Case Study: Warehouse Roof Insulation – Bournemouth
From failing roof to finished system
The Challenge
Duratite’s approved contractor, Spray Foam Tech Limited, was commissioned to complete a comprehensive warehouse insulation project for TJW Grab Hire’s new industrial unit in Bournemouth. The customer had recently acquired the warehouse to accommodate plant, vehicles, and workshop operations as part of their growing business. Although the metal box profile roof was in excellent overall condition, the uninsulated structure was subject to significant surface condensation, temperature variation, and heat loss — all of which posed risks to machinery, stored materials, and working conditions.
To provide a long-term solution, 50mm of Enverge Nexseal LE closed-cell spray foam insulation was specified and applied to the internal face of the roof sheeting. The system was selected for its superior vapour resistance, structural reinforcement benefits, and thermal efficiency.
Project file
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The Solution — step by step
Installation Process
Prior to application, the Spray Foam Tech team prepared the internal workspace, ensuring all plant and equipment were covered with polythene sheeting to prevent overspray. Access to the full roof area was achieved using an electric scissor lift, allowing the technicians to apply the foam safely and evenly across all roof bays.
The installation covered approximately 505m² and was completed within two working days. Careful detailing ensured that polycarbonate skylights were left uninsulated, maintaining natural light levels within the building.
The Enverge Nexseal LE system adheres directly to the corrugated metal substrate, following every contour and profile of the sheet to create a monolithic, bonded layer. This seamless insulation eliminates air gaps and forms a highly durable surface that cannot delaminate or sag over time.
Product Focus – Enverge Nexseal LE
Enverge Nexseal LE is a premium closed-cell spray foam insulation system designed for industrial and agricultural buildings, offering outstanding thermal, structural, and vapour control performance. Its dense cellular composition delivers a high compressive strength while achieving a low thermal conductivity value, making it ideal for metal-clad environments.
Applied directly to the substrate, Nexseal LE forms a continuous bonded layer that prevents air leakage, eliminates cold bridging, and resists delamination. It is a durable, maintenance-free solution for condensation control, energy efficiency, and long-term protection of metal roof systems.
The Outcome
Once installed, the spray-applied Nexseal LE formed an airtight, rigid insulation layer that immediately transformed the internal environment of the unit. The closed-cell structure of the foam provides a vapour-impermeable barrier, preventing condensation from forming on the underside of the roof sheets during cold weather. This significantly reduces the risk of dripping condensation, corrosion, and mould — common issues in single-skin metal-clad buildings.
In addition to its condensation control, the foam contributes to the structural integrity of the roof assembly. The strong chemical bond between the foam and the substrate helps to stabilise the roof sheets, reducing vibration, flexing, and noise from wind uplift or thermal movement. This added rigidity also helps protect fixings and joints against long-term fatigue, extending the lifespan of the building envelope.
Thermally, the 50mm closed-cell layer provides a substantial improvement in energy efficiency and occupant comfort, helping maintain a more consistent internal temperature throughout the year. Operatives now benefit from a more stable working environment, while machinery and equipment are protected from the extremes of condensation and cold.
The finished installation delivered a neat, seamless, and uniform coating throughout the building, reflecting the high standards expected of Duratite Approved Installers. The client reported an immediate improvement in comfort levels and air quality, with the interior now feeling warmer, drier, and free from dripping condensation.
Spray Foam Tech completed the project on schedule with minimal disruption, and the solution now provides long-term protection, thermal regulation, and moisture control for the building’s operations.
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