Spray Foam Roof Replaced With Versico TPO in Lakewood
Project Overview
- Location: Lakewood, CO
- Building Type: Commercial block building
- Size: 4,400 sq ft
- Roofing System: Versico 60-mil TPO, fully adhered over 2.6 inch polyiso on a concrete deck
- Duration: 3 weeks
- Completed: May 2025
- Manufacturer: Versico
- Warranty: 20-year Versico Total Systems Warranty
Roof Condition
This Lakewood commercial building had an old spray foam roof buried under river rock ballast. With the rock off, the foam was cracked and weathered across the whole surface and was no longer worth repairing.
- Old spray foam roof buried under river rock ballast
- Foam cracked and weathered across the whole surface
- Foam at the end of its life and no longer worth repairing
Evaluation & Approach
The foam had reached the end of its life, so coating it would have sealed in a failing surface. Tearing it off to the concrete gave a clean, solid deck. Adhering the insulation and membrane means no fasteners through the concrete and a smooth finish. Taking the membrane up and over the walls removes the wall-top joints where water usually gets in. The full Versico system carries a 20-year Total Systems Warranty.
Why This Approach
- Tearing the foam off to the concrete gave a clean, solid deck
- Adhering the insulation and membrane means no fasteners through the concrete
- A fully adhered membrane leaves a smooth finish
- Taking the membrane up and over the walls removes the wall-top joints where water usually gets in
- The full Versico system carries a 20-year Total Systems Warranty
Scope of Work
- Ballast Removal: Removed and hauled away 22 tons of river rock ballast.
- Foam Tear-Off: Tore off 4 inches of spray foam down to the concrete deck.
- Insulation: Adhered one layer of 2.6 inch polyiso insulation to the concrete with low-rise foam adhesive.
- TPO Membrane: Fully adhered Versico 60-mil TPO to the insulation.
- Parapet Walls: Ran TPO up and over the parapet walls.
- Drip Edge Metal: Installed 430 linear feet of drip edge metal at the walls and gutter line.
- Gutters and Downspouts: Follow-up work added new 6 inch seamless gutters tied into the roof metal and custom 4x4 open downspouts.
Result
Warranty: 20-year Versico Total Systems Warranty
- Failed Foam and Ballast Gone: Failed spray foam and 22 tons of river rock ballast removed down to the concrete deck
- New Insulated White TPO Roof: Versico 60-mil TPO fully adhered over 2.6 inch polyiso insulation, with a 20-year Versico Total Systems Warranty
- Walls Wrapped: TPO run up and over the parapet walls, removing the wall-top joints where water usually gets in
- New Edge Metal and Gutters: 430 linear feet of drip edge metal, new 6 inch seamless gutters and custom 4x4 open downspouts