Burn Brighter

Spray Foam Magazine – Late Summer 2026 – When retired coal miner Lonnie Dison needed help with an important project, spray foam proved to be the perfect solution. Lonnie left high school to work in the coal mines of East Tennessee and now dedicates his time to preserving the region’s rich mining heritage as a board member of the Coal Creek Miners Museum in Rocky Top, Tennessee.

Funded through donations and operated by a volunteer board, the nonprofit museum currently occupies the building’s main level. As part of an exciting expansion, the board is constructing a second floor that will feature a replica company store, recreating the type of store commonly found in historic coal mining towns. The new exhibit is scheduled to open in Summer 2026.

In 2018, U.S. coal mines employed just over 53,500 workers, and more than half of the nation’s coal mines have closed since 2007. Coal mining was once a thriving industry in East Tennessee, where it played a significant role in shaping the region’s economy and history. The industry also sparked one of the area’s most notable labor conflicts, the Coal Creek War of the 1890s. Today, visitors can explore this rich industrial heritage at the Coal Creek Miners Museum in Rocky Top, formerly known as Coal Creek. The museum preserves the stories of local miners and features exhibits on the Coal Creek War, mining disasters, and the lasting impact of coal mining on the community.

To help bring the next phase of the museum to life, Lonnie reached out to an established spray foam contractor for assistance.

Superior Spray Foam Systems, based in Knoxville, Tennessee, is a locally owned and operated company backed by more than 50 years of combined experience in the spray foam industry. Founded in 2017 by Dan Mothershed, the company is owned and operated by Dan and his wife, Amber. As a family-owned business, Superior Spray Foam Systems takes pride in providing clients with exceptional service built on quality workmanship, integrity, and honesty.

Amber currently runs Superior Spray Foam Systems’ operations, as Dan now works for Quadrant Performance Materials as a technical support representative. Lonnie called Amber to talk about a project at the Coal Creek Miner Museum. They were creating an exhibit in the new expansion of the museum with a tunnel resembling a coal mine and thought spray foam could look like coal once applied and painted.

Superior Spray Foam Systems has a strong appreciation for local history and is always eager to support a worthwhile community cause, making this project an easy yes for Amber. After visiting the museum to view the exhibit and take measurements, she quickly determined that the tunnel could be successfully completed using the company’s materials and experienced crew. With a plan in place, the team got to work.

The tunnel measures approximately 18 feet long, six feet wide, and six feet tall, and is built around a wood-and-metal framework designed to replicate a mine tunnel. The museum wanted the structure foamed and planned to paint the finished surface themselves to resemble coal. To complete the effect, they also purchased a mural featuring a mine car that would be installed at the end of the tunnel, creating the illusion that the mine extends farther into the distance.

The museum operates primarily through donations and has a limited budget, so Superior Spray Foam Systems stepped up. The company donated the foam, UPC Classic 500 open-cell, while the museum covered the labor costs required for the installation.

Superior Spray Foam Systems also contributed paint leftover from a previous project which was Sherwin-Williams A-100 in a dark gray, giving the exhibit the materials needed to complete the tunnel’s coal mine appearance.

The museum was delighted by the support and agreed to recognize the company’s contribution with a plaque displayed at the exhibit when the new section opens. To complete the project, Superior Spray Foam Systems sent a two-person crew consisting of lead sprayer Fernando and helper Jessica.

The crew arrived on site with their Graco H-25 proportioner, AP Fusion gun, and 210-foot hose, accessing the new exhibit space on the museum’s second floor. To complete the work safely, they scheduled the installation while the museum was closed and used fans with 50-foot ducting to provide continuous air exchange throughout the spraying process.

Before spraying, the crew carefully protected the area by covering the wood framing and the floor with plastic to prevent overspray. They also sealed any gaps, cracks, and openings to ensure the foam remained contained within the tunnel structure.

Once preparations were complete, the team applied approximately four to six inches of open-cell foam to the walls and ceiling of the tunnel. After the foam had been installed, they used a paint sprayer to apply the donated dark gray paint, creating the appearance of a coal mine.

The Superior Spray Foam Systems crew is used to a butter-smooth application process, and in fact applied it too smoothly. Going against their usual spray foam application mantra, they made a second pass to rough it up and make it look more like a coal mine.  

The entire project was completed in a single day. Throughout the installation, Amber and Spray Foam Operations Manager Blake Book checked in regularly to ensure everything was progressing as planned and that the museum’s vision was being brought to life.

Lonnie was thrilled with the result and look the foam added to the tunnel. He is hoping the new exhibit will bring new visitors and engage the younger generations. He was also very grateful Superior Spray Foam Systems were able to work within his budget and time frame.

This unique museum is a crucial part of American history and a way to showcase East Tennessee’s coal-mining past. With the help of some former miners and a reputable spray foam company, this new exhibit is keeping that history alive for generations to come. “This project was a small sacrifice for us that made a huge impact on the museum. We are so glad they called us, and we were able to meet their needs. Today's world is a tough market, but we still try to help in our communities and remain grateful for the opportunities to be involved,” says Amber.