Pulse Aero, a leading aerospace engineering firm with a premises in Ilkeston, Derbyshire, recently worked with us to undertake a comprehensive roof refurbishment project. With a focus on safety, longevity, and light optimisation, the project aimed to enhance the structural integrity and operational efficiency of Pulse Aero’s facility. The scope of work included the installation of a new Mansafe system, replacement of roof components, and application of Cladding Coatings’ renowned 15-Year Guarantee System.

The project began with a detailed site survey, this initial assessment identified several key areas requiring attention, including deteriorating roof fixings, aged GRP rooflights, and compromised foam fillers. The client’s priority was to ensure the building remained safe for maintenance personnel while improving natural light penetration and extending the roof’s lifespan.

One of the most critical upgrades was the installation of a new Mansafe system. As a fully trained installer, we selected the 3M™ DBI-SALA® RoofSafe Anchor and Cable System, a state-of-the-art horizontal lifeline solution designed for continuous, hands-free access across roof surfaces.

Following the safety system installation, our team proceeded with the removal and replacement of all roof fixings. This step was essential to restore the roof’s structural integrity and prevent future water ingress. The team carefully stripped out the top skin of eight existing GRP rooflights, ensuring minimal disruption to the building’s operations. Once removed, the inner skins were meticulously cleaned to maximize the transmission of natural light into the workspace below.

To further enhance daylighting, Cladding Coatings supplied and fitted eight new Class 3 GRP rooflights. These units are classified as non-fragile when new, offering both durability and safety. Installed in the same locations as the originals, the new rooflights significantly improved the internal lighting conditions, reducing reliance on artificial lighting and contributing to energy efficiency.

Another vital component of the refurbishment involved the installation of high-density foam fillers. These were fitted to both sides of the flashings across four hips on the roof. Foam fillers play a crucial role in sealing gaps and preventing moisture ingress, and their replacement was necessary to maintain the building envelope’s integrity.

With the structural and safety upgrades complete, Cladding Coatings turned its attention to the final and most transformative phase: the application of their exclusive 15-Year Guarantee System. This high-performance coating system is designed to deliver long-term protection and aesthetic enhancement for metal roof surfaces. It features a water-based acrylic elastomer formulation with 200% elasticity, allowing it to expand and contract with the substrate without cracking or peeling.

The coating system is also fire-rated, non-flammable, and ultra-low in VOCs (just 8g/l), making it an environmentally responsible choice. Its fast-drying properties—touch dry in three hours and ready for recoating in six—enabled the team to complete the application efficiently, minimising disruption to Pulse Aero’s operations. The coating was applied via spray, ensuring a smooth and uniform finish across the entire roof surface.

In addition to its technical benefits, the 15-Year Guarantee System offers comprehensive coverage for both labour and materials. This assurance gave Pulse Aero peace of mind, knowing that their investment was protected against future wear and environmental stressors. The coating’s resistance to corrosion, particularly in industrial environments, was a key factor in its selection for this project.
Throughout the project, our teams maintained close communication with Pulse Aero, providing regular updates and ensuring that all work met the highest standards of quality and safety. The result was a fully refurbished roof that not only meets current health and safety regulations but also enhances the building’s functionality and appearance.

In summary, the Pulse Aero roof refurbishment project exemplifies Cladding Coatings’ commitment to delivering tailored, high-quality solutions. By integrating advanced safety systems, improving natural light access, and applying a durable protective coating, Cladding Coatings has helped Pulse Aero future-proof their facility for years to come.