Industrial Roof Overclad for IGUS UK, Brackmills

IGUS UK had been dealing with ongoing water ingress across approximately 2,400m2 of industrial roofing at their Brackmills site in Northampton. The roof incorporated rooflights and a siphonic gutter system.

Two previous attempts had already been made to stop the leaks. The entire roof, including the rooflights, had been treated with a liquid roofing system, and the gutters had been overlaid with a single ply system. Both solutions were failing and water was still getting into the building.

The gutters presented a further problem. The previous overlay had been installed without the specialist outlets a siphonic system requires, which meant the gutter system had never been correctly adapted to work with the building’s existing siphonic drainage.

Following a detailed survey, RDP Cladding developed a complete overcladding and gutter refurbishment solution designed to address the underlying problems rather than repeat the earlier repairs.

The existing 40mm composite roof system was retained and upgraded with an additional 200mm of Cladroll insulation. Combined with the thermal performance of the existing composite roof, the upgraded build up achieved the U-value required to comply with current Building Regulations.

An Ash & Lacy grid system was installed and mechanically fixed through the existing roof construction directly into the existing purlins, providing the supporting structure for the new overclad roof.

New outer roof sheets were then installed with a 30-year coating warranty, giving the building a completely renewed and durable external roof covering.

The existing rooflights were overclad rather than replaced. New 30-year non-fragile rooflights were installed as part of the new overclad roof system, improving both long-term performance and safety.

The existing gutters were refurbished using a Sharmans Plygene gutter lining system with a 25-year warranty, complete with specialist outlets designed specifically for siphonic gutter systems. This allowed the building’s drainage to operate as it was always intended to.

A full perimeter scaffold handrail system was installed to provide continuous edge protection throughout the roofing works.

Sacrificial safety netting was laid over the existing rooflights and left permanently in place before the new rooflight system was installed, providing additional protection to these areas as part of the completed roof build up.

If you have a roof that keeps leaking despite previous repairs, it is worth having it looked at properly before spending money on another coating. Get in touch with the RDP team to arrange a free site survey and we will tell you honestly whether an overclad is the right answer for your building.

RDP Cladding delivered a comprehensive refurbishment that addressed the recurring water ingress and rectified the shortcomings of the previous repair works.

The completed project provided IGUS UK with a fully overclad and thermally upgraded roof, combining the existing 40mm composite construction with an additional 200mm of insulation to meet Building Regulations thermal requirements.

Alongside the 30-year warranted external roof sheets and the 30-year non-fragile overclad rooflights, the Sharmans Plygene gutter lining system with purpose-designed siphonic outlets gives IGUS UK a robust, long-term solution built to protect and improve the performance of the building for years to come.

The new roof sheets carry a 30-year coating warranty and the refurbished gutters are covered by a 25-year Sharmans Plygene warranty, so the client has long-term cover across both the roof covering and the drainage.

RDP Cladding hold SMAS Worksafe accreditation and provide full project documentation as standard, including Risk Assessments and Method Statements and O&M manuals. For a refurbishment of this size, that documentation matters as much as the workmanship when it comes to compliance and future property records.