Polyroof Products Ltd

As a company passionate about UK manufacturing, Aston Martin’s choice to work with Polyroof - the only independent UK manufacturer of cold-applied liquid systems - was a natural one.The new roofing system had to be cold-applied to eliminate the risk of accidental fire during installation. New insulation was also desirable to further improve the thermal performance of the roof. It was essential to reduce disruption to the operations of the facility, meaning any new system must be rapid to install with the existing roof predominantly being kept in place.After leaks were reported, The findings of Polyroof’s survey were presented to Aston Martin in the form of a bespoke specification, where the Protec Warm Roof System was the recommended solution. Core tests taken during the inspection had revealed that despite the leaking through the existing PVC single-ply membrane, the existing build-up of 60mm PIR insulation was found to be dry and in sound enough condition to be retained as the base for the new roofing system, saving the client time on the project.It was also identified that the current insulated roof configuration was missing a Vapour Control Layer, meaning the roof was at risk of condensation issues. This problem was designed out by the installation of 120mm Polyroof RES Insulation above the existing single-ply membrane, which was made good to form an effective vapour control layer.By creating a “hybrid” roof with double the insulation above the vapour barrier than below, the risk of condensation was eliminated and this was demonstrated by analysis conducted on the proposed build-up.To eliminate the standing water issues, sumps were placed around the existing outlets, greatly improving their drainage capacity, and offering a highly cost-effective solution when compared to the need to alter the falls of the roof.Polyroof Technical Services visited site regularly to advise and assist architects, specifiers and contractors in all aspects of the project.The finished roof provided a seamless and extra-tough waterproof membrane that was supported by the trusted Polyroof Accredited System Guarantee, with a separate insurance-backing scheme provided at no cost to the client. Aston Martin Lagonda now have the peace of mind that the roof above this landmark facility will be leak-free for decades to come. 

Barton Hill Primary School was converted into an academy. As part of these works the structure of the school required renovating and expanded to meet the standards expected. Areas using Polyroof’s systems included new extension roofs, refurbishment of existing roofs, and the creation of colourful dormer pods.The requirements of this project were as varied as they were demanding. With it being a school the works had to be carried out as rapidly as possible and with as minimum disruption. For safety reasons cold-applied systems were preferred to traditional hot-applied solutions.polyroof.co.uk

Beckfoot Allerton opened on 19th November 1894, a proud day for the village of Allerton and its people. The school underwent many changes throughout the years surviving and contributing to both war efforts, while continuing to hold their high standards of education. In 1928 the school official became a primary school and later in 1960 a junior and infants’ school further undergoing changes. After a local authority change in 2000 Beckfoot Allerton Primary school was reborn. In the present day the school is much different to when it was opened generations ago and continues to serve as a corner stone of the village and its community.Taking into consideration all of the requirements of the roof, a bespoke specification was prepared to refurbish the roof. Polyroof’s Protec System, a hybrid polymer liquid system with extremely fast curing and installation times, was the chosen system of use for the project. Due to its fully cold-applied application the works could be carried out during the Primary Schools term times, without having to wait for closure periods between terms.

The building that would be the St Margaret’s Primary School, officially opened by Robert Leitch the local parish vicar in 1889 provided education to children up to fourteen. The school underwent many changes in structure throughout its over 100-year existence continuing to provide the high level of teaching it always held. In 2012 it underwent a further change in the form of a huge modernisation project that would extend the school and allow more students to be taken. Unfortunately, leaks were reported on the older parts of the building and despite localised repairs were not ultimately solving the problem.After reports of leaks it was imperative that the roofs in question were inspected to find where the issues were originating, in action to this a site survey was undertaken. The survey highlighted the original build-up consisted of an asphalt on a timber deck, this original system was in a aged condition. It was also shown that standing water and vegetarian had developed on the roof. In order to protect the building from further leaking it was determined that the roof would benefit greatly from the installation of a high-performance waterproofing system.Along with waterproofing improvements, there would also be improvements made to the falls which would reduce the amount of standing water present on the roof.Waterproofing would not be the only recommendation; the roof was also to receive a full thermal upgrade which would further provide the benefit of increase fuel bills and less energy consumption for the school.Taking into consideration all these points, the Polyroof Technical team began creating a bespoke specification that would provide the details needed to make these recommendations a reality. The Polyroof Approved contractor Thomas Cassie & Sons was specifically chosen to undertake this project due to their experience in liquid roofing systems. With a specification and approved contractor ready the project could officially commence.

Broughton & Yeamans House are high rise apartment blocks in Bristol, Avon, under the management of Bristol City Council. The roof areas, totalling over 3,500m2, had originally been waterproofed with asphalt and then later treated with a coating repair.Unfortunately, water ingress continued to be a problem with leaking occurring at numerous locations. Not wanting to cause further disruption to the residents and to avoid costly damage to the interior of the buildings, the council contacted Polyroof and a survey of the roof was arranged.The survey by Polyroof’s Technical Services highlighted the extent of the issues within the roof, including identifying water ingress through the many vertical sections present on the roofs, including parapet walls and the lift house building. After performing core tests on the roof, it was shown that the existing roof build, which contained insulation as part of a warm roof design, was in a suitable condition to be retained and overlaid – avoiding costly disruption for the client and residents.A bespoke specification was drawn up by the Polyroof Technical Team that provided a comprehensive set of recommendations to ensure the apartment blocks were fully protected from the elements.To make sure the roof could be left in a totally weatherproof condition, it was necessary to treat not only the flat roof sections but the vertical areas too. The client was keen to improve the thermal performance of the buildings by adding additional insulation, but it was imperative that disruption was kept to a minimum – not only would stripping works impact on the buildings’ residents, but hauling waste materials from such a great height would be costly and logistically challenging.With BBA approval, top-rated fire performance and Polyroof’s trusted 20 Year Accredited System Guarantee, the client has total peace of mind that the apartment block could not be better protected for decades to come.

Burton Green Primary School is located in the historic city of York, an outstanding school at the heart of a local community this primary school strives for excellence. The challenging and nurturing learning environment allows children to learn and grow, while achieving the highest potential possible in all areas of the 21st century curriculum.When the roof began showing signs of ageing, it was clear that a long-term solution was required. Working with Project Managers Charles Garth and Principal Contractor Castle Special Projects, Polyroof would work towards providing the best solution to refurbish the ageing roof.The work required and condition of the roof needed to be established first, to do this a survey was scheduled to take place. The survey was conducted on roofing area and it was determined that there were 6 flat roofs that required refurbishment. Areas 1 to 2 were constructed of a built up felt with mineral cap sheet, 50mm PUR insulation, bituminous vapour control, asphalt, 12mm fibreboard and a 50mm woodwood slab deck with timber joists. Areas 3 to 5 were constructed of a built up felt with mineral cap sheet, 50mm Jablite insulation, bituminous vapour control, asphalt, 12mm fibreboard and a 50mm wood wool slab deck with timber joists. Roof area 6 was made up of built-up felt with mineral cap, plywood and timber joist. The original build-up of roofs 1 to 5 needed to be stripped back to the asphalt due to the aged condition of the built-up felt, numerous leak reports were reported. Roof 6 and its original waterproofing was to be retained and made good, later this surface would act as the substrate for the new waterproofing system.Once the survey was completed, a bespoke specification was written and it was recommended that the roofing areas would all benefit from a high-performance waterproofing system. In addition to this it was specified that the roof would be thermally upgraded to reduce the risk of condensation and provide lower fuel bills and energy consumption for Primary School further adding benefits to making improvements to the roof.Liquid Roofing Limited an experienced roofing contractor and Polyroof Approved Contractor was chosen to undertake the work to this project. The proposed system for this project would be Polyroof Protec Warm Roof System. Protec’s liquid roof membrane has a unique flexible hybrid polymer formulation and can be applied to virtually all common roof surfaces.The areas that were required for installation firstly needed to be stripped and removed back to the asphalt, areas 1 to 5 required this. Area 6 was then repaired of any defects and made good where necessary. All roofs required a deep clean, removing any dirt or debris that remained from the first stage. Once this preparation was completed an Air & Vapour Control Layer (AVCL) was then installed to roof areas 1 to 5 making sure that all surfaces are smooth and without voids.Using a Polyroof Twin Pack Insulation Adhesive the Polyroof RES insulation (T&G) boards were bonded and laid to each of the 6 roof areas completing the second stage of the warm roof upgrade. Before the last stage of the installation could begin all joints in the insulation were sealed using taping matt and Polyroof Protec Resin. Polyroof’s extra-tough GRP trims were then installed to create neat and robust edge detailing for exposed perimeters before the main Protec system application commenced.During the project there were some challenging aspects that required care and attention. The project featured a large array of different details ranging from installation of new substrates and trims for parapet walls to the removal of and preservation of tiles/cladding so that the Protec system could be applied correctly. These features required delicate work so that the original tiles/cladding could be reinstated after the application of the system was completed. During the project the rooflight that was originally in place was removed and replaced with a new, before this could happen the Protec system was taken up the upstands and then sealed under flange.Once the project was completed within the relevant time frame of the client and within the budget specified, the Polyroof Technical Services team conducted a detailed inspection showing a high level of workmanship which lead to the client gaining the trusted Polyroof Accredited System Guarantee.

