Emplas Windows – Sustainable Roof Replacement and Solar Integration
case study
Project Overview
Emplas Windows planned to install a large-scale solar PV system on their main manufacturing facility in Wellingborough. However, a roof condition survey revealed significant deterioration — the existing metal roof sheets were peeling and exposing bare steel, leaving the roof unfit for solar installation.
RDP Cladding’s Solution
Initially, Emplas considered re-coating the roof, but RDP Cladding advised against this due to both environmental impact and long-term performance concerns.
- Environmental Risks: Roof coating requires jet washing to remove loose paint, which allows contaminants and chemicals to enter drainage systems.
- On-Site Chemicals: Applying new coatings introduces various chemical substances to the site, which are harmful to the environment and require strict handling controls.
- Durability: A coating would offer only a short-term cosmetic improvement and would not provide the structural integrity needed to support solar panels.
RDP Cladding recommended a full strip and re-sheet approach. The existing sheets were removed and fully recycled, and a new high-performance roof system was installed with a 30-year manufacturer coating and guarantee. All rooflights were replaced with Man-Safe 30-year service life rooflights, and stainless steel fixings were used throughout to ensure long-term corrosion resistance.
Partnership with Green Revolution Ltd
For this project, RDP Cladding partnered with Green Revolution Ltd, a specialist in renewable energy systems. This partnership allowed the roofing and solar installation to be managed as one seamless package, providing the client with a single point of contact and a fully coordinated service — significantly simplifying the process and reducing project timescales.
During the design stage, Green Revolution came up with a unique idea — arranging the solar panels to spell out “EMPLAS” across the roof. This creative feature turned out brilliantly, creating a striking and distinctive result that looks impressive from a bird’s-eye view and highlights the company’s commitment to sustainability and innovation.
Environmental & Energy Benefits
- 1,558 solar panels fitted
- 613,000 kWh of clean energy generated per year
- 159 tonnes of CO₂ saved annually
Summary
This project demonstrates how sustainable refurbishment can align with renewable energy goals. By working together, RDP Cladding Ltd and Green Revolution Ltd delivered a complete solution — removing an ageing, environmentally harmful roof and replacing it with a long-lasting, solar-ready system that now powers the facility with clean energy.
Details
Project Scope & Challenges
Client: Emplas Windows
Location: Wellingborough
Scope of Works: 3,500 m² Strip and Resheet
Solar Partner: Green Revolution Ltd
This project was led by our Managing Director at RDP Cladding, Robert Peters. If you have a requirement for a project like this, please click the button above and get in touch.
