MTD Facility – Robotic Spray Foam Roof Restoration (384,000 sq ft)

Introduction

MTD entrusted West Roofing Systems to restore its 384,000 sq ft metal roof. Three spray-foam robots worked together to apply 2.5″ of closed-cell SPF in a single pass. The project was completed in 52 days by a 14-person crew, delivering a high-performance roof backed by a 20-year full-system warranty.

Project Challenges

The project presented several challenges: a massive 384,000 sq ft metal roof, a tight 52-day schedule, overspray risks from high-output robotic sprayers, temperature fluctuations during installation, and maintaining building operations throughout.

Our Solution

West Roofing first tested a 16,000 sq ft section over five years before committing to the full roof. Three spray-foam robots applied PremiSEAL 60R averaging ~7,384 sq ft/day. Custom foam-blocking skirts and wind screens managed overspray. After foam, 30 mil SeamlesSEAL ULTRA HS silicone coating was applied for UV protection and waterproofing, completed with new metal edge flashing, gutters, and downspouts.

Warranty & Protection

The system is backed by a 20-year manufacturer's total system warranty. The new roof also provides R-28 insulation value — more than double the previous R-value.

Results & Benefits

The robotic application completed the roof in under two months. The high R-value reduces energy costs significantly. Instead of tearing off the metal roof, this restoration reused the substrate, minimizing waste and cost.