The five-star Cameron House Hotel is set within 400 acres of beautiful Scottish countryside on the world-famous banks of Loch Lomond. The Hotel is the prestigious home to a collection of 140 bedrooms including 24 suites. The hotel offers a variety of dining experiences, including the Michelin starred restaurant Martin Wishart at Loch Lomond.When the flat roof areas above the main kitchen and the dining area began to leak, it was imperative that a rapid waterproofing solution could be found that could be installed without disturbing operations at the restaurants below.When the flat roof areas above the main kitchen and the dining area began to leak, it was imperative that a rapid waterproofing solution could be found that could be installed without disturbing operations at the restaurants below. The roof area itself was covered with an aged felt membrane that had been treated with a variety of localised repairs which could no longer prevent water ingress. A large amount of M & E plant was present throughout the roof, and any new waterproofing system would be required to seal the numerous stanchions and plinths in a fully weatherproof condition. After researching waterproofing systems online, Cameron House Hotel contacted Polyroof Technical Services for a recommended waterproofing solution that met their stringent criteria. Following discussions, the regional technical manager carried out a detailed roof survey of the roofs. The survey report formed the basis of a bespoke specification that covered a comprehensive set of recommendations to fully solve the roof’s problems.Polyroof Approved Contractor Skyform Roofing successfully tendered the project and the refurbishment works soon began. In order to avoid disruption to the hotel’s operations the existing roof coverings were retained as a substrate for the Protec system, without the need for stripping / replacement works. Due to the complex nature of the roof, works were carried out within a phased approach with the most problematic regions being refurbished first. Loose-laid M & E plant was relocated and the felt coverings cleaned and made good as required. The remaining roof details were then prepared as necessary before being primed ready to accept Polyroof’s cold liquid-applied Protec system.A key advantage of the Protec system for phased refurbishments is its speed of application and rapid curing. Unlike moisture-curing liquid systems, Protec forms a solid, extra-tough membrane that can be walked on 30 – 60 minutes after application. Not only does this reduce labour times and keep costs down, but crucially it allows the full system to be laid in it’s entirety in a matter of hours – rather than days. With its fibreglass reinforcement, the Protec resin is able to rapidly mould around any protrusion, stanchion, plinth or upstand to quickly form a totally seamless watertight seal – without the need for any time consuming cutting or patching work. This meant that the many complex roof details were able to be rapidly made waterproof, further reducing installation times.The contract monitoring undertaken by Polyroof Technical Services allowed the contractor and manufacturer to work effectively together to ensure the roofing solution delivered on all the client’s needs. The application by Skyform Roofing was completed to a very high standard with every roof detail meticulously sealed in a fully weatherproof condition.

The Castle Cove Sailing Club in Weymouth, Dorset, constructed a new terrace area to provide a viewing platform for the sailing events in the London 2012 Olympic and Paralympic Games.The sailing club required a waterproofing system that could be installed directly to the concrete construction in order for the works to be completed as quickly as possible. It was essential that the system was compatible with timber decking and would provide long-term protection from the elements.The sailing club contacted KG Roofing, their local Polyroof Approved Contractor, to provide a waterproofing solution that could meet the demands of the project. The BBA-Approved Protec System was specified for the works due to its rapid cure times and high waterproofing performance. Timber battens were incorporated into the system to create fixing platforms, creating a striking yet functional support for the timber decking and glass balustrade.With the Protect System affording rapid curing times, the terrace was finished within the desired time-frame, leaving ample time before the beginning of the Olympic Games. The lucky viewers at Castle Cove Sailing Club witnessed many record-breaking performances from Team GB’s sailing team, including Ben Ainslie becoming Britain’s greatest ever Olympic sailor.

The proprietors of this domestic property in Harrogate added a large extension with a total roof area of 150m2. The client wanted the new roof sections to complement the slate work and aesthetics of the original building whilst adding a contemporary and stylish look to the extension.Originally considering a zinc sheeted roofing system, the client explored alternative materials that could achieve the same visual impact but at lower cost. After discussions with Cure Roofing Ltd, a Polyroof simulated metal finish was proposed as a roofing solution that would meet all the client’s requirements.Not only do Polyroof’s range of liquids offer cost savings over traditional metals, but they are also lighter in weight, totally seamless and can be pigmented to any RAL colour. Having no scrap value, the client also had the added peace of mind that the roof would not be a target for theft.A timber warm roof was constructed which incorporated 120mm PIR insulation to achieve a U-Value of 0.18 W/m2K in compliance with building regulations. An OSB3 TG4 deck was fitted above the insulation and Polyroof pre-formed GRP standing seam trims were fixed at 600mm centres into the deck. Next, the first coat of the Protec waterproofing system was applied over the whole roof area and encapsulating the standing seam trims. The roof was finished with a second coat of Protec pigmented to RAL 7016 providing an anthracite grey colour to the whole roof, accurately simulating the appearance of zinc roof sheets.The workmanship by Polyroof approved contractor Cure Roofing was second to none and the quality of the finish left the client delighted with their new roof. With BBA approval, top-rated fire performance and Polyroof’s trusted 20 Year Accredited System Guarantee, the client has total peace of mind that their new extension could not be better protected for decades to come.

The project consisted of two similar flat roof areas totalling 1,100m2 above high-rise residential blocks in a city centre location. The existing roofs were an inverted roof design that had been waterproofed with single-ply that had failed prematurely. Numerous short-term, localised repairs had failed to stop the water ingress and leaks had been a long-term problem.It would have been impractical to remove the tons and tons of ballast and insulation from the top of the high-rise building and it was imperative to the client that removal or replacement works were not involved at all. The specific nature of this project required careful consideration, and so a survey of the roof was arranged.The SolutionA report from an independent consultant commissioned by the client identified a problematic challenge with an overlay option. The existing falls of the roof were assessed to be poor, and so standing water would be an issue for any new waterproof covering. The report concluded that this would reduce the lifespan of an overlay waterproofing system and so was advised against. The client initially thought this to be a stumbling block and that costly and impractical modifications to the roof would need to be made.Having worked with Polyroof on scores of other projects, the client turned to Polyroof Technical Services for a solution that could meet their stringent criteria. Following on from the preliminary discussions, Polyroof’s Technical Services assessed the site, taking core samples and then providing a suitable specification to overlay the roof with the Protec System.The BBA certification of the Protec system specifically covers use for zero falls (completely flat) applications, meaning the client had absolute peace of mind that standing water would not be a detriment to the integrity of the waterproofing system. The client was able to achieve the original objective of an overlay system and benefited from the associated cost and time savings. Furthermore, the BBA certificate states that when used in inverted roof scenarios the lifespan of the Protec system is as long as the design life of the roof.Work was started with J R Flat Roofing, a Polyroof approved contractor with national coverage, moving the ballast and insulation to one-side in four phases of 140m2 at a time, exposing the single-ply membrane to which the Protec system was directly applied.Due to Protec’s rapid cure and walk-on times (30-60 mins dependent on conditions), the system is ideal for larger, phased refurbishment, as specific sections of the roof can be made waterproof with the full Protec system in one day. When carrying out the next section, the new Protec membrane forms a totally seamless and watertight joint to the existing Protec-covered areas.Another objective was to reuse the original inverted insulation and ballast pebbles as this was cost saving and negated the need for the lifting logistics that would have been involved in bringing the ballast to ground level. Additionally, it made the process as environmentally compliant as possible by keeping waste to a minimum. The insulation and pebbles were re-applied in its original format and, due to the weight of the pebbles, was a mammoth task that required three miniveyors to help with the handling. A series of special aluminium breather vents were also fitted down to the concrete slab roof substrate to enable the surface to dry out over a period of 12 months.The whole job was completed in three weeks and the client was delighted with the finished work. With a 20-year insurance back-guarantee and a maintenance-free waterproof membrane that will last as long as the roof stands, the client was once again left with total peace of mind that their buildings could not be better protected.

