Introduction
In 2023, West Roofing Systems completed a 28,553 sq ft roof restoration in Chardon, Ohio, applying spray foam over an existing low-slope metal roof and gravel BUR. The roof’s shape is unique — it slopes in all directions, meaning there is no flat area. Spray foam’s seamless fluid application made the job more efficient and cost-effective than traditional roofing systems.
Project Details & Challenges
- Roof size: 28,553 sq ft
- Completion: 29 days
- Roof composition: low-slope metal sections + gravel BUR
- The shape is complex — every foot slopes up or down
- Gravel had to be removed (hydro-vacuum)
- Skylights and sensitive areas covered for protection during install
Our Solution
- Removed all loose gravel using hydro-vacuum methods
- Covered skylights & exposed roof areas with plywood to protect them
- Applied an average of 1.5 inches of closed-cell polyurethane foam (SPF)
- Installed 20 mils of urethane coating over the foam
- Manufacturer specs:
- Foam: SWD
- Coating: Neogard
- Issued a 10-year full-system renewable warranty after completion
Results & Benefits
- Seamless, waterproof, and durable roof over a difficult, highly sloped surface
- Eliminated risk of leaks at transitions or slopes thanks to fluid SPF
- Cost savings compared to a full tear-off and re-roof
- Long-term protection backed by a 10-year warranty
Want more project details and before, in-progress, and after photos? View the PDF
📄 View the Chardon Roof Case Study (PDF)
Need a free quote for your commercial roofing project?
Have a complex or sloped roof that seems impossible to restore conventionally? Contact West Roofing Systems today — we specialize in spray foam systems that adapt to challenging geometries, protect your structure, and come with solid warranties.
