How Spray Foam Roofing's Seamless Membrane Helps Military

In 2008, the US soldiers at the Jabala Military Base in Iraq faced a serious problem. The metal roofs in the barracks had aged and cracked, allowing animals, dust, moisture, and extreme heat to enter. In Iraq, where temperatures regularly exceed 100°F, efficient HVAC is critical. The U.S. Army Corps of Engineers called West Roofing Systems to install spray foam roofing systems across six buildings.

The Problem with Traditional Roof Systems

Traditional roofing systems with ballasts make leak detection incredibly difficult — there's no clear way to inspect the membrane beneath gravel. Similarly, seamed systems like TPO and EPDM present challenges: even a slight uplift in a seam can become a water entry point that's nearly impossible to detect and costly to repair.

The Benefits of a Seamless Roof

Spray polyurethane foam creates a continuous, monolithic membrane that adheres directly to any surface, eliminating the risk of leaks from seams, cracks, or gaps. It also increases R-value, improving thermal insulation and reducing HVAC load — critical for extreme climates.

Real-World Application: Jabala Military Base, Iraq

West Roofing Systems applied a minimum of 1.25 inches of spray foam directly to the original transite panels, covering 150,000 sq ft across six buildings. The existing roof contained asbestos fastened from the inside through the roof, leaving thousands of exposed bolts — the foam encapsulated all of them. Two coats of silicone were then applied to protect the foam from UV rays.

Results

The seamless system eliminated pest infiltration, reduced dust, stopped all moisture penetration, and significantly improved energy efficiency — allowing HVAC systems to maintain comfortable temperatures for military personnel for the first time.