Seamless Roof Replacement Transforms Industrial Printing Facility

For facility managers and commercial property owners, few things pose a greater risk to operations than a leaking roof—especially when sensitive equipment is at stake. That was the case for a high-output sticker and label printing facility whose aging ballasted EPDM rubber roof was leaking on their newly acquired commercial building.

Roof = Operational Risk

The facility’s original roof was a ballasted EPDM membrane, a system once common in industrial applications. But after decades of exposure, the rubber was dried out, cracking, and pulling away at the seams. Ballast stones were no longer holding down the failing membrane, and water intrusion had become a recurring problem—not suitable for a multi-million dollar printing operation.

Leaks weren't just a nuisance—they were a direct threat to business continuity and asset protection.

The Solution: Spray Foam and Gravel Roof System

After evaluating the needs of the facility and the demands of their equipment, we recommended a spray polyurethane foam (SPF) roofing system topped with protective gravel—a modern, high-performance alternative that checks all the boxes for long-term durability and energy efficiency.

Why A Spray Foam Roofing System Made Sense:

• Seamless & Leak-Free: SPF forms a fully adhered, joint-free membrane across the entire roof—eliminating the weak points that plague EPDM systems.
• High R-Value Insulation: With closed-cell foam, the roof now acts as a thermal barrier—lowering energy costs and helping maintain stable interior temperatures.
• Durability + Protection: A gravel top layer shields the foam from UV damage and weather, while allowing for straightforward future maintenance or recoating.
• Minimal Disruption: The SPF application process is quick and non-invasive, allowing us to complete the install with minimal disruption to operations.

The Outcome: A Watertight, Energy-Efficient Roof Built for the Long Haul

With the new spray foam and gravel roof in place, the facility now enjoys:

• Zero active leaks
• Lower heating and cooling costs
• Improved thermal performance
• Extended roof lifespan with simplified maintenance
• Peace of mind knowing their capital equipment is protected

This wasn’t just a roof replacement—it was a strategic building upgrade that improved the asset’s value, reduced operational risk, and delivered a measurable ROI.

Takeaway for Facility Managers & Building Owners

If you’re managing an aging flat roof—especially one with EPDM, TPO, or built-up membrane—and you’re seeing signs of wear or water infiltration, it’s time to explore modern alternatives like SPF roofing systems.

This project proves that the right roofing solution can do more than stop leaks. It can:

• Improve energy performance
• Reduce long-term maintenance
• Extend building life
• Protect your core operations

Thinking about your next roof upgrade?
Let’s talk about how spray foam roofing could solve your challenges and protect your investment—seamlessly.

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