The roofs of The Dungannon & South Tyrone Borough Council offices had fallen into a poor condition and a large amount of standing water was threatening to leak into the offices below. With the office roof areas in such a poor state, the council turned to Polyroof to refurbish nearly 1,000 square metres of roof, split into 13 areas, before they fell into a further state of disrepair. DTL Construction, a local Polyroof Approved Contractor, were tasked with installing the Protec System, removing the issue of standing water and giving the roof a long service life, whilst giving the council peace of mind that leaks would not pose an issue in future.The standing water was cleared before the existing roof materials were stripped back in order to install the new system. This allowed a new warm-roof system to be installed, along with new cut-to-falls insulation. Polyroof’s Protec Cut-to-Falls insulation is an innovative two-layer system which doesn’t only improve thermal performance, it also directs standing water away from the roof.Following this, the BBA-approved Protec system was used to seamlessly waterproof the entirety of the office roofs. The system, once inspected by Polyropof’s Technical Services team, was issued with a 20-year guarantee, so the client could now have reassurance their roof would last for decades to come.

The Durham Gateway project is a major new development at the Durham University that houses a variety of departments. Although aesthetically stunning, the concept presented several challenging issues.The project was carried out to a BREEAM ‘Excellent’ Standard and as such only used components that had minimal environmental impact. Cold-applied liquid roofing membranes, such as those manufactured by Polyroof, have been recognised by BRE to help roofing elements achieve up to an A+ rating (depending on the roof construction).Part of the works involved the construction of three curved roof areas that required a high-performance and durable waterproofing system which was to be covered by a timber shingle system. The shingles were supported by over 1,170 steel stanchions – all of which were seamlessly waterproofed with the Protec System.The main contractors of the project, Laing O’Rourke, were able to achieve the visual impact they wanted with the peace of mind that the roof was protected by a totally seamless and highly durable waterproofing membrane.

As described by Eastleigh Borough Council, the £25 million facility underpins the council’s commitment to promoting a healthy borough. It incorporates a high quality design in keeping with the parkland environment and has high environmental standards. The new building will boast many facilities that are larger than at present, including an eight-lane, 25-metre swimming pool, a larger, versatile learner pool, 15-badminton court sports hall, a versatile, multi-station gym and a group spinning studio. This case study will look at the challenges and solutions of this vast project that involved insulating and waterproofing over 8,500m2 of flat roof areas.Following decades of experience using Polyroof’s liquid systems to protect buildings throughout the district, including waterproofing the original Fleming Park Leisure Centre back in the early 1990’s, Eastleigh Council specified the Protec system for the project.

The Protec System was used to waterproof the domed green roof areas of this striking, sustainable house development which was featured on Chanel 4’s Grand Designs. With an ambitious vision and a tight budget, Robert and Milla Gaukroger set about transforming a dated 1980’s house overlooking Lake Windermere into a state-of-the-art, eco-conscious home. Since the house lay in beautiful hillside surroundings, in order to blend into this setting, the domed roofs of the house were to be covered with a wildflower meadow mix to provide a green roof construction.The SolutionThe Protec System was chosen as a waterproofing membrane for the roofs as it is ideally suited for green roof applications. Lightweight, flexible and highly durable, the system can easily accommodate structural expansion movements and is tough enough to resist root penetration. The Protec system was applied to over 350m2 of domed roof to provide a long-lasting waterproofing membrane.The key reasons why Eastleigh chose Protec are the same reasons that has seen it become one of the fastest growing cold-applied liquid roofing systems in both the new build and refurbishment markets. Combined with the timber cladding to the verticals of the building, the finished aesthetics of the development blended seamlessly with the surrounding areas.A warm roof build-up that can be made waterproof at multiple stages:For larger projects the Protec system can be made temporarily waterproof at two stages prior to the application of the full waterproofing system. The first stage is upon installation of the sealed, aluminium-faced vapour barrier.The second phase follows the reinforcing of the foil-faced insulation board joints with Protec resin and taping mat. This enables a much more controlled approach to the installation with a greatly reduced chance of rain causing disruption and damage during the works.Highly flexible membrane:Regardless of the size of the roof, Protec forms a homegenous membrane, without a single joint or seam and without the need for any expansion joints.RapidCure technology for quick installation:The application of Protec as a liquid, through to the curing process where a solid, tough membrane that can be walked over, takes only 30 – 60 minutes. This enables large sections of the roof to be fully completed in a short space of time.Installing the Roofing SystemsThe Protec System provided waterproofing to all flat roof areas as well as the extensive parapet wall sections. The roof areas were made up of two designs: the Protec Warm Roof System (approx 7,500m2) and Protec applied to concrete as part of an inverted roof design (approx 1,000m2).The roof installation was carried out with a planned, phased approach that was synchronised to the wider construction schedule. For the warm roof areas, the first stage was to fill the troughs of the structural metal roof deck with acoustic insulation infills that will dampen external noise within the leisure centre. Next, the crowns of the deck were primed ready to receive the self-adhesive vapour barrier.The use of a high-performance aluminium vapour barrier not only eliminates the risk of condensation within the roof, but also provides temporary waterproofing protection, which is extremely useful on larger works such as this.The Polyroof RES Insulation boards, which comprised of a two layer system totalling 170mm to achieve a U-Value of 0.14 W/m2K, were bonded using high-performance PU adhesive to the vapour barrier. Following the wind uplift calculations it was determined that mechanical fixings were not required for this application – making for an extremely rapid installation. As you can probably imagine, fixing through 170mm of insulation into the crowns of the metal deck can be a tricky and time-consuming task.A key advantage of using a tongue and groove insulation system is that the finished surface of the roof is smooth and level without any unsightly board steps that can also lead to standing water issues. The insulation board joints were sealed using Protec resin with Polymat Taping Mat 450 which, in addition to providing additional strength to the joints, also creates a temporarily waterproof layer.For the inverted roof sections, Protec was applied directly to the primed concrete/screed surface. The membrane was inspected by Polyroof Technical Services, signed off and then covered with inverted roof components. An interesting fact when using Protec in inverted roof situations is its incredible durability performance – as tested by the BBA, Protec “can provide an effective barrier to the transmission of liquid water and water vapour for the design life of the roof in which it is incorporated”.Monitoring and CompletionThroughout the duration of the contract, Polyroof Technical Services carried out regular site visits that were reported back to Interserve as part of Polyroof’s free-of-charge contract monitoring service. This enabled the client to keep up-to-date with the progress of the roof installation in detail and also provided peace of mind that the original specification was being closely followed and implemented.Polyroof worked closely with the Roofline Group during the installation, enabling the challenges were identified and solved in an efficient and coordinated manner – saving the client time and money.

