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

Macmillan Academy Adds Another Green Initiative.

Set up as a City Technology College in 1989, Macmillan Academy strive to improve the economic prospects and social opportunities for the 1600 pupils who attend. Registered as an Eco-school over 15 years ago, Macmillan Academy are committed to reducing carbon emissions and waste. Their aim to develop an awareness of the issues around sustainability is a key value at the very heart of the academy’s mission statement.

Located in inner city Middlesborough, the Academy is one of two sites monitoring air quality across the area. Working in conjunction with Middlesbrough council, automatic monitors measure pollutants associated with road traffic activities and the site was selected due to its proximity to the intersection of the A66 and A19.

As the government looks to tighten its commitment to reaching net zero carbon by 2050 – and local authorities declare climate emergencies, Macmillan Academy approached Faithful & Gould consultants to help secure funding via the CIF on behalf of Endeavour Academies Trust. The brief included procurement and project management of the build to help deliver a sustainable solution to future proof Macmillan Academy’s buildings and support their green initiatives.

Client Brief

As part of the application for funding, Faithful & Gould needed to evidence the condition need for the roofs’ replacement and demonstrate value for money, in line with The Department of Education’s minimum standard of quality and warranty requirements.

The Alumasc technical team conducted several site visits to assess the full extent of the project. A full survey was carried out and core samples were presented to the client. The investigation resulted in a comprehensive report that recommended a full refurbishment using Alumasc’s Derbigum Olivine roofing system. The report concluded using this system would meet and exceed the requirements of the clients brief.

A Sustainable Solution

Sustainability and value were at the heart of this project. By recommending the Derbigum Olivine system, first and foremost CO₂ emissions associated with the academy’s location would be dramatically reduced. Secondly due to its underlays and insulation, energy efficiency would be increased reducing energy costs, and finally Derbigum Olivine would exceed The Department of Education’s minimum quality and warranty standards. The proposal would provide maximum long term performance and a low maintenance solution going forward.

Alumasc’s innovative roofing system comprises of a CO₂ neutralising APP/TPO plastomer modified, composite reinforced bituminous waterproofing membrane, underlays, insulation boards, with air and vapour control layers.

The system is surfaced with a naturally occurring mineral upper layer that initiates a chemical reaction with CO₂ from rainwater, irreversibly neutralising the pollutant on contact.

This chemical reaction converts to silicon dioxide (sand) and magnesium carbonate, two elements harmless to the environment. When rainwater rolls off the roof and reaches the drains, it’s totally carbon free. The system demonstrates innovation in construction industry science at its finest!

Its proven performance means that 1m² of olivine has the capacity to capture approximately 1.75kg of CO₂. In addition to Derbigum Olivine’s CO₂ neutralising capabilities the Alumasc underlays and insulation boards deliver impressive energy savings. It was estimated that the new Alumasc roofing system would deliver a 26% reduction of annual gas consumption for the Academy.

Derbigum Olivine complete with its BBA certification, is a fully warranted system that requires minimal routine maintenance with a life expectancy of up to 50 years. The olivine grains decrease in size with each reaction, however the grains are large enough to last 30 years before having completely reacted. In addition, membranes on this innovative roofing system are 100% recyclable.

Challenges

Matty Hyson Alumasc Regional Manager North and Midlands commented “Updating this huge 3,500m² site without disruption was a challenge. Mid programme the scope of works were altered to mitigate time and costs. Our team supported the changes, attending the site at short notice. By conducting a significant amount of core analysis, we were able to confirm the changes were appropriate and ensure they were delivered on time.”

Collaboration for a Green Future

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.

Sarah Foster Faithful & Gould Senior Surveyor – “Alumasc’s service is exemplary. They support at all stages of the project from survey/conception through to post completion/warranty works. They are always looking to improve their service and never try ‘the hard sell’ – their service and product speaks for itself, no need to convince. Their team is always available to assist no matter how short the notice, with some clearly highly experienced team members in the industry.”

Chris Bott Everlast Director “This is another key education project completed with Alumasc. Again Alumasc and our delivery team have worked together to ensure the client has received a quality installation to maintain their building assets for long term sustainable future.”

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 and warranties.

