This project involved the emergency remediation of a newly constructed barn that experienced a catastrophic roof failure of unprecedented scale. The original roof assembly utilized SIP panels; however, in less than three years, severe moisture intrusion led to extensive rot. The roof sheathing had deteriorated so completely that it would turn to powder when compressed by hand, putting the entire structure at risk.
The contractor engaged our team to stabilize and repair the roof assembly by applying closed-cell spray polyurethane foam from the exterior—a solution that is typically straightforward but, in this case, presented significant technical and logistical challenges. The project took place during the onset of winter, with ambient temperatures frequently dropping near 30°F. These conditions raised serious concerns regarding proper foam adhesion and cure. Compounding the issue were repeated rain and snow events and sustained high winds, all of which forced constant rescheduling and required precise timing to execute each phase safely and effectively.
Due to the urgency of the failure and an already full production schedule, our team accommodated the project as an emergency repair. The work had to be completed in carefully sequenced sections so that each area could be sprayed and immediately re-roofed, minimizing exposure to the elements. Adding to the complexity, the roof elevation reached approximately 40 feet, necessitating strict fall-protection measures and detailed safety planning throughout the project.
Through careful coordination, weather monitoring, and disciplined execution, our crews completed the work on schedule despite the adverse conditions. The result was a stabilized, protected roof assembly that restored the structural integrity of the barn and prevented further deterioration. This project highlights our team’s ability to respond rapidly, adapt to challenging environments, and deliver high-quality spray foam solutions under extreme conditions—ultimately saving the customer’s barn.
