Ultimate Guide to Warehouse Insulation

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With energy costs increasing significantly in the UK over the last few years and not likely to fall back to previous levels, owners of warehouses are looking for ways to reduce their bills. Insulating commercial property, including warehouses, can effectively control energy costs while reducing carbon footprints. By investing in the benefits of insulation, warehouse owners are waking up to the fact that they can make their buildings much more energy efficient, lower their fuel costs, and prevent a range of problems that warehouse buildings are prone to simply by choosing the right insulation. ThermoFoam are always happy to provide more information about the benefits of warehouse insulation.

What’s On This Page?

  • Warehouse Insulation Benefits
  • How To Insulate A Warehouse
  • What Is The Best Warehouse Insulation
  • Spray Foam for Warehouse Insulation
  • Warehouse Insulation Costs

Warehouse Insulation Benefits

First, look at some of the benefits of insulating a warehouse structure. It doesn’t matter what time of the year you choose to insulate your warehouse; the thermal benefits of a robust insulation material will help to control the internal temperature year round. During the winter, when the internal space is heated, this can cause condensation when heat reaches the colder exterior surface. The reverse situation occurs during the summer when solar gain penetrates through the roof and walls to create a hot indoor climate.

Improve Energy Efficiency

Many warehouses use steel, cement-fibre or asbestos roof and wall sheets on a timber or steel frame. When left uninsulated, internal temperatures can fluctuate significantly, affecting the internal environment. By insulating your warehouse, the u-value is lowered, and the building has greater temperature regulation. This could lower your energy usage and consequently lower your carbon emissions. An added bonus of improved temperature regulation is that it’s beneficial to stored stock and will make the environment more comfortable for workers. Choose a suitable insulation material such as Enverge Nexseal LE Closed Cell to improve energy efficiency and conserve heat and power. This is one of the most thermally efficient insulation materials per inch. Once installed, it should last the life of the substrate to provide seamless, monolithic and airtight thermal performance.

Improve Structural Integrity

Depending on what type of insulation you choose, you could improve the stability of older warehouses. Some forms of insulation are well suited to providing additional structural stability for your warehouse, which can increase the lifetime of the building as a usable space. Enverge Nexseal LE Closed Cell is the best option as it is spray-applied to the substrate and has excellent adhesion to provide a rigid closed-cell structure. The problem when using pre-manufactured materials for warehouse insulation, such as PIR board or mineral wool, is that they also require mechanical fixings, which can further reduce the strength of the substrate, offering little dimensional stability. Additionally, pre-manufactured materials are subject to gravity, meaning they may slip as they are not bonded to the substrate, unlike Enverge Nexseal LE Closed Cell spray foam insulation.

Improve Acoustic Performance

If you have a busy and noisy warehouse space and are concerned about noise pollution for nearby neighbours, insulating your warehouse can help provide sound attenuation. Suppose your warehouse is located on a noisy industrial estate, and you want to reduce surrounding noise pollution from affecting your operatives and personnel. In that case, the insulation can also help to stop sound transfer into the building. To achieve this, we recommend our hybrid spray foam system comprising of a 25mm layer of Enverge Nexseal LE Closed Cell, spray-applied to the roof or wall substrate which is then coated with at least 150mm of Enverge Sucraseal Open Cell. This low-density insulating material helps to absorb airborne sounds.

Reduce Leaks & Environmental Conditions

Some forms of insulation can help to protect your commercial property from water ingress by adding structural integrity to failing roof and wall panels and sealing voids or cracks. Although insulation should never be used as a substitute for fixing failing or ageing roofs, a solution such as Enverge Nexseal LE Closed Cell is spray-applied to the substrate to strengthen the structure and reduce the movement of the fixings. With many warehouses made from metal, cement fibre or asbestos, some types of insulation can prevent problems with condensation and the mould or mildew that may occur. This can increase the longevity of the building, prevent a loss of stock and make the internal environment healthier for your operatives. 

How To Insulate A Warehouse

Warehouses come in all shapes and sizes; therefore, how to insulate a warehouse can depend on several factors. Size, substrate condition, substrate type, age of building and its daily use are all considerations for what insulation material may be best suited. As warehouses are often made from corrugated metal or materials such as cement fibre or asbestos roof and wall sheets (for older buildings), insulating them can be more difficult than insulating other industrial or domestic buildings. Traditional insulation methods, such as mineral wool, Rockwool, PIR boards, or any pre-manufactured materials, are the least effective for several reasons. 

