The challenge
Corrugated roofs are common on college, agricultural and estate buildings, but the profiled sheets are thermally poor and prone to condensation. In cooler weather the underside of the sheet drops below dew point and moisture forms, dripping into the space below — a problem on a working education and agricultural campus like Hartpury College in Gloucestershire.
The corrugated profile itself makes conventional insulation awkward: rigid boards cannot follow the ridges and troughs without leaving voids, and any gap becomes a path for heat loss and condensation. The roof needed a system that could seal tightly to the irregular underside of the sheeting.
The ThermoFoam solution
ThermoFoam applied Enverge closed-cell spray foam to the underside of the corrugated sheeting. As it cures the foam self-bonds to the profile, flowing into every ridge and trough to form a continuous, gap-free layer — no fixings, no boards and no voids behind the insulation.
Closed-cell foam is dense and resistant to moisture, so it both insulates the roof and keeps warm internal air from reaching the cold metal underside where condensation forms. Supplied by Duratite as UK distributor of record and certified, it gave the college a documented, recognised roof specification.
The result
The corrugated roof now carries a seamless, fully bonded insulating layer that lifts its thermal performance and sharply reduces the condensation that previously affected the space below. The application is robust and low-maintenance, suited to a working campus, and carries a 25-year manufacturer-backed product warranty.
