“I was originally hired by E-Systems (L-3’s predecessor) in February of 1981. As Maintenance Manufacturing Liaison Representative, I estimated electrical and support equipment, design work, and related projects, so I was involved in many, many aspects of facilities operations. However, for at least 20 of those years, anytime there was a roof leak or any roof problems, they automatically came to me. About half of the roofs are plain, standing-seam metal with no coating, but we also had some hot tar built-up roofs, and one or two small membrane systems.

Early experiences with spray foam roofing

Before I went to work there, in the late 70s, E-Systems actually purchased foam application equipment and our own people applied foam to several roofs. The results were not that super, and then, probably 25 years ago, I started working with my first spray foam contractor. In addition to foam’s waterproofing qualities, we used it to bridge bad spots on metal roofs and for its insulation value. Using a three-pound density urethane foam adds structural strength. Also, as computers became more prevalent, we realized that the heat load from all the electronics in one building exceeded the ability of the air conditioning system. So, about 20 years ago, we added two inches of foam to the roof – not due to a leak, but for the insulation value alone. To this day, the chillers in that building have been able to keep up with the heat load.

Unfortunately, with our prior foam contractor’s system, we had a huge problem with blistering, which can happen if the spray foam is not applied correctly. After working with them for a while – and when we slowed up on new projects – getting a warranty repair was becoming more and more difficult. In addition, the topcoat that the previous vendor had been using oxidized. It was not sun resistant; it would actually degrade over time, so that obviously left an unhappy feeling.

DFW Urethane starts a new chapter

In 2003, we had a hailstorm come through which negated any warranty. That’s when we decided to start fresh. We had to get competitive bids on everything we did, and with John Ewell’s winning bid on one of the buildings, we got involved with DFW Urethane.

John, his partner Bengy Hurd, and their installer, James Webb, all do excellent work – their quality is fantastic. When they spray the foam on, it’s nice and smooth. When I retired, they had upwards of eight years with their application, and the only blistering we had was due to the previous contractor’s work. There was not one blister on a roof in the whole facility where DFW Urethane did the original work. They did an excellent job.

Superior application methodology and people

What makes the biggest difference in the quality of a foam roofing system is the methodology of application. When you’re up on a roof, you can see whether it’s nice and smooth – or that it’s rough – and that’s totally in the realm of application. The equipment and the methodology are huge factors in foam application, and that’s where John and his guys excel. Their methodology is superior to any other – and they remain the only company using that methodology to ensure the proper mix. They do it the way it’s supposed to be done.

What’s more, polyurethane foam is climate-sensitive, and this was a 15-month project that spanned all four seasons. So, DFW Urethane worked hand-in-hand with BASF, the foam manufacturer, throughout the job. They purchased foam for the job multiple times during the project so that it would be adjusted for the specific season. In addition, BASF sent out two men to the job site at least monthly to evaluate how things were going. John also gave similar attention to the topcoat from Neogard, which had representatives come out regularly to make sure it was being applied properly.

L-3 is a secured facility, so anyone with access has to have a clean record, with no felonies or other major marks against them. But, you have to see how they conduct themselves on the job – that’s where pride and personal ethics come into play. John’s crews are good people and consistently did good work.

I’ve hired lots of contractors in 30 years and you develop an eye for workmanship and standards. Some of them you just don’t want around while others you welcome in, and John’s crews were always welcome.

Accountability and responsiveness

Accountability is another factor that differentiates DFW Urethane from other vendors. John’s workmanship was backed by a third-party accountability system through Arizona State University and I guarantee that would put your feet to the fire. All of us do better when we’re accountable, and that was self-imposed on John’s part.

They are also extremely responsive. If I called in something on a Tuesday and the weather was good, they’d be there that afternoon. If the weather wasn’t perfect, they’d come later in the week and take care of whatever I had called in. And, the truth was, probably 80 percent of the leaks they came in and fixed weren’t their problem – but they took care of them anyway.

They have done a fantastic job – they truly have. They stand behind their work; they have been absolutely excellent to work with. Obviously there are other contractors that I’ve worked with that have done well, but I guarantee you none has ever surpassed John’s crew. He and his group are right there at the top of all the contractors that I’ve ever worked with. When you consider how few calls I get on the 1.1 million square feet of roofing they installed, that’s a high recommendation that what they have done has worked well.

