Commercial Flat Roof Refurbishment Sunderland
Gentoo Flat Roof Refurbishment in Sunderland
DVC Commercial Roofing Contractors completed a commercial flat roof refurbishment project for Gentoo at its main depot in Sunderland.
The project involved the refurbishment of approximately 700m² of existing flat roof, replacing the ageing waterproofing system with a new Protan single-ply roofing system and high-performance insulation.
The refurbishment was designed to provide Gentoo with a long-term, watertight roofing solution while allowing the building to remain operational throughout the works.
Project Overview
The existing flat roof was constructed using a structural metal deck, ½-inch fibreboard and two layers of roofing felt. Following a roof survey and inspection, the existing roofing system was found to have reached the end of its serviceable life, with signs of deterioration developing across the roof.
Continuing to rely on the existing system could have increased the risk of water ingress and potentially caused damage to the building and disruption to the day-to-day operation of the site.
A full roof refurbishment was therefore recommended to replace the ageing system and provide a more reliable long-term solution.
The Roofing Challenge
One of the main requirements of the project was to complete the refurbishment while the Gentoo building remained operational. This meant the roofing works needed to be carefully planned and managed to minimise disruption while maintaining safe access to the building.
The project required consideration of:
- Safe working conditions for the roofing team
- Continued access for staff and visitors
- Minimising disruption to daily operations
- Protecting the building from changing weather conditions
- Efficiently completing the refurbishment across the large roof area
The works were completed in controlled sections, limiting the amount of the existing roof exposed to the weather at any one time.
The Roofing Solution
Following the roof survey and assessment of the existing system, DVC recommended a Protan single-ply roofing system. The new roof build-up incorporated high-performance insulation supplied by Moy Materials, helping to improve the thermal performance of the building while providing a suitable base for the new waterproofing system.
The completed roofing system was also provided with a 20-year warranty, giving Gentoo long-term assurance following the refurbishment.
Protan single-ply roofing was selected for its suitability for large commercial roof areas, providing a durable and reliable waterproofing solution that could be installed efficiently across the approximately 700m² roof.
Roof Refurbishment Process
The refurbishment began with the removal of the existing roofing materials to expose the structural metal deck beneath. Once the existing system had been removed, the roof was prepared for installation of the new system.
The refurbishment was completed in several stages:
Removal of Existing Roofing
The existing layers of roofing felt, and fibreboard were removed from the roof to expose the structural metal deck and prepare the surface for the new roof system.
Vapour Control Layer
A new vapour control layer was installed as part of the refurbished roof build-up.
High-Performance Insulation
New high-performance insulation was installed to improve the thermal performance of the roof and provide the required substrate for the waterproofing membrane.
Protan Single-Ply Membrane
The Protan single-ply membrane was installed across the refurbished roof area, creating a new waterproofing layer designed to provide long-term protection.
Heat-Welded Joints
The membrane joints were heat-welded to create secure connections between sections of the roofing membrane and form a continuous waterproofing system.
Working Around an Operational Building
Completing a commercial roof refurbishment on an operational building requires careful planning, particularly when working across a large roof area.
At Gentoo, the refurbishment was completed in sections to minimise disruption and reduce the amount of roof exposed to changing weather conditions.
The project also involved challenging weather conditions, including periods of heavy rain and strong winds. Careful planning and management of the roofing works allowed the project to progress safely and the new roofing system to be completed successfully.
The Result
The completed refurbishment provided Gentoo with a renewed commercial flat roof incorporating a new Protan single-ply waterproofing system and high-performance insulation.
The new roof system provides:
- Improved waterproofing protection
- A renewed commercial roofing system
- Improved thermal performance
- Increased resistance to weather exposure
- Long-term protection for the building
- A 20-year roofing warranty
By replacing the ageing roofing system, the project provided a long-term solution designed to reduce the risk of future water ingress and the disruption associated with recurring roof repairs.
Commercial Flat Roof Refurbishment
The Gentoo project demonstrates DVC Commercial Roofing Contractors’ experience delivering large-scale flat roof refurbishment projects for operational commercial buildings.
Our commercial roofing services include flat roof refurbishment, commercial roof replacement, single-ply roofing, roof surveys and ongoing roof maintenance.
If your commercial roof is showing signs of deterioration, recurring leaks or has reached the end of its serviceable life, a professional roof survey can help determine whether repair, refurbishment or replacement is the most appropriate solution.
Contact DVC Commercial Roofing Contractors to discuss your commercial flat roof refurbishment requirements.
