Tubular Steel – Spray Foam Roofing over Metal Panels
Introduction
In 2024, West Roofing Systems tackled a 3,712 sq ft roof restoration project at Tubular Steel in Lorain, Ohio. The existing trapezoid metal panel roof presented challenges in aesthetic leveling and insulation. Our solution: strategic substrate installation and spray foam application to deliver a seamless, cost-effective, high-performance roof.
Project Challenges
The metal roof had deep trapezoidal panels, requiring extra foam to level Installing 3" of foam across the board would have been very expensive Desired solution needed to balance aesthetics, cost, and structural safety Preventing water infiltration under panel ends and panel gaps
Our Solution
Fastened 3/4" plywood strips (30" wide) in between each metal panel to serve as a leveling substrate This approach reduced the required foam thickness from 3" down to 1.5", saving on material and cost Applied 1.5" of spray polyurethane foam (SPF) over the newly prepared surface Specified manufacturer: Carlisle for SPF Coating manufacturer: Progressive Materials Installed a flanged-back gutter system to prevent water backup under panels and sealed panel ends to stop wildlife infiltration.
Project Details
Project Year: 2024 Location: Lorain, Ohio Size: 3,712 sq ft Completion Time: 7 days
Warranty & Protection
20-Year Full System, No Dollar Limit, Non-pro-rated Warranty
Project Results & Benefits
A visually level, uniform roof surface over formerly deep trapezoid panels Lowered foam thickness while retaining performance, yielding cost savings Added drainage and prevention of water entry beneath panels A robust commercial roofing system over an existing metal substrate
Want to learn more and see before, in-progress, and finished photos?
View the Tubular Steel Full Project Profile (PDF)
Need a quote?
Looking to restore or level a metal roof cost-effectively? Contact West Roofing Systems today — we'll design a custom spray foam roofing solution that balances performance, aesthetics, and budget.