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Spray foam systems for aircraft hangars, maintenance bays and large-span steel structures. Nexseal LE — performance declared to BS EN 14315-1 — bonds directly to the underside of corrugated metal, asbestos cement and cement fibre roof sheets — creating a seamless thermal barrier, vapour control layer and structural reinforcement in a single application.
Nexseal LE is the go-to insulation system for aircraft hangars and large-span steel structures. This closed-cell spray foam — performance declared to BS EN 14315-1 — bonds directly to the underside of corrugated metal, asbestos cement and cement fibre roof sheets — creating a seamless thermal barrier, vapour control layer and structural reinforcement in a single application.
With a lambda value of 0.027 W/m·K, Nexseal LE delivers exceptional thermal performance at minimal thickness, preserving valuable headroom in tall hangar structures.
Eliminating hangar condensation: uninsulated hangars suffer massive condensation problems — warm moist air meets cold metal roofing, creating persistent dripping that damages aircraft, equipment and infrastructure. Condensation on aircraft surfaces causes corrosion, paint damage and electrical faults; water on electrical panels, lighting and mechanical equipment creates safety hazards. Closed-cell foam raises the internal surface temperature above the dew point and prevents moisture formation entirely — no separate VCL membranes, taping or mechanical fixings needed.
Single-skin corrugated metal is the most common hangar roof type — and the single biggest cause of condensation and heat loss. Many older hangars carry asbestos cement or cement fibre sheets instead. Nexseal LE handles all three.
Foam follows every ridge and trough — box profile, sinusoidal, standing seam and trapezoidal. Continuous coverage with zero gaps and zero penetrations across the full span.
Foam bonds to AC roof sheets, encapsulating loose fibres in line with HSA guidance — insulating and structurally reinforcing brittle sheets without removal.
The post-1980s replacement for AC roofing. Foam bonds to the textured surface, creating a rigid composite that reduces flexing and extends serviceable life.
Raises the internal surface temperature above dew point — stops dripping onto aircraft, equipment and flooring for good.
The composite panel effect dramatically reduces movement, rattle and wind uplift across large spans — extending roof life by 20+ years without re-roofing.
500–1,000m² per day. Foam sets in minutes with no drying time — large hangar roofs completed in days, not weeks.
Hangars come in every size and construction type — from private airfield buildings to former RAF stations and large commercial MRO facilities. Duratite has experience across every type.
Single-skin steel structures where condensation drips onto aircraft, corroding airframes and damaging paint and electrics. 25–50mm eliminates it. Most completed in 1–2 days.
Maintenance, repair and overhaul facilities need controlled temperature and humidity for paint shops, avionics and composite repairs. Nexseal LE at 50–80mm delivers it, with fire rating options.
Hundreds of decommissioned RAF, MOD and USAF hangars are being repurposed. Many have asbestos cement roofing needing safe encapsulation alongside insulation — one application achieves both.
Film studios, data centres, indoor sports, exhibition halls, manufacturing and distribution. Spray foam is the essential first step — a thermally-efficient shell meeting TGD L.
Which spray foam system is right for your hangar? Here is how closed-cell and open-cell compare across every metric that matters.
| Feature | Enverge Nexseal® LE (Closed Cell) | Enverge Sucraseal® (Open Cell) |
|---|---|---|
| Cell Structure | Closed — rigid, high density | Open — soft, flexible |
| Density | 32–40 kg/m³ | 8–12 kg/m³ |
| Lambda (W/m·K) | 0.027 | 0.039 |
| Vapour Barrier | Yes — integral (Class 1) | No — vapour open |
| Moisture Absorption | <2% by volume | Absorbs moisture if exposed |
| Structural Reinforcement | Adds rigidity to substrate | Soft foam — no structural benefit |
| Adhesion to Metal | Excellent — bonds to corrugated steel, aluminium | Good — but no structural bond |
| Adhesion to Asbestos Cement | Excellent — encapsulates fibres | Not recommended for AC roofing |
| Wind Uplift Resistance | Reduces sheet movement and rattling | Minimal effect |
| Compressive Strength | 78 kPa | <10 kPa |
| Fire Rating (with DC315) | Euroclass B-s2-d0 achievable | Class 1 achievable |
| Suitable for Metal Roofs | Ideal | Limited — needs separate VCL |
| Anti-Condensation | Eliminates — integral vapour barrier | Requires separate VCL |
| Thickness for 0.25 W/m²K | ~100mm | ~150mm+ |
| Lifespan | 25+ years | 25+ years |
Free site assessment, engineered design, professional installation, full documentation.
