Case Study: Warehouse Insulation – Nuneaton
From failing roof to finished system
The Challenge
Nuneaton Signs, a leading UK manufacturer and printer of commercial signage, operates from a large production facility housing extensive plant, printing equipment, and fabrication machinery. As part of a wider energy-efficiency initiative, the company sought to enhance the warehouse’s thermal performance and environmental stability.
A grant-funded upgrade was approved to encapsulate the existing insulated roof panels and complement the 150 mm of mineral-wool insulation already in situ. The additional layer of closed-cell spray foam also served a crucial safety function by sealing and encapsulating the roof assembly to prevent any potential asbestos fibre release from the original roof sheets above the mineral wool layer.
Project file
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The Solution — step by step
System Specification
Duratite specified Enverge Nexseal LE, a premium closed-cell, spray-applied polyurethane insulation system. The foam was applied directly to the internal face of the existing insulated roof panels at a uniform 25 mm thickness, forming a continuous, airtight, and durable thermal envelope across the 2,924 m² of roof and wall surfaces.
Because Nexseal LE is spray-applied directly to the substrate, it bonds on contact and expands to create a complete air seal, eliminating gaps, overlaps, and thermal bridging that can degrade insulation performance. This results in a substantial improvement in U-value efficiency and airtightness, stabilising internal temperatures and reducing uncontrolled energy loss.
Installation Process
The works were undertaken by Duratite Approved Contractor, Spray Foam Tech, in May 2025.
Due to the operational demands of the manufacturing facility, the installation team scheduled work over weekends, using scissor lifts to access high-level areas around fixed plant and production lines. Every piece of equipment was meticulously protected with heavy-duty plastic sheeting to prevent overspray and dust exposure.
Strict control measures were observed throughout, including real-time ventilation, temperature and humidity monitoring, and precise foam yield management to ensure optimal adhesion and curing.
Completed By
Spray Foam Tech
Duratite Approved Contractor
Completed: May 2025
The Outcome
Upon completion, Nuneaton Signs reported a marked improvement in internal comfort and energy control.
During warmer months, the roof coating provided superior resistance to solar gain, keeping working areas noticeably cooler and more stable. In winter, the enhanced airtightness dramatically improved heat retention, reducing heating costs and maintaining a more comfortable environment for staff and equipment.
The project successfully delivered both energy-efficiency gains and occupational safety improvements, extending the lifespan of the existing roof structure while achieving measurable carbon-reduction benefits.
- Seamless air seal improves airtightness and overall U-value
- Encapsulation of existing roof panels, preventing asbestos fibre release
- Noticeably reduced solar gain and improved heat retention
- Fast, low-disruption installation working around live equipment
- Durable protective barrier bonded directly to roof and wall surfaces
- Supported by grant funding to improve sustainability performance
Products used
Density: 35 kg/m³
Thermal Conductivity (λ-value): 0.027 W/m·K
Service Temperature Range: –40 °C to +80 °C
Fire Classification: BS 476 Part 7 – Class 1 and Euroclass E
CE Certified to BS EN 14315-1
Warehouse Insulation
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