The flat roof area at above the vast Guernsey Power Station had been suffering from water ingress as a result of failings in the existing EPDM membrane. Due to the expensive machinery housed within and the potential for widespread and costly disruption should the leaking continue.Guernsey Electricity turned to Sarnian Roofing Limited, a Polyroof approved contractor, to provide a rapid and effective waterproofing solution. The Protec System was specified, and work began quickly.The SolutionRemoval of the failed roof coverings to expose the concrete deck below began, and the BBA-approved Protec 20-year system was installed directly to the concrete. Due to its RapidCure technology, the system cures within 30-60 minutes, meaning less disruption for the client.The Protec System provides an flexible and seamless membrane that eliminates the risk of water ingress around penetration points common in industrial unit roofs. As the system is cold applied, there are none of the safety risks associated with the open flames and hot torches used with traditional roll-applied systems.Polyroof’s reputation has been built on the high level of technical support provided to clients before, during and after every contract.We like to work closely with our clients from the very beginning of a flat roofing project right through to completion and throughout the lifespan of the roof. From our experience, this is the best way to guarantee that all aspects of the roof are finished to the superior standards that our clients expect.

The Host Helix building, also known as the “Helter-Skelter,” was a unique and striking structure built in 2011 with stunning views of North London and Wembley Stadium. Over time, the building experienced general wear and tear and water began to enter the buildings’ complex structure.Polyroof Products were called in to consult with the clients and offer a seamless, encapsulated solution that could address the many unusual details associated with the building’s design.The SolutionA full survey of the roof terrace areas was conducted by the Polyroof Technical Services, after which a bespoke specification was produced for the works. The proposal document detailed a comprehensive set of recommendations for producing a seamless solution to encapsulate the problematic roof, therefore solving the issues that had arisen over the years due to its condition and age, as well as the issues associated with the original design of the pitched, curved roof.Polyroof SA Carrier Layer was then applied over the cement particle boards with Polyroof pre-formed GRP Drip Trims fixed to the external edge. For continuity and to create a uniform finish, the SA Carrier Layer was extended onto the main roof sections as a substrate for the Protec system.Any details requiring local reinforcement were treated with Protec Resin and 75mm wide Polymat 450. The curing process was allowed to take place. To accommodate structural expansion / contraction movements at appropriate details, 25mm disbondment tape was installed prior to local reinforcements.The first coat of Protec Resin and Polymat 450 was applied at a minimum coverage rate of 1.3 – 1.5Litres/m² (0.66 – 0.77m²/Litre) and was allowed to cure. To complete the system, a second coat of Protec Resin was applied at a minimum coverage rate of 0.5Litres/m² (2.0m²/Litre) and was allowed to cure.ComplexitySuch an iconic building in the local community, the client wanted to protect the original aspects of the building to the fullest extent, so the Protec system installed at the perimeter was color-matched to the original blue and grey colours. This was achieved by blending pigments until they matched the desired colors, in turn the pigment was then blended into the Protec resin before application. The survey revealed concerns about the original building designs from 2011 and the roof’s drainage system. Due to the roof’s pitch, rainwater was cascading down the curved slopes at high velocity and causing water to bounce into the building under the original capping.After many discussions between the main contractor and Polyroof, as well as the provider of the external cladding, it was agreed that the perimeter detail needed to be encapsulated with the new waterproofing system to prevent further water ingress. Fire-retardant cement particle boards were fixed to the internal and top faces of the external parapet walls, and the Polyroof SA Carrier Layer was applied over them with Polyroof pre-formed GRP Drip Trims fixed to the external edge.The Protec System was then applied to encapsulate the entire parapet detail, meaning its waterproof integrity would be covered under the Polyroof Guarantee. The curvature of the building added complexity to this process, and the contractor took great care in cutting the trims to size and fixing them to the external edge to ensure they followed the profile of the structure. Due to the building’s height, all the trims were face-fixed to prevent wind uplift.WorkmanshipIn order to improve drainage and prevent water from accumulating in hotspot areas of the roof, the contractors were instructed to install new internal curved gutter channels at the point where the roof and building met. These channels were designed to have a sufficient height and angle to effectively direct rainwater towards the outlets, preventing water from pooling on the roof. However, the installation process was made more complex due to the curved nature of the building’s architecture, which required careful measurement and customization of the gutter channels to fit the unique shape of the building.Additionally, the contractors had to consider the many joins of the gutters and how they would hold up to the elements over time as the building structure expands, contracts and moves. Extra steps were taken to ensure the gutters liquid membrane was properly sealed and secured to prevent leaks.The contractors were instructed to repair all protrusion and mansafe post details as necessary in order to allow the Protec System to be installed to a minimum height of 150mm, and to terminate it underneath a suitable weathering flange or jubilee clip. In addition, all right angles were to be reinforced with double taping. Any protrusions that were liable to significant movement was required to have disbondment i.e., bond break, tape applied to it to stop the external coating from stressing on expansion. Furthermore, all pipes were to be abraded, solvent wiped, and where necessary, primed in accordance with the Polyroof coatings manual. A flashing detail was also to be created with a weathering flange or seal.All outlets were inspected to ensure that they were functioning properly. Any outlets that were deemed unsuitable were replaced with new ones. The outlets were cleaned, prepared, and primed as necessary. The Protec system was then dressed into the outlets as far as was practical. The inspection and replacement of the outlets and the preparation of the Protec system helped to ensure that the drainage system functioned effectively.ConclusionThe refurbishment of the roof was completed within the client’s target timeframe and budget. Following a final inspection by Polyroof Technical Services, which highlighted quality workmanship of Tower Asphalt Ltd, the client received Polyroof’s trusted Accredited System Guarantee and now has the peace of mind the roof will be leak-free for decades to come.

KAL is a member of the Gowan Group, a family-owned holding company, directly controlling many successful trading companies as well as significant property holdings and financial investments in public and private companies in Ireland, Northern Ireland and the UK.The largest appliance distributors in Ireland, KAL rely on a 30,000 square foot designer showroom for unique kitchen and domestic appliances. Their showroom at Dublin’s Citywest is one of the largest of its kind in Europe showcasing all their kitchen and consumer appliance brands.The ChallengeAfter conducting a survey of the 1,000m2 roof, it was determined that the areas of the roof, specifically the office area, were in need of repair. Some areas of the original roof build-up were starting to leak and lap joints failing due to a poor install.Following the site survey and adhesion tests, a site-specific specification was produced for the client and contractor to overview once all parties were happy with the proposals. With some complex detailing work involved, a decision was made to overlay the existing roof build with Polyroof Protec System.The SolutionPolyroof’s Protec System, a hybrid polymer liquid system with extremely fast curing and installation times, was the chosen system of use for the project. Due to its fully cold-applied application, the works could be carried out during working hours, with little disruption to the office staff below and little working time lost for the client.IPRS Limited, an experienced roofing and panel repair contractor and Polyroof Approved Contractor, were chosen to undertake the work on the project. Firstly, before any work could begin, the original waterproofing of the office roof was pressure-washed and cleaned down. Once all initial preparation was completed, the Protec System application could begin.All areas requiring priming before the main system application were primed and allowed to cure. Any joints were sealed using taping mat and Protec Resin and allowed to cure. Once this preparation had been completed the main Polyroof Protec System, chosen in light grey by the client, was applied.The first coat was allowed to cure before the final coat was applied. Due the Protec System Rapid Cure technology, the finished roof could be walked on after just 30-60 minutes after applications. This allowed for large roof areas to be made fully waterproof within a matter of hours. After the inspection was completed, the client received Polyroof’s trusted Accredited System Guarantee.Taking away the challenges of flat roofing projects.Polyroof’s reputation has been built on the high level of technical support provided to clients before, during and after every contract. We like to work closely with our clients from the very beginning of a flat roofing project right through to completion and throughout the lifespan of the roof. From our experience, this is the best way to guarantee that all aspects of the roof are finished to the superior standards that our clients expect.

