Previously owned by travel giants Tui, Jetset house was used as a training centre and offices for the travel and tourism company. After being sold to a private company in January 2023, the new owners found that this 56,00 sq. ft building, located on a 2-acre site adjacent to Gatwick Airport, was in need of some renovation work.

Brief

reaching the end of its serviceable life. Alumasc were tasked with providing a cost-effective resolution to renovate this substantial 4000m² roof.

As with all our projects the client is assigned to one of our technical teams, who work closely with them to ensure that we provide the best possible outcomes for their criteria.

After lengthy consultation, and a number of conditional site surveys to understand the buildings requirements, we opted to overlay the existing roof with Alumasc Euroroof Torch-On. By using this proven system we were able to transform the existing roof to safeguard the building against future challenges.

Solution

What is Euroroof Torch-On? Used across all building sectors, Euroroof Torch-On systems are perfect for both refurbishment, new-build roofing and waterproofing projects.

Fully adaptable to meet the criteria of Jetset House, the system comprises of a premium torch applied reinforced APP polymer modified bituminous waterproofing membrane, underlays, insulation boards with air and vapour control layers.

How does it work? The membranes are formulated with a superior APP modification and heavy-duty reinforcement. These components result in a long-lasting waterproof roof that has excellent resistance to puncture and UV degradation. Specifically designed and tested to perform in the most severe conditions, Euroroof Torch-On has a service life in excess of 25 years.

Why was Euroroof Torch-On selected for this project? Due to the superior waterproofing properties and durability of the system, combined with an exceptional 25-year wear warranty, Euroroof Torch-On provided the client with the ability to restore the watertightness of the existing structure, improve the roof drainage, and thermal efficiency of the building.

Challenges

Timescales for completion were extremely important to the client. With 4000m² to complete, time was of the essence. Overlaying vast areas of the roof in a short time frame and within a specified budget, meant it was critical for our teams and our registered contractor, Inspire Contract Services Ltd, to work in tandem.

All our contractors are skilled and fully proficient with the installation of our products, which ensures there is no downtime in terms of training and product awareness. This meant works could start immediately. Additionally, our products are designed with ease of installation in mind, reducing all timescales.

Our relationship with contractor Inspire Contract Services, meant that our collaborative approach kept the client up to date with the progress of the project.

Situated in the picturesque area of Surbiton in Surrey, Edward Pinner Court is made up of 21 one bedroom and 11 studio flats. Facilities at the court include a communal room, laundry room, guest room, walkways with landscaped communal gardens maintained by residents.

The association’s Court Manager Service is an important and integral part of their approach to supporting residents. It is designed to offer support and security to those residents who need it. The service is about promoting and encouraging individuals to maintain their independence in their own home.

Brief

During routine maintenance, it was reported that some of the covered walkways linking the different areas of the site were showing signs of general wear and tear. With remedial works attempted throughout. A concern for the elderly residents. The pitched roof had several leaks and was beginning to show signs of structural issues.

Alumasc were approached to find a solution to the problem. Our technical team got to work. James Cramp Regional Technical Manager said “we used the latest technology available to us and undertook a drone survey to understand the full extent of the pitched roofing works”. We analysed the walkways to propose a solution. James adds “in addition, after a full and detailed investigation, we were able to identify that the existing pitched roof was starting to bow under the strain of the traditional heavy roof tiles. Highlighting concerns over health and safety”.

Solution

Due to Alumasc’s comprehensive portfolio, the team were able to present the client with two products working in conjunction with each other to solve the pitched roofs’ problems.

To ensure the walkways were completely waterproof, Caletch QC Balcony, with its thick, fully reinforced
waterproofing layer and a proven track record of more than 20 years, was the obvious solution.

This high-performance system comprises of a range of rapid curing two-component, cold-applied, reinforced PMMA waterproofing. Solvent free, the product is specifically designed for walkways and terraces over occupied premises. BBA Certified and available in a wide range of colours, textures and surface finishes, the team were able to fully tailor the system to meet and exceed the clients’ expectations.

To ease the structural strain on the building, the team presented Alumasc’s Airtile metal roofing system for the main roof area.

Manufactured from high quality Aluzinc Steel, Airtile Slate is extremely lightweight, in fact 7 times lighter than a traditional roof tile, this component also gives the product excellent long-lasting strength and performance, way above that of traditional materials.

