Every project brings its own scale and surprises. When Seamless Systems was called into the Falcon Construction LLC welding shop in Gillette, the crew faced a very large red-iron building with exposed structure and a long list of prep tasks. To create a durable, usable shop and office environment we applied spray insulation foam where it mattered most, the walls, roof envelope, and specialty areas, while taking extra care to protect finished metal surfaces.
This was a big, multi-phase job. Work began July 2 and the project ran intermittently over about four to five weeks as the building was completed in stages. Because the foam would remain exposed in many areas, we coordinated closely with the GC on masking, staging, and sequencing so finishes stayed clean and the foam could be applied correctly.
This Falcon / NC Welding project was one of the largest spray jobs the team has handled. The red-iron building was so large that the crew had to back the spray trailer inside because the hose could not reach every area from outside.
The work began on July 2 (2025) and continued intermittently over roughly four to five weeks. Instead of spraying everything at once, the crew returned multiple times as construction progressed, insulating the two wings first, then the main shop envelope, and later the offices once interior metal partitions were installed.
Weather added another layer of difficulty. Strong winds and thunderstorms frequently pushed through the large open doors of the building, so the team used plastic masking to control airflow and prevent foam particles from blowing onto finished metal surfaces.
By coordinating masking, staging, and careful application of spray insulation foam to the wings, upper shop, offices, and floor underside, Seamless Systems turned a massive red-iron shell into a functional, acoustically separated workspace.
Every large-scale project brings its own challenges. Whether it’s a welding shop, a commercial building, or a specialized workspace, success comes down to preparation, coordination, and getting every detail right.
If you have a project that requires reliable spray insulation foam and a team experienced in handling complex, large structures, let’s make it work together.
4 Westridge Road, Moorcroft, Wyoming
Tel: (307) 680-6103 [email protected]
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