125,000 Sq Ft Industrial Warehouse Foam Roof Restoration — Tempe, AZ
A 125,000 square foot industrial warehouse in Tempe had a foam roof that was leaking in multiple areas and damaging equipment inside. The coating was failing, and the foam underneath had started to blister, bubble, and crack. We made all the necessary repairs, then restored the entire roof with 2 coats of ARMORCOAT AC100. The building now has a 10-year warranty, and the job took 3 weeks from start to finish.
The ChallengeA leaking Tempe warehouse roof that was damaging equipment inside
This industrial warehouse in Tempe, Arizona has a spray polyurethane foam (SPF) roof covering about 125,000 square feet, with rows of skylights and rooftop HVAC units across the field. Foam is the right system for a building like this in the Phoenix heat, but only if the protective coating on top stays intact.
By the time we got the call, it hadn't. The coating was failing across the roof, which left the foam exposed to UV. Once foam loses its coating, it starts to break down: it blisters, it bubbles, and it cracks. Water got in through those openings, and the roof was leaking in multiple areas. Those leaks were damaging equipment inside the warehouse.
When a leak is damaging equipment inside an operating warehouse, the roof stops being a maintenance item and becomes a business problem. The owner needed the leaks stopped and needed a roof they wouldn't have to think about again for years.
What We FoundBefore: failing coating, blistered and cracked foam, and active leaks
The ScopeRepair the foam first, then coat the whole roof
The coating is what protects the foam, but a coating can't fix foam that's already blistered or cracked. So the order matters: repair the damaged foam and the leak areas first, then lock the whole roof in with a new coating system.
Project scope of work
- Leak repairs: Found and repaired the leak areas that were letting water into the building and onto the equipment inside
- Blister and bubble repair: Repaired the blistered and bubbled foam across the roof so the new coating goes over sound foam
- Crack repair: Repaired the cracks in the existing foam before any coating went down
- Coating system: 2 full coats of ARMORCOAT AC100 across the full 125,000 sq ft, creating a continuous protective layer over the foam and every repair
- 10-year warranty: Issued on completion of the restoration
During the Job125,000 square feet in 3 weeks
On a roof this size, the during-the-job photos tell the story best: you can see exactly where the new AC100 ends and the old, worn surface begins.
The ResultA bright white, watertight roof with a 10-year warranty
The finished roof is a uniform, bright white AC100 surface across the whole building. The leak areas are repaired, the damaged foam is fixed and sealed under 2 coats, and the skylights and rooftop units are coated in. A white roof also reflects much more of the Arizona sun than a dirty, failing surface, which takes some of the heat load off the building through the summer.
The Warranty10-year coverage on a restored roof, not a replaced one
This restoration comes with a 10-year warranty. And because the existing foam was repaired and kept in place instead of torn off, the owner avoided the cost and disruption of a full tear-off on a building this size.
Why the coating matters on a foam roof
Spray foam is an excellent roof system for Arizona, but the foam itself can't take the sun. The coating is what protects it. When the coating fails, UV starts breaking down the foam, and you get the blisters, bubbles, and cracks this roof had. Catch it early and a recoat is all you need. Wait until the roof is leaking and you're paying for foam repairs too, plus whatever the leaks damage inside. Keeping the coating maintained on schedule is the cheapest way to keep a foam roof working.
About the PropertyIndustrial warehouse in Tempe
The building is a large industrial warehouse in Tempe with truck docks, rooftop HVAC, and rows of skylights. It's the kind of building where a roof leak can shut down a section of the floor or damage equipment, so the roof has to work.
If you own or manage an industrial building in Tempe or anywhere in the Phoenix metro and your foam roof is showing a failing coating, blisters, cracks, or leaks, we'll inspect it and give you an honest restore vs replace assessment. See our industrial & warehouse roofing services →