100% recyclable, Alumasc Airtile is a high performing, versatile and elegant looking modern-day version of a traditional slate tile. It has all the characteristics you can expect from a traditional slate tile such as authentic finish and riven edges. However, unlike natural slate, Airtile Slate will not crack, break, chip or delaminate.

In summary, the team, together with the client, were able to select two products which solved the issues with the main roof and walkways, making them waterproof, easing the strain on the structure and providing an aesthetically pleasing and consistent look. With a 20-year warranty, the new revamped walkway can be enjoyed by the residents, plus the client can be confident in the structure for many years to come.

Challenges

As with many of our residential projects, the repairs needed to be completed with minimal disruption to the residents within the building and the surrounding area. Working closely with our approved contractor Inspire Contract Services, who undertook the works to a high level of workmanship, we were able to keep the client updated throughout every stage of the project.

Both products dramatically reduced the contractor’s installation times. Extremely quick to cure, Caletch QC can be waterproof within 30 – 40 mins per coat. Not only reducing the installation times, but it is also perfect for use in the unpredictable British weather.

As Airtile is much lighter than traditional roof tiles, installation times were reduced even further. Unlike moving heavy traditional tiles, Airtile is quick, simple, and easy to install, not only ensuring that deadlines are met, but in addition giving the client and contractors the added cost savings over the lifetime of the building.

Board24 are the largest sheet feeder in the UK, the company supply corrugated board to specification across three locations in England and Scotland. Their impressive manufacturing site is situated on the outskirts of Preston in Lancashire, close to the national motorway network.

Certain areas of their vast manufacturing facilities roof were beginning to suffer from age related wear and tear. Our position as the leading UK based roofing supplier and our network of approved installers appealed to the client, which led to the Alumasc team being approached to find a solution.

Brief

Due to visible age-related damage, the risk of water ingress was a major concern for the client. The client wanted to bring the roof areas back to a condition that was both weatherproof and aesthetically renewed, all whilst avoiding disruption to the manufacturing operations within the factory below.

Upon investigation and extensive survey across the huge 24,000m2 site, the Alumasc team identified several issues; extensive peeling of the plastisol coating, large areas of rusting, cut edge corrosion, and several defective rooflights.

Solution

Alumasc were chosen for our metal roof coating system – Caltech METcoat and Caltech QC gutter system. Both products are subject to the highest levels of certification and testing and with a proven track record they offer up to 20 years of protection, with only minimal routine maintenance required.

Caltech METcoat was also used across the site. Developed for the refurbishment of mechanically sound existing pitched roofs and cut edge corrosion, it was perfect for this project. The product comprises a two component, cold-applied, moisture-triggered modified acrylic/urethanebased resin. Applied in liquid form in two or three coats, Caltech METcoat forms a seamless, durable membrane.

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.

An added benefit to the Caltech range of products is that we can offer an extensive range of colours, offering a true match to any RAL/BS/NCS shade. We were able to present a wide range of colour samples to ensure the aesthetics of the roof were to the client’s approval.

The combination of these products provided the client with a weatherproof and aesthetically pleasing roofing solution, meeting and exceeding their expectations.

Challenges

Due to the sheer size of the project the main challenge was achieving 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.

Our longstanding relationship with our contractor BBR Roofing Ltd, meant that our collaborative approach kept the client up to date with all aspects of the installation.

Battersea Power Station is at the heart of central London’s largest visionary new development. The vast 42-acre site is a former industrial brownfield site, now the home to a community of over 250 shops, cafes, restaurants, theatre, hotel, medical centre and nineteen acres of public space, including 450 metres of river frontage and a six-acre park. The £9bn project sees the creation of a vibrant, mixed-use development including a new office district with over 3 million sq. Ft of commercial space, alongside new private and affordable homes.

Brief

The project design was divided between two architect practices, Foster and Partners and Adamson Associates. Both designs played a key part in the regeneration of zones 3A and RS4 of the Battersea site.

The redevelopment included a residential area and high street, known as The Electric Boulevard, situated south of this instantly recognisable landmark.

The goal was to create a neighbourhood that connects into the historic fabric of the city of London, but one that has its own identity. The architect’s vision was to create a humanistic environment that feels good to live and visit.

Collaboration – A Key to Success

After the completion of several successful projects across London’s iconic landmarks, including the Shard and Canary Wharf, Fosters and Partners and Adamson Associates approached the Alumasc team to provide a single source solution for the whole roofing design.

