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. Their position as a 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 their 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 they can offer an extensive range of colours, offering a true match to any RAL/BS/NCS shade. They 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.

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