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Enverge Spray Foam Systems

Industrial Soffit Insulation

Closed-cell spray foam to factory, warehouse, mezzanine and distribution-centre soffits. Direct to metal deck, Metsec slab or corrugated profile. Euroclass B-s2-d0 fire rated, Nexseal LE declared to BS EN 14315-1.

FactoryWarehouseDistribution CentreMezzanineMetsec DeckCorrugated Profile
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BS EN 14315-1Nexseal LE Declared Performance
B-s2-d0Euroclass Fire Rating
FullPublic Liability Cover
Ireland-WideSpecialist Installer

Why Industrial Soffits Lose So Much Energy

Industrial corrugated metal soffit underside before spray foam insulation — exposed thermal bridges Before: bare corrugated soffit

The exposed-deck problem

Industrial soffits — exposed metal deck, Metsec, trapezoidal profile and corrugated steel — are almost always uninsulated or under-insulated. The trough-and-flange geometry creates a continuous cold bridge across every primary beam. Heated air rises, hits the cold deck, and condenses — dripping onto product, racking and operatives below.

  • 30-50% of warehouse heating energy lost through uninsulated soffits
  • Condensation drips on stock + slip-hazard puddling
  • Bare deck = no Euroclass fire rating under occupied space
  • PIR board can't span trough profiles without fixings + tape

4 Failure Modes That Closed-Cell Spray Foam Eliminates

Heat-Loss Hotspots

Foam fills every trough and conforms around every primary beam — no fixings, no joints, no continuous cold bridges.

Stock Drips

Closed-cell foam acts as vapour barrier + insulation. Raises surface temperature above dew point — no more condensation falling on stock.

HVAC Load

Insulating the deck reduces winter heating + summer cooling demand by 30-50% in most uninsulated industrial buildings.

Fire Compliance

DC315 intumescent topcoat over closed-cell foam delivers Euroclass B-s2-d0 — TGD B compliant for occupied industrial buildings.

The Closed-Cell Spray Foam System

Enverge Nexseal LE closed-cell foam being applied to industrial metal deck soffit trough profile Spraying: Enverge Nexseal LE

Enverge Nexseal LE + DC315 intumescent topcoat

We spray Enverge Nexseal LE closed-cell polyurethane foam direct to the underside of the deck, finishing with DC315 intumescent topcoat. Typical 50 mm build-up bonds chemically to galvanised steel, Metsec, concrete or hybrid composite slabs — no primer, no fixings.

DC315 over cured foam delivers Euroclass B-s2-d0 reaction-to-fire performance — fully compliant with TGD B (ROI) and Technical Booklet E (NI) for industrial occupied buildings.

  • Nexseal LE declared performance to BS EN 14315-1 (independent test basis)
  • Sprays around primary beams, purlins, conduit, sprinkler pipework
  • Zero fixings = zero thermal bridges
  • Vapour-barrier + insulation in one layer

Industrial Buildings We Insulate

Live distribution, manufacturing and warehousing schemes across Ireland and Northern Ireland. Phased install around live operations.

Distribution Distribution centre warehouse soffit with closed-cell foam and DC315 finish

Distribution centres

5,000-50,000 m² distribution hubs. Phased zone-by-zone install around live racking and ambient/chilled operations.

Factory Factory soffit spray foam between structural steel beams

Manufacturing & factory

Live factory floors. Out-of-hours and weekend works available. Closed-cell foam survives dust, racking knock and forklift activity below.

Warehouse Warehouse metal deck soffit insulation with hybrid Nexseal Sucraseal system

Ambient & chilled warehouse

Standard and temperature-controlled warehouses. Closed-cell foam delivers vapour-barrier-grade airtightness on cold-store soffits.

Mezzanine Mezzanine deck soffit underside with Nexseal LE closed-cell foam applied

Mezzanine decks

Pre-cast and steel mezzanine decks. Insulation + fire rating + condensation control across the underside in one application.

Metsec Metsec light steel framing soffit with Nexseal LE closed-cell foam

Metsec light-steel decks

Metsec sections and light-steel framing soffits. Spray-applied insulation conforms to every flange and connection.

Corrugated Corrugated metal industrial roof underside with closed-cell foam insulation

Corrugated & trapezoidal

Corrugated steel and trapezoidal profile undersides. Closed-cell foam fills every trough — no cutting, no waste.

