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Historic Chocolate Works preserved with Sika Sarnafil

Eight years after being put on the ‘At Risk’ register by English Heritage, the landmark Terry’s Chocolate Factory has a new lease of life, following extensive refurbishment. The 1926, Grade II listed building now starts a new chapter as a care village owned by Springfield Healthcare.

Once home to famous brands such as Chocolate Orange, the factory and offices were closed in 2005 and fell into disrepair over the subsequent decade. Eventually the building, which is part of a 27-acre site, was acquired by Henry Boot Developments for conversion. The renovations included a full roof refurbishment that was undertaken by Hull-based roofing contractor L.A. Hall using a Sika Sarnafil single ply system.

One of the key focuses of the work was to preserve and retain the art deco features of the building while increasing its lifespan. A vital element of the repairs was the work on the existing flat and slate roof areas that were in a very poor state, and a roof for the new additional floor of the building.

Principal contractor Simpson (York) Ltd., brought L.A. Hall on board to complete the roofing works, which comprised a number of disciplines, including heritage Westmorland slating, single ply, zinc cladding and leadwork.

L.A. Hall suggested using a Sika Sarnafil system for the flat roof areas, as it matched the client’s requirements for longevity and sustainability, and is the company’s preferred membrane choice. The project’s conservation officer was initially concerned that the system would be too shiny, but Sika Sarnafil provided a number of samples, and after discussions, the specification was welcomed by all parties.

The project was complex due to the multiple roof areas and detailing. To begin, the existing slating on the central north light roof slopes, which were remaining in place as part of the new scheme, were re-covered using a fully adhered Sika Sarnafil system including G410-EL membrane in Lead Grey.

In addition to the existing roof areas, an extra floor to the building was constructed around the north lights. Its steep slated mansard-type external elevation included approximately 60 dormer windows, which required zinc on all the vertical faces and Sarnafil on the tops. The flat roof area of the extension was then also covered in the Sarnafil system, along with 140m of parapet guttering detailing, and a new roof terrace area.

Nigel Drysdale, Technical Advisor at Sika Sarnafil said “We had a great number of details to consider in order to preserve the original look of the building. For example, the architect and conservation officer required a timber mop roll detail to the perimeter of the main roof and the dormers. So all the parties worked closely to achieve a practical and aesthetic solution, which involved creating detailed life-sized models of key elements. This collaborative and applied approach gave the conservation officer confidence that the detailing was sympathetic to the building’s heritage and that’s what we eventually installed.”

The L.A. Hall team overcame various challenges, including working on sloped areas, tight time scales and challenging winter weather, but thanks to the skill of the fitters and the flexibility of the Sarnafil system, the project was finished to an impeccable standard and on time.

All members on the team agree that the newly refurbished roof looks stunning and will defend this iconic building from the elements for many years to come.

For more information please call 01707 394444, or visit http://gbr.sarnafil.sika.com
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Sarnafil plus has Market roof covered

The roof refurbishment of Kirkgate Market in Leeds is a story of problem solving and partnership. Rising to the challenge, Protech Roofing and Sarnafil Plus delivered an exemplary solution, which allowed the market to remain open throughout.

Europe’s largest covered market, Kirkgate has 800 stalls attracting over 100,000 visitors a week. As part of a £14m refurbishment to improve the market for the stallholders and the public, the leaking roof, extending over both the 1976 and 1981 halls, needed renewing while the building was fully operational. Being such an important and iconic city landmark, viewable from many of the surrounding buildings, attention to detail and aesthetics were also incredibly important to the final result.

The Sarnafil Plus team did the groundwork to secure the tender with the architect, asserting the benefits of a Sarnafil system, Sarnafil Plus technical support and guarantee. Following this, Protech Roofing, a registered Sarnafil contractor, spent many hours visiting the site and attending meetings, gaining the trust of all parties.

