Finished urethane coated roof over spray foam in Chardon, Ohio

Spray Foam Roof Over Low-Slope Metal & Gravel in Chardon, Ohio

Greg PalyaOther

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.

Finished photo of spray foam and urethane coating over existing roof in Chardon, Ohio

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
Plywood used a flute fill into metal panels before spray foam gets installed

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
Spray foam and urethane coated roof in Chardon, Ohio

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.

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.