Problem Identification

The single-skin fibre cement sheeting above the warehouse was severely aged and deteriorated throughout.

Water would enter the building during rainfall, causing interruption to internal operations and resulting in damage to/loss of stock and trade disruption.

Evaluation

The warehouse unit consisted of 3 large bays and a canopy.  The extent of the deterioration spread throughout the whole building.

Due to the fragile nature of the roof covering, and the cost of the necessary Health & Safety requirements to work on a roof of this construction, it would have been neither practical nor cost-effective to carry out a repair only specification or apply a weatherproofing coating.

During discussions with the Client regarding options available for this roof, it was determined that that their priority was to weatherproof the worst affected area of the building where leakage was more extensive.
The Client also required more natural light transmission into the building and the long-term aim of the Client was to increase the thermal efficiency of the building.

The Client further expressed concerns regarding the ‘asbestos’ coverings remaining on site and budget constraints meant that the whole building could not be weatherproofed as one continuous project.

Solution

It was agreed that a phased approach would be adopted to remove and replace the existing fibre cement sheeting, with one third of the building and the canopy roof being selected as the first phase.

Our proposal was to replace the roof with a 115 mm thick composite roof panel system to the main warehouse roof area, which would incorporate factory-assembled insulated translucent rooflights, replace all associated gutters within this roof section and replace the canopy roof with a 40mm composite panel system.

Factory-assembled composite panels consist of a sealed unit comprising of a bright white inner liner, an insulated core and a Plastisol coated metal sheet outer which provides a long life expectancy and excellent thermal properties.

We also proposed to incorporate the Client’s colour scheme into the roof by providing coloured details and trims.

The Client agreed that this approach would suit their requirements for their long-term plans for the building.

To provide reassurance to personnel working inside the building, we provided air-monitor testing throughout the removal process to confirm that no ‘asbestos’ fibres were being released.

All ‘asbestos’ containing materials were disposed of in accordance with current legislation using a licensed waste disposal provider.
The new roof covering will now realise a life expectancy in excess of 20 years and, once the remaining roof areas are also replaced, the thermal efficiency of the building will vastly improve.