The challenge
A former aircraft hangar gives film and media work enormous clear space, but the original corrugated roof was built to shelter aircraft, not to hold a stable internal environment. Over a span that large, the profiled metal sheeting loses heat readily and condenses freely on its cold underside whenever the warm interior meets cooler outside air.
At Black Hangar Studios in Hampshire, that scale was the core difficulty. Any insulation had to address a very large area of irregular corrugated profile consistently, sealing the full underside of the sheeting without the seams and gaps that conventional board systems leave across a big, complex roof.
The ThermoFoam solution
ThermoFoam applied Enverge closed-cell spray foam to the underside of the hangar's corrugated sheeting. The foam self-bonds to the profile as it cures, filling every ridge and trough across the whole span to create one continuous insulating layer — no boards, no fixings and no voids, even over a roof of this size.
Being dense and moisture-resistant, the closed-cell foam both insulates the roof and prevents warm interior air from reaching the cold metal where condensation forms. The system is supplied by Duratite, UK distributor of record, and certified — important for a large commercial conversion.
The result
The hangar roof now has a seamless, fully bonded insulating skin across its entire span, giving the studio a far more stable and usable internal environment and removing the condensation that came off the bare metal sheeting. The application is durable across the large area and carries a 25-year manufacturer-backed product warranty.
