Warehouses in Telford often feature steel portal frames with profiled metal cladding erected from the 1960s onward. Spray foam applied to the underside of roofs and walls traps condensation against the metal, accelerating corrosion along fixings and purlins. Removal requires isolating sections to prevent dust migration into stored goods while maintaining structural access for forklift routes below.
Shropshire winters bring prolonged damp conditions that soften polyurethane bonds unevenly. In older Halesfield units the foam frequently conceals original asbestos-containing coatings on steelwork, so inspection must precede any mechanical scraping. High-reach cherry pickers are needed where eaves exceed six metres and floor slabs are cracked from heavy plant traffic.
Edge cases include foam injected into cavity walls between brick and blockwork on 1970s distribution sheds near the M54. These installations create hidden voids that release fibres when disturbed. Containment tents with negative air pressure and HEPA filtration become mandatory to protect adjacent tenancies still operating.
Post-removal the exposed metal must be cleaned of residue and treated with rust inhibitor before new insulation is considered. Failure to address thermal bridging at eaves and ridge details leaves cold spots that reappear as surface condensation within the first heating season.
Technician insight
In Telford the thing that catches most people out with warehouse spray foam removal is the hidden condensation trapped behind foam on 1970s steel frames around Halesfield. Once you start stripping you find purlins already thinned by rust, especially on units that have sat unheated through Shropshire winters.
Halesfield distribution unit roof strip
Foam on the underside of a 1980s warehouse roof had caused widespread corrosion along the purlins. We found the metal cladding fixings had lost most of their threads. Sections were removed under negative pressure, steel treated, and new temporary weather protection installed before the client arranged cladding replacement.
How it works
- 1
Site Survey and Risk Assessment
Measure foam depth and map steelwork condition across the warehouse roof and walls.
- 2
Containment Setup
Erect sealed zones with negative pressure and dust extraction to protect stock and operatives.
- 3
Mechanical Removal
Use heated scrapers and vacuum systems to strip foam without damaging cladding or structure.
- 4
Surface Treatment and Clearance
Clean metal, apply corrosion protection and carry out final air-quality testing before handover.
Pricing
Cost depends on warehouse height, foam thickness and access restrictions; quotes issued after survey.