How to Re-roof a Felt Roof with IKO Armourplan
Transforming an Ageing Felt Roof with IKO Armourplan
Felt roofing systems have long been one of the most widely used flat roofing solutions across the United Kingdom. Found on both residential and commercial properties, traditional felt flat roofs provide effective waterproofing when installed correctly.
However, as roofing systems age, they can become susceptible to wear and tear, leading to leaks, water ingress, and structural concerns.
At DVC Commercial Roofing Contractors, we specialise in flat roof replacement, roof refurbishment, and commercial roof waterproofing solutions designed to extend the lifespan of buildings and protect valuable assets.
This project involved replacing an ageing felt roof system with the industry-leading IKO Armourplan mechanically fixed membrane, delivering a durable and watertight roofing solution backed by a comprehensive warranty.
The Challenge: An Ageing Felt Flat Roof
The existing roof had reached the end of its serviceable life. Like many older felt roofing systems, it consisted of multiple layers of traditional felt that had deteriorated over time. Visible signs of failure included worn seams, degradation around wall abutments, and evidence of water ingress around perimeter details and drip edges.
These issues are common in ageing felt roofs and can lead to costly internal damage if left unresolved. The client required a long-term flat roof waterproofing solution that would eliminate leaks, improve durability, and provide confidence through a manufacturer-backed warranty.
Following a detailed roof inspection, our team recommended a complete felt roof replacement using the IKO Armourplan roofing system.
Roof Stripping and Preparation
A successful flat roof installation starts with thorough preparation. As experienced commercial roofing contractors, DVC understands that the performance of any new roofing system depends heavily on the quality of the underlying structure.
The first stage of the project involved stripping the existing felt roof covering and removing the timber decking down to the roof’s structural timber joists. All waste materials and debris were carefully removed from site, ensuring a clean and safe working environment throughout the project.
Once the roof deck was exposed, our roofing specialists carried out a comprehensive inspection of the timber joists and supporting structure. Any signs of rot, moisture damage, or structural defects were identified and addressed before work progressed.
To create a solid foundation for the new flat roofing system, we installed new OSB tongue and groove timber roof boards. These boards were securely screw-fixed directly into the existing joists. Using screw fixings rather than nails helps prevent movement