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Impressive Center Parcs roof refurb completed with zero guest disruption

With capacity for almost 4000 guests and 96% occupancy, keeping the central area of Center Parcs Longleat Forest open was key to the refurbishment of its impressive Subtropical Swimming Paradise. A massive challenge for Delomac Roofing, the project to renew the roof with a Sika Sarnafil membrane was accomplished with two years of meticulous planning and 30 months of onsite construction.

Originally completed in 1994, the Subtropical Swimming Paradise roof and glazed rain-screen systems were in need of refurbishment. The new roof installation was planned in close discussion with the Sika Sarnafil and Delomac supply chain, developing the specification to address all the client’s strict performance, environmental and aesthetic requirements.

Chris Meadows, Technical Advisor, Sika Sarnafil explained: “The client needed a durable, long lasting roof system that would complement the woodland setting. This was complicated by differences between the swimming pool side and dry side, with restaurants and meeting rooms, of the building.

“We proposed two distinct solutions– a mechanically fastened system using Sarnafil S327-18EL for the dry side and an adhered system using Sarnafil G410-18EL for the more humid area. Both were specified in Patina Green to blend with the natural environment. Sarnafil membranes are cold applied and free from naked flames, the obvious choice for an open site.”

An innovative temporary terraced platform was designed and installed, suspended underneath the main structure by cables and lattice beam scaffold units. Work was carried out over 16 separate sections, like a wagon wheel – ensuring the structure was not compromised by uneven load distribution. This stepped, terraced temporary roof was then covered with plywood and completely weathered by Delomac with a Sarnafil membrane.

With the temporary roof in place, existing glazing and coverings could be safely removed, maintaining water-tightness with guests enjoying the facilities below. Scheduled over more than two years, this way of working resulted in a dry building envelope, despite some of the wettest weather on record.

Comprehensive vapour barrier measures were used on the pool side of the building to ensure the high humidity chlorinated environment was contained. Robust SFS sealant and Sarnafil metal-lined vapour barrier detailing at all Glulam beams and fascia interfaces ensured no risk of condensation.

Sarnafil membrane and accessories were used for all the coverings, and again overall specification development was tailored to suit the varying build-ups; new, overlay, bonded and mechanically fastened. An increased thickness membrane was manufactured in one single batch to ensure colour consistency. Sika added further value with an impressive 17 visits to the site by the Applications Team to advice and support.

Brendan McNulty, Delomac Roofing, described the challenges the team faced during the project: “Installation methods and curved roof areas required our operatives to work from harness and rope access. We developed an innovative material loading trolley with the builder to deliver materials to the work sections safely, without compromising finishes.

“Workmanship standards remained exceptionally high, despite the challenging logistics, and met the client requirement of consistent lap and detail arrangement. This was also helped by the quality of the Sarnafil membranes. The finished installation has transformed the internal and external appearance of the building. Rooflights and white soffit finished decking have provided a bright and airy environment, with the external green finish blending subtly with the landscape.

“Most importantly, safe, unlimited guest access to the pool, restaurants and meeting areas was maintained throughout the entire project; something we’re very proud of.”

For more information please visit www.sarnafil.co.uk.
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Blending the old and the new

Ashdowne handcrafted clay tiles transform 17th century pub.

Marley Eternit’s Ashdowne handcrafted clay plain tiles have been used to help transform a derelict 17th century pub into a new fine dining restaurant and village centre. The £3 million restoration project by David Bishop has seen the Wheatsheaf pub in Rettendon brought back to life as an exciting new complex which, in addition to Le Benaix Bar and Brasserie, includes a village store, hair dresser and separate beauty salon.

Famous for being a drovers’ pub back in the 17th century, the former Wheatsheaf pub in the Essex village of Rettendon is a building of significant historical importance but had remained derelict for almost ten years. The challenge was to restore and extend the ageing building, retaining many of the existing features.

Owner David Bishop selected the handcrafted Ashdowne clay plain tiles from Marley Eternit to replicate the aesthetic of the clay peg tiles used on the original roof. 38,000 tiles were used to create the beautiful clay roof, creating a heritage appearance that connects both the old and the new parts of the building. The roof includes a large octagonal shaped section to create a striking design feature.

