How spray foam solved a complex spherical roofing project in Las Ve…

Useful takeaways from this story.

SPF was chosen because it contours to complex curved geometry that rigid systems could not match.

Using 5 inches of General Coatings Ultra-Thane 230 HFO created a seamless, lightweight, watertight assembly and simplified logistics.

Switching to SPF avoided an estimated 45–65 truckloads of material and reduced material waste by about 20–25%.

# Project overview In 2021 Commercial Roofers, Inc. learned about a major roofing project: an orb-like entertainment venue in Las Vegas measuring 366 feet tall and 516 feet wide. The spherical shape meant the roof curved in every direction, producing continuously changing conditions across the surface. Conventional materials and installation approaches for flat or planar roofs would not adapt well.

# Why spray foam was selected The contractor initially planned a single-ply roofing system. After assessing the geometry and installation challenges, Commercial Roofers' leadership recommended spray polyurethane foam (SPF) instead. The vice president of operations, Dennis Perry, led the recommendation. Curtis Perry, the quality superintendent, summed up the practical reason: SPF can contour to the building in ways the original system would have struggled to do.

# Product and assembly used The team used General Coatings' Ultra-Thane 230 HFO Spray Foam, installed at a thickness of five inches. That configuration delivered a seamless, lightweight, and watertight roofing assembly suited to the spherical surface.

# Logistics and material savings The choice of SPF simplified on-site logistics. Had the original single-ply system been used, the project would have required roughly 45 to 65 truckloads of material. Using SPF avoided that volume of deliveries and the staging congestion a spherical structure would create. The SPF approach also reduced material waste by an estimated 20 to 25 percent, because rigid components would have required extensive cutting to fit curved surfaces.

# Supply and support Curtis Perry credited General Coatings with meeting both product specifications and supply needs during the project. The manufacturer provided the Ultra-Thane 230 HFO formulation and supported the higher supply and demand required for a large, nonstandard roof.

# Recognition Commercial Roofers' work on the Las Vegas sphere received a 2026 National Insulation Excellence (NIE) award, acknowledging the installation approach and execution.

# Practical takeaways for roofers

For structures with nonplanar geometry, evaluate SPF early as a candidate because it eliminates many fit-and-seam issues of rigid or sheet systems.
Consider supply chain impacts when comparing systems: SPF can cut truckloads and staging needs for complex shapes.