Firstly, mineral wool and PIR boards require mechanical fixings to the warehouse structure. Fixing pre-manufactured insulation materials to the existing structure can create more opportunities for water ingress and leaks, eventually undermining the integrity of the warehouse structure itself. Pre-manufactured insulation materials will not follow the profile of the roof or walls. They will leave any corrugated pockets uninsulated, which can further enhance the opportunity for condensation and sweating to occur.

The gravitational pull exerted on pre-manufactured materials can dislodge them from the roof or wall substrate, significantly reducing their effectiveness. We have seen many cases of failed warehouse insulation where such materials aren’t cut out for the job. Pre-manufactured insulation materials offer little or no structural support and may hide the impacts of further roof or wall degradation. 

The quickest and most effective warehouse insulation option is Enverge Spray Foam insulation, which can insulate up to 1000 square metres of surface area in just a matter of days. ThermoFoam-approved installers provide fast and effective warehouse insulation solutions by spray-applying Enverge Nexseal LE Closed Cell neatly and uniformly, following the roof and wall profile to ensure a seamless and airtight layer of durable insulation.

What Is The Best Warehouse Insulation?

Enverge Nexseal LE Closed-Cell spray foam is widely considered the best solution for warehouse roof insulation. It adheres to any surface without requiring additional fixings and strengthens roof and wall surfaces to reduce future movement and weathering. The results of choosing closed-cell spray foam are often felt instantly, with better thermal performance, heat retention, solar gain reduction, and condensation elimination. Because of its adhesive properties, spray foam will attach itself to the roof and wall substrates and follow the corrugated profile to add long-term durability.

Check out our range of Enverge Spray Foam products and solutions here: https://thermofoam.co.uk/nexseal/

Spray Foam For Warehouse Insulation

Spray Foam Insulation is not a DIY solution. It is installed by experienced professionals who use specific machinery and installation techniques to provide a compliant result. You can expect to work with a professional team to protect stock, machinery, and assets within the warehouse and use safe and robust access equipment to reach the substrate. Like any building work, there will be a degree of disruption during the installation. This may require a temporary closure and the removal of stock, machinery and other assets that restrict access around the floor area. No other insulation material can be installed as quickly as spray foam insulation, so it should be your first choice. 

To ensure the success of a spray foam warehouse insulation project, the roof and wall substrates should be free from condensation; there should be good floor access to ensure that Mewps, Scissor Lifts or Scaffold Towers can reach every area safely; plant, machinery and stock should be moved or at least covered over to protect them from overspray droplets; operatives and employees should work at least 15 metres or more from the installation zone and the roof and wall substrate temperature should be at least 5 degrees celsius to ensure that the spray foam can expand and yield sufficiently to the required thickness.

Warehouse Insulation Costs

Cost will always be a primary consideration for any building owner when undertaking a warehouse insulation project, and we understand that it can be a large investment. However, with energy costs continually rising, the initial upfront cost of warehouse insulation will often yield a greater return on investment while adding additional lifespan to the warehouse, reducing the potential for expensive remedial repairs. Building owners often look for the cheapest solution, but rarely does cheap insulation yield the best long-term results.

When considering all factors, spray foam insulation costs are comparable to most other insulation types. Although it may be cheaper to buy pre-manufactured insulation materials off-the-shelf, by the time you close down your warehouse while the insulation is installed, buy mechanical fixings, and spend several days or weeks carrying out the installation, the final costs can often be higher than choosing spray foam insulation. 

The cost of spray foam for warehouse insulation can depend on many factors. Size and economy of scale are the first considerations, with the initial mobilisation costs of a spray foam installer quite high for any project less than 75 square metres. The thickness of the insulation can also impact cost. 25mm of Enverge Nexseal LE provides anti-condensation solutions, while 50-100mm is needed for better thermal performance. Regarding warehouses with a surface area above 200 square metres, spray foam insulation costs less than pre-manufactured materials.

As a starting point, most warehouse insulation projects using spray foam will cost between £14 to £30 per square metre. Up to 1000 square metres of roof and wall substrates can be insulated in a few days, ensuring your warehouse operations can be back up and running swiftly. We see many instances where building owners start a warehouse insulation project with pre-manufactured materials but quickly realise there must be a faster, more effective way! This is why spray foam insulation is the number one choice for warehouse insulation projects.

ThermoFoam is one of the UK’s most experienced spray foam warehouse insulation suppliers, and we have completed thousands of projects of all shapes and sizes. From film studios and airport hangars to major distribution warehouses and manufacturing facilities, we’ve been there, seen, and done it! If you choose spray foam insulation, you can be assured that ThermoFoam is the right choice to deliver compliance, efficiency, diligence, and long-term results for your warehouse insulation project.

You’ll even see our spray foam insulation in the Tide Climbing Centre by visiting their website here: https://www.tideclimbing.com/

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