Case Study: 42,000 SF Foam Repair and AC100 Recoat — 3 Buildings on Huntington Dr, Tempe
Three side-by-side flex-industrial buildings at 2403, 2425 and 2525 W Huntington Dr in Tempe — 42,000 sq ft of spray polyurethane foam roof across all three — got a full foam repair scope and two coats of ARMORCOAT AC100 in a single continuous project. Bubbles cut and refilled, scuppers and drains sealed with ArmorPutty and reinforcing membrane, vents and cracks re-detailed, and every tenant stayed open.
Project Snapshot42,000 sq ft foam repair and AC100 recoat across three adjacent Tempe flex-industrial buildings
2403, 2425 and 2525 W Huntington Dr sit side by side in the Peterson Park industrial corridor of west Tempe — a short block just west of Priest Dr and inside the freeway triangle formed by I-10, US-60 and Loop 202. The three buildings are all multi-tenant flex-industrial / office-flex product, the kind of building that fills the Tempe 85282 employment core between Sky Harbor and ASU. 2525 W Huntington is marketed as the Huntington Tech Center — a renovated flex building with 100% A/C suites — and 2403 and 2425 next door share the same construction era and roof system. All three are working properties with active tenants: property management and medical supply corporate offices, environmental services companies, community and worship uses, and light-manufacturing suites.
42,000 SF Foam Recoat — 3 Buildings, Huntington Dr, Tempe
| Property | Three adjacent flex-industrial / office-flex buildings on Huntington Dr — includes the Huntington Tech Center (2525) |
| Address | 2403, 2425 & 2525 W. Huntington Dr., Tempe, AZ 85282 |
| Building type | Multi-tenant flex industrial / office flex — 3 buildings, side by side |
| Roof size | 42,000 sq ft total spray polyurethane foam (SPF) roof across all three buildings |
| Scope | Clean roof surface, cut and re-fill foam bubbles with new SPF, seal all scuppers and drains with ArmorPutty + reinforcing membrane, seal all vents with ArmorPutty, repair cracks / splits / holes, 2 coats ARMORCOAT AC100, clean up all debris |
| Neighborhood | Peterson Park, Tempe 85282 — I-10 / US-60 / Loop 202 industrial corridor, minutes from Sky Harbor and ASU |
| Warranty | 5-year no-leak (materials + labor) |
| Completion | July 2026 |
The ProjectThe building, the client, and what we were solving for
2403, 2425 and 2525 W Huntington Dr sit side by side in the Peterson Park industrial corridor of west Tempe — a short block just west of Priest Dr and inside the freeway triangle formed by I-10, US-60 and Loop 202. The three buildings are all multi-tenant flex-industrial / office-flex product, the kind of building that fills the Tempe 85282 employment core between Sky Harbor and ASU. 2525 W Huntington is marketed as the Huntington Tech Center — a renovated flex building with 100% A/C suites — and 2403 and 2425 next door share the same construction era and roof system. All three are working properties with active tenants: property management and medical supply corporate offices, environmental services companies, community and worship uses, and light-manufacturing suites.
The roofs across all three buildings are spray polyurethane foam — SPF — the same seamless closed-cell foam system that Vanguard has installed and maintained across thousands of Arizona flat roofs since the 1970s. Foam is the right product for this kind of building because it goes on monolithic (no seams to fail), it insulates and waterproofs in one pass, and it can be re-detailed and re-coated indefinitely as long as it's maintained on the right cycle. When Vanguard was called out to Huntington Dr, the foam substrate across all three buildings was still fundamentally sound — good closed-cell density, no soft spots — but the coating had chalked and thinned, several foam bubbles had developed from years of UV and thermal cycling, and the scuppers, drains, and roof-top penetrations needed to be re-sealed before another coat went on.
The SystemThe system: cut and refill every bubble, re-detail every penetration, then two coats of AC100 across all 42,000 sq ft
A foam recoat is only as good as the repair work underneath it. When foam bubbles are ignored and simply coated over, they keep growing under the new topcoat and eventually blister through — that's how you end up needing a tear-off five years later on a roof that could have gone another decade. Vanguard's scope on Huntington Dr addressed every failure point in the foam substrate before a single gallon of coating was applied, then locked the whole 42,000 sq ft under two full coats of ARMORCOAT AC100.
- Full clean of the foam surface across all 3 buildings — pressure-washed to remove chalked coating, dust, and airborne debris from the surrounding industrial corridor.
- Cut and re-fill every foam bubble — bubbles were opened, dried, and re-filled with fresh spray polyurethane foam to match the surrounding density and elevation, then feathered smooth.
