Leading applicator of specialist coatings for the refurbishment of commercial properties across the UK
When a commercial roof begins to show signs of age, refurbishment can often provide a more practical and cost-effective alternative to replacement. At 4 Newopaul Way, Warminster Business Park, Cladding Coatings Ltd delivered a complete roof renewal solution featuring a new Mansafe system, replacement GRP rooflights and a 30-year Alltimes Graphene coating system, providing enhanced safety, improved weather resistance and decades of ongoing protection for the property.
The Challenge with this Refurbishment
The client was responsible for maintaining a large commercial facility with a roof that was beginning to show signs of age-related deterioration. While the roof structure remained fundamentally sound, the external surface required protection from further weathering and environmental exposure.In addition, the property’s existing roof access arrangements required improvement to ensure ongoing maintenance could be undertaken safely. The original rooflights were also approaching the end of their serviceable life and no longer provided the level of performance or safety expected from modern roofing systems.
Addressing Cut Edge Corrosion
During our detailed roof survey, signs of cut edge corrosion were identified across sections of the existing metal roof. Cut edge corrosion is a common issue on ageing coated steel roofing systems, occurring when the protective factory-applied coating at the sheet edges begins to deteriorate, exposing the underlying galvanised steel to the effects of weathering and oxidation.
If left untreated, cut edge corrosion can progressively spread beneath the roof coating, leading to further deterioration and potentially shortening the service life of the roof system.
Fortunately, the selected 30-year Alltimes Graphene Roof Coating System incorporates specialist preparation and treatment procedures designed to address cut edge corrosion as part of the wider refurbishment process. By treating affected areas before the application of the graphene coating system, the roof’s vulnerable edges were encapsulated and protected within the seamless waterproof membrane.
This integrated approach allowed the client to resolve existing corrosion issues while simultaneously benefiting from a complete roof restoration system, eliminating the need for separate remedial works and helping to maximise the long-term performance of the refurbished roof.The client wanted a solution that would:
Extend the operational lifespan of the existing roof.Improve weather resistance and waterproofing performance.Upgrade roof safety systems.Replace ageing rooflights.Minimise disruption to day-to-day operations.Avoid the significant costs associated with complete roof replacement.
The Refurbishment Solution
Following a detailed site survey and assessment, Cladding Coatings developed a comprehensive refurbishment package designed to address both the roof’s condition and the site’s ongoing safety requirements.
The project included the installation of a new roof safety system, specialist access equipment, replacement rooflights and the application of a premium graphene-enhanced roof coating system.
New Mansafe Fall Protection System
A key element of the project was the installation of a new Mansafe system across the roof area.
The roof-mounted safety system provides secure anchor points and continuous protection for future maintenance personnel working at height. The upgraded system enables safe access for inspections, cleaning programmes and maintenance activities while helping the building owner meet their responsibilities regarding work-at-height safety requirements.
By incorporating a modern safety solution into the refurbishment programme, the client has significantly improved the long-term accessibility and maintainability of the roof.
Specialist Access Equipment
To ensure safe and efficient project delivery, the refurbishment programme included:
Scaffold access tower installation.
Scissor lift hire.
Cherry picker hire.
Specialist working-at-height equipment.
The combination of these access systems allowed our operatives to safely reach all areas of the roof while maintaining high productivity and strict adherence to health and safety standards.
Rooflight Replacement Programme
As part of the refurbishment works, Cladding Coatings carried out a full replacement of the existing GRP rooflights.
The project involved removing the top skin of all existing rooflights before supplying and installing 24 new GRP rooflights on a like-for-like basis.
The new rooflights were carefully fitted using new fixings and sealants to ensure long-term weatherproofing performance. Importantly, the replacement rooflights were specified to achieve Class 3 Non-Fragile performance when new, providing enhanced safety compared with ageing rooflight systems.
Benefits of the rooflight replacement included:
The rooflight replacement programme was carefully coordinated alongside the roof coating works to ensure a seamless finish across the entire roof surface.
Application of the Alltimes Graphene Roof Coating System
The centrepiece of the refurbishment project was the application of the Alltimes Graphene Roof Coating System across the entire roof area.
Graphene-enhanced roof coatings represent one of the most advanced roof refurbishment technologies currently available. The incorporation of graphene helps improve durability, flexibility and long-term resistance to environmental exposure.
Following thorough roof preparation, cleaning and substrate assessment, the coating system was applied in accordance with the manufacturer’s specification to create a fully encapsulated protective barrier across the entire roof surface.
Key Benefits of the System
The 30-year Alltimes Graphene System provides a range of long-term advantages, including:
Extended Roof Life
The coating system creates a robust, seamless waterproof membrane that protects the existing roof structure and significantly extends its service life.
Reduced Lifetime Costs
By refurbishing rather than replacing the roof, the client was able to avoid the substantial disruption and capital expenditure associated with a complete roof replacement project.
Improved Weather Resistance
The finished system offers excellent protection against rain, UV exposure, thermal movement and environmental pollutants.
Sustainable Refurbishment
Retaining the existing roof structure dramatically reduces waste generation compared with complete roof replacement, making refurbishment a more environmentally responsible solution.
Long-Term Asset Protection
The coated roof is now protected against ongoing deterioration, helping the building owner safeguard the value of the property while reducing future maintenance requirements.
Project Delivery
As with all Cladding Coatings projects, safety, quality and communication remained at the forefront throughout the programme.
Our experienced roofing specialists coordinated the installation of the Mansafe system, rooflight replacement works and coating application to ensure works progressed efficiently and safely. Careful planning enabled the project to be completed with minimal disruption to the building’s ongoing operations.
Regular quality inspections were undertaken throughout each stage of the refurbishment to ensure every element of the specification was delivered to the highest standards.
The Outcome
The completed roof refurbishment has delivered a modern, protected and safer roofing system that will continue to provide reliable performance for decades to come.
The client now benefits from:
A fully refurbished roof protected by a 30-year graphene coating system.
Improved roof waterproofing and weather resistance.
Twenty-four new non-fragile GRP rooflights.
A modern Mansafe fall protection system.
Enhanced safety for future maintenance activities.
Significantly extended roof lifespan.
Reduced future maintenance costs.
A sustainable alternative to full roof replacement.
By refurbishing rather than replacing the existing roof, the client was able to significantly enhance the building’s weather protection, safety credentials and long-term performance while achieving substantial cost savings. The completed project has transformed an ageing roof into a fully protected, maintainable and sustainable asset backed by a 30-year roofing solution.
Whether addressing cut edge corrosion, rooflight deterioration, waterproofing failures or access safety requirements, Cladding Coatings provides complete roof refurbishment packages tailored to the needs of commercial and industrial property owners across the UK.
Looking to refurbish your commercial or industrial roof? Contact Cladding Coatings today to discuss how our roof coating systems, rooflight replacement services and access safety solutions can deliver long-term protection and value for your property.