David Bishop comments: “With such an important local building, we wanted to stay as close as possible to the aesthetic of the original clay peg tiles and we chose the Ashdowne handcrafted tiles because they had a very similar appearance and were more cost effective.

The aged look of the handcrafted tiles also meant we could use them to blend the new parts of the development in with the renovated historical pub.

“As the building was disused for almost a decade, many of the original roof tiles were missing, so we would have had to find a huge number of old clay peg tiles, so the City Council planning department acknowledged the benefits of the handcrafted tile instead. The finished effect is stunning and the tiles really do help to combine the two parts of the building and ensure the new build is sympathetic to the old. Complementing the local village surroundings was very important and we’ve had several local people comment on what a beautiful roof it is and how well it blends in.”

Ashdowne handcrafted clay plain tiles are available in two weathered colours making them the ideal choice to enhance the beauty of a new build development or for a refurbishment project. The traditional handcrafted finish ensures each and every roof takes on a character of its own.

Charlotte Hughes, product manager at Marley Eternit, adds: “The roof on this project certainly is stunning and demonstrates how handcrafted tiles like these can be used very sympathetically on restoration projects, at the same time as adding beauty to new builds. The Ashdowne tiles on this project help to blend the old and the new buildings very effectively, with the aged clay appearance complementing the vernacular style.”

Ashdowne clay tiles also offer impressive environmental credentials, including the ability to achieve an A+ rating in the BRE Green Guide to Specification, BES 6001 Responsible Sourcing accreditation and certified carbon footprint data at product level.

For further information, visit www.marleyeternit.co.uk/Roofing/Clay-Tiles/Ashdowne-Clay-Tile
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Cembrit B5 the alternative to old asbestos roofs

Gorsgoch village hall benefits from Cembrit B5, the versatile and aesthetically pleasing, modern fibre cement corrugated sheets. The material has been used to transform a 60 year old village hall and improve the roof’s performance through its superior water shedding capacity when compared with the old 3″ profile.

A village near Lampeter in the county of Ceredigion, Wales is developing at a high rate and is currently seeing increase in planning applications and new housing developments. Located at the heart of the Gorsgoch, the village hall is the main community building in the area and provides the local community with a common meeting place. After being closed for a number of years, the village hall required a refurbishment. In particular, the narrow asbestos cement corrugated sheet needed to be replaced with a durable and attractive looking roof. Local contractor, Jeff Thomas worked on this project, and Huw Davies from Pensaer HD Architect specified Cembrit’s B5 corrugated sheet.

“The durable and low maintenance credentials of Cembrit’s B5 corrugated sheet made it ideal for use on this project,” comments Huw Davies from Pensaer HD Architect. “Cembrit’s robust onsite service options and the technical support representatives were of great use on this project. The team were extremely helpful, assisting me with all of my enquiries. This has helped to make the project a success.”

Natural grey coated B5 corrugated sheets have provided a spectacular finish that blends in well with the countryside setting. The contractor installed a Plain Wing Angle Ridge to provide sufficient ventilation.

The rust and rot free B5 Corrugated Sheet is the perfect solution for someone looking to clad or repair single-story buildings such as stables and garages. B5 is available in fourteen different lengths ranging from 4′ to 10′ 6″ the sheets are approximately 40% wider than traditional 3″ profile which allows for much better coverage per sheet. They also offer superior water shedding capacity due to the profile of its corrugations.

B5 offers numerous advantages that are helpful for the installer. B5 sheets have a small overlap, and as sheets are approximately 40% wider than comparative products, so it offers a much better coverage per sheet. This has the advantage of decreasing the weight of the roof covering. There is less side lap and overhang, and increased maximum end lap. B5 can be laid to a 5° pitch for small roof areas if the end laps are extended to 300mm and are double sealed with mastic strips. A number of accessories come with the B5. A one-piece close fitting Cranked Crown ridge that can fit into roof pitches, two-piece lose fitting ridge which is adjustable to roof pitches and the Plain Wing Angle ridge that can create high level ventilation. Also there is the Cemsix Barge Board which is used to close verges at gable ends and the one-piece and two-piece Roll Top Finial which forms an integral part of closing a verge apex.