The overall aesthetic appearance of this project was very important. Originally, traditional metal roofing was considered, but the client had reservations with possible noise issues and theft problems, and local planning constraints did not permit the use of traditional slate. So, Williams Roofing Contractors of Chandlers Ford were tasked in finding an alternative solution.Polyroof’s BBA approved 185 GRP System can replicate the look of metal sheeted roofing at a fraction of the weight and the price and, having no scrap value, is not prone to vandalism or theft.The contractor worked closely with the Polyroof Technical Department, the client, and the planners to produce a detailed specification for the project incorporating pre-formed trims to create a lead effect. The system was successfully installed within the project time frame and upon completion was given the usual insurance-backed 20 year guarantee from Polyroof Products Limited.Polyroof’s simulated metal finishes are achieved through the installation of Polyroof pre-formed GRP trims which are fixed to the deck or substrate prior to the application of the Polyroof waterproofing membrane. The project was nominated for the LRWA Roofing Awards due to the high level of intricate detailing that was undertaken and the care that was taken to ensure that all preformed profiles were fitted in balanced, parallel positions. The overall attention to detail by the Polyroof approved skilled operatives was first class.

Liberty Point is a large student accommodation building positioned in a prime location in Southampton, close to the marina and city centre. The old asphalt and felt coverings had begun to display defects including splits, blisters and delamination; through which water ingress was occurring.The property management company responsible for the maintenance of the buildings decided to act quickly and find a permanent solution to the leaking that could be installed without disruption to the busy students living there.The SolutionPolyroof’s Protec System was decided upon as the best option due to the numerous details that would have to be encapsulated on the roof area. There is no liquid system that can do this quicker or more effectively than Protec; its unique RapidCure technology sees it turn from a liquid to a robust and flexible membrane that can be walked on after 30-60 minutes following application. Furthermore, its ability to coat an old roof without the need for stripping existing means that installations can be carried out within stringent time frames and with minimum disruption.CompletionWilliams Roofing Contractors Ltd, a highly experienced Polyroof approved contractor, carried out the installation. The quality of the workmanship coupled with the right choice of roofing material made for a superior refurbishment solution that remedied all the existing issues. The client was delighted with the finished roof and will have guaranteed peace of mind for decades to come.

Queens Crescent is a bustling retail street situated in London’s Kentish Town. The roof area above the Post Office building, which also served as a communal walkway area with access to the upper level of the adjacent buildings, had been suffering from leaks. To add to the issues, the aged promenade tiles had worn and become a slip hazard when trafficked. Looking for a lasting waterproof solution that can also provide heavy duty anti-slip surfacing, the client turned to Polyroof for a solution. To minimise access disruption to the upper level adjacent buildings, the client had organised a 5-day window for the waterproofing and surfacing works to be completed.The SolutionThe main contractor had removed the old paving slabs and membrane back to the concrete deck underneath and carried out repairs to create a level surface.Approved Polyroof Contractor Emperor Roofing began by priming the concrete surface to create a sealed, non-porous substrate. With its quick-curing properties, the Polyroof primer was ready to be over-coated only 30 minutes after its installation.A specialist twin-pack epoxy metallic primer was applied to metal detailing sections, including ducting vents and the intricate balustrade detail alongside the communal stairwell, which also formed part of the specified works.Local reinforcements were carried out to these details involving taking Protec resin and PolyMat 450 up by 150mm before applying the full waterproofing system.Upon completion, the balustrades were re-painted, with the paint being taken over the waterproofing membrane to create a neat detail. A key advantage of liquid systems in general is their ability to seamlessly seal around complex detailing; in this instance, quite simply, the balustrades could not have been sealed effectively using a traditional waterproofing technology.Polyroof’s Protec System enjoys exceptionally fast detailing speeds, where its formulation allows it to rapidly break down the chopped strand mat reinforcement and neatly moulds around the detail it is covering. To the left of the stairwell, the Protec system was chased in at a height of 150mm above the level of the stairs.The termination point of the waterproofing membrane was sealed with mastic to create a fully weatherproof detail. The Protec system was dressed onto the wall abutments to the main areas but left self-terminated as new render is to be applied to the walls and taken down over the top of the Protec system.After local reinforcements were completed the main waterproofing system was applied to the walkway and stair areas.The two-coat Protec system was able to be rapidly installed with its 30-60 minutes cure times, meaning the project was comfortably ahead of schedule by the time it was complete.Next, the designated anti-slip areas were carefully masked off, leaving the exposed waterproofing to the roof perimeters, detailing and vertical sides of the step and stairs. A third coat of Protec was applied to the masked sections and, whilst the liquid was still wet, 0.7-1.2mm quartz sand aggregate was broadcast into the resin.Once dried, the aggregate is embedded within the membrane and lose sand was brushed off and collected to be re-used. In order to provide an extra-tough surface that sealed that aggregate in place, a coating of PolyFinish was applied over the aggregate in the client’s choice of light grey.

The Rhondda Heritage Park is a renowned tourist destination in South Wales, offering a glimpse into the coal mining community that thrived in the area for over 130 years until the early 1980s. Every year, thousands of visitors take a guided tour led by former colliery workers to experience the life of coal miners.The Heritage Park takes great pride in its appearance and the local heritage it represents. However, the aging asphalt roof terraces that covered the old mine shafts had been leaking constantly, damaging the visual appeal of the visitor site.The ChallengeThe Polyroof technical team was called in to help with the waterproofing and refurbishment of the two roof terraces, measuring over 1100m², that protected the underground mining attraction. After conducting a thorough survey of the roof terrace areas, a customized specification was prepared. This specification included a comprehensive set of recommendations for addressing the issues that had caused the aged and worn condition of the terrace areas over the years. To support the proposal, additional information was provided to the client to demonstrate how a liquid system could seamlessly encase and waterproof the terraces while maintaining an aesthetically pleasing solution that was true to the authenticity of the site.Satisfied that the solution proposed would provide the long-term peace of mind they were looking for, the Heritage Park awarded the contract to RM Polymers Ltd.Before starting the work, any areas affected by fungal growth or moss were treated with Polykill Anti-Fungal Wash to eliminate all spores. Any holes in the asphalt were smoothed out or removed, and levelled using Polyroof Structural Repair Mortar. All large cracks and voids were cleaned and repaired using the same mortar.PVC protrusions were removed and surfaces were cleaned with acetone. Any damaged, loose, or unsound concrete or brickwork was removed and repaired using Polyroof Structural Repair Mortar. All repairs were allowed to cure and dry before priming.The SolutionOne of the main features of the tourist attraction is the mining carts that were used to transport coal around the mine tunnels during its operation. Similar to train tracks, the mining cart tracks are fixed into the ground using metal bolts and fixings which over time had become a weak point for water ingress. Concrete and sandstone had been used as a “quick fix” to prevent rainwater entering the mine shaft below but a long-term solution was now needed. The cement and sandstone was carefully chiselled from the rails, exposing the original metal tracks which were then lifted and abraded back to their original condition. Whilst lifted, the underlying surface was made good before the application of the Protec System. Railway sleepers were then laid on a sacrificial layer on top of the waterproof membrane, upon which the tracks and mining carts were re-instated.As the terraces are constantly trafficked by the general public, the client was clear that an anti-slip finish would be required on any walkway areas.Following the application of the Protec System, Polyfinish and Quartz Sand Anti-Slip was applied to all walkway areas, to provide slip resistance and surface protection. A 50mm margin around the perimeters of the terrace was masked off to provide a neat termination of the anti-slip finish. Ensure masking tape was removed whilst resin was still wet. Then a third coat of Protec Resin was applied at a minimum coverage rate of 0.5Litres/m² (2.0m²/Litre) and whilst wet, clean dried quartz sand (0.7 – 12mm) was broadcast at an approximate coverage rate of 4.0kg/m². Once cured, the loose sand was removed.WorkmanshipThe engine houses along the tour experience featured vast amounts of intricate details and unique items and structures, such as “Bertie and Trefor” – the names given by the mine owner to the mine head stock wheels. This presented an exceptional challenge, particularly in regards to the difficulty of working on the intricate details of the degraded mastic asphalt upstands and decking.As a result of many years of weathering and gravity, the vertical sections of asphalt on the raised terraced roof had slumped and rippled, leading to stress cracks and ultimately water ingress. To overcome this ugly problem, the asphalt was stripped from these vertical sections back to the concrete and removed from site in accordance with the Health and Safety policies in place. The contractor then installed new 18mm OSB3 to these areas to create a flat substrate for the Protec System. The incorporation of Polyroof pre-formed GRP Drip trims at the bottom of the OSB3 ensured the timber would not be exposed to any rain water in the future as well as provide a neat, edge detail.To keep the overall aesthetic feel of the site, the application of the liquid waterproofing system at wall abutments was critical. This, combined with the undulating nature of the stone and brickwork meant that the contractor would not be able to install a cover flashing or termination bar. Instead, the contractor carefully dressed the system onto the wall to the standard minimum 150mm upstand height and into a chase.The edging was then finished with a mortar to provide a neat and clean weatherproof finish, in-keeping with the traditional methods of the site at the time of its construction.The roof terraces that cover the old mining areas also act as the main walkways to the Heritage Centre’s tour routes. Therefore, one of the main challenges of the project was the complex planning of the works to ensure that the site continued to operate so not to financially impact the heritage park. It was imperative that works were complete within an 8-week period with 17,500 visitors booked in for their annual Santa’s Grotto Experience Tour beginning in early December.The application speed of the catalyst cured Protec System, combined with communication between the contractor and the site to ensure unobtrusive installation, meant the centre stayed open and the tours running with minimum disruption.The benefits of using a fast-curing liquid waterproofing solution were also vital due to the ever-changing micro-climate in the Welsh valleys. On any single day, the weather would serve up anything from bright sunshine to windy, rainy conditions. Therefore, the fast-curing Protec System, combined with the flexibility of the installation team, who gave up weekends when required, ensured the project was finished on schedule. The works were completed to an extremely high standard with full encapsulation of the roof terrace areas and without a single detail being left exposed to the elements.ConclusionThe unique aspects of this project certainly kept the team on their toes. But they were determined to complete the project on time.The team worked tirelessly, even giving up their weekends to ensure that the project was completed on schedule. Despite the harsh Welsh weather, they pushed on and were determined to make sure that Santa could visit the children of the Welsh Valleys. It was a challenging project but the team’s hard work and dedication paid off.Finally, the project was completed and the results were astounding. The roof terraces are now fully waterproofed and refurbished, and the visual appearance of the visitor site was greatly improved. It was a project that was both memorable and rewarding to all those involved.

