Projects
Our project records, by building type: warehouses, factories, hangars, schools, venues, soffits and pool halls. Each one says what we found, what we specified and why, how the work ran, and what the client reported. The figures are the ones on the record; nothing is added.
01Project records
13 of them are written up in full: the building, what we specified and why, how the work ran and what it did. The rest carry what the record states and nothing more. Filter by the kind of building you have.
013 records
Thin steel skins over a lot of air and movement: condensation, heat loss and rain noise, treated from below with the floor in use.
Project recordMetal roof undersideA Midlands distribution warehouse: 75 mm of closed-cell under a corrugated metal roof.Air leakage, condensation and rain noise from one bare sheet. 75 mm of NexSeal closed-cell to the underside, bay by bay, with the building in use. The client reported a substantial fall in energy use, steadier temperatures and a quieter roof.
Project recordMetal roof undersideTJW Grab Hire, Bournemouth: a 505 m² metal roof that stopped dripping on the lorries.A sound box-profile roof condensing onto vehicles and equipment. 50 mm of NexSeal LE to the underside from a scissor lift, polycarbonate rooflights left clear, two working days.
Project recordMetal roof underside · Events venueDepot Events, Cardiff: a warehouse venue roof over the crowd.A bare profiled warehouse roof over a venue that fills with people: little thermal resistance, and condensation forming above the crowd. NexSeal LE closed-cell sprayed to the underside of the sheet, following the profile and the steelwork. Warmer, better controlled, and the condensation risk addressed.025 records
Production floors, process buildings and the roofs, walls and vessels around them, worked at weekends or in zones.
Project recordEncapsulation · FactoryNuneaton Signs: 2924 m² of roof upgraded and sealed, at weekends, without stopping production.Insulated panels over mineral wool, original sheets suspected to contain asbestos. 25 mm of NexSeal LE across the whole assembly from below, at weekends, plant sheeted. Cooler in summer, warmer in winter, as the factory reported.
Project recordExternal encapsulation · Packaging plantSAICA Warrenpoint: 1090 m² of fragile asbestos-cement roof sealed with the plant in production.Moss holding water on a fragile asbestos-cement roof that was starting to shed fibres, over a plant that never stops and vehicles live below. Walkways, netting and edge protection first; a biocidal clean with no pressure washing; then 30 to 35 mm of closed-cell roofing foam and a two-coat urethane finish over 1090 m². No sheet was cut, the plant stayed in production, and Unit 3 is the prototype for the remaining 6240 m².
Project recordWalls · Process envelopeIbstock Brick, Walsall: a drying chamber that has to hold its temperature.Brick drying depends on tightly controlled conditions, and board insulation leaves joints that let them slip. A seamless NexSeal LE closed-cell layer over the chamber envelope, supporting stable process conditions.
Project recordTanks and vesselsModular Cubed, Ripon: a ribbed water tank that stopped sweating.A curved, ribbed tank losing heat and condensing on its surface. NexSeal LE closed-cell sprayed directly to the tank, following the ribs and fittings, for a seamless bonded layer that steadies the tank's temperature and suppresses condensation.
Project recordWalls · Timber studRBW Carpentry, Oxfordshire: stud walls filled in a working joinery.Uninsulated timber stud walls: cold, draughty and prone to condensation, with friction-fit insulation leaving gaps. NexSeal LE closed-cell sprayed into the stud cavities, self-bonding to the timber and sheathing and expanding to fill them completely.033 records
Big spans and curved corrugated shells, the geometry rigid boards cannot follow.
Project recordHybrid build-up · Aircraft hangarBlack Hangar Studios: a 4000 m² hangar roof made quiet enough to film under.A film sound stage under a fragile asbestos-cement roof that drummed in wind and rain. 25 mm of NexSeal LE to bond and seal the sheets, 150 to 200 mm of SucraSeal over it. Three weeks; the studio reported the drumming virtually eliminated.
Project recordCoated system · Nissen hutA Nissen hut for Rolls-Royce Motor Cars: 50 mm of closed-cell, coated for fire.A corrugated steel arch used for finishing work on cars. 50 mm of closed-cell to the inside of the arch, DC315 intumescent coating over it, rooflights kept clear. Warm, dry and finished to the fire requirement set for the space.