Eamonn Cahill, Interserve senior project manager, said “Protech showed outstanding levels of proactive problem solving and integrity throughout the project. The Sika Sarnafil membrane has given the market hall roofs a smart, clean finish with the durability to keep the building weatherproof for years to come.”

The original design specification called for the existing felt waterproofing to be removed back to the metal decking. However, as this would cause massive disruption and with no guarantee of a watertight building. To combat this issue, Protech recommended a mechanically fastened Sarnafil system that could be overlayed onto the existing substrate.

A full Sarnafil Plus survey and moisture mapping revealed the worst areas for water ingress before the project started to assist with planning the work.

The nine-month project saw a team of between eight and 10 people working on the roof through all four seasons, including rain showers and temperatures of over 27°C., without the project or waterproofing ever being compromised.

Sarnavap 5000E SA a cold applied, self-adhesive vapour control layer was used to ensure temporary waterproofing for the market while the roofing work was being carried out. The SarnaTherm insulation boards were mechanically fixed into the existing roof and installation of Sarnafil S327-15EL Light Grey membrane with stainless steel fixings created a durable, weathertight and aesthetically pleasing finish. Sarnafil membranes are certified by the British Board of Agrement to have a service life in excess of 40 years, giving the client confidence in the durability and longevity of the roof.

A further feature of Sarnafil roofing systems that appealed to the client was that the Sarnafil S327-15EL Light Grey membrane is cold applied – welded together using hot air rather than with a naked flame. The system can be used without restrictions as it meets the fire performance requirements of BS476-Part 3:2004 and BS EN 13501-5:2005. This was an important safety consideration as the market had suffered a terrible fire back in 1975.

Six rooflights over 51m long were replaced with SarnaLites, situated close together in rows, making sure that the market continued to benefit from natural daylight. This part of the refurbishment was carried out at night to limit any disruption to the market below.

Sarnafil Plus visited the site regularly and a successful final inspection resulting in the issuing of a Sarnafil Plus guarantee.

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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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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Stunning roof for London pub with new Sika Sarnafil self-adhered membrane

Specialist roofing contractor Hambro Roofing has recently completed works to a new JD Wetherspoon pub in London, known as ‘The Mossy Well’, which now boasts 500sq m of Sika Sarnafil Self Adhered membrane.

JD Wetherspoon has spent just over £3 million developing the outlet on Muswell Hill, which opened in October.

Extensive refurbishment and adaptations to the building needed to take place due to the existing roofs being in such a bad state. Essex-based Sika Sarnafil contractor, Hambro Roofing, was awarded the contract after proposing to use Sika Sarnafil single ply for the flat roof repairs.

The refurbishment comprised of complex work on the existing pitched roofs, lead flashings, guttering and renewal of the flat roof. A section of new barrel roof was also required in the centre of the building; comprising of flat, vertical and soffit detailing.

The client required the new roof area to look like a traditional zinc roof covering. Sika Sarnafil G410-15 FSA was specified for the job, with décor profiling to match the surrounding roofs. Ideal for the job, the system is lightweight, cost effective and offers a flawless finish.

Built on Hambro Roofing’s previous experience this was a highly successful project without any major setbacks and completed in the given timeframe.

The barrel roof was also fitted with SarnaTherm insulation over a SarnaVap vapour barrier. Sikalastic Liquid Applied Membrane was used on the detailing around the guttering to achieve a seamless waterproof finish.

Jon Hammersley, Hambro Roofing Director, explained “The works were incredibly challenging as there was a vast amount of awkward detailing including vertical fascia and soffit works. However, the new Self Adhered membrane allowed us to work fast and make the roof look fantastic. Sarnafil remains our preferred partner when it comes to single ply roofing because it is so reliable and gives the best results.”

“We had to work to a tight deadline in order to get the premises open on time which was achieved with our own in house labour force and great workmanship with the product,” he added.

Feedback was enormously positive on completion of the project. The client was particularly impressed by the effectiveness of the Self Adhered solution and the speed in which the project was completed, resulting in a stunning roof that fulfilled the architect’s vision.

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

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