After careful planning and detailing, two complementary products from our portfolio were the perfect solution to delivering the vision. Hydrotech Hot Melt from Alumasc waterproofing system and our Extensive Green Roof would deliver imaginative design complete with durability.

During the extensive planning stage, our collaborative approach with both architectural teams and our registered contractor VolkerLaser, meant the team resolved numerous complex detailing elements across the varied roof zones. Specifically, the soft and hard landscaped podium, which was the central focus to the design.

Lifetime Performance

With zero failures in over 50 years worldwide, Hydrotech Hot Melt from Alumasc offers lifetime performance. Designed for use across all building sectors, primarily in new build construction, this unrivalled system comprises of a one-component, hot applied, fully reinforced, flexible, self-healing hot melt membrane, a range of bituminous protection sheets, insulation boards and ancillary products.

Subject to the highest levels of certification and testing. This fully warranted, BBA and European Technical Approved system is manufactured to last the lifetime of the structure to which it is applied.

Using 40% recycled content, Hydrotech Hot Melt from Alumasc is applied in a liquid state, complete with a special formulation of refined asphalts and synthetic rubbers for a 100% seamless bond. Therefore, avoiding any chance of water tracking. Its monolithic nature ensures no possibility of lap failures and is ideal for the expansive podium required at the Battersea site.

In addition to its impressive performance, the system requires little maintenance. In terms of installation, it is fast and simple to apply, especially over complex roof details like those at Battersea, so time on site is significantly reduced.

Unlike other methods, the system is extremely versatile, and not weather dependant, it can be laid at extreme temperatures (down to -18°C for winter installations).

An Environment that Considers Our Planet

The architects wanted to provide a humanistic environment that evokes a sense of wellbeing by incorporating landscaping across the roof areas.

Modernistic in its approach, our Extensive Green Roof solution is used for lightweight roof decks, inaccessible roofs, or flat and sloping roof spaces.

With stunning visual aesthetics, the introduction of roof landscaping creates a positive impact to the wellbeing of the users, encouraging social interaction as well as playing a key role in providing a positive environmental impact.

Its lightweight construction and shallow substrate, provides versatile range of planting options, comprising of succulents such as sedum, rockery, and alpine plants, which provide ecological benefits by reducing environmental impact with air purification and the reduction of CO₂.

Easy to install, the Blackdown extensive green roof is different to other systems, as they do not require a permanent irrigation system. Another advantage is that general maintenance is kept to a minimum.

Futureproof Design

The inspiring regeneration of Battersea Power Station, showcase’s the world’s best architects and designs. Creating a unique environment for a vibrant community. A combination of our ground-breaking products, careful planning and a 35-year warranty, together we have delivered a design that will be used and enjoyed by residents and visitors for many years to come.

Located within a bustling part of Bromley, London. Darwin House is a residential cul-de-sac comprising a cluster of apartments within a short distance of Anerley and Crystal Palace.

After residents reported major leaks, which resulted in apartments being evacuated, the Alumasc team were instructed to deliver an urgent solution.

Firstly, the client instructed Alumasc to survey the roof and deliver a recommendation to solve the water ingress issue. Secondly, Alumasc were asked to suggest a suitable fixing method for a renewable energy source in the form of solar panels.

Solution

The Alumasc team identified that water was seeping into the 400m² roof through a number of penetrations, over 95 in total. After a full investigation and consultation with the client, it was agreed that stripping the existing roof back to the deck and re-waterproofing using the Alumasc Euroroof Torch-On system would be the best solution.

Subject to the highest levels of certification and testing, the Alumasc Euroroof Torch-On system is fully adaptable to meet the requirements of this project. This proven solution is used across all types of building applications in both refurbishment and new-build.

The system is not only high performing but also extremely durable. It comes with an impressive 25-year guarantee. This assured the client that our range of products are the very best available.

During the client consultation it was also agreed that Alumasc ProSolar; a nonpenetrative photovoltaic mounting system specifically designed for mounting the proposed solar panels would be included within the specification.

The priority was to make the roof watertight again. Euroroof Torch-On with its premium torch applied reinforced APP polymer modified bituminous waterproofing membrane, underlays, insulation boards and air and vapour control layers (AVCL) solved the issues with the existing roof.

