These structures usually have metal, cement fibre or asbestos roof sheeting which are often corrugated to allow channels for rain water to escape. Without insulation these materials are great thermal conductors and are highly susceptible to temperature extremes, condensation and poor energy efficiency.
Pre-manufactured insulation materials, such as PIR, lack the flexibility to sufficiently insulate corrugated structures for the long term. Spray foam solves these issues when spray-applied as a liquid, expanding into all voids to provide seamless insulation coverage.
We recommend a Closed-Cell formula, such as ThermoFoam CC-2000 to prolong the life of your corrugated roof. In addition to being a high performance insulator Closed-Cell foam will help to bind and seal any damaged or degraded panels to limit moisture ingress.
When a building suffers from condensation, you may be impacted financially through stock damage and liability to personnel, equipment and furniture.
For property experiencing this problem an application of 15-20mm will resolve the issue and completely eliminate all future condensation.
Over time, roofs can start to degrade where cracks may appear or the bolts and gaskets that hold roofing sheets together start to fail.
50mm of Closed-cell spray foam offers a solution which helps to stabilise the roofing sheets by bonding all joints and seams to create a single membrane.
We regularly come across such buildings where a pre-manufactured insulation, such as PIR, has been used and it’s always sad to see the costly impact when these solutions fail the test of time.
When the time comes to upgrade and replace existing insulation, a property survey will help us determine the options to create the most effective thermal envelope for the long term.
Although cost should always be considered, the insulation choice that you make is imperative in achieving optimal performance. Warehouses and factories are rarely small in size and the disruption and downtime you might experience throughout the installation makes the choice of insulation an important factor.
It’s not just the performance of spray foam, it’s the speed of application that can truly help to minimalise down-time during install and this should help form a part of any cost-benefit analysis when selecting the right option for your property.
Although we install both open and closed-cell products, not all spray foams are created equal, therefore we are always careful to respect the application uses for both products in achieving the correct install for your building.
Open Cell is a low density sponge like foam, making it an effective barrier against noise transmission and adds good thermal performance to a building.
When used in areas that are susceptible to moisture intrusion, Open Cell foam will absorb this moisture which can create issues within the building or structure it is applied to.
To overcome this, we always recommend an application of Closed Cell foam for buildings that have metal, asbestos or cement roofs. These are commonly held together by bolts and gaskets, which when rusted or broken, act as the first entry point for moisture.
Closed Cell is a high density rigid foam, that acts as a very good vapour barrier. It helps to bind all aspects of a roof substrate to prevent the degradation or loosening of bolt fixings and adds structural integrity.
As little as 25mm of Closed Cell insulation will eliminate condensation whilst an application of 50mm will provide exceptional thermal performance. Both depths offer strong adhesion to the substrate to future-proof its integrity.
Absolutely. We get hundreds of calls every winter from customers who are experiencing condensation issues when cold air from the outside competes against warmer internal air. With warehouses where stock and valuables are stored, condensation can be very damaging.
A thin layer of Closed-Cell insulation is the antidote that eliminates condensation for good. As little as 20mm will achieve the desired results although we always recommend around 25-30mm is spray-applied to the corrugated roof and walls for the very best results.
The greater the depth of insulation, the harder it is to get it looking neat. We appreciate in public areas and warehouses that the finished result should look as good as possible, therefore, each job isn’t so much about rushing as it is taking your time to get a nice finish.
Not everyone who says they can spray foam can actually spray it very well. It takes precision, technique and years of experience to become good at spraying Closed Cell foam neatly. Always do your due diligence and ask installers to provide a portfolio of their works.
If the insulation is to be left exposed and you want a different colour, it can be painted a different to blend with its surroundings. We use specialist paint coatings that can add additional Class 0 fire resistance and vapour control layer coupled with a decorative colour.
The finished surface of Closed-Cell Spray Foam is much like an orange peel texture whereas Open-Cell Spray Foam is very absorbent allowing paint to soak into it. We recommend that Spray Foam Insulation is coated using an Airless Spray Paint machine for maximum adhesion and to ensure that a seamless colour layer is the end result.
In most circumstances, the installation of insulation could impact on the use-ability of the building during the process. We realise the impact of closures on warehouses, therefore, our Spray Foam solution helps to minimise down time.
ThermoFoam is a versatile solution that requires no storage of materials, virtually no mess and is vastly superior to pre-manufactured rivals such as Rockwool or Rigid-PIR in terms of performance, durability and speed of application.