Real Industrial Soffit Installs — Photo Gallery

Every photo is a Duratite-installed industrial soffit. Closed-cell foam direct to deck, finished with DC315 intumescent. Shot from below on the working floor.

Completed steel deck soffit profile on industrial soffit Steel deck · profile
Nexseal LE applied to industrial metal deck soffit Nexseal LE · applied
Nexseal LE in trough profile of industrial soffit Trough · coverage
Spray foam between primary steel beams on industrial soffit Between primary beams
Closed-cell foam around steel beam web on factory soffit Asbestos cement · substrate
Hybrid Nexseal and Sucraseal foam system on warehouse soffit Asbestos encap · industrial
Completed steel deck soffit insulation in industrial building Condensation · controlled
Completed industrial warehouse soffit insulation project Hybrid system · completed

30-50% heat-loss reduction.

Closed-cell foam direct to deck. Sprayed in days. Pays back in seasons.

From Survey to Handover

Industrial soffit installs need to work around live operations. Here's how we sequence a typical 5,000 m² warehouse.

1

Free Site Survey

Ireland-wide. Senior surveyor measures the soffit area, checks substrate, fire spec, access constraints, racking layout.

5 working days
2

Specification & Quote

Bespoke spec to your U-value target and Euroclass fire rating. RAMS, chemical agents risk assessment, MEWP/access plan bundled.

5 working days
3

Zoned Install

Zone-by-zone phased works around live racking and operations. Out-of-hours / weekend slots available.

5-10 working days
4

Handover

Test certificate, 20-year manufacturer-backed warranty registration, photo dossier, FM walk-through.

1 day

Works on Every Industrial Substrate

Corrugated metal industrial roof underside with closed-cell spray foam application Corrugated profile

Steel, Metsec, corrugated — same system

Closed-cell foam bonds chemically to every common industrial substrate. No primer for steel; no special prep for galvanised deck, trapezoidal profile or corrugated sheet.

  • Galvanised metal deck (composite or non-composite)
  • Metsec light-steel framing & sections
  • Trapezoidal / corrugated steel profile
  • Reinforced concrete (pre-cast & in-situ)
  • Hybrid concrete-on-metal-deck slabs
  • Non-friable asbestos cement (encapsulation spec)

Indicative Industrial Soffit Pricing

Every industrial scheme is bespoke — final pricing depends on substrate, access, fire rating and thickness for your U-value target. Indicative bands for a standard 50 mm closed-cell build-up with DC315 intumescent topcoat.

Industrial schemeTypical areaIndicative supply & installLead time
Small factory / mezzanine500-2,000 m²Priced after survey2-3 weeks
Mid-size warehouse / factory2,000-5,000 m²Priced after survey3-5 weeks
Large distribution centre5,000-15,000 m²Priced after survey5-8 weeks
Major scheme (super-shed / multi-bay)15,000-50,000 m²By tender8-16 weeks

Every fixed quote includes MEWP/scaffolding allowance, RAMS, chemical agents risk assessment, Nexseal LE foam, DC315 intumescent topcoat and 25-year manufacturer-backed warranty registration.

Why Industrial FMs & Main Contractors Specify Duratite

Declared performance to BS EN 14315-1

Enverge Nexseal LE thermal and physical performance is declared by the manufacturer to BS EN 14315-1 for spray polyurethane foam to the underside of suspended floors and industrial decks.

Euroclass B-s2-d0 fire performance

DC315 intumescent topcoat over closed-cell foam achieves Euroclass B-s2-d0 — fully compliant with TGD B for industrial buildings.

Public liability cover

Installer carries public and product liability insurance. Standard buildings insurance retained on every scheme.

Live-operations install

Phased zone-by-zone install around live racking and shifts. Out-of-hours and weekend slots available.

RAMS & Safe Pass pre-mobilisation

Full RAMS, chemical agents risk assessment and Safe Pass-carded operatives.

20-year manufacturer warranty

Manufacturer-backed product warranty on the closed-cell foam system. Registered with Enverge on completion.

Recent Industrial Soffit Work

Four recent install types — distribution, warehouse, factory and mezzanine.

Distribution centre warehouse soffit insulation completed install
Distribution Centre

Distribution super-shed

Large-scale distribution centre soffit — closed-cell foam to a multi-bay steel composite deck. Eliminated condensation across the entire racking footprint.