- Every scupper and drain sealed with ArmorPutty + reinforcing membrane — the highest-risk detail on any low-slope roof. High-solids urethane putty with embedded polyester membrane wraps every scupper throat and drain bowl.
- Every roof vent and pipe penetration sealed with ArmorPutty — HVAC curbs, plumbing vents, gas lines, and every roof penetration re-sealed monolithically.
- All cracks, splits, and holes repaired — any thermal cracks or splits in the foam field patched with ArmorPutty and reinforcing membrane before coating.
- 2 full coats of ARMORCOAT AC100 — the premium white elastomeric applied at spec across all 42,000 sq ft, in cross-hatched directions across each of the three roofs.
Our ApproachThe approach: 3 buildings, 42,000 sq ft, one continuous mobilization
The economic case for doing three buildings on one contract is compelling — one mobilization, one crew, one delivery of foam and coating materials, one set of dumpsters, one pass through the property. Vanguard sequenced the work building by building so the crew could keep momentum from one roof to the next without ever demobilizing. Each building started with a clean-and-inspect pass, then foam repair, then detail work at scuppers and drains, then vents and penetrations, then the two AC100 coats. Because these are working flex-industrial buildings with active tenants — offices, warehousing, environmental services, medical supply — the crew was disciplined about parking access, delivery lane clearance, and staging all equipment so no tenant lost customer or vendor access.
Vanguard's 8-step scope for the Huntington Dr foam recoat
- Clean roof surface — full pressure-wash of all 42,000 sq ft across the three buildings to remove chalked coating and industrial-corridor debris.
- Cut and re-fill foam bubbles with new SPF — every bubble opened, dried, and re-filled with fresh spray polyurethane foam to match the surrounding density.
- Seal all scuppers and drains with ArmorPutty + reinforcing membrane — the single most common failure point on any low-slope roof, monolithically re-sealed and reinforced.
- Seal all roof vents with ArmorPutty — every HVAC curb, plumbing vent, and roof penetration wrapped and sealed.
- Repair all cracks, splits, and holes — any thermal or mechanical damage in the foam field patched with ArmorPutty and reinforcing membrane.
- Apply 2 coats of ARMORCOAT AC100 — premium white elastomeric at 1.5 gallons per 100 sq ft per coat, 3 gallons per 100 sq ft total spread rate, in cross-hatched directions across each roof.
- Clean up and dispose of all job-related debris — dumpsters staged out of the tenant traffic lanes, parking lots swept, no drums or trash left overnight.
- 5-year no-leak warranty — materials and labor covered for 5 years across all 42,000 sq ft.
The finished drone photography shows the outcome across all three buildings from one flight: three side-by-side flex-industrial roofs, all finished in the same bright white AC100 topcoat, all with sharp parapet edges and clean penetration details. From the drone's perspective the three roofs read as a single continuous project — which is exactly what an owner or property manager with a portfolio of adjacent buildings wants to see. One contractor, one system, one warranty, one visual result across the whole property.
The DetailThe detail: why foam recoats are the highest-value move on an Arizona flex-industrial roof
A spray polyurethane foam roof isn't a coating with a lifespan — it's a substrate with a maintenance cycle. Closed-cell SPF, installed correctly, will last essentially indefinitely as long as it's protected from UV by a properly-maintained elastomeric topcoat and its detail work is kept up. That means every 8-12 years in the Arizona climate, a foam roof needs to be inspected, its bubbles cut and re-filled, its penetrations re-detailed, and a fresh two-coat topcoat applied. Do that on schedule and you can own a foam roof for 30 or 40 years without ever needing a tear-off. Miss the maintenance window and you end up with UV degradation of the foam itself, which is when you're actually looking at a tear-off.
The Huntington Dr buildings were exactly at the right point in that cycle — foam still fundamentally sound, coating chalked and thinned, bubbles forming, details ready for re-work. Vanguard's scope reset the clock: repaired foam substrate, freshly detailed penetrations, and 42,000 sq ft of new AC100 elastomeric topcoat at spec. The three buildings now have another 8-12 year maintenance window before they need to be looked at again, and the owner has a written 5-year no-leak warranty on top of that.
The Warranty5-year no-leak warranty backed by an Arizona commercial roofer since 1957
The Huntington Dr recoat is covered by a 5-year no-leak material and labor warranty. If any covered part of the 42,000 sq ft roof surface leaks in the next 5 years — coating failure, ArmorPutty detail failure at a scupper, drain, or vent, foam-bubble repair failure, or workmanship defect — Vanguard returns to make it right at no cost to the property owner. Vanguard Roofing AZ is a division of MSW Contracting LLC, a Chandler-based Arizona contractor on Valley roofs since 1957. AZ ROC CR-42 #289663 and R-62 #283025. GAF, Versico, and ARMORCOAT certified. A+ BBB.