Once the structure was watertight, the team were able to install ProSolar to the newly refurbished roof. ProSolar is a non-penetrative mounting system which can be installed without the need to ballast or mechanically fix into the underlying roofing membrane. Without the need for further ballast, the system adds minimal load to the building. The framing structure consists of 92% aluminium resulting in the system being lightweight, strong and resistant to corrosion.

Challenges

The damage to the original roof was extensive. Stripping the roof back to the deck, fixing 95 penetration points, and the installation of the new system all came with different challenges. As with any residential project, time was of the essence as the residents needed to be back in their properties as soon as possible. Working in close partnership with the client and roofing contractor, the Alumasc team delivered this project in 8 weeks.

High Performance and Durability

The combination of Alumasc Euroroof Torch-on with its high performance and increased insulation properties, together with the installation of Alumasc ProSolar, means the residents of Darwin House can enjoy their homes again with the added benefit of lower energy costs for many years to come.

Galileo Multi Academy Trust are a leading provider of education, recognised for their core values, ensuring each pupil thrives and develops a love for learning. With a family of ten primary schools all in Redcar and Cleveland, each have their own distinctive ethos and character, all with children at the heart of everything they do.

The Galileo Trust have been working alongside property consultants Sanderson Weatherall as part of a Planned Preventative Maintenance programme, to develop the budget requirements for the next 5 years. Alumasc were commissioned to survey five of the ten schools: Galley Hill Primary School, Ings Farm Primary School, Westgarth Primary School, John E Batty Primary School, and The Lakes Primary School. The objective was to identify potential issues with the buildings and propose appropriate solutions.

After a lengthy consultation and survey period, each project came with quite different challenges, however due to the wide range of products available in our portfolio, a solution was found for each of the schools.

Enhanced Environment for Education

Galley Hill Primary School, Ings Farm Primary School, and Westgarth Primary School.

Products: Derbigum Olivine built-up warm roof system, Alumasc Rooflights, ProDrain Outlets, and Alumasc gutters.

In terms of the brief, all three schools were very similar. The trust wanted a watertight roofing solution that was durable and enhanced the environment for the attendees, by increasing access to natural light.

Our technical team surveyed the roofs at Galley Hill Primary School (1,600m²), Ings Farm Primary School (900m²), and Westgarth Primary School (1,275m²), and began to identify areas of failure.

Matty Hyson, Regional Manager for the North & Midlands, Alumasc Roofing, “Our reports advised full removal of the existing waterproofing systems and installation of Alumasc’s environmentally focussed Derbigum Olivine waterproofing solution, alongside complementary rainwater products. In addition to this, Alumasc’s registered contractor installed several new rooflights across all projects to capture as much natural light as possible. The roof at Westgarth Primary School was designed to divert rainwater into ground level water butts for the school to water their gardens and allotments with.”

Derbigum by Alumasc’s most environmentally focussed product is Derbigum Olivine. Olivine (magnesium iron silicate) granules cause a chemical reaction in CO₂ in rainwater which converts it to harmless silicon dioxide (CO₂, i.e., sand), magnesium carbonate (MgCO₃, i.e., inorganic salt) and water. One square metre of Derbigum Olivine will neutralise approx. 1.75kg of CO₂ over its lifetime.

Our technical experts were able to design a solution to meet warranty and quality expectations of the trust. The system provides a waterproofing solution and increases the thermal efficiency of all buildings. With the addition of the rooflights we were able to flood the structures with natural light, creating a bright interior space for the pupils, teachers, and visitors to the school.

Matty adds “We have calculated that the Derbigum Olivine systems will neutralise 2,800kg of CO₂ at Galley Hill Primary School, 1,575kg at Ings Farm Primary School, and 2,231kg at Westgarth Primary School. All projects have a 35-year warranty.”

Another added benefit to using Derbigum by Alumasc is that the system has a life expectancy of up to 50 years and after this time it can be overlaid using Derbigum by Alumasc membranes giving the system a lifespan up to 100 years. The Derbigum Olivine waterproofing solution will help the trust work towards its’ carbon neutral targets. Installing a high-performance waterproofing solution that carries a BBA certificate confirming its’ exceptional service life, means less landfill and no more leaks.”

Challenges

To ensure the trusts maintenance programme ran to specified timescales, we prioritised areas in urgent need of repair to contribute to the trust’s budget planning process. Areas of the roof had to be adapted due to complex detailing and low thresholds.

