A spray foam roofing robot installing foam on a 384,000 sq. ft. facility in Ohio

MTD Facility – Robotic Spray Foam Roof Restoration (384,000 sq ft)

Greg PalyaProject Profiles

Introduction

MTD entrusted West Roofing Systems to restore its 384,000 sq ft metal roof. What made this job unique: instead of a standard manual application, three spray-foam robots worked together to apply 2.5″ of closed-cell SPF in a single pass.

The project was completed in 52 days by a 14-person crew, delivering a high-performance, energy-efficient roof backed by a 20-year full-system warranty.

Robotic application of spray polyurethane foam on MTD metal roof

Project Challenges

  • Massive roof size: 384,000 sq ft of metal requiring restoration
  • Tight schedule: needed to complete the work in 52 days
  • Safety concerns: potential overspray when using high-output robotic sprayers
  • Temperature fluctuations: ambient weather changed drastically during installation, affecting foam behavior
  • Maintaining building operations and ground-level safety during installation

Our Solution

  1. Pilot Test
    • Before committing to the whole roof, West Roofing tested a 16,000 sq ft section with 2.5″ of SPF over five years. The performance met expectations, giving MTD confidence to move forward.
  2. Robotic Foam Application
    • Deployed 3 spray-foam robots to apply PremiSEAL 60R in a single continuous pass.
    • A 14-person crew worked in tandem, averaging ~7,384 sq ft/day to hit the 52-day timeline.
    • To manage overspray risks, custom foam-blocking skirts were used on the robots. Hand-held wind screens were used during windy periods.
  3. Coating & Finishing
    • After foam application, they installed 30 mil SeamlesSEAL ULTRA HS silicone coating over the foam for UV protection and waterproofing.
    • Completed the system with metal edge flashing, new gutters, downspouts, and rake edges.

Warranty & Protection

  • The entire restored system is backed by a 20-year manufacturer’s total system warranty.
  • Added insulation value: the new roof provides R-28 (more than double the previous R-value).
Silicone coating being installed over spray foam at MTD in Willard, Ohio.

Results & Benefits

  • Speed & Efficiency: Using a robotic application enabled the roof to be completed in under two months.
  • Thermal Performance: With 2.5″ of SPF, MTD got a high R-value roof (~R-28), reducing energy costs.
  • Cost Savings & Sustainability: Instead of tearing off the metal roof (and generating scrap), this restoration reused the substrate, minimizing waste.
  • Quality & Safety Control: Daily quality checks, a safety checklist, and onsite QC/CRFC inspections kept the job tight.

Want to see the scope of work and before, in-progress, and finished photos? View the PDF:

📄 View the MTD Full Project Profile (PDF)

Need a free commercial roofing quote?

Do you have a large industrial or commercial roof that seems too big or complex for traditional restoration? Our robotic spray foam solutions can help — fast, efficient, and backed by long-term warranties.


👉 Contact West Roofing Systems to discuss your project or get a free assessment.

About the Author

Greg Palya

Greg Palya is the Digital Content Manager of West Roofing Systems, Inc. He has a B.S. in Marketing from the University of Akron and an MBA in Marketing from Walsh University. When he's not trying to teach others about spray foam roofing and silicone roof coatings, you can find him on the basketball court or golf course. He's been with West Roofing Systems since June of 2019. All of the content he has produced has been with the help of subject matter experts (namely the internal salesman who all have decades of spray foam and coating experience.)