Project recordNissen hut · Food productionRoddas Creamery, Cornwall: a Nissen hut that could not drip on a creamery.A curved corrugated steel arch over a creamery, where condensation falling from the roof is a hygiene problem, not a nuisance. NexSeal LE closed-cell to the inside of the shell across the full arc, the geometry rigid boards cannot follow. Condensation controlled, thermal performance improved.043 records
Flat roofs, halls, corrugated blocks and the containers in the yard, booked to the school calendar.
Project recordFlat roofs and cavity walls · ProgrammeTwenty-nine schools across Hampshire and Berkshire: flat roofs and cavity walls, school by school.More than 29 primary and junior schools under flat roofs. 150 mm of SucraSeal open-cell within the flat roof construction at every school, cavity walls filled at several, to a recorded U-value of 0.20 W/m²K and the surface condensation risk taken out of the year.
Project recordShipping containers · SchoolThe Regis School, Bognor Regis: a storage container that stopped raining on its contents, and one we refused to spray.Container rain rusting school storage from the inside. One container emptied, sheeted and fully encapsulated inside at 25 mm in a day. The second had an active leak, so we declined it and reduced the invoice.
Project recordCorrugated roof underside · CollegeHartpury College, Gloucestershire: a corrugated roof that stopped condensing.A corrugated roof over a college building, thermally poor and condensing. NexSeal LE closed-cell sprayed to the underside, filling the ridges and troughs in one bonded layer. Condensation sharply reduced, as reported.055 records
Museums, venues, hospitals and electrical buildings whose interiors cannot be cold or wet.
Project recordHybrid build-up · VenueThe Alban Arena, St Albans: 100 mm of open-cell and 25 mm of closed-cell in the roof of a working venue.A performing-arts venue with high energy costs and a roof letting the warmth out. SucraSeal open-cell to the roof structure above the auditorium and stage, NexSeal closed-cell at the air-seal lines, around the show diary. Steadier temperatures and lower plant costs, as the venue reported; nothing the audience sees changed.
Project recordConcrete soffit · MuseumThe Box, Plymouth: 787 m² of concrete soffit at 120 mm, to a specified U-value of 0.18.Irregular soffits, tight access and many penetrations ruled out boards. 120 mm of NexSeal LE closed-cell bonded to the concrete, adhesion and thickness checked, signed off by site inspection on the contractor's schedule.
Project recordConcrete soffit · Coated systemPondswick primary substation, Luton: 127 m² of concrete soffit insulated and coated beneath live switchgear.A cold slab under switchgear rooms that must hold steady temperature and humidity. 90 mm average of NexSeal LE to the soffit, DC315 intumescent coating in ice grey over it, through the passive fire contractor for the site.
Project recordConcrete soffit and walls · Plant roomUniversity Hospital of Wales, Cardiff: a plant room that stopped dripping on its plant.A hospital plant room congested with pipework, its cold structural soffits and walls condensing and dripping onto plant and corroding fittings. NexSeal LE closed-cell applied directly to the soffit and wall surfaces around the supports and services, lifting them above the dew point.
Project recordConcrete soffit · Government facilityDEFRA Sevington, Kent: an exposed concrete soffit brought above the dew point.An exposed concrete soffit at a government facility: high thermal mass, cold, and condensing, with beams, services and penetrations that defeat board insulation. NexSeal LE closed-cell sprayed direct to the concrete around every obstruction. Condensation controlled, thermal performance improved.065 records
Retail roofs and soffits, business parks and forecourt buildings, including the two ways to keep an asbestos-cement roof.
Project recordMetal deck soffit · Hybrid build-upDerriford District Centre, Plymouth: a ribbed metal soffit taken to U 0.18 with two foams and no fixings.A new retail centre with an exposed ribbed galvanised soffit and a design U-value of 0.18 W/m²K. 25 mm of NexSeal LE bonded to the deck, 160 mm of SucraSeal over it, from scissor lifts in two stages, paused in wind and rain.
Project recordExternal encapsulation · Business parkGlobal House, Surbiton: 1575 m² of asbestos-cement roof sealed from above, 30 m from the neighbours.Four pitched asbestos-cement roofs and an office roof, worn and suspected of microfractures, with homes within 30 m. A biocidal wash, 25 mm of roofing foam in lifts and an airless silicone coat as one bonded system, rooflights and valley gutter included. No waste, nothing cut.
