Case Study

Theatre Clwyd

Flat roof refurbishment.

Client / Main Contractor
Gilbert Ash Ltd.
Location
Mold, Flintshire, North Wales.
SectorCommercial.
Roof Area (approx)4000m2
Scope of Works

Full flat roof replacement across multiple roof areas combining different roof build ups.

Technical Details

System InstalledProteus Ultima RBM felt warm roof system.
ComplianceInstalled to NHBC, BS 6229 / BS 5534, Safe2Torch, and manufacturer specifications.
WarrantyProteus 20 year Guarantee.

Build-Up / Specification

  • Deck – mixture of new ply and existing concrete
  • Primer – Protues SA primer
  • VCL – Proteus SA sanded VCL
  • Insulation – mixture of different PIR schemes inc: 80mm overlays, 2 layer 170mm flat systems and tailor made cut to fall schemes

Challenges & Solutions

  • Large scale refurbishment of the full building, working around and alongside multiple different trades constantly required permanent high quality levels of communication with the PC and other trades.
  • Weather constraints – had to deal with the constant bad weather and rain of north wales inc high winds and snow during both winters spent there.
  • Complex detailing at roof junctions throughout the whole roof due to many variations of roof interfaces and different levels of adjacent roofs – had to work closely with the manufacturer and PC with the help of our knowledge to overcome copious amounts of complex details.
  • Restricted access requiring scaffold and again different levels which made it difficult for loading out materials etc – combination of elevated manpower when needed, working closely with PC and scheduling deliveries and offloading with on site telehandler to assist and use of mobile cranes when needed.

Outcome / Results

  • Delivered on time and within programme.
  • Fully warranted system signed off by manufacturer.
  • Improved thermal performance and drainage.
  • Client satisfaction / positive feedback.