We were contacted by a homeowner whose recently renovated home was experiencing roof performance issues less than two years after project completion. The roof displayed cupping and unusual snow-melt patterns. Upon inspection, we discovered that the original closed-cell spray foam—installed by another contractor—was shrinking and separating. Core samples confirmed our assessment. Importantly, our team did not install the original foam; we were brought in specifically to correct the issue.
The homeowner had removed the shingles and sheathing, allowing us to fully remove the failing foam. This was a meticulous process, as many roof slopes corresponded with cathedral ceilings, which required careful handling to avoid interior damage. Additional complexity arose in attic spaces and inaccessible kneewall areas, making cleanup and preparation challenging.
To properly reapply spray foam, we installed friction-fit foam board as a backing substrate in difficult areas, providing a secure surface for the new closed-cell foam. Interior attic areas were then sprayed and coated with intumescent paint to meet fire-protection requirements. Throughout the project, our team maintained strict fall protection, coordinated closely with the roofing contractor, and worked around weather constraints to ensure safety and efficiency.
The project was successfully completed, restoring the roof’s integrity, energy efficiency, and long-term performance. The homeowner was extremely satisfied with the results and subsequently scheduled work on their second property. This project demonstrates our team’s expertise in problem-solving, precision application, and delivering high-quality spray foam solutions even under challenging conditions.
