Case Study: Hangar Roof Insulation | Alton, Hampshire
From failing roof to finished system
The Challenge
Black Hangar Studios in Alton, Hampshire, is home to major film productions including Dumbo, Salmon Fishing in the Yemen and Live Another Day. The large 4,000m² aircraft hangar used as a main sound stage was suffering from excessive noise from the corrugated asbestos/cement fibre roof during high winds and rainfall. The constant drumming and resonance from the roof sheets made sound recording difficult and disrupted filming schedules.
Duratite were tasked with specifying a roof insulation system that would strengthen the roof structure and eliminate the noise problems caused by weather impact.
Challenge
The hangar’s ageing asbestos/cement fibre roof was fragile and prone to vibration, generating a loud echo throughout the internal space. The sheer size of the roof area meant any solution had to provide:
- Structural reinforcement to prevent panel movement in strong winds.
- Sound attenuation to absorb rain impact noise.
- Thermal insulation to stabilise internal temperatures.
- Full compliance with British fire performance standards.
The work also needed to be carried out safely and efficiently, with minimal disruption to studio operations.
Project file
Book a free survey and we’ll come back with a fixed price for your own roof.
The Solution — step by step
Specification
Duratite specified a dual-foam insulation system combining the structural and acoustic benefits of two Enverge spray foams:
- 25mm Enverge Nexseal LE Closed-Cell Foam
- Sprayed directly onto the corrugated asbestos/cement fibre roof.
- Formed a tough, bonded layer that sealed the substrate and improved rigidity.
- Added resistance against vibration and movement under wind load.
- Provided a continuous moisture-resistant membrane and improved base thermal value.
- 150–200mm Enverge Sucraseal Open-Cell Foam
- Applied beneath the closed-cell layer to form a thick acoustic and thermal barrier.
- Greatly reduced external noise from rain and wind.
- Delivered high breathability and excellent sound absorption.
- Achieved British Class 1 Surface Spread of Flame fire performance rating.
This combination created a reinforced composite system — structurally sound, thermally efficient, and acoustically stable for film recording.
Installation
The insulation works were completed by Duratite-approved contractors British Insulation Services and Spray Foam Tech over three weeks in April 2021.
- Full scissor lift access was utilised to reach all roof spans safely.
- Controlled spraying methods were used to ensure no disturbance to the asbestos/cement substrate.
- The Nexseal LE base layer was applied first to seal and stabilise the roof sheets.
- Sucraseal open-cell foam was then sprayed in multiple passes to achieve the target 150–200mm depth.
- Final inspection confirmed uniform coverage, adhesion, and finish across the 4,000m² roof area.
The Outcome
The completed system provided immediate acoustic improvement. The drumming and resonance from rain and wind were virtually eliminated, transforming the hangar into a quiet, controlled environment ideal for high-quality film and audio production.
Key outcomes included:
- Significant reduction in noise transmission from the roof.
- Improved structural stability and vibration resistance.
- Enhanced thermal performance and internal comfort.
- Fully compliant fire performance and material safety.
Black Hangar Studios now benefits from a long-term warehouse insulation solution that strengthens the roof, controls sound intrusion, and supports ongoing film production without disruption.
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Newfoundland Road, Bristol, England Commercial — Asbestos Roof EncapsulationAsbestos Roof Encapsulation – Dove Lane, Bristol
Read the case studyHave a similar hangar insulation project?
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