Case Study: Partnership in Action

Background

In early 2025, Rugged Coatings was approached with an opportunity in the Caribbean, where a building owner was seeking a long-term roofing solution for a highly complex facility with a history of roof failures. Originally built with a 24,000-square-foot asphalt roof over a concrete deck, the building later received a standing seam metal system installed over sub-framing. This created numerous roof sections, internal gutters, and difficult flashing details—all of which had become sources of leaks. Energy efficiency was also compromised by inadequate fiberglass batt insulation and large air voids.

The owner’s goals were clear:

Eliminate persistent leaks
Improve insulation and energy performance
Ensure a durable, long-term solution with ROI

Rugged Coatings collaborated with Bahamas Foam Insulation (BFI) to evaluate the best solution.

The Rugged Roofing System Solution

SPF roofing was identified as the optimal approach. The spray-applied system offered:

Seamless insulation that eliminated air gaps
Custom flashing details to resolve complex transitions
High wind-uplift resistance for Caribbean weather
Long-term watertight performance with resistance to windblown debris

Together, Rugged Coatings and BFI finalized a specification of 2 inches of 2.8# density SPF roofing foam topped with 30 mils of bright white silicone coating with granules for added aesthetics and weatherability.

Training and Partnership in Action

While BFI was an established insulation contractor, this project represented their first SPF roofing application. Rugged Coatings provided the technical expertise and on-site training needed to help them transition into roofing.

Our role included:

Conducting a pre-construction meeting with the property owner and BFI to review details, logistics, and public safety requirements.
On-site training during the application, where our team worked side-by-side with BFI’s applicators, teaching them how to adapt their spray techniques from insulation to roofing.
Adjusting for project conditions, including weekend-only work schedules and unique preparation challenges on the metal roof surface.
Providing creative equipment solutions, including the use of modified tools for granule broadcasting and efficient coating application.

By the end of the project’s first phase, BFI’s team had advanced from novices in SPF roofing to a fully capable roofing crew. They were able to run two rigs simultaneously, keep up with prep and coating work, and complete applications with confidence.

Project Outcome

The Rugged Roofing System delivered:

A watertight, energy-efficient SPF roof system
Extended service life with superior weather resistance
A highly trained local contractor, equipped to take on future roofing projects

For Bahama Power and Supply, the investment meant stopping leaks, reducing energy costs, and gaining a reliable solution for one of their most visible facilities. For BFI, the partnership with Rugged Coatings opened the door to a new market opportunity—roofing—backed by the confidence of proven products and ongoing support.

Conclusion

This project underscores Rugged Coatings’ commitment to partnering with contractors to expand their capabilities. By combining high-performance products with hands-on training and technical support, Rugged Coatings not only delivered the right roofing solution but also helped Bahamas Foam Insulation build lasting expertise in SPF roofing.