David Fairley, Partner, Sanderson Weatherall LLP commented, “Over the last 2 years we have worked closely with the Alumasc team to make sure our programme of preventative maintenance runs smoothly for the trust.”

Tim Bethell, Headteacher, Ings Farm Primary School, “The Derbigum Olivine range provides fantastic sustainability benefits for the school, especially with energy crisis at the forefront of our minds, we feel by installing a quality product, this guarantees peace of mind for the academy.”

Once the project ended, in a bid to further the green credentials of the schools, a cherry tree was planted in a project coordinated by Alumasc Roofing, property consultants Sanderson Weatherall and Galileo Multi Academy Trust.

Strength and Aesthetics Combined

John Emmerson Batty Primary School

Products: Airtile and Caltech Alpha

The school required a new roofing solution that was quick and easy to install and gave extra peace of mind with a longer warranty than traditional pitched products.

Working alongside experts in building consultancy Sanderson Weatherall, a pitched and flat refurbishment solution was necessary with the addition of Alumasc rooflights to increase the amount of natural light for the pupils.

David Fairley, Partner, Sanderson Weatherall LLP, “Airtile was the obvious choice for this type of educational refurbishment. Airtile has the advantage of giving a traditional appearance whilst being guaranteed for 40 years against weather penetration. It was a pleasure working onsite with both the Wensley Roofing and Alumasc teams, working on any refurbishment comes with challenges and the regular reporting from Alumasc ensured this was a smooth process.”

Strength and Performance

The aesthetically pleasing Airtile system is a versatile, simple, and elegant modern-day version of a traditional slate tile. 100% recyclable it has all the characteristics of a traditional roof tile with authentic finish and riven edges. However, due to its ground-breaking design, unlike a normal roof tile it will not crack, break, chip or delaminate.

Manufactured from Lightweight Aluzinc Steel (up to seven times lighter than a traditional tile) gives the product excellent and long-lasting strength and performance, far exceeding anything that has gone before it.

Challenges

Critical to the project strategy was ensuring the safe removal of the original asbestos tiles. Wensley Roofing Ltd executed a sound plan to ensure their safe removal and disposal.

James Roy, Quantity Surveyor, Wensley Roofing Ltd, “It’s been over two decades since the use and import of asbestos has been banned in the UK and we see many refurbishment projects like this. Critical to this type of job is designing a safe access point and removing the tiles intact following asbestos removal guidelines, ensuring the safety of the employees and pupils.

Matty Hyson, Regional Manager for the North & Midlands, Alumasc Roofing, “Safe removal of the original roof was a huge component to the success of this project. Alumasc provide a total design service and only work with our registered contractors to ensure the quality and safety of our projects. Airtile and Caltech Alpha worked together as a great combination for the pitched and podium areas. Caltech Alpha was the perfect choice for the school setting because it is an extremely low odour, single component product that requires no mixing and is flame-free.

A Mile of Guttering Waterproofing

The Lakes Primary School

Products: Caltech UV & GRP Trim

Our condition report showed significant areas of failure caused by poor detailing across the school’s internal guttering system which spanned over a mile.

The trust urgently required a quality, non-disruptive waterproofing solution. We were able to design a refurbishment plan using Caltech UV and our range of accessories to minimise disruption to the pupils.

Liam Jackson, Northern Technical Manager, Alumasc Roofing said, “Caltech UV was ideal to give this guttering system an extra lifeline.”

Caltech UV is applied in liquid form in two layers with an embedded reinforcing glass fibre matt to form a seamless, durable, smooth waterproof finish. With 20 years waterproof protection, Caltech UV gave this roof an extended life, meaning no need for a roof strip and therefore less landfill. The product is quick and easy to apply so there was no disruption to the operation of the school.

Challenges

Matty Hyson, Regional Manager for the North & Midlands, Alumasc Roofing, “The application of the Caltech liquid is usually very quick, but we factored in additional time to accommodate the tight details all around this uniquely designed roof.

Sarah Hindmarch, Galileo Trust, “Matty and the team walked us through every step of the process. From the design and specification, a competitive cost breakdown, right through to site support and sign-off.”

Collaboration

Working together with the trust and our approved contractors we have delivered a single source solution across several different projects. All projects come with their own specifications, objectives, and challenges. By utilising our expertise, working with our approved contractors, and applying our groundbreaking product portfolio we can deliver impressive performance, high-tech design, and exceptional customer service to ensure we exceed the expectations of the customer.

