Showcasing the power of spray foam

By Emma Peterson. 

Spray foam roofing’s role in bringing an iconic landmark to life. 

Spray foam roofing is one of the most energy efficient and multifaceted roofing materials on our current market. And there’s no better example of the performance benefits of spray foam than the work done by Commercial Roofers, Inc. on Las Vegas’ iconic orb-like entertainment venue. 

The Commercial Roofers team first learned about the project in 2021. Curtis Perry, the quality superintendent for Commercial Roofers, recalled their introduction to the design, sharing, “From the initial review we were attracted to the uniqueness of the design. It was a very intriguing project for us, and we were excited to take on the endeavor.”  

As they got further into the project, they quickly realized that it would be more than just an endeavor – it would be a challenge. Amy King described it in detail in an article for Spray Foam Professional, saying, “At 366 feet tall and 516 feet wide, the building's dimensions were extraordinary. More importantly, the structure's spherical shape created roofing conditions that continuously changed from one area to the next. Traditional installation methods and material layouts for conventional roofs could not be applied to a surface that curved in every direction.” 

After considering these challenges, Dennis Perry, the Commercial Roofers vice president of operations made a game-changing recommendation – instead of the original plan of using single-ply, install spray foam. Curtis explained the reasoning behind this switch, saying, “There were many reasons why we found SPF to be the preferred roofing solution. The main reason being the Sphere's unique design. SPF is able to contour to the building in a way that the initial system would have struggled to.”  

Specifically, the team chose to use General Coating’s Ultra-Thane 230 HFO Spray Foam. By installing five-inches of this product, they were able to not only create a seamless, lightweight, watertight assembly, but also save time and materials. As Amy writes in their article:  

Had the original system been installed, the project would have required approximately 45 to 65 truckloads of material. Managing those deliveries, staging materials and coordinating installation across a spherical structure would have created significant congestion and complexity. The SPF system simplified those logistics while reducing 20% to 25% material waste that would have resulted from cutting rigid components to fit curved surfaces. 

Looking back at the decision to switch to spray foam, Curtis could not be more thankful they made the choice. He explained, “General Coatings provided the exact product that we needed to complete this project. Ultra-Thane 230 HFO met the specifications, and they were also extremely supportive in supplying the extensive supply and demand that we needed.” And Curtis and the Commercial Roofers team weren’t the only ones thrilled with the results. Their work on the project won them a 2026 National Insulation Excellence (NIE) award! 

Overall, the work done on this iconic landmark and the accolade it won by the Commercial Roofers team is a great representation of what can spray foam roofing can accomplish. As Curtis put it, “The capabilities for spray foam roofing systems are endless. It is a versatile material that we believe is an excellent option for difficult installations and projects.” 

See what spray foam can do for you!