How spray polyurethane rescued a convention giant

By Jesse Sanchez. 

A shortage, a storm zone and a supersized roof challenge led to a high-stakes rethink. 

When the New Orleans Ernest N. Morial Convention Center, the sixth largest in the nation, needed a roof restoration, traditional materials weren’t an option. Supply chain disruptions during the pandemic had choked national availability of TPO roofing materials. Faced with nearly 2 million square feet of aging rooftop and mounting environmental concerns, project leaders took a bold turn. Instead of a full reroof, they opted for a spray polyurethane foam (SPF) system — a decision that saved time, expenses and more than 41 acres of material from heading to landfills. The Henry Spray Foam Roof Restoration System, applied by Brazos Urethane and supplied by Green Shield Products, was backed by SPFA standards and training. Proving to be more than a workaround, it was a strategic solution. 

Spray foam offered the structure superior wind uplift resistance, a critical factor in the hurricane-prone Gulf region, while also supporting the convention center’s pursuit of LEED Gold certification. The renewable system extended the roof’s lifespan and eliminated the need for a full tear-off, diverting approximately 1.9 million square feet of material from landfills. 

The scale of the project was immense. Crews of 30 to 50 worked across 601 days, sectioning the roof into 14 zones to inspect for moisture intrusion and substrate readiness. Visual and infrared inspections, along with adhesion testing, informed a tailored application strategy. The result: a seamless monolithic SPF layer, reinforced with coatings like Henry HSLV Silicone and Poly+ Aliphatic Polyurethane to accommodate zone-specific demands. 

The weather didn’t cooperate. Seven-day operations became the norm. Crews built protective boxes for rooftop equipment, and fast-action foam spraying kept rain from derailing progress. Large gutter troughs were reinforced with 30 mils of coating to prevent failure under heavy water flow. Brazos Urethane’s track record and technical rigor played a key role in seeing the project succeed. Their workforce included certified SPFA roofing project managers, OSHA-trained foremen and credentialed applicators. Specialized robotic technology from Spray Works also gave them a cutting edge, ensuring a smooth surface despite variable wind conditions. 

The jobsite itself stayed active, no small feat for a venue that hosts more than 750,000 visitors annually. Project leaders coordinated closely with AECOM, the general contractor and the convention center to schedule work around events and ensure uninterrupted operations. The restored roof doesn’t just shelter one of the country’s busiest convention hubs; it sets a new bar for sustainability and adaptive strategy in commercial roofing.  

While the finished product speaks for itself, the full story, of weather battles, supply chain pivots and engineering on the fly, might just surprise you!