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

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.

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

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

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.