Situated eighteen miles north of Birmingham, Lichfield is the home of The Chequers, a housing development managed by Bromford Housing Association. Overlooked by the treasured landmark Lichfield Cathedral, Chequers is set on the edge of a conservation area amongst a city steeped in history, making it a traditional haven amongst the more modern, urban landscape of the surrounding towns. The development at Vernon Street in Ashton-Under- Lyne saw the creation of 23 modern and contemporary apartments. Nicknamed “Cottonopolis” in the 19th century, this modern three storey building was specifically designed to pay homage to the heritage of the local area and recreate the historic Manchester cotton mills from days gone by.

Client Brief

The client sought to futureproof and maximise the lifespan of Sixteen bungalows by converting the existing flat roofs into modern and attractive pitched roofs.

There were two factors of the project that needed careful consideration. The first was location. Due to its location and the surroundings, the aesthetics of the roof needed to be carefully considered. The second was disruption – As residents needed full access to the property whilst work was in progress, it was important to keep any disruption to a minimum.

High Performance and Elegance

After a number of collaborations over several projects, there was no hesitation from Bromford Housing Association when they opted for Alumasc’s Airtile Villa system.

This versatile, simple and elegant modern day version of a traditional slate tile, has all the characteristics you would find from a traditional roof tile with its authentic finish and riven edges. However due to its ground breaking design, unlike a normal roof tile it will not crack, break, chip or delaminate.

Manufactured from Lightweight Aluzinc Steel (up to 7 times lighter than a traditional tile) gives the product excellent and long-lasting strength and performance, far exceeding anything that has gone before it.

Aesthetic Stress Free Installation

Situated on the edge of a conservation area, the new pitched roofs needed to seamlessly integrate with the historical nature of the surroundings.

Bromford and the Alumasc team opted for Airtile Villa – a modern roman style tile, to ensure the character of the building worked with the existing buildings in the vicinity. The team could also achieve a consistent look across the whole site with the ranges extensive choice of accessories and flashings.

Disruption to the residents would be kept to a minimum due to installation times being dramatically reduced compared to traditional installation techniques. The quick and easy installation ensures the job is completed quickly and efficiently, a reason the system is favoured by contractors from all over the U.K.

Long Lasting Strength

A combination of its durability, security and maintenance-free attributes, Airtile slate is made in the U.K and comes complete with BBA certification and 40 years warranty to provide 4 decades of protection against weather penetration.

It’s impressive vandal resistance (0.9mm steel base) and AA classification for Fire resistance is equal to any
traditional roof tiles and slate. The Airtile systems provides added security for the residents within the property in addition to providing the clients with a stress free, cost effective and durable solution to the refurbishment.

To ensure we reduce our footprint on the world the Airtile’s range of roof tiles and systems are 100% recyclable after its life expectancy of 60 years.

Shaun Clewes, Operation Manager from Novus Solutions commented “Alumasc products are innovative and always of the highest quality. Add the teams reliable, professional and supportive service, their collaborative approach to each projects mean we always achieve our goals.

Dan Arrowsmith from Bromford Housing Association “Working with Alumasc is always stress free. We have worked with them on several projects. Their products are world class, and the team are always professional and dependable. It makes us feel very confident in both the company, the products and the service they deliver.

The development at Vernon Street in Ashton-Under-Lyne saw the creation of 23 modern and contemporary apartments. Nicknamed “Cottonopolis” in the 19th century, this modern three storey building was specifically designed to pay homage to the heritage of the local area and recreate the historic Manchester cotton mills from days gone by.

Client Brief

Watson Homes provide sustainable developments, future-proofing social housing schemes for their valued clients. As their preferred supply chain partner, we have worked extensively with Watson homes, producing a detailed specification in-line with their requirements for this project.

Alumasc’s Alkorplan system was a key element in meeting all the requirements needed. A 20-year warranty ensured a technically robust system, with a proven track record of almost 45 years, it is subject to the highest levels of certification and testing. Meeting all current building regulations & guidance.

Due to the local area being well known for its cotton mill industry, the appointed Architects – TADW’s brief was to design a building to “embrace the rich heritage of the area”. The architects impressive roof design, in addition to installing Alumasc’s Alkorplan roof profiles gives the building a pleasing aesthetic finish – replacing the need to use a standing seam roof.