Long standing and rich in history, Rhyl Railway station was opened on 1st May 1848 and was part of the Chester and Holyhead Railway Company’s line. The Station itself is located close to the centre of Rhyl, a lively seaside town on the North Wales coastline and a popular destination for many tourists across the country.As part of a Railway Upgrade Plan, Network Rail have invested £50 million into the restoration of stations across the North Wales Coast. Rhyl was one of the first stations to receive this upgrade and when it was shown that various roofs of the station were in need of restoration.The ChallengeRhyl was one of the first stations to receive this upgrade, and when it was shown that various roofs of the station were in need of restoration, Polyroof was chosen to help restore them to their former glory, and a survey was organised.The specified areas that were in need of refurbishment included the roof over Platform 2 and the bridge walkway roof which connected the two platforms. The existing waterproofing on these areas consisted of built-up felt with a mineral cap sheet, which was in an aged condition and beginning to show signs of failure such as splits and blisters. Leaks were now beginning to occur which were in danger of affecting the condition of the roof structure itself.The SolutionBased on the findings of the survey conducted by Polyroof Technical Services, a bespoke specification was designed that would eliminate the current issues through the installation of the BBA-approved Protec system. Due to the roof being situated above unheated areas, there was no requirement for new insulation within the build up. Firstly the existing built-up felt was stripped and removed from site to expose the original close-boarded timber which was inspected for defects, made good where required and retained where possible. Defective areas where replaced with new timberwork as required. In order to provide a sound, solid substrate a new OSB3 TG4 deck was mechanically fixed across the whole area within a phased approach, ensuring the roof was kept watertight as works progressed.The Protec system was then applied directly to the timber; with its RapidcureTM technology large areas where able to be made fully waterproof within short periods of time. Polyroof Technical Services visited site regularly to ensure works were being completed to the high standards required and regular reports were fed back to the client. Upon completion a final inspection by Polyroof led to the roof being signed off and guaranteed, giving the client complete peace of mind that their roof will be fully watertight for at least the 20 years. Polyroof were proud to be part of this project to restore Rhyl and its Railway station to its former glory.

The Pride development is a £60 million investment which includes a new 122 bed hospital being built on the former Ryhope Hospital site in Sunderland. Laing O’Rourke, the main contractors of this project, specified Polyroof waterproofing systems for the flat roof areas.Barclay Roofing Ltd carried out the works, having previously worked with Laing O’Rourke on the 2013 Roofing Award Winning Durham Gateway Project.The SolutionThe roofs were of a complex nature and involved many details such as vents, level changes, handrail abutments, plant supports, protrusions, stanchion blocks, and parapet walls. It was essential that these details could be waterproofed in the most effective and rapid way possible. Protec, being liquid-applied, was dressed onto the upstands of the details without the need for lengthy and complicated ‘patching’ work, creating a totally seamless interface between the details and the flat roof membrane.The client required designated, permanent walkways for maintenance purposes. Quartz Sand & Polyfinish was used to create a durable and hard-wearing anti-slip finish, without the need for costly ancillary walkway systems. The system is capable of withstanding heavy foot traffic and is impact resistant meaning the client had peace of mind that the walkways can be used without the risk of damaging the waterproofing integrity. Some of the roof areas are to be covered with a green roof system. The waterproofing membrane that was used therefore had to be highly durable, lightweight, fully root resistant and maintenance-free. The Protec System meets all the criteria for use with green roofs and was specified as the ideal solution for the green roof areas.It was essential that health & safety and hazard risks were kept to an absolute minimum during works. Being cold applied and low in VOC content, Protec was able to satisfy the stringent requirements of this aspect of the project.Due to the size of the roof areas, structural expansion and contraction movements had to be considered. Ideally the client wanted a waterproofing system that could accommodate these movements without the need for any additional and potentially costly modifications such as expansion joints. Protec is specially formulated to be highly flexible whilst also maintain its durability and hard-wearing properties.

Working with Williams Roofing Contractors Ltd of Eastleigh, Hampshire, the winning project involved the refurbishment of a large water treatment plant that imposed stringent environmental and performance requirements.The outstanding workmanship and attention to detail by the Polyroof approved contractor during this large scale installation allowed this project to really stand out from the crowd. The below is a case study for this LRWA award-winning project, highlighting the many challenges and how they were overcome through innovation, workmanship and product choice.The SolutionFollowing a survey of the roof area conducted by Williams Roofing and Polyroof Technical Services, a detailed report was carried out after which a bespoke specification was produced and handed to the client. This document detailed a comprehensive set of recommendations for solving the issues that had arisen due to the aged condition of the roof coverings.The client, satisfied that the solution proposed would provide the lasting peace of mind they were looking for, awarded the contract to Williams Roofing Contractors Ltd to install the Polyroof Protec System.There were many challenges on this project as this was a live ‘Clean Water’ environment site, so all Williams Roofing Contractor staff on the project had to have the EUSR National Water Hygiene Cards and be fully inducted by Southern Water’s high standards. Working within these type of environments brings additional Health & Safety implications as the National Water Hygiene scheme is in place to ensure the protection of public health and promote safe drinking water practices. Further risks had to be considered and covered including the risk of working over open water areas with additional buoyancy aids on site to reduce the risks as described under CDM regulations.Williams Roofing Contractors Ltd had to be especially vigilant providing additional protection to ensure that no potential contamination or spills caused any contaminants to the clean water processes/water courses and environment with additional spill kits on hand. Due to the varying conditions of the roof construction(s)/substrates the preparation had to be thought through thoroughly. Certain roof areas needed to be scarified which would have caused reverberations through the roof/concrete deck. This would have possibly created contaminants by spooling of concrete/debris/dust to within the MF Compound Water Lanes/Tanks.

