Commercial Warehouse Insulation Retrofit Case Study

Large Industrial Warehouse – Arizona Desert Climate

Project Overview

• Project Type: Commercial Warehouse Retrofit

• Building Size: 82,000 sq ft

• Roof Area Insulated: 78,500 sq ft

• Wall Area Insulated: 18,000 sq ft

• Location: Southern Arizona

• Building Type: Steel warehouse with metal roof deck

• Project Duration: 12 working days

• Contractor: Spray Foam Arizona

• System Installed: Spray Polyurethane Foam (SPF) Insulation System

Problem

A large distribution warehouse built in the early 1990s was experiencing severe thermal performance issues typical of older desert industrial buildings.

The structure was originally constructed with minimal fiberglass insulation and large areas of uninsulated metal deck, which allowed extreme solar heat gain during Arizona summers.

The facility operator reported several operational problems:

• Interior summer temperatures exceeding 105°F• HVAC systems running continuously with limited cooling effectiveness• Significant energy costs and utility demand spikes• Heat buildup in the roof deck causing thermal expansion and condensation risk• Poor indoor comfort for warehouse staff• Difficulty maintaining temperature stability for stored goods

The building owner needed a solution that could:

• Improve energy efficiency• Reduce heat load on the building• Install with minimal operational disruption• Work with the existing metal structure

Solution

After evaluating multiple insulation strategies, the project team selected a spray polyurethane foam insulation retrofit applied directly to the interior roof deck and targeted wall assemblies.

SPF was chosen because it simultaneously provides:

• High R-value per inch• Continuous air sealing• Structural adhesion to metal decking• Moisture resistance• Rapid installation in large commercial environments

Installed System

Roof Deck Insulation

• 3 inches closed-cell spray polyurethane foam

• Average R-value: R-21

• Direct-to-metal deck application

Wall System

• 2 inches closed-cell spray foam applied to metal wall panels

• Air sealing at framing and penetrations

Additional Work

• Sealing of structural penetrations

• Insulation of expansion joints and roof transitions

• Targeted air barrier improvements around loading dock areas

Materials Used

Material	Specification
Spray Foam Type	Closed-cell polyurethane foam
Density	2 lb roofing-grade foam
Roof Thickness	3 inches
Wall Thickness	2 inches
Total Foam Installed	~92,000 board feet
Adhesion Method	Direct application to metal deck
Equipment	High-pressure proportioning system with heated hoses

Installation Timeline

Day 1–2

Site preparation, safety setup, surface inspection, and equipment staging.

Day 3–9

Spray foam installation across roof deck and wall sections. Work completed in large continuous zones to maximize efficiency.

Day 10–11

Detail work around penetrations, transitions, and mechanical equipment.

Day 12

Final inspection, quality verification, and cleanup.

The facility remained operational during the entire retrofit process.

Outcome

The retrofit produced immediate and measurable improvements in building performance.

Temperature Reduction

Interior temperatures dropped by 18–25°F during peak summer conditions.

Energy Savings

Utility monitoring indicated a 28–35% reduction in cooling energy demand during the first summer after installation.

Improved Comfort

Warehouse staff reported significantly improved working conditions and reduced heat stress.

Building Envelope Performance

The continuous foam insulation eliminated many of the air leakage paths common in metal warehouses, improving both temperature stability and humidity control.

Structural Benefit

The adhered spray foam added additional rigidity to the metal deck and reduced thermal expansion movement.

Key Performance Metrics

Metric	Before Retrofit	After Retrofit
Peak Interior Temp	105°F+	~82–87°F
Cooling Demand	Very High	Reduced 28–35%
Air Leakage	Significant	Minimal
Building Comfort	Poor	Stable & controlled

Why Spray Foam Was the Right Choice

For large industrial buildings in the Arizona desert climate, spray foam provides a combination of performance advantages:

• Continuous insulation with no gaps or seams• High thermal resistance in minimal thickness• Integrated air barrier• Fast installation on large surfaces• Excellent performance on metal structures and warehouses

Conclusion

This commercial warehouse retrofit demonstrates how spray polyurethane foam can transform the performance of older industrial buildings without requiring a complete roof or structural replacement.

By installing a continuous foam insulation layer directly on the building envelope, the facility achieved dramatic improvements in comfort, energy efficiency, and operational performance.

Spray Foam ArizonaRoofing • Insulation • Coatings

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