Winner of the NFRC 2022 Scottish Roofing Awards – Reinforced Bituminous Membranes.

The best of roofing projects in Scotland were celebrated at the NFRC Scottish Roofing Awards on 28th
October 2022 at the Grand Central Hotel in Glasgow. The judges rewarded standout projects for quality
workmanship, innovation, strong supply chain management and impressive responses to challenges on
the project.

The Diamond Offshore Drilling project came first place in the Reinforced Bituminous Membranes
category, for its impressive example of technical innovation to find a solution for the client.

Project

Alumasc Roofing was selected to carry out a full roof refurbishment at the Scottish headquarters of
contract drilling services provider, Diamond Offshore Drilling. The site comprises offices contained within a two-storey building topped by a metal roof which had become severely corroded. This compromised the roof’s insulation, with other issues such as excessive leakage, major condensation and poor termination at drainage points resulting in disruption to day-to-day operations for office staff. As a matter of urgency, the client required a roofing solution that irradicated the risk of water ingress and condensation whilst improving the building’s overall thermal performance. Thanks to the company’s decades of experience in supplying roofs that meet a range of complex requirements, Alumasc Roofing had the ideal solution.

Innovative Design

The 1,200m² roof’s complete redesign was necessitated by the existing system’s severe corrosion and
failure. The client, considered numerous replacement options, including over-sheeting the building with
a metal roof and providing a painted finish. In conclusion, Alumasc Roofing devised a hybrid option that
was fairly unique in its methodology, and comprised a plywood frame overlaid with Alumasc’s Euroroof
Mono bituminous system. This built-off-frame solution was seen as the most credible design in terms of
robustness, the thermal outcomes it facilitated and the time and cost-effective speed with which it was
delivered.

Installation Benefits

When it came to the installation, the existing roof was overlaid with a new structural timber deck. This
was mechanically-fixed to steels below the existing metal roof, allowing the installation of the new,
bituminous roofing system from Alumasc Roofing. The benefit of this option meant that the air and vapour control layer (AVCL) could be installed directly to the timber deck; thus providing immediate waterproof protection to the structure.

Alumasc’s GTF PIR Insulation was PU adhered to the AVCL in a single layer built-up roofing system. The
Alumasc Euroroof Mono cap sheet was also bonded in PU adhesive and hot air gun-welded at all
termination points. Detailing to the roof was achieved using Alumasc’s Euroroof Self-Adhesive Underlay
and Euroroof Self-Adhesive Cap Sheet.

Sustainable Option

The roofing system was installed totally flame free, mitigating the risk of fire and resulting in a low-energy
application. In addition, the roofing solution has a proven life expectancy in excess of 25 years and after
this period, it can be overlaid with another waterproofing layer to give the roof an additional lease of life,
this eliminates the need to send the existing system to landfill.

Assurance

Alumasc Roofing’s design and technical expertise was integral to the successful roof refurbishment works
at Diamond Offshore Drilling. The system itself came with a 25-year system warranty, adding to the client’s peace of mind that their new, hybrid solution will keep their flagship office building warm and dry for many years to come.

Project Data:

Completion: June 2022
Building Type: Commercial
Product Application: Euroroof Mono & Euroroof Self-Adhesive
Approvals: BBA Certified & Fire Classification of Broof (t4) in accordance with BS EN 13501-5

Alumasc Replaces 13-Year-Old EPDM Roof Short of its Declared Lifespan

Since 2004 upon what was once Belfast City’s Gasworks, overlooking the River Lagan, James House has
been home to office accommodation for various government agencies. Originally complete in the early
aughts on a historic brown field site during the population and housing boom, a mere two decades later
the building is part of a major initiative to upgrade and modernise for the next technological office age.

Bespoke Roof Condition Report

Technical re-design service included the most suitable waterproofing – incorporating efficient drainage and thermal performance. Full strip and replacement of the existing EPDM roof.

Derbigum sustainable flat warm roof system. Full capabilities including carbon cleaning technology, and 40 years+ lifecycle.

