A Smarter Roof Built in Moorcroft
~4.5" closed-cell sprayed between vertical roof boards with a 1" vent gap — high R-value without the "hot roof" moisture risk.
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Every project brings its own concerns, and for this home near Moorcroft, the priority was getting the roof insulated the right way. Dan wanted a solution that delivered performance without risking trapped moisture, which meant thinking beyond a standard approach to foam spray insulation.
The "hot roof" concern
Dan had a specific worry about "hot roof" assemblies and the potential for moisture to become trapped beneath the roofing system. Rather than taking chances, he wanted a design that allowed airflow while still achieving the thermal performance spray foam is known for. The goal wasn't just insulation — it was long-term protection of the roof structure.
A custom vented assembly
That's where Seamless Systems came in. Working closely with Dan, the team designed a custom roof assembly sprayed from the top side. The roof was built in layers: sheeting, vertical boards, and then spray foam applied between those boards, followed by another layer of sheeting.
This design intentionally left about an inch of space between the foam and the roof decking, allowing air to move through and vent the system. The result is a roof that stays cooler while avoiding moisture issues — exactly what Dan was looking for. The crew applied approximately 4.5 inches of closed-cell spray foam, creating a highly efficient thermal barrier without compromising ventilation.
Working conditions
This project had a few challenges. The roof was steep, so the crew wore cleats to work safely. Because the work was done outdoors, wind and temperature had to be carefully monitored. To make sure the spray foam applied correctly, heaters were used to warm the structure before installation. Along with the main home, the same roof system was also installed on a small guest house on the property.
The result
After the installation was complete, Dan was clear about the outcome: "It works great, I'm impressed with how energy efficient the home became."
“It works great — I'm impressed with how energy efficient the home became.”
Photos from the project.
Other spray foam work.
Cistern & Pump House — Pine Haven
Custom cistern with 2" closed-cell on the tank and 3" on the pump house, plus a frost barrier sprayed 4 feet out around the building.
Commercial Shop Insulation — Falcon Construction / MC Welding
Full-envelope closed-cell spray foam on a large red-iron commercial shop for Falcon Construction’s MC Welding build — walls and roof deck between the purlins, with tall overhead doors integrated into the thermal envelope.
Custom Spray-Foam on an Oil Storage Tank
2" closed-cell foam wrapped around a curved metal oil storage tank. No framing references — depth confirmed by hand throughout.
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