We survey your hangar — roof condition, substrate type (metal, asbestos cement or cement fibre), height access and operational constraints. Free and no-obligation.
U-value calculations, condensation risk analysis, thickness specification, fire strategy and access plan. Fully engineered before work begins.
Manufacturer-trained technicians spray bay-by-bay using boom lifts and scissor lifts. DC315 fire coating applied where required. Foam cures in minutes.
Thickness verification logs, site photographs, fire certificates, warranty documentation and U-value compliance paperwork — everything needed for building control.
Delivered by our approved installer network.
A 12,000 sq ft maintenance hangar with severe condensation dripping onto aircraft and electrical systems. Nexseal LE at 50mm to corrugated metal roof sheets. Condensation eliminated, working conditions transformed, corrosion risk removed entirely.
A former military hangar repurposed for high-value vehicle and equipment storage. Asbestos cement roof sheets encapsulated and insulated with 40mm Nexseal LE — HSA-compliant asbestos management alongside full thermal upgrade.
A large aircraft hangar converted into a film production studio. Nexseal LE at 80mm to roof and walls for Part L compliance, plus Sucraseal open-cell on internal partitions for acoustic separation between studio spaces.
Trusted spray foam insulation specialists — delivering expert installations for hangars and large-span buildings nationwide.
Duratite has delivered professional spray foam insulation projects for hangars and industrial buildings since 2015 and now supports projects across Ireland and Northern Ireland.
Commercial projects across Ireland and Northern Ireland including aircraft hangars, warehouses, industrial units and large-span steel structures.
Our approved installer network is directly trained and certified by Enverge to ensure every installation meets manufacturer specifications.
From initial survey through to completion and handover — we manage every aspect of your hangar insulation project.
Enverge Nexseal LE and Sucraseal performance is declared to BS EN 14315-1 — backed by manufacturer product warranties.
Extensive experience insulating aircraft hangars, maintenance bays, storage hangars and hangar conversions of every type and size.
Independently certified products — all documentation supplied with your project pack or on request. Email info@duratite.ie.
Distribution centres, cold storage, industrial units. Same Nexseal LE system for metal-clad buildings.
Learn more →SoffitsConcrete soffits, metal deck soffits, Metsec systems. Hybrid Nexseal and Sucraseal builds.
Learn more →AgricultureLivestock buildings, grain stores, poultry houses. Condensation and temperature control for farm structures.
Learn more →Below GroundSheet piling, retaining walls, basement structures. Specialist below-ground spray foam systems.
Learn more →Curved SteelSpray foam bonds directly to curved steel surfaces.
Learn more →HubExplore all commercial spray foam insulation applications, systems and sectors.
Learn more →Book a free site survey and get expert advice on the best spray foam solution for your hangar — or email us directly at info@duratite.ie.
U-value calculations, condensation risk analysis and a fixed-price quotation.
Mon–Fri 8am–5pm · info@duratite.ie
Real Duratite projects — building type, location, system used and the outcome on site.
Alton, Hampshire, EnglandAircraft Hangar
Bournemouth, Dorset, EnglandIndustrial WarehouseTell us about your building and we’ll recommend the right system — foam, waterproofing or both — surveyed, specified and quoted at no cost.
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