Sustainable warm roof performance includes:

• BROOF (t4)
• BBA system certification
• 35-Year system warranty
• Olivine waterproofing resulting in neutralising 3,500kg of CO₂

Client Brief and Design

Alumasc Roofing’s Site Technician team explained, “The core sampling showed 4 inches of saturated insulation, rucking, and insufficient upstand heights. The membrane was found to have had an inadequate fixing pattern to the loose laid EPDM membrane. The termination to the existing roof outlets was also a major contributing factor to the failure of the total roof system. Along with wear on the rainwater outlets, cracking, blistering, and distortion, all contributing to the significant failure of the original waterproofing.”

Working closely with the Kennedy Fitzgerald Architects, Alumasc Roofing technical experts were able to design a solution to meet the key longevity, warranty, and quality expectations of the client.

“Given the immediacy of the roof failure our report advised a full roof strip of all existing roof covering back to the concrete structural deck. This allowed full access to the concrete deck for structural repair work to the defects caused by the original waterproofing system. This allowed the new sustainable warm flat roofing system to be installed efficiently and incorporating a full high performing AVCL to the structural deck. This system was completed with a full cut to falls insulation design improving the drainage strategy and thermal performance. The warm roof system was completed utilising 2-layer BUR waterproofing, consisting of Hi-Ten Universal underlay and environmentally focussed Derbigum Olivine cap sheet.”

Challenges

• Re-design of current drainage positions (both internal and external)
• Thermal upgrade to meet current building standards
• Tying in with existing building envelope
• Working in close proximity of live railway network
• Meeting current fire regulations

Environmentally Focussed Solution

Derbigum by Alumasc have a full range of environmentally focussed product ranges. Derbigum Olivine is an APP polymer modified bituminous waterproofing membrane, with underlays, insulation boards, and air and vapour control layers (AVCL). CO₂ neutralising, with a composite glass fibre high tensile polyester core and magnesium iron silicate (olivine) grain finish.

Over the next 35-years the 2,000m² roof could potentially absorb 3,500kg of CO₂.

Project Data:

James House is a five-storey office block located in the Gasworks, Cromac Avenue, Belfast. Full refurbishment works were completed in 2022.

Architect: Kennedy Fitzgerald Architects
Main Contractor: Tracey Brothers Ltd
Alumasc Registered Roofing Contractor: McCaughey Roofing & Cladding

Heslington East Campus Student Residences: Sustainable and Efficient Expansion

Goals

Architects Sheppard Robson alongside Graham Construction sought to futureproof accommodation by incorporating multi-use buildings, including catering outlets and social hubs. Key to the brief was using the latest in safety, energy efficiency, longevity, and warranty credentials. Graham Construction’s use of modular external sandwich panels, prefabricated steel bathroom pods, and pre-assembled services distribution racks used Modern Methods of Construction with off-site construction techniques.

Challenges

The major challenge was to specify a roofing system that could keep up with the pace of the build, given the typical building was constructed from start to finish in circa 14 weeks.

The roof deck comprised of precast concrete slabs which facilitated the works programme for speed of construction and consistency in build quality.

Alumasc’s challenge was to find not only a waterproofing solution that was able to keep up with such speed of construction but also to meet a truly sustainable life cycle equalling the lifetime of the building.

A key consideration in the design was the roofing materials’ thermal properties. To meet the u-value target of 0.15, Alumasc’s XPS Plus insulation was specified, providing a single layer of 175mm, which reduced the height of the overall build-up when compared traditional XPS.

Solution

Hydrotech 6125 Waterproofing System / Derbigum Hybrid Upstands

For over half a century Hydrotech Monolithic Membrane has been successfully used by architects and specifiers, ensuring some of the world’s most prestigious buildings and structures are kept watertight. With no product failures in over 50 years and guaranteed waterproofing integrity for the lifetime of the structure, Hydrotech offers a total life cycle solution for the building.

Hydrotech was specified on the main roof areas for this project as it easily meets individual requirements of the buildings. In addition, the system is designed to last the lifetime of the building or structure to which it is applied, giving long-term waterproofing integrity and no future replacement costs.

Applied in a hot liquid state to the deck, and including a polyester reinforcement, the bond of Hydrotech MM6125 is 100% absolute. There is no risk of water tracking below the membrane and because it is monolithic, no possibility of lap failure.

