The Architecture of Curves

Spray Foam Magazine – Summer 2025 – The Japanese are recognized for applying distinctive concepts to architectural design, and in the West, we are starting to acknowledge, respect, and embrace these ideas. A perfect example of this is a distinctive structure in Farmington Hills, Michigan, where spray foam is used to help shape the vision of an architectural joint venture, and one of their clients. Spray Foam Magazine spoke with Mike Doran, Vice President at Stony Creek Services Inc., to find out more.

The Contractors

Stony Creek Services (SCS) has provided insulation solutions to the Great Lakes and Tri-State region of Michigan since 1982. 20 years ago, Anton Cornellier and James Sullivan bought SCS from its previous owners. They then transformed it into what it is today—an accredited and highly skilled spray foam insulation and sound control contractor offering various building envelope and roofing solutions.

SCS focuses on employing talented, hard-working individuals with the most extensive and broad-range experiences in the industry. Having a strong workforce coupled with the latest in materials, tools, and technology has contributed to their success. This outstanding reputation has helped them land some impressive jobs.

The Vision

This unique project started with a collaboration between architectural teams Ryuichi Ashizawa Architects & Associates (RAA) from Japan and Arcari + Iovino Architects from New Jersey. Their client, JST Corporation, a Japanese auto parts manufacturer, wanted their new plant’s design to incorporate earthen elements, blending the structure as seamlessly as possible to the surrounding landscape.

Within architecture, the Japanese notion of “Ma,” refers to dimensions and intended space, which in turn creates energy with possibilities and life occupying space. In modern Western architecture, this can be translated as the blending of the inside/outside space. The aesthetic is grounded on a relationship with nature, and the desire to work with and preserve natural materials within a structure.

The project has been ongoing for several years now and is expected to continue for at least two more before it is finished. Once completed, the project will support plant life, use geothermal energy for heating, and repurpose the trees removed during construction. Additional features include spray foam mounds and ellipses, thatched roofs, a conserved “animal road” for local wildlife, salvaged wood, and covered walkways.

The Hire

The construction company, Cunningham-Limp Development Co. contacted SCS for estimates on various spray foam jobs. Alexandria Bushong, SCS’s estimator, provided these in addition to offering the client suggested budgets. In the original design document, it was suggested that SPF should be applied on top of the wood structure first and then covered by a concrete dome.

However, after CM and A/E teams assessed the weight and cost savings, a change to the original concept was proposed. The client ultimately decided to eliminate the concrete portion from the initial design altogether. By using SPF, SCS would save money with no concrete, while also making the structure lighter and potentially easier to assemble.

Spray foam suddenly had even more value to the client—not only as an insulator and sound dampener, but also as a shapeable product that would fit the architect’s vision.

The Mockup Roof

To show the clients how this idea would actually work, the SCS team constructed an eight-foot-long by four-foot-wide mockup of one of the rooftop ellipses. They knew this would help their client visualize their idea.

The architects provided PDF files detailing the intended profile shapes for the face of the ellipses. Using these, SCS had precise profile templates laser-cut by Faro Imaging in Livonia, MI. They then used these templates—along with chicken wire, aluminum strapping, and numerous screws—to construct a skeletal framework, which was subsequently covered with closed-cell foam.

The SCS crew used four-wheel sanders, horsehair brushes, and grinders to grind the foam down to get it to the shape the client wanted and to show that they had a good product and shape for the silicone coating and the granules to bond to.

The Spray Foam Crew

For the project’s ongoing phases, the SCS spray foam crew has been on and off site for the past two years. Their main spray foam project, which the crew is still actively working on, is on the central hub of the site called the ‘Center Circle.’ 

However, the main spray foam roof, which measures 4,000 sq. ft., and an additional 4,000 sq. ft. sprayed on the interior, was completed in September 2024. The main crew members working on this project are Mike Caudill, Lead Sprayer/SCS Superintendent, and sprayers Eric Sauve, Steve Vandagriff, Will Reyes, and Josh Nestor.

The Spray Foam Equipment

Throughout the project, they used their two rigs which include 350 ft of hose, a Gusmer H-20/35, Fusion AP guns for spraying 2lb foam on the inside, and an X-7 gun for 2.8lb foam on the roofs.

They also utilized PPE consisting of respiratory protection, lanyards, harnesses, roof tie offs, safety glasses, Tyvek suits, cut gloves, and leading-edge protection.

The SPF

Since the structure was blended into a hill, there was no need for exterior scaffolding on this project. For any roof work, the crew just climbed up the hill onto the roof. For reaching the interior and the ceiling of the ellipses, the crew used just a section and a half of scaffolding with walkable balloon tires or small boom lifts, both of which the client provided. 

The entire Center Circle is built out of Douglas Fir trees, which is in the evergreen pine family. The wood was cut into 4x10 beams and treated with a citrus base sealer. They were then put together with tens of thousands of bolts.

This structure was made to create three large ellipses that are connected in the middle by two smaller ellipses, and by applying 2.8lb foam to roof and face off building, it helped create the shape of the ellipses.

For the Center Circle structure, the crew applied two different closed-cell foams from NCFI. Pulling their 350 ft. hose on top of the hill, they used their GX-7 guns to spray an average of six inches of EnduraTech HFO 2.8lb. roofing foam (10-016) to the exterior of the roof’s wood, applying approximately six sets of foam. This would eventually be covered with a Progressive Materials silicone roof coating, followed by Progressive’s ‘Sands of Time’ granules. 

The crew then used their Fusion AP guns to apply between two to three inches of InsulBloc HFO 2lb foam (11-037) to the inside walls and interior ceiling, which was molded to follow the ellipses, applying five sets of foam. The crew systematically sprayed and shaved, then sprayed and shaved again to produce the shape the client wanted. After which the client had Japanese mud plasters flown in from Japan to apply an earth and plaster mix on top of the interior’s foam.

On areas where metal decking is present, a two inch thick application of 2lb spray foam and a one-and-a-quarter-inch thick application of black Ure-K thermal barrier as manufactured by International Cellulose Corporation was applied. This was applied to the ceiling to meet code and provide sound control.

Challenges of The Project

The main challenge for the crew has been navigating Michigan’s fall and winter weather—ensuring that the foam was applied at the right temperature to achieve a good bond, and ultimately good foam. The task to make the client’s and architect’s vision and renderings a reality was challenging but thanks to all their roofing experience with SPF, the SCS team knew it’s one they would rise too. The SCS team’s structures on how the idea could be achieved, the crews shaving and sculpting skills, and the superior spray foam applied, all helped make the Japanese idea of “Ma” come to life.  

Published by Spray Foam Magazine

SprayFoam / Spray Foam Insulation