For further information, please visit www.cembrit.co.uk. Follow us on Twitter at @CembritUK and Facebook at Cembrit UK.
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Acme clay plain tiles used for pioneering Zero Bills Home

An innovative, affordable zero bills home created by architects Zed Factory, is using Acme clay plain tiles from Marley Eternit to help meet strict sustainability criteria.

The demonstration house launched at the BRE Innovation Park in March 2016. It will be one of the first properties to be assessed under the new Home Quality Mark (HQM), which gives credits for the use of responsibly sourced building materials with the lowest environmental impact.

Zero Bills aims to be the first commercially viable home with no net annual energy bills and enough surplus electricity to power a small electric car. Built with traditional construction materials, Zed Factory has incorporated high levels of energy efficiency and renewable energy into the design. A mansard roof has been created with a clear integrated photovoltaic roof on one side and Marley Eternit’s Acme single camber clay tiles in Red Sandfaced and Red Smooth on the other.

Rehan Khodabuccus, from Zed Factory, explains: “As well as looking at energy efficient products for the home, we also needed to consider the construction materials themselves to make a building with the lowest embodied carbon possible. Responsible sourcing was also very important, not only from an HQM assessment point of view but also because we wanted to maximise the use of materials from the UK to minimise the carbon footprint. We wanted a clay tile to create a traditional aesthetic as a contrast against the solar PV on the other side of the mansard roof. We selected the Marley Eternit tiles based on their responsible sourcing and sustainability credentials.”

The Acme single camber clay plain tiles have a ‘Very Good’ BES 6001 responsible sourcing accreditation, an A+ rating under the BRE Green Guide and low embodied carbon. As well as the demonstration home, the tiles are included in the specification for the first 96 Zero Bills Homes planned to be built on a site owned by the Sir Arthur Ellis Trust at Newport, near Saffron Walden in Essex.

The Zero Bills Home is a pre-designed, engineered and costed housing system with a wide range of custom build design options. The concept is aimed at low to medium density developments with a range of house types available from a kit of parts, delivered to site in containers for easy assembly.

Daniel Weait, specification manager at Marley Eternit, adds: “We are delighted to be providing tiles for such a pioneering zero bills development, which could not only help to meet carbon reduction targets but also tackle the need to increase the output of quality homes in the UK. The homes offer a sustainable and cost effective alternative that still uses traditional construction materials and local labour and minimises cost. This blend between traditional materials and renewable technologies creates homes that could quickly and affordably be replicated across the country, yet can be sympathetic to local vernacular.

“Responsible sourcing is becoming an increasingly important part of specification and we are proud that using our products helps architects and housebuilders to get credits under the environmental section of the Home Quality Mark. As one of the first homes to be assessed under the new HQM scheme, we hope to see the Zero Bills Home being offered at developments across the country.”

Marley Eternit’s range of clay plain tiles is now available in 24 different colours to help match local vernacular and meet planning requirements. For further details and samples, go to www.marleyeternit.co.uk/clay.

For more information about the Zero Bills Home, visit www.zerobillshome.com.

For further information on our range of products and services just ask ME at www.marleyeternit.co.uk or call ME on 01283 722588. You can also follow ME on Twitter @MarleyEternit. If it matters to you it matters to us, that’s why with ME it’s all about you.
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Cembrit BBA certified slates provide natural finish to new housing development

Jutland, smooth and Zeeland, textured BBA certified fibre cement slates from Cembrit, have demonstrated their versatility, design and performance features on a stylish, nature-inspired housing development in the seaside town of Weymouth.

Pemberly consists of 176 houses, townhouses, apartments and bungalows, varying from one bedroom to four bedrooms in size. While the development is centrally located and within walking distance to shops, schools, amenities, a community centre, library and local transport, it still offers a tranquil living space.

Poole-based building contractor, F.H.Cummings worked with roofing specialist, Weatherbury Roofing on this project. Having installed Cembrit slates in the past, the roofer specified Jutland and Zeeland fibre cement slates for the new build properties. Finding a roofing material that would blend in with the natural surroundings, accommodate the varying roof pitches and meet the high specification requirements was a challenge for the contractor.