A friendly and welcoming school based in Blackburn in the North West of England, St Stephens Church of England Primary School is a place where pupils can develop their skills in a school that is proud of its Christian values and high standards of teaching. The school has been praised for its philosophy of continuous improvement by a recent ofsted inspection, providing a nurturing environment for children.Continuing the high level of teaching facilities was paramount for the school, and after discovering that the gutters and parapets of the building were aged and leaking, it was vital that a solution was found before this caused issues.The ChallengeIn coordination with Polyroof Products Ltd a survey was scheduled to take place at the site to determine the exact nature of the issues and formulate a solution. Upon inspection it was discovered that the existing waterproofing consisted of a single-ply membrane which had become aged with various leaks being reported and localised repairs carried out with not much effect. The underlying build-up consisted of a galvanised steel metal deck and had been coated in plasticol. Once the survey was complete it was clear that the gutters and capping’s would benefit from a high-performance waterproofing system installation, this would protect from further leaks occurring.The SolutionThe System of choice for this project was Protec Xtraflex. Protec Xtraflex is a highly flexible version of the Protec system designed for coating gutters. Its fast curing technology and imperviousness to standing water fulfilled the rapid solution needed to offer durable waterproofing performance for this project. Taking into consideration the information obtained from the survey, a bespoke Polyroof specification was created to combat all of the issues discovered. The chosen Polyroof Approved Contractor to carry out the work on this project was the KSD Group, a contractor with a wealth of experience in the roofing and construction sector.Once all these aspects were in place, work could officially begin. Firstly, it was highlighted that falls and drainage were already present, so the Polyroof specification made use of the existing falls, combining this with the chosen waterproofing system. During this project, there was no need to strip back any of the existing waterproofing. It was made good where required, allowing a smooth substrate for the new system to be bonded to. Once this stage was complete, the area was cleaned and prepared for the new system by removing any dirt and debris. The Protec Xtraflex system was now ready for installation. Firstly, all surfaces that required it were primed, including the single ply existing waterproofing, which required a Polyroof SP Primer 202. During this installation, all lap joints and bolt heads were applied with Polyroof Butyl Tape and Polyroof Butyl Lap Tape, reinforcing these points before application. Pre-formed high-quality Polyroof drip trims were installed to the outer edge of the metal capping, and new flashings were also installed to cover the exposed insulation at this detail.The first coat of Polyroof Protec Xtraflex was applied to the substrate. This consisted of Xtraflex resin and Polymat 450 and was allowed to cure. Due to the rapid cure technology of the system, this only took 30 – 60 minutes, allowing for quick installation. Once complete, the second coat of Protec Xtraflex Resin was installed and allowed to cure.CompletionThe project was efficiently managed by both the contractor KSD Group and regular Polyroof Technical Services visits to ensure that each aspect of the project from start to finish was carried out within the client’s specification, time frame and budget. The project was a great success showing the high-quality work from KSD Group. The customer can now be confident that this new Polyroof Protec Xtraflex membrane will last for many decades to come.

Teesside University’s Greig Building, named in honour of the founding father of computer science Bill Greig, is the home of the university’s Computer and Mathematical Sciences Studies department. When the aged bituminous roof coverings had shown failures including splits, blow holes and crazing, it was of paramount importance that a waterproofing solution could be provided as quickly as possible to prevent the risk of water damage and disruption.The university’s site maintenance team turned to Polyroof for a solution, which started with a detailed survey of the three roof areas totalling 750m2.The ChallengeCore tests taken at appropriate locations throughout the roof areas demonstrated that the existing warm roof build-ups were free from signs of decay. This meant that the roofs could be retained and over-coated with a new waterproofing system allowing for a rapid, minimal-disruption solution.A bespoke specification was put together based on the findings from the Polyroof Survey Report that provided a comprehensive set of recommendations, including remedial instruction for many problematic roof details. With the peace of mind and satisfaction that the various problems on the roof would be solved through Polyroof’s proposals, the client progressed with a tender process that resulted in a successful application by Polyroof Approved Contractor BBR Roofing Ltd.The SolutionPolyroof’s Protec System, a hybrid polymer liquid system with extremely fast curing and installation times was chosen as the ideal solution for the project. Due to its fully cold-applied application, the works could be carried out during the university’s term times, without having to wait for closure periods between semesters.Works began with the existing asphalt and felt coverings being made good where required, including the levelling and filling of blow holes and cracks with Polyroof Structural Repair Mortar. Next, the surfaces were thoroughly cleaned and degreased to provide a sound substrate for the new waterproofing system.Many of the roof perimeters and junctions featured parapet walls which were identified as a potential point of water ingress during the survey. The inner faces and tops were therefore boarded-over with 18mm Polyroof approved plywood which would allow these details to be fully encapsulated with the Protec System, meaning their waterproof integrity would be covered under the new system’s guarantee. Protec can waterproof vertical areas with the greatest of ease due to its thixotropic formulation, which means slumping and running is minimised during application.Polyroof’s extra-tough GRP trims were then installed to create neat and robust edge detailing for exposed perimeters before the main Protec system application commenced. After priming surfaces where required, the first coat of Protec was applied and reinforced with PolyMat 450. With its RapidCure technology, the Protec can be walked on and over-coated after only 30-60 minute after applications, meaning large roof areas can be made fully waterproofed within a matter of hours.After the second coat of Protec was applied to complete the waterproofing system, designated maintenance walkways were formed through embedding quartz sand aggregate into a third coat of Protec liquid.Completion and InspectionThe refurbishment of the roof was completed within the client’s target timeframe and budget. Following a final inspection by Polyroof Technical Services, which highlighted quality workmanship of BBR Roofing, the client received Polyroof’s trusted Accredited System Guarantee and now has the peace of mind the roof will be leak-free for decades to come.

The Little Chapel in Guernsey was built in 1914 and, at only 16 feet by 9 feet, is said to be “one of the smallest functioning chapels in Europe, if not the world”. The chapel and its unique appeal gained national fame after an article accompanied with a colour photograph was published in the Daily Mirror, and it has since been considered one of, if not the most famous tourist attraction in Guernsey.In 2015, work began to weatherproof the intricate building, with the Protec System specified as the best solution for the job.The ChallengeHaving never been finished by its original builder, Brother Déodat, the chapel has been undergoing a long-term restoration project to create a structurally sound building that retains the beauty of the original vision. Firstly, the foundations were underpinned and properly secured for the first time since they were created over 100 years ago. The next priority was to fix the roof, as described by Pat Johnson, chairman of the Little Chapel Foundation:“The asphalt on the roof was hollow and had to be taken off. The concrete underneath was hollow. We ended up with a substrate of soil and clink, so to repair it we had to go inside and grout all the cracks in the ceiling. [The new roof] comprises three layers of concrete, 340 stainless-steel plugs, a stainless-steel mesh and a final coating of concrete”.The task of making the new concrete surface waterproof fell to local Polyroof approved contractor Sarnian Roofing Ltd. Andy Gavey (Company Director) said about the project:“As a boy I would regularly visit The Little Chapel and I’ve always been blown away by its beauty and character. To get the chance to help restore the building to its full potential is a dream come true for me – this has to be my favourite roofing project yet. Polyroof’s contribution towards the roofing works has meant that we were able to provide a top-quality roofing solution that has done justice to the amazing exterior of the building.”The SolutionWith its ability to be applied directly to the concrete to form a lightweight, seamless and durable waterproofing membrane, Polyroof’s Protec System was a clear choice for waterproofing the chapel roof.The first stage was to make the entire roof area fully watertight. Following a coating of primer to seal the porous concrete surface, the first coat of Protec was applied which incorporated fibreglass reinforcement. After 30 minutes the coating had cured and the second coat was applied to the whole roof area. To areas where new mortar was laid to re-embed the pebbles and seashells, which had been painstakingly removed from the old roof, a coating of Polyfinish was applied to provide extra protection.The architect chose a sanded decorative finish to complement the exterior of the building, which is covered in a mosaic made from seashells, pebbles and broken china. To create this finish, a third coat of Protec was applied and, whilst still wet, Quartz Sand was broadcast into the resin. After brushing off the excess sand, the whole roof surface was sealed with an application of Polyfinish Clear.