Project recordFibre-cement encapsulation · CommercialA 2340 m² asbestos-cement roof, kept in place and sealed from below.A single-storey commercial building under profiled asbestos-cement. The sheet stayed; 50 mm of closed-cell went on from the underside. Calculated for the build-up: a treated-roof U-value of about 0.53 W/m²K and an underside about 9 °C warmer in winter. Completion pack issued 15 June 2026.
Project recordMetal roof underside · RetailTrago Mills, Cornwall: a retail roof that stopped condensing onto the stock.A large profiled metal roof over a retail store, condensing onto the stock beneath it and losing heat. NexSeal LE closed-cell to the underside of the sheeting across the span: one continuous anti-condensation and insulation layer.
Project recordFlat roof · Forecourt buildingA BP filling station: a flat roof at 150 mm, and the condensation gone.A flat-roofed building at a BP filling station: uninsulated, with high energy bills and surface condensation damaging what was beneath it. 150 mm of closed-cell to the flat roof, taking the build-up to a recorded U-value of 0.16 W/m²K and eradicating the surface condensation.075 records
Humid, high-occupancy halls where the roof structure is the coldest thing in the room.
Project recordSoffit · StadiumLNER Community Stadium, York: soffits over the concourses.Stadium soffits are large exposed surfaces over concourses full of people. Cold and uninsulated, this one condensed and dripped onto public areas. NexSeal LE closed-cell applied directly to the soffit underside around the structure and services. Condensation controlled over the public areas.
Project recordSports hall roofCamelford Leisure Centre, Cornwall: a sports hall roof that holds its heat.A large-volume hall losing heat through its roof, with the humidity of a busy hall condensing on the cold structure above and purlins defeating boards. NexSeal LE closed-cell to the underside of the roof structure in one continuous, well-bonded layer.
Project recordPool hall · HotelPenventon Park Hotel, Cornwall: a pool hall whose roof stopped condensing.A hotel pool hall where humid air meets a cooler roof and walls and condenses: damp, corrosion and decay in the fabric. NexSeal LE closed-cell to the pool hall structure, following the roof and its supporting members, for a warmer, better-controlled envelope.
Project recordPool hall · Public leisure centreNewport Leisure Centre, Telford: a public pool hall and the humidity that comes with it.A high-occupancy public pool hall, putting the roof structure at risk from condensation. NexSeal LE closed-cell applied directly to the pool hall structure for a more thermally stable, better-protected envelope.082 records
Thin-skinned barns and farm buildings shared by animals, visitors and the weather.
Project recordMetal roof underside · Farm attractionHobbledown, Surrey: a barn shared by visitors and animals, made warm.An uninsulated metal barn roof at a farm attraction, cold and condensing over a space shared by visitors and animals. NexSeal LE closed-cell to the underside of the roof and structure for a warmer, better-controlled barn.
Project recordMetal roof and walls · FarmBeth Haven Farm, Teesside: a thin-skinned steel building in a working yard.A thin-skinned steel farm building losing heat and condensing, in a working agricultural environment. NexSeal LE closed-cell to the profiled sheeting, roof and walls, for better thermal control and sharply reduced condensation.092 records
Slabs and walls that stay cold: car-park soffits and a concrete bunker.
Project recordConcrete soffit · Undercroft car parkRichmond House, Bournemouth: a car-park soffit under cold floors.An unheated car park under a residential block, with the heat from the homes above leaking down through the slab and the floors above running cold. NexSeal LE closed-cell to the underside of the car-park soffit around beams, columns and ducts, with no work inside the homes.
Project recordConcrete soffit and walls · Below groundCullompton, Devon: an underground concrete bunker brought under control.An underground concrete bunker with persistent condensation: irregular cast concrete, restricted access and no ventilation. NexSeal LE closed-cell applied directly to the soffit and walls, lifting the concrete above the dew point and bringing the condensation under control.Every photograph labelled Project record is from the job it sits on. Where a record has no photograph of its own, it carries none.Find your building type
02Footage and photographs
From our own jobs: warehouses, portal frames and fibre-cement roofs, sprayed from beneath.
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