Project Overview

When the roof of this large industrial building housing the manufacture of corrugated sheet board and boxes became due for refurbishment BBR Roofing were appointed by local commercial property surveyors NSW Commercial to carry out the refurbishment.

The overall refurbishment involved re-coating of the entire 21,500m2 profiled metal roof surface, re-waterproofing of the valley gutters, and replacement of 143 barrel-vault roof-lights.

Alumasc Caltech liquid applied waterproofing systems were specified as the refurbishment materials for the metal roof and gutters, while Hambleside Danelaw Zenon Arc roof-lights were chosen for the barrel-vault roof-light replacements.

All of the waterproofing and roof-light replacement work had to be carried in close liaison with the factory management in order to ensure minimum disruption to the manufacturing operations.

The existing roof covering was cleaned by pressure washing to remove the loose and flaking original coating. The newly cleaned roof sheeting was then primed with Caltech METprime before being covered with two coats of the spray-applied Caltech METcoat, providing a new weathering surface to the metal roof sheeting.

Almost 1 km of gutters, with a girth in excess of 1,000mm were lined with Alumasc’s Caltech QC system incorporating reinforcement matting to provide security over the gutter joints.

Caltech QC comprises of a rapid curing two-component, cold-applied, fully reinforced PMMA waterproofing solution. The wet-on-wet application with embedded polyester fleece, is quick to install and forms a seamless, durable membrane that is rainproof in just 30 minutes. Reducing installation times and keeping disruption to a minimum.

All of the existing barrel-vault roof-lights were also replaced with custom-made Zenon Arc roof-lights by Hambleside Danelaw. In total, 1,740 linear metres of the roof-lights were installed.

The logistics involved in the removal of exiting roof-lights, and replacement with the new products required close co-operation between all parties.

Due to the large scale of the project a major challenge was to achieve successful adhesion and preparation of the damaged roof surfaces within the specified timescales. This was an important consideration as work needed to be carried out with minimal disruption to their manufacturing operations.

The strong relationship with the waterproofing manufacturer Alumasc, meant that our collaborative approach kept the client up to date with all aspects of the installation.

Project Details

CLIENT

NSW Commercial

ROOFING SYSTEM

Alumasc Caltech Liquid Waterproofing Systems

Hambleside Danelaw Zenon Arc Rooflights

ROOF AREA

21,500m2

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