SPF Foam · Industrial / Warehouse
150,000 SF Warehouse — SPF Foam Retrofit
Irving, TX
150,000 SF Warehouse — SPF Foam Retrofit
After150,000 SF Warehouse — SPF Foam Retrofit
BeforeDrag the slider to compare before and after — BUR over metal deck replaced with SPF Foam
Project Details
Property Type
Industrial / Warehouse
System Installed
SPF Foam
Previous System
BUR over metal deck
Square Footage
150,000 SF
Duration
14 days
Completed
May 2025
Location
Irving, TX
The Challenge
A 150,000 SF warehouse with a deteriorating BUR roof over metal deck, experiencing chronic ponding water in multiple areas and escalating energy costs. The building owner wanted to avoid a full tear-off due to the cost and operational disruption of removing the existing BUR system. The roof had heavy penetrations from exhaust fans, HVAC units, and pipe runs.
Our Solution
SPF foam was the ideal solution — sprayed directly over the existing BUR substrate, eliminating tear-off entirely. The seamless application self-flashed around all 40+ penetrations, filled ponding areas to create positive drainage, and added R-30 insulation value. Protective elastomeric topcoat applied for UV resistance.
The Result
No tear-off waste — 100% of existing material stayed in place. Energy costs dropped 28% in the first summer due to the added insulation and reflective topcoat. All ponding areas eliminated through foam contouring. 20-year warranty with recoat option to extend indefinitely.
What the Client Said
“The SPF option saved us the entire cost of tear-off and gave us better insulation than we would have gotten with a traditional replacement. Our energy bills in July were lower than they'd been in a decade.”
Building Owner
Industrial Properties, Private Ownership
Additional photos coming soon
Similar Projects
200,000 SF Distribution Center — Complete TPO Replacement
After200,000 SF Distribution Center — Complete TPO Replacement
Before200,000 SF Distribution Center — Complete TPO Replacement
TPODistribution Center · Grand Prairie, TX
Multi-Tenant Retail Center — Silicone Coating Restoration
AfterMulti-Tenant Retail Center — Silicone Coating Restoration
BeforeMulti-Tenant Retail Center — Silicone Coating Restoration
Silicone CoatingRetail / Shopping Center · Plano, TX
Medical Office Complex — Leak Repair & Restoration
AfterMedical Office Complex — Leak Repair & Restoration
BeforeMedical Office Complex — Leak Repair & Restoration
Modified BitumenMedical Facility · Dallas, TX
Ready to See Results Like These on Your Building?
Schedule your free roof assessment and get a custom recommendation for your facility.
Got Questions About Your Roof?
Our AI advisor can help with system recommendations, maintenance planning, and repair questions — and connects you with the MAZE team when you're ready.
Your Roof. Documented Results.
Schedule Your Free Assessment Today.