Case Study: Corrugated Roof Insulation | Metal Roof Insulation

Hartpury University College | Gloucestershire


Hartpury University and College is among the UK’s leading specialist education providers in animal, agriculture, equine, sport and veterinary nursing. ThermoFoam were appointed to install Corrugated Roof Insulation during the renovation of a sports hall into a hang out zone for students.

Located in Gloucestershire, the campus is set within 360 hectares and caters for 4500 students studying A-Levels, diplomas and degrees. With a commitment to investing in the state or the art facilities, Hartpury reached out to ThermoFoam for help turning an unused hall into a cool chill out zone for its students. With a metal roof susceptible to condensation and the need to reduce airborne echoing, spray-foam was considered as a suitable option thanks to its speed of installation and lifetime of performance. Due to the irregular profile of the roof, ThermoFoam were appointed to install Corrugated Roof Insulation using Enverge Nexseal LE Closed Cell Spray Foam Insulation.


Vectis Insulation Solutions



Project Type

Corrugated Roof Insulation

Product Used

Nexseal LE Closed Cell and ThermoShield Paint Coating

Install Date

January 2019

Install Size


Install Duration

5 Days

The Project

Corrugated Roof Insulation Brief

Keen to deliver a brand new space for students to relax, chill, play games and socialise, the property manager at Hartpury University needed a solution that would stop surface condensation on the roof, reduce the impact of airborne echoing and help to keep the large hall warm in the winter and cool in the summer. Fortunately, spray foam insulation is one of the very best solutions for ticking all of these boxes in a commercial environment. With the fit out taking place within an allotted time-frame, it was important that our solution was fast to install so that project timelines were not delayed.

Corrugated Roof Insulation Specification

The primary brief was to eliminate condensation issues that were forming on the underside of the roof surface during autumn and winter months. Working within an allocated budget, we recommended 30mm of our Nexseal Closed Cell Insulation, spray-applied to the box-profile corrugated roof panels. The solution would also add some heat retention to the extensive space during winter months, helping to reduce and control energy costs. The off-white colour of the Closed Cell Spray Foam would leave a bright finish which was in contrast to Hartpury’s desire to make this zone a cosy and comfortable chill out space. With a nice decorative effect in mind, we recommended the application of a black ThermoShield paint coating to the underside of the Nexseal Closed Cell which we were confident would impress the students.

Corrugated Roof Insulation Results

Delivered over a period of 5 working days, our team worked hard to initially coat the roof and wall surfaces with 30mm of Nexseal Closed Cell Foam. Working off scissor lifts, the installation team managed to finish the 1119m2 project in just three days, something that would have taken several weeks with any other form of pre-manufactured insulation. The speed of installation and the strong bond of the insulation direct to the substrate is what helps to make spray foam an increasingly popular choice in commercial and industrial environments. Once the insulation works were complete, we left the foam to finish curing over the next 12 hours, returning the next day to spray-apply the ThermoShield paint coating. Completed in just one day, the end result was a seriously cool space where the suspended lighting offset the darkness of the insulation and paint system above to create an impressive space that Hartpury students could enjoy for many years to come. Find out more about Hartpury College here:

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