Location: Lorain, Ohio
- Size: 3,712 sq ft
- Completion Time: 7 days
Warranty & Protection
- 20-Year Full System, No Dollar Limit, Non-pro-rated Warranty
Project Results & Benefits
- A visually level, uniform roof surface over formerly deep trapezoid panels
- Lowered foam thickness while retaining performance, yielding cost savings
- Added drainage and prevention of water entry beneath panels
- A robust commercial roofing system over an existing metal substrate
Want to learn more and see before, in-progress, and finished photos?
📄 View the Tubular Steel Full Project Profile (PDF)
Need a quote?
Looking to restore or level a metal roof cost-effectively? Contact West Roofing Systems today — we’ll design a custom spray foam roofing solution that balances performance, aesthetics, and budget.
