whatsNewBarrier has a reputation for taking on –  and succeeding – at challenging job sites. A re-roofing job for the Costco on Morena Boulevard in San Diego is a case in point.

The 218,000-square-foot Costco store was in desperate need of a new roof, but the store had to remain in operation while the work was being done. Adding to the challenge was the fact that the metal building is a historical landmark and had already been through a few transformations – from its start as the Hughes Aircraft Company manufacturing facility, to being used as a Price Club and later as a storage facility.

“We took an 80-year-old metal shed and turned it into an insulated retail center,” described Barrier CEO Blair Cunnings. “It was probably the toughest project we’ve ever completed as a company. A steep roof slope, bad weather and the fact that the store was operating while we were working made the project quite a challenge.”

Barrier applied 2 inches of polyurethane foam and 50 mils of United Diathon High Tensil Coatings to the roof. The Barrier crew also installed 200 Energy-Star skylights, repaired and replaced three interior gutters and installed 60 new drains. To create a water-tight seal, foam was used to seal the seams where the metal walls meet the roof.

The project took 12 employees 70 days to complete.

“The building had more than 135 leaks before we installed the new roof,” Cunnings said. “Because of the multiple uses of the building over the years, there were many flashing details and irregularities that only spray foam could seal. The building had no existing insulation, so adding a polyurethane foam roof was beneficial to the owner.”

The project was nominated for a Spray Polyurethane Foam Alliance Industry Excellence Award.