The ResultsThe results — 42,000 sq ft of foam roof reset for another decade across three tenant-occupied Tempe buildings
The drone photography tells the whole story: three adjacent flex-industrial buildings, all finished in the same bright white cool-roof coating, all with clean sharp parapet edges and re-detailed penetrations, all done under one mobilization without a single tenant losing access. The owner gets a written 5-year no-leak warranty, a foam roof that's been properly maintained for its next 8-12 year cycle, and a cool-roof reflective surface that lowers HVAC load on all three buildings through Arizona's peak summer months.
Photo GalleryProject photos
Drone FlyoverSee the finished roof
FAQCommon questions
What was the scope on the Huntington Dr Tempe foam recoat?
Vanguard repaired and recoated 42,000 sq ft of spray polyurethane foam roof across three adjacent flex-industrial buildings at 2403, 2425 and 2525 W Huntington Dr in Tempe. The 8-step scope was: full pressure-clean of the foam surface across all three roofs; cut and re-fill every foam bubble with new SPF to match density; seal every scupper and drain with ArmorPutty and reinforcing membrane; seal every roof vent and pipe penetration with ArmorPutty; repair all cracks, splits, and holes in the foam field; two full coats of ARMORCOAT AC100 white elastomeric at 3 gallons per 100 sq ft total spread rate in cross-hatched directions; complete debris cleanup; and a 5-year no-leak warranty on materials and labor.
Why did Vanguard cut and re-fill the foam bubbles instead of just coating over them?
This is the single most common way a foam recoat fails prematurely. If bubbles are left in the foam substrate and simply coated over, they continue expanding and contracting with thermal cycling and eventually blister through the new topcoat — sometimes within 2-3 years. The correct move is to open every bubble, dry it out, re-fill it with fresh spray polyurethane foam that matches the surrounding density, and feather it smooth before the topcoat goes on. That's what Vanguard did across all three Huntington Dr roofs. Doing it that way is the difference between a recoat that holds for 8-12 years and one that fails inside the warranty period.
Why is a foam recoat higher-value than a tear-off on a building like this?
Spray polyurethane foam isn't a coating with an expiration date — it's a substrate with a maintenance cycle. A properly-maintained SPF roof will last 30-40 years or more in the Arizona climate as long as the topcoat is refreshed and the details are re-worked every 8-12 years. A tear-off on a building like Huntington Dr would cost multiples of what a repair-and-recoat costs, would put the tenants through weeks of noise and disruption, and would throw away a foam substrate that's still fundamentally sound. The right move on Huntington Dr was the repair-and-recoat that Vanguard delivered — it resets the maintenance cycle and buys the owner another decade before the roof needs to be evaluated again.
Why a 5-year warranty on this project instead of a 10-year?
Warranty length on a coating recoat depends on the scope, the age and condition of the substrate, and the mil thickness of the topcoat that goes on. For this project — a foam substrate on three buildings with the specified two-coat AC100 application — the written no-leak warranty is 5 years on materials and labor. That means Vanguard returns to make it right at no cost to the owner if any covered part of the 42,000 sq ft roof surface leaks in the next 5 years due to coating failure, ArmorPutty detail failure, foam-bubble repair failure, or workmanship defect. Larger scopes with higher mil thicknesses can carry 10-year or 15-year warranties, and Vanguard will lay out those options against any bid.
Was Vanguard able to keep all three buildings occupied and open during the work?
Yes. All three Huntington Dr buildings are multi-tenant flex industrial and office flex with active tenants — property management and medical supply corporate offices, environmental services companies, community uses, and light-manufacturing suites. The crew sequenced the work building by building so that at any given time only one roof was being actively worked on, staged all foam and coating equipment out of the primary tenant traffic lanes, coordinated with the on-site contacts about parking and delivery access, and swept the parking lots clean at end of every workday. No tenant lost occupancy or access to their suite during the project.
What is the reflectivity and cool-roof performance of the finished coating?
ARMORCOAT AC100 is a premium white elastomeric roof coating with high initial solar reflectance — typically 85+ SRI at installation, which meets Title-24 and ENERGY STAR cool-roof performance standards. On a 42,000 sq ft flex-industrial property with rooftop HVAC on every building, that's a real operating-cost effect: the reflective white surface reflects the majority of incoming solar radiation instead of absorbing it, which lowers the roof-deck temperature by 40-60°F on a peak-summer day, which in turn lowers the load on the HVAC systems and extends the life of the rooftop equipment. On buildings like these where every suite has its own package unit, that HVAC-load reduction adds up quickly over a hot Phoenix-Tempe summer.