“We have experience of working with a number of different roofing materials, and this allowed us to make an informed decision that fibre cement slates would be the best option for this project”comments Simon Coleman, Contracts Manager of Weatherbury Roofing. “Cembrit fibre cement slates are lightweight and pre-holed, two features that were beneficial to us. This, combined with the fact that these slates don’t require any grading or sorting, meant that we were able to speed up the installation process. The fact that Cembrit’s slates come in a variety of surface textures allows us to choose a slate for each design.”

Cembrit holds five BBA (British Board of Agrément) Certificates for its fibre cement slate range, ensuring that whichever system is chosen, roofers and architects can be confident in the specified product. To achieve this status, Cembrit fibre cement slates completed a comprehensive testing process and successfully met all the requirements set out by the BBA.

Jutland and Zeeland slates are manufactured to the highest European standards using Portland cement together with a formulation of superior blended synthetic and cellulose fibres. Cembrit fibre cement slates are finished with a high quality, semi-matt acrylic coloured coating to the face and edges and a tinted, high performance binder to the back face. The slates are manufactured in accordance with a quality assurance system to ISO 9001 and to the requirements of BS EN 492:2012 product specification for fibre cement slates and their fittings.

Cembrit A/A+- rated fibre cement slates can contribute to achieving an environmentally outstanding building. The five variations (Jutland, Zeeland, Westerland, Moorland and Diamond) allow designers to achieve the highest ratings for roof specifications and are currently the only fibre cement slate certificated.

For more information, and to download the fibre cement slate guide, visit www.cembrit.co.uk. Follow us on Twitter at @CembritUK and Facebook at Cembrit UK.
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Achieving the impossible with Sika Sarnafil

In a complex new build roofing project that was deemed almost impossible, Contour Roofing stepped up to the challenge with a Sika Sarnafil membrane to achieve truly stunning results.

32 Ewart Grove, a Paul Simon Homes residential development minutes from Wood Green tube station, required a high-performance roof with a striking aesthetic result to match the contemporary luxury flats within. Located in a prominent position at a fork in a road, the roof can be seen when travelling up to the building, as well as from the upper floors of surrounding buildings.

With its extremely intricate design, including two barrel roofs and a large, unique triangulated tower at the front, the project presented a real challenge. Originally the specification for the 400sq m area called for a metal roof but the cost implications of this meant that another solution was needed, and fast.

It was thought that such a complex roof design could not be done, especially with the time and budget available. However Jonathan Woods, director at Contour Roofing, alongside senior contracts manager, Lee Clift, sought to prove that the roof could indeed be covered using a high quality single ply membrane, if the correct product and level of expertise were applied.

Jonathan and Lee met with the architect and the director of Paul Simon Homes to discuss amending the roofing specification. Jonathan explained: “With our previous experience of Sika Sarnafil products, we knew that we could get the perfect finish within budget. In partnership with Sika Sarnafil we quickly presented a new bespoke specification; an adhered system using Sarnafil G410-15ELF Lead Grey with a polyester fleece backing as the main roof sheet for a flawless result and Sarnafil G410-15EL Lead Grey for all the detail work flashings.”

The installation was very challenging, with various shapes, details, upstands and intricate sections to cover.

Lee added: “Working closely with the carpenter, the plywood deck had to be spot on to make sure the membrane could be laid smartly and correctly. Absolute attention to detail and skill were required to make sure the membrane was flush with the substrate below. Décor profiles were used to imitate the standing seams of a metal roof, which is what the original designs had envisaged.

“The project really took installation to new frontiers and pushed the boundaries of what can be achieved in roofing.”

Sikalastic was used for the guttering when the space was just too tight for single ply, demonstrating the compatibility between Sika’s various roofing products. Both the Sika Sarnafil and Sika Liquid Plastics systems were awarded a 20 year guarantee.

Carly Tan, quantity surveyor, Paul Simon Homes, said: “We didn’t think this project could be done within the budget, but Contour assured us that they could take on the challenge with single ply. No one else would even try.

“The roof is unique and when I saw the end results on a site visit I was really impressed with the finish. The Sika Sarnafil membrane looks very smart and mirror the metal look we originally wanted. The skill of Contour is obvious in the results. It meets our requirements perfectly, matching the luxury feel we wanted to achieve throughout the building.”

The project impressed the judges of the upcoming NFRC UK Roofing Awards and has been shortlisted in the Single Ply category. The winners will be announced in May.