Container City is an outstanding example of upcycling architecture in the London Docklands. The buildings are constructed from old shipping containers that have been refurbished and then fixed and welded together, creating an innovative modular building solution that houses offices.The roofs had been waterproofed with an EPDM membrane as part of an inverted roof design, however due to failings within the roof coverings leaks were occurring.It was also felt that the inverted roof insulation was unable to provide satisfactory thermal performance, leading to excessive fuel bills during winter. The architect responsible for finding a solution used Polyroof’s Solution Finder Tool to quickly find a recommendation for improving the thermal properties whilst providing long-term waterproof protection. Equipped with the key information needed, the architect specified the Protec Warm Roof System for the roof refurbishment works.Polyroof Technical Services carried out a full technical survey of the existing roof to identify all existing issues and provide a full set of recommendations. One of the key drivers for the refurbishment was the ability to easily access the roof membrane to carry out regular cleaning and maintenance works, so the specification included for converting the roofs from an inverted roof to a warm roof design.Polyroof Approved Contractor A R Roofing Ltd began by stripping away the old inverted roof components and the failed EPDM membrane to expose the metal roofs of the containers below. A self-adhesive vapour barrier was then laid onto the metal decks and Polyroof RES Insulation (T&G) was bonded on top using PU adhesive. Lastly, the Protec system was laid direct to the insulation boads to create a seamless, smooth and long-lasting finish that came with a 20 year insurance backed guarantee. This striking piece of upcycled architecture now has a roofing solution to match the innovation behind its creation.

At Polyroof, we take pride in providing innovative liquid roofing solutions that meet the unique needs of our clients. From project conception to completion, our expertise lies in creating high-performance roofing systems that offer both durability and aesthetic appeal.This case study highlights our collaboration with Woodholm, a picturesque property located in Southerness, constrained by the Dumfries & Galloway Council Planning’s “room in the roof” design.The SolutionWoodholm’s owners were determined to create a home that would evolve organically while adhering to the council’s planning regulations. To achieve their vision, they enlisted the services of David Lamb Architectural Services to submit a Planning Application on their behalf, seeking approval for a modification from an existing apex roof design to a curved roof. After going through the rigorous process, the application successfully obtained full Planning Committee approval on 14 February 2017.To realise their desired construction, Woodholm’s owners had a preference for using wood and oak, aiming to incorporate these elements into the design. To accomplish this, they collaborated with Carpenter Oak Woodland, a renowned timber construction company known for their expertise in oak framed structures. The company skillfully designed an oak framed structure that perfectly met the owners’ requirements. By mid-November 2017, Woodholm had a stunning and aesthetically pleasing frame in place.However, finding an ideal roofing solution proved to be a challenging task for Woodholm. Initially considering a zinc roof, they encountered obstacles due to the prohibitive costs and the challenges posed by their maritime environment, as Woodholm is located directly on the shores of the Solway Firth. It was at this point that David Lamb’s initial positive impression of a roofing product caught their attention. Woodholm’s owners approached Polyroof’s simulated metal finishes with their needs and were introduced to the Polyroof technical team. The team guided them through the necessary technical specifications to meet the Scottish Building Warrant for a Warm Roof, ensuring compliance with the required standards.Fortuitously, Woodholm’s owners discovered that Polyroof would be exhibiting at the “Homebuilding & Renovating Show” from 21-22 October 2017. At the event, they had the opportunity to meet the Polyroof team as well as Contractor, Kenny Scott of LK Roofing, Lochmaben. The Woodholm team was highly impressed and reassured by the collective experience, knowledge, and technical expertise demonstrated by Polyroof and LK Roofing. Equally important, they appreciated their ability to attentively listen to and understand their concerns.Following the show, a site meeting was promptly arranged with LK Roofing, allowing all parties to discuss the project in detail. As a result, a comprehensive and competitive quotation was provided, falling comfortably within Woodholm’s budgetary requirements.By early December 2017, Woodholm’s joiner had installed the sub-decking, which served as the foundation for the roofing system. LK Roofing then expertly applied the Alutrix membrane, a high-quality waterproofing layer, providing Woodholm with a watertight working cover.Thanks to our collaborative efforts with Woodholm, the project achieved a seamless integration of their desired curved roof design, wood and oak elements, and our advanced liquid roofing system. Woodholm’s owners were delighted with the final result—a beautiful, organically evolving home that not only met their needs but also exceeded their expectations.At Polyroof, we are dedicated to providing roofing solutions that offer both outstanding performance and stunning aesthetics. The Woodholm case study is a testament to our commitment to delivering innovative products and excellent customer service, tailored to meet the unique requirements of each project.

The JG Graves Woodland Discovery Centre is being constructed in the Ecclesall Woods Sawmill as part of the Sheffield Woodlands Environment Enhancement Project.The centre runs craft courses all through the year from cider making to wood work skills. Public events in the autumn and spring celebrate Sheffield’s rich woodland heritage and demonstrates the unique facilities of the centre, as well as providing activities such as story telling, discovering nature and traditional uses of wood in the home and garden.The SolutionThe project entailed designing a center that harmoniously blended with the enchanting surrounding woodlands. The main building featured a grand ‘ski slope’ style roof, initially planned to be waterproofed using metal sheets. However, the client quickly realised that this approach would be prohibitively expensive.To meet the client’s requirements for a cost-effective alternative that maintained the intended appearance, they turned to Charlesworth Contractors—a Polyroof approved contractor with a proven track record of excellence. Recognizing the need for a swift and efficient waterproofing solution, we recommended the BBA Approved Polyroof 185 System with Lead Roll Effect trims.The first step involved fixing high-quality plywood boards onto the roof’s support beams to create the ski-slope shape. This foundation was then enhanced with GRP trims meticulously applied to replicate the appearance of traditional lead rolls. Finally, our renowned Polyroof 185 System was expertly installed, swiftly forming a seamless and highly durable waterproofing membrane.The implemented solution not only met the project’s time constraints but also exceeded expectations in terms of performance and aesthetics. With a 20-year insurance-backed guarantee, our Polyroof 185 system provided the client with peace of mind, assuring long-lasting protection for the roof. Furthermore, not only did our solution prove to be an attractive alternative to metal sheets, but it also offered significant cost savings.The successful collaboration between Polyroof, Charlesworth Contractors, and the client resulted in a waterproofing solution that seamlessly blended into the natural surroundings of the woodlands. Our advanced liquid roofing system, coupled with expert craftsmanship, delivered an outcome that was both visually appealing and economically viable. With the Polyroof 185 System, we demonstrated once again our ability to provide efficient, durable, and cost-effective solutions for even the most challenging roofing projects.

As described by the Woodland Trust, Glen Finglas is a great expanse of ancient woodland, lochs and open heathland, sitting at the heart of Loch Lomond and The Trossachs National Park and home to one of the best examples of upland wood pasture in Scotland.The newly constructed Gateway Building was designed to blend in with the surrounding woodlands and featured a circular timber-clad exterior with a spiralling, curved roof. The Woodland Trust approached RTA Building Limited, a Polyroof Approved Contractor, to provide a guaranteed waterproofing solution that would complement the aesthetics of the building.After comprehensive discussions and careful evaluation, we recommended the Polyroof 185 Warm Roof System for this unique project. This system stood out due to its exceptional BBA 30-year durability rating, impressive life-cycle costing performance, and an insurance-backed guarantee that offered the client peace of mind.The implementation process involved the meticulous installation of the Polyroof membrane, which flawlessly covered the flat roof areas while seamlessly following the curved perimeters and intricate spiral design. To ensure a fully waterproof edge detail that complemented the building’s contours, we installed a bespoke GRP capping. This robust combination provided Woodland Trust with a reliable and long-lasting roofing solution.Through our collaboration with Woodland Trust, we successfully implemented the Polyroof 185 Warm Roof System, delivering a durable, and cost-effective roofing solution. Our system’s exceptional durability rating, long-term life-cycle costing performance, and insurance-backed guarantee provided Woodland Trust with the confidence that they had chosen a roofing solution that would stand the test of time. With Polyroof, Woodland Trust achieved a seamless, reliable, and environmentally conscious roofing solution for their unique project.