Highest Levels of Certification

Alkorplan is a solution suitable for mechanically fastened applications. Ideal for lightweight fast-track construction, the system is fully adaptable to meet the individual requirements of every project across all building sectors.

The system comprises of a multi-layered thermoplastic 1.5mm PVC-P roofing membrane reinforced with woven polyester, ancillary components, insulation boards & air and vapour control layers. This is a highly effective system with excellent tensile strength and durability. Perfect for residential properties like the Vernon Street development.

Sustainable

The first stage of the installation was to loose lay the vapour control layer, as this would be mechanically fixed into position at a later stage. This mechanically fixed PVC system has the advantage of being easily removed at the end of its life and recycled back into the production to process into new raw material.

Outstanding Performance

The insulation layer was then installed utilising a 200mm Alumasc FF PIR Insulation. This was specified due to the U-Value requirements and its high level of thermal efficiency.

To complete the build-up, the Alkorplan by Alumasc Reinforced Membrane was mechanically fixed in a dark grey colour was installed to compliment the visual design of the project.

Finally, to achieve the desired aesthetic requirements Alkorplan profiles were used to give the appearance of a standing seam roof finish. Creating a stylish and attractive design with substantial cost savings.   

Challenges and Collaboration

This was a challenging yet rewarding project. The roof was designed as an alternative to a traditional pitched roof, using the Alumasc Alkorplan Single-Ply membrane to create a sleek look for a modern build. The roof was finished with Alkorplan standing seam profiles, which complemented the finish perfectly offering an aesthetic alternative to zinc, slate, or tile.

Using our collaborative approach, we worked alongside our approved contractor Enviroply Roofing, who have completed an impeccable job installing the waterproofing with precise placement of the profiles. They overcame the restraints and challenges that come with a multi-pitched roof and the waterproofing was completed in a record time of under 3 weeks.

The result is a high performance, durable, sustainable, and visually appealing building in keeping with the area’s history and heritage, which will be enjoyed by future residents for many years to come.

Bromford Housing Association is one of the largest housing associations in the country. They manage
and maintain more than 45,000 homes spread across central and south west England. They believe in
providing warm, safe and secure homes to their residents in order for them to thrive.

Client Brief

When Bromford Housing Association approached Alumasc to propose a new roof refurbishment to
Bromford Rise, the brief was to provide a complete redesign of six existing low rise blocks of flats. The
existing bituminous roofs had reached the end of their serviceable life and the task was to create a
modern look in keeping with the surrounding area.

Aesthetic Solution

After conducting a full condition survey of the 6 blocks of flats, the Alumasc team identified that a
bespoke solution was required. Alumasc’s Airtile Slate roofing system was the obvious solution.

The system is a high-performing, versatile and elegant looking modern-day version of a traditional slate
tile.

It has all the characteristics you can expect from a traditional slate tile such as authentic finish, riven
edges and is available in a traditional colour finish.

Unlike natural slate Airtile Slate will not crack, break, chip or delaminate through its ground-breaking
design and cutting-edge manufacturing process.

Airtile’s range of roof tiles and systems are 100% recyclable after their life expectancy of 40 years. They are extremely lightweight being manufactured from high quality Aluzinc Steel, giving the product excellent long-lasting strength and performance, way above that of traditional materials.

Challenges

As this is a residential project, the re-design needed to be completed with minimal disruption to the
residents within the building and the surrounding area.

As Airtile Slate is up to 7 times lighter than traditional roof tiles, installation times are dramatically reduced. Its quick, simple installation gives the client and contractors the added cost savings over the lifetime of a building.

Due to the location of the site, aesthetics were of great importance, a traditional slate look was opted
for and with an extensive range of accessories and flashings, the Alumasc team were able to provide a
consistent look across the whole of the building.

Dan Arrowsmith from Bromford Housing Association “Working with Alumasc is always stress free. We
have worked with them on several projects. Their products are world class and the team are always
professional and reliable. It makes us feel very confident in both the company, the products and the
service they deliver.”

Daniel Grant, Area Technical Manager for the Midlands “A great project to be involved in and a credit to
the whole team delivering another successful flat to pitch project.”

Futureproof

A combination of its durability, security and maintenance-free attributes, Airtile slate is made in the U.K.
and comes complete with BBA certification and 40 year warranty to provide 4 decades of protection
against weather penetration. It’s impressive vandal resistance (0.9mm steel base) and AA classification
for fire resistance is equal to any traditional roof tiles and slate. The Airtile systems provide added security
for the residents and in addition, provide the clients with a stress free, cost effective and durable solution
to the refurbishment.