For more information on Sika Sarnafil’s products and services, call 01707 394444, email sarnafilroofing@uk.sika.com or visit http://gbr.sarnafil.sika.com.

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MVHR-Easy with Posi-Joist

The Posi-Joist floor system was recently used on high quality homes for Severnside Housing, incorporating the latest in Mechanical Ventilation and Heat Recovery systems.

Severnside Housing is one of Shropshire’s largest social landlords owning more than 5,400 properties in Shrewsbury and the surrounding areas. A not-for-profit company they invest in their neighbourhoods and work closely with residents, partners and the wider-community to deliver their vision of ‘Excellent Homes in thriving communities’. Morris Property Ltd were chosen by Severnside due to their reputation for building high quality homes and the long standing relationship between the companies. Morris Property are keen to partner on future development projects in Shropshire. The contract commenced on the 23rd March and is scheduled for completion in June 2016.

MITEK-INSET-1

AC Roof Trusses were chosen by Morris Property to supply and install the timber frame walls, roof trusses and Posi floor joists for the 28 room, 3 floor apartment block. The apartments are to have a robust detail sound floor along with a MVHR system in each of the apartments.

The two bedroom apartments all have ‘state of the art’ Mechanical Ventilation Heat Recovery systems supplied and installed by SCS Group (Shropshire Cooling Services) who although local to the site also operate nationwide.

MITEK-INSERT-2SCS commented on the Abbey Foregate job “We recently used Posi joists supplied by AC Roof Trusses and found that because of this, we were able to provide a more competitive installation price due to the reduced labour costs. Because they were metal web Posi joists we did not have to cut any holes for the ducting to pass through. It also enabled our electricians and plumbers to save time on installation and on materials costs. Having to use a core drill every time our ducting passed through a joist would have taken a lot of time and effort, but we didn’t because they were Posi-joists.”

 

“As a company we design and install whole systems and with the Posi joists we were able to bring it all together much quicker and more efficiently.”

For more information please visit www.mitek.co.uk.

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IKO Polymeric & FK Group finish 48,000m2 roof in four months

IKO Polymeric and contactor FK Group have completed a roofing project for one of the biggest online grocery centres in the world – in under four months. This incredibly tight deadline was met with minimal material waste, thanks to a number of innovations developed specifically for the project by both companies.

The new fulfilment centre for premium British online supermarket, Ocado, is based in Erith, Kent, and will be operational in 2017. It will handle 200,000 orders a week and represents £185 million local investment.

The project started in September 2015 and was completed in December, a very short construction programme for a large – 48,000m2 – and challenging roofing project.

IKO Polymeric, the UK’s only single ply manufacturer, delivered several innovative solutions to complete the job with minimal waste.

Steve Hall, Managing Director of FK Group, comments: “IKO Polymeric demonstrated its usual proactive approach with innovations such as bespoke roll lengths and specific membrane overlap positioning allowing significant efficiencies to be achieved on site.”

Standard length membrane is typically 20 linear metres which then has to be cut or extended (by fixing additional sections on) to fit the required dimensions. IKO Polymeric manufactured its Amourplan PVC single ply membrane in bespoke rolls of 22.35, 19.20 and 8.00 linear metres to reduce waste and installation time for this project.

Another first was manufacturing half the rolls with the membrane overlap positioned on the opposite side to the other rolls. This 50/50 split meant the contractor could use two teams working simultaneously on either side of the ridge, rolling the membrane out in the same direction. Usually one team works on one side at a time.

FK Group developed a new technique for the project, welding eight rolls together to create a large (320m2) membrane ‘blanket’, rolling half back and then applying the adhesive to the area, rather than doing one roll at a time. This was possible because IKO’s Polymeric’s PU adhesive can be exposed for up to 25 minutes.

These innovative manufacturing and fitting methods saved time, resources and waste on a very large project, with 5,500m2 typically installed each week.

Steve Hall adds: “Working alongside FK Group, IKO made a significant contribution to the success of this job. As a key part of our supply chain, they helped us to develop and deliver a bespoke solution to our client in impressive time. ”

For more information on IKO Polymeric please visit www.ikogroup.co.uk/polymeric call 01257 488000. Follow @ikopolymeric on twitter.