Keep in mind when selecting a contractor

My advice for those who are considering spray foam roofing and hiring a foam contractor is to get a recommendation and then investigate – look into their equipment; look into their crew; go to a job where they’re actually doing it. Spend the time, go out and see who’s doing the work and what their workmanship is like.

Competitive bidding is always appropriate, because when you don’t competitive bid, the price tends to increase. But consider each company’s methodology, follow-up and warranty. DFW Urethane is definitely competitive. Some foam roofing people may give a lower bid, but you get less for it – less quality and inferior application.”

Bob Woodworth, Facilities Engineer
Retired in 2011 from L-3 Communications

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“We needed to come in and put a roof over an old building without tearing the old roof off, and also get the insulation that we needed, so that’s what we started using … Dallas-Ft. Worth Urethane has done an excellent job for us.”
Ernie Wright – Retired architect
30-year user of SPF roofing; worked with DFW Urethane

“We simply haven’t had any warranty claims with you [DFW Urethane] at all. Period.”
Mike Steele – President (retired), NEOGARD^®
Industry partner – coating manufacturer

“If you have issues with your existing roof right now – ponding, leaking, deterioration in general – I would recommend calling John Ewell with DFW Urethane and having him come out and give you an assessment.”
John Day – Director of Maintenance
Christ for the Nations

“We’ve discovered over the years that our heating and cooling bills have dropped; we’ve found the church much quieter with the insulating properties of the foam … and we’re not worried every time it rains.”
Chuck Parmele – Church representative
Saint Anne’s Church 

“Maintaining a dry and healthy campus is a high priority to us. We knew our urethane roofs were saving us money – up to 30 percent on average – which opens up more possibilities and opportunities for capital investment.”
Frank Tillery – Director of Facilities
Parker College of Chiropractic

L-3 Communications, located at Majors Airport in Greenville, Texas, rebuilds and updates military and government aircraft. We were brought in for a project that would last more than one year and spanned 1.2 million square feet of metal roofing on multiple buildings. The L-3 facility is highly secured, and even works on Air Force One. This meant working around their schedule when important aircraft were onsite. In addition, we were required to have individuals on-hand who were dedicated to making sure debris was removed immediately from the premises to avoid disrupting or damaging the aircraft.

This complex project presented several challenges to the DFW Urethane team:

• The need to apply a roofing system to nearly every type of known metal roof design
• Dealing with a closed facility, where every person has to pass security and background checks in order to enter
• Days when the team was unable to work because of the presence of high-level government personnel
• Working in close proximity to all types of military aircraft, which posed an overspray risk of great concern to L-3’s facility personnel
• A roofing operation that required working through all four seasons

DFW overcame each obstacle while working closely with our L-3 Communications clients and keeping the lines of communication open at all times. We met all of their commercial roofing expectations on this operation and we continue to partner with L-3 to provide them with years of problem-free roofing. Subsequent projects at L-3’s Greenville facility include making repairs to our roofs damaged by other contractors; sealing in new penetrations; making client-requested changes; insulating several interior buildings; and sealing a containment pit.

View of polyurethane foam prior to application of elastomeric coating

CFAN Corporation is a manufacturer of carbon fiber turbine blades for jet aircraft engines. It operates a 160,000-square-foot facility located between Austin and San Antonio. Its manufacturing process requires strictly controlled temperatures, and cooling this enormous facility was sending their energy costs literally “through the roof.”

The client was contemplating the purchase and installation of additional HVAC units to help address its temperature control challenges. However, that would have only driven its energy costs even higher. Instead, CFAN selected DFW Urethane to install a new polyurethane roofing system over its existing metal roof and help address its energy usage concerns.

DFW Urethane installed an SPF roofing system over the entire facility’s existing standing-seam metal roof. Not only has it lowered their energy costs, it has provided CFAN with a leak-free environment for years to come.

Tamko contacted DFW Urethane to replace the very old roofs on its manufacturing facility. The roofing project was intended to address a number of problems. These ranged from deteriorated metal substructures to problematic additions to the original buildings, to nonperforming mod bit roofs. DFW Urethane provided the facility with a 100-percent leak-free environment for the first time in years.