Derbigum Waterproofing

Derbigum sustainable roof system was selected for the upstand areas. This hybrid solution was developed to improve the thermal efficiency in all areas to mitigate against cold-bridging with minimal insulant thickness. Derbigum bituminous membranes are high-performance waterproofing systems offering extended warranties and the highest levels of project support. The upstand zones benefited from Derbigum Mineral which is a mineral surfaced composite reinforced membrane.

Rooftop Management Strategy

In addition to the waterproofing solution the buildings benefit from the full Alumasc rooftop management service. This included the design and supply of safety systems, accessories, and over 20 AOV smoke hatches meeting all British and European standards.

Specific safe zones were designed by Alumasc Roof-Pro and positioned around all roofs for safe access. Purpose made clips for installing lightning conductor tape without roof penetration were also provided. All rooftop accessories are part of the Alumasc Roofing specification and therefore can be found back-to-back within the Alumasc 35-year system warranty.

Project Data

Completion: Autumn 2022

Building Type: Student Accommodation

Product Application: Hydrotech & Derbigum waterproofing systems

Certification: BBA Approved & European Technical Approval

Architect: Sheppard Robson

Main Contractor: Graham Construction

Alumasc Registered Roofing Contractor: Tandragee Roofing

Scotland’s Largest Single Office Building with Rooftop Running Track and 360 Panorama.

A Sustainable and Futureproof Roof, Harnessing the Power of the Outdoors

Bothwell Street in Glasgow is now home to an exceptionally progressive office space – making way for
a new chapter in the rich history of the area. If there are any doubts about what Grade A office space
really means, then think touchless entry, bike storerooms, lux changing facilities, an 8,000 sq. ft roof
terrace, a 150-metre rooftop running track, 4 activity zones/terrace spaces and panoramic views.
The project complements the sustainable regeneration programme along the Clyde Waterfront also,
home to the new financial Northern European hub, firmly cementing the business district at the heart of
modern Glasgow

Goals

The architects at Sheppard Robson have made sure sustainability and lifecycle credentials remain
central to the design specification. Occupants’ wellbeing has been carefully considered with a stunning
panoramic rooftop and 150m running track and general outdoor employee wellness facilities.

A roofing solution was required to support the lifecycle of the building along with an excellent
product reputation for this distinguished office space. Given the quality, longevity and environmental
considerations required from the roofing design, the insulation properties and warranty performance
were extremely important from the outset.

Challenges

Our Technical department assisted the architectural and construction teams to resolve numerous
complex design elements across the varied roof zones including running track, ballast walkways, green
zones, and pedestal zones, to determine the best roofing solution.

Installation of the Davit Arm System for a building of this scale was especially important so personnel can
be safely suspended whilst working at height. This presented us with a unique challenge in providing a
workable solution that aligned with the sequence of works, whilst facilitating future routine inspection of
its base plates, and maintaining waterproof integrity without compression.

Careful planning and detailing were required around roof penetrations to minimise aesthetical impact,
and roof equipment was safely installed above the roof assembly.

Solution

The construction comprises a composite concrete slab receiving our Hot Melt Hydrotech Waterproofing System. Offering a true lifecycle – Hydrotech high performance waterproofing, through its’ unique characteristics and installation process, now forms part of the building fabric. The result offers complete watertightness for the lifetime of the building.

The building is also insulated to a high u-value target offering exceptional thermal performance and achieving a high kPa rating. This was essential to receive loadings from all components including
overlying finishes, roof equipment and the end use for the building occupants.

Key fire performance standards were achieved throughout including the lift overrun and lower roof terrace areas where the preferred solution was switched to our Derbigum sustainable warm roof system to maintain project performance targets.

Lifecycle Management

Designed with BREEAM credentials and an EPC rating coming in at below 10 the careful focus on lifecycle
considerations and the choice of materials throughout the building envelope is exemplary.

Hydrotech hot melt is a high-performance solution containing 30% recycled content and zero product
failures in over 50 years, offering lifetime peace of mind, designed for the service life of the roof.

Project Data

Completion: Autumn 2022

Building Type: Commercial Office

Product Application: Hydrotech & Derbigum waterproofing systems

Certification: BBA Approved, European Technical Approval & FM Global Class 1

Architect: Sheppard Robson

Main Contractor: HFD Group