Standards and Service

Manufactured in accordance with ISO 9001:2015 and ISO 14001:2015, Alumasc offers a comprehensive range of options. Installed exclusively by Registered Contractors and underpinned by Alumasc’s extensive project support service.

Project Data:

Project: To deliver a 2,500m² flat to pitch conversion
Products: Alumasc Airtile Slate
Performance: Aesthetically pleasing, recyclable system with a 40 year warranty

Pen-Y-Dre High School Becomes First Carbon Neutral Refurbishment School in Wales.

Renowned for its high standards of discipline, behaviour and achievements, Pen-Y- Dre High School is
Merthyr Tydfil’s award-winning education centre. The school caters for the educational and development
needs of 800 pupils aged 11-16.

Set in a beautiful green campus, Pen-Y-Dre is famous for its outstanding academic and sporting facilities.
The schools extensive site can accommodate a variety of activities including a full size swimming pool.
Pen-Y-Dre High School is more than an educational building, it is at the heart of the local community, and
is used by many groups outside the traditional school day.

When Pen-Y-Dre High School were looking to refurbish their buildings, they approached Jim Allen award
winning Architectural Service Manager at Blaenau Gwent council, looking for a long-term solution to
update their site.

Client Brief and Design

Building lasting relationships is important to Alumasc, and this project is testament to that. After
collaborating on several successful projects, Jim approached the Alumasc team to survey the roof area
of the site, with a view to providing a durable and green proposition.

After an initial survey of the roof, our team agreed that to meet the clients brief, Alumasc’s Derbigum
Olivine system was the best option. Not only would it meet the need for longevity and durability with its
35 year warranty, the system would substantially reduce CO₂, assisting in making Pen-Y-Dre the first net
carbon High School in Wales.

The First of its Kind

Calculations carried out by the team demonstrated there were several benefits to the Derbigum Olivine
system compared to a traditional felt roof. This environmentally friendly roofing system neutralises CO₂
via an irreversible chemical reaction when it comes into contact with rainwater. Its proven performance
means that 1m² of olivine has the capacity to capture approximately 1.75kg of CO₂.

The teams’ calculations highlighted the U value of the current roof was very poor. Installing the Derbigum
Olivine system would improve the performance to 0.1, increasing the efficiency of the construction,
keeping heat flow through the structure to a minimum, therefore reducing the school’s energy costs.

With these calculations alongside a 35 year warranty, the proposal was instrumental to secure funding
for the new refurbishments to Pen-Y-Dre High School, helping the school deliver their vision to become
carbon neutral.

Technical Information

Alumasc’s innovative roofing system comprise a premium CO₂ neutralising reinforced APP polymer
modified bituminous waterproofing membrane, underlays, insulation boards, with air and vapour control
layers.

Surfaced with a naturally occurring mineral upper layer, this layer initiates a chemical reaction with CO₂
from rainwater, irreversibly neutralising the pollutant on contact.

The Olivine granules cause a chemical reaction in CO₂ in rainwater which converts it to silicon dioxide
(sand) and magnesium carbonate, two products harmless to the environment.

Complete with BBA certification, Derbigum Olivine is a fully warranted system with a life expectancy of up
to 50 years. Although the olivine grains decrease in size with each reaction, the grains are large enough
to span an impressive 30 years before having completely reacted. Not only is the system durable, it is
sustainable, as the membranes used are 100% recyclable.

Long Term Relationships

We pride ourselves on building strong relationships within the industry. Our clients trust us to deliver on
our promises. Having worked with Jim Allen and Morgan Sindall on previous successful projects meant
they knew they were in a safe pair of hands. Construction of the site is being completed whilst the school
is still in operation. Together with the contractors the Alumasc team are supporting the build to ensure
minimum disruption to the school’s activities.

As part of the Alumasc Roofing service we offer transparent quality checking and timely site reporting.
We are always on-site to assist clients before, during and after the installation.

All projects come with their challenges but a roofing supplier’s ability and willingness to tackle them in
collaboration with the client and contractor is of key importance to Alumasc Roofing.

Project Data:

Project: To deliver a 7,000m² sustainable roofing system
Products: Derbigum Olivine
Performance: CO₂ neutralising capabilities, improved U value with a 35-year warranty