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Cembrit B5 upgrades Penlan holiday homes

Cembrit B5 corrugated sheets have been installed on eight Swiss-style lodges at a holiday village in Swansea. The refurbishment of the roofs has updated the building, and provided a finish that exudes that holiday retreat feel.

Located in the heart of the beautiful Teifi Valley, Penlan Holiday Village is a small family run holiday park that is set amongst beautiful woodland and parkland. The development includes two and three bedroom detached lodges, a heated open-air swimming pool, picnic area, playing field and parking. The holiday village attracts many visitors throughout the year, as it provides quick access to the beautiful Teifi Valley and the West Wales Coastline.

Graham and Alistair Greenshield, the owners of Penlan Holiday Village wanted to replace the thirty year old roofs, as they were looking tired, and not performing very well. Graham chose to take on the job himself, and after looking at the options, decided to purchase Cembrit B5 corrugated sheets. Approximately 150 black coated B5 corrugated sheets have been installed on five lodges also utilising close-fitting one piece Cranked Crown Ridge to fit perfectly into the roof pitches.

“The exceptional quality of Cembrit’s B5 corrugated sheet helped us to enhance the exterior design of the lodges,” comments Graham Greenshield, part-owner of Penlan Holiday Village. “Time has been of the essence, considering the size of the project, and the fact that we didn’t want to close the business for too long. Cembrit’s B5 corrugated sheets have saved us a great deal of time, as it is quick and easy to install. In addition, its cost-effectiveness and design features ticked all the right boxes for us. I am not only pleased with the end result, but I enjoyed installing the product.”

The rust and rot free B5 Corrugated Sheet is the perfect solution for someone looking to clad or repair single-story buildings such as stables and garages. B5 is available in fourteen different lengths ranging from 4′ to 10′ 6″ the sheets are approximately 40% wider than traditional 3″ profile which allows for much better coverage per sheet. They also offer superior water shedding capacity due to the profile of its corrugations.

B5 offers numerous advantages that are helpful for the installer. B5 sheets have a small overlap, and as sheets are approximately 40% wider than comparative products, so it offers a much better coverage per sheet. This has the advantage of decreasing the weight of the roof covering. There is less side lap and overhang, and increased maximum end lap. B5 can be laid to a 5° pitch for small roof areas if the end laps are extended to 300mm and are double sealed with mastic strips. A number of accessories come with the B5. A one-piece close fitting Cranked Crown ridge that can fit into roof pitches, two-piece lose fitting ridge which is adjustable to roof pitches and the Plain Wing Angle ridge that can create high level ventilation. Also there is the Cemsix Barge Board which is used to close verges at gable ends and the one-piece and two-piece Roll Top Finial which forms an integral part of closing a verge apex.

For further information, please visit www.cembrit.co.uk.

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Midland Lead launches new cladding solution at RCI 2016

Midland Lead, leading British manufacturer of machine cast lead, launched a new range of metal cladding solutions at this year’s RCI Show; the UK’s annual roofing, cladding and insulation event.

Industry professionals visiting Midland Lead’s stand were given the opportunity to see the firm’s new customised cladding range for individual facades, available in zinc, copper, aluminium and lead.

With the company’s machine cast lead having been successfully used to weatherproof a number of prestigious projects across the UK construction sector over the past 30 years, Managing Director Boudewijn Tuinenburg explains that diversifying into metal cladding was a natural progression for Midland Lead and a response to customer demand.

“Having established our reputation as a manufacturer of high-quality lead sheet, we’ve built up extensive expertise in the metals arena. Keen to expand our offering, metal cladding was a natural bolt-on to our current product range and a great way to offer our customer base a new range of architectural design solutions,” says Boudewijn.

As well as opening up new possibilities for a building’s aesthetics and working to preserve the structure, the new metal cladding solution is an environmentally-friendly, lightweight, weatherproof product that offers a full suite of practical features, including fast installation, low maintenance, large panel size opportunities and pre-fabrication options.

Launched under Midland Lead’s Construction arm, the introduction marks part of a longer-term strategy that will see the firm diversify into differing markets and products, alongside its core business of manufacturing and suppling machine cast lead.

For more information please visit www.midlandlead.co.uk.

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