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 Warehouse soffit insulation with hybrid Nexseal and Sucraseal system
Warehouse

Ambient warehouse retrofit

Retrofit closed-cell + open-cell hybrid system to an ambient warehouse soffit. Targeted dual U-value + vapour-barrier brief.

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 Factory soffit closed-cell spray foam between primary steel beams
Factory

Live factory floor

Phased weekend works to a live manufacturing facility. Foam direct to deck around primary steel beams without disrupting production.

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 Mezzanine deck soffit underside with Nexseal LE applied
Mezzanine

Mezzanine underdeck

Closed-cell foam to a steel mezzanine deck underside. Insulation + fire rating + condensation control delivered in a single application.

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Industrial Soffit Insulation FAQs

What's the typical install for an industrial warehouse soffit?
A 2,000-5,000 m² warehouse soffit is normally sprayed from MEWP in 5-10 working days. Closed-cell foam direct to the steel deck or Metsec, finished with DC315 intumescent if Euroclass B-s2-d0 fire rating is required. Works around live racking with a marshalled exclusion zone.
Can you spray over corrugated metal deck?
Yes. Closed-cell spray foam bonds directly to galvanised metal deck, trapezoidal profile, corrugated sheet and Metsec slab. No primer required. The foam fills every trough — zero cutting, zero waste, zero thermal bridging at every fastener.
Will this work over asbestos?
For industrial soffits with non-friable asbestos cement or AIB, closed-cell foam can be used as an over-encapsulation system after a survey-led containment plan. Combined with DC315 intumescent it provides insulation + asbestos encapsulation + fire rating in one application. Always specified after an accredited asbestos survey.
What U-value can you achieve on an industrial soffit?
50 mm closed-cell delivers around 0.40 W/m²K. For TGD L industrial new-build or major retrofit, 75-100 mm achieves 0.18-0.25 W/m²K. We spec to your target U-value at survey based on the substrate U-value baseline and any existing insulation.
Will operations stop during installation?
Not necessarily. Most industrial soffit installs are sequenced in zones — racking can be sheeted with poly, MEWP works one bay at a time. We agree the sequence with the FM/H&S manager before mobilisation. Out-of-hours and weekend work is offered if production cannot be interrupted.
What's the cost for a 5,000 m² distribution centre soffit?
Priced after a free site survey for closed-cell foam to an exposed metal deck soffit at standard 50 mm build-up, including DC315 finish, RAMS, MEWP allowance and 25-year manufacturer-backed warranty registration.
Will the foam handle racking impact and dust?
Closed-cell foam is structurally inert and resists racking-knock and dust ingress. The DC315 intumescent topcoat creates a hard, paintable, dust-shedding white surface. Pressure-washing is fine — closed-cell is hydrophobic.
How does this compare to PIR board on the deck?
Spray foam wins on speed (no fixings into structural deck), continuity (zero thermal bridging vs PIR's bridge at every fastener), conformity (sprays around primary beams and trough profiles without cutting), and longevity (closed-cell foam is structurally inert vs PIR's facer degradation). Supply cost is usually similar, but labour is lower on industrial schemes.
What's the payback period on the energy savings?
Most industrial buildings see 30-50% heating energy reduction after insulating the soffit. Combined with reduced HVAC summer cooling, typical payback is 3-6 years on a 5,000-15,000 m² warehouse. We can run an indicative U-value + energy-savings calc at survey stage.
Can I include this in a wider M&E or roof refurb programme?
Yes — Duratite often works alongside roof refurb, HVAC upgrade and LED-lighting programmes. Soffit insulation runs in parallel since MEWP access is already mobilised. Speak to our PM team to sequence the works.

More Soffit Applications

Part of Duratite's full soffit insulation service. See the related specialist applications.

Parent Hub

Soffit Insulation — Full Service

Overview of Duratite's Euroclass B fire-rated soffit insulation system — Nexseal LE + DC315 — across all building types.

View hub → Car Park

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Commercial Soffit Insulation

Offices, retail, schools and hospitals — BS EN 14315-1 declared performance, intumescent finish, U-value targeted.

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Free Site Survey

Get a Free Site Survey & Quote

Tell us about your building and we’ll recommend the right system — foam, waterproofing or both — surveyed, specified and quoted at no cost.

  • Reviewed by a Duratite specialist
  • No obligation, no hard sell
  • One team from survey to warranty
  • Ireland and Northern Ireland coverage
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