At West Roofing Systems, we recently completed a large-scale restoration at Ironrock Building #1, where an aging metal roof and vertical wall panels needed long-term protection. Instead of a costly tear-off and replacement, our team installed a spray polyurethane foam (SPF) roofing system with silicone coatings and granules.
The result: a watertight, energy-efficient system backed by a 15-year renewable warranty.
Project Challenges
Ironrock Building #1 had multiple issues:
- Aging TPO membrane and insulation layers
- Flute fill and iso-board that had reached the end of their service life
- Vertical wall panels that needed reinforcement to keep water out
Rather than remove the entire metal roof, our approach was to preserve the existing structure while building a new system directly over it.
Our Solution
Roof Work
- Removed the existing TPO, iso-board, and flute fill
- Kept the original metal roof in place as a stable substrate
- Installed an average of 1.5 inches of spray polyurethane foam (SPF) across the roof surface
- Applied 15 mils of silicone basecoat and 10 mils of silicone topcoat
- Embedded granules into the topcoat for added durability, UV protection, and slip resistance
Vertical Wall Panels
- Installed 10 mils of silicone around all vertical metal wall panels on every side of the building
Warranty Coverage
- Roof System: 15-Year Full System Warranty – Non-Prorated, No-Dollar-Limit (NDL), and renewable
- Vertical Walls: 5-Year Warranty
Project Results
The Ironrock Building #1 restoration created a roof and wall system that is:
- Watertight – no more leaks or failures from the old system
- Energy-Efficient – spray foam adds insulation value and lowers heating/cooling costs
- Sustainable – instead of a tear-off, we extended the life of the existing roof
- Backed by Warranty – peace of mind with a renewable 15-year system warranty
See the Full Case Study
We documented the entire process with photos of the roof before, during, and after the installation.
📄 View the Full Ironrock Project Profile (PDF)
👉 Interested in learning how spray foam can restore a metal roof like this one? Contact our team today to discuss your building’s needs.
