Introduction
The historic 125-year-old Spencer Forge & Manufacturing facility in Spencer, Ohio required a full roof restoration across three separate roof sections totaling 26,500 sq ft. Rather than tearing off and replacing the entire roof, the team at West Roofing Systems applied a high-performance spray polyurethane foam (SPF) system over existing metal and shingle substrates. The result: a durable, insulated, leak-free roof with a 20-year full-system warranty.
Project Challenges
- The building had metal and shingle roof sections with basically zero insulation, resulting in energy loss and leaks.
- Operating a 125-year-old manufacturing facility meant that roof work needed to be fast and minimally disruptive.
- Replacement via full tear-off would have been extremely costly and generated considerable waste and business disruption.
Our Solution
- Conducted a comprehensive roof survey and found that less than 5% of the deck needed to be replaced.
- On metal roof sections: cleaned, prepared, and applied 2 inches of spray polyurethane foam (SPF) to increase the insulation (R-value) significantly.
- On shingle roof sections: removed shingles, installed cover board, then applied foam over the board.
- Over the foam, 30 mils of protective coating was applied, embedded with granules to increase durability.
- Eliminated two internal drains and rerouted drainage to exterior gutters to improve performance.
- Completed the work in 21 working days with a 6-person crew — minimizing downtime and cost.
Warranty & Protection
A 20-year full-system, non-prorated warranty was issued after the final walkthrough, providing Spencer Forge with long-term peace of mind and coverage for their restored roofs.
Results & Benefits
- Cost savings: Avoided a full tear-off and new roof installation, cutting the cost roughly in half.
- Energy efficiency: The addition of spray foam over previously uninsulated metal and shingle roofs significantly improved thermal performance. They went from an R-1 to an R-13.
- Durability: The foam + coating system created a continuous waterproof envelope, eliminating many common leak points.
- Minimal disruption: Work was completed quickly with a small crew, allowing the manufacturing facility to continue operations.
- Sustainable solution: The 20-year warranty can be easily renewed with a recoat.
Want to see before/after images, along with the scope of work? View the PDF below:
📄 View the Spencer Forge & Manufacturing Full Project Profile (PDF)
Want a free quote for your commercial roofing project?
If your commercial or industrial facility is dealing with leaks, uninsulated roof decks, or costly roof replacements — let’s talk. At West Roofing Systems, we specialize in spray foam roof renewal solutions that restore performance, reduce cost, and provide long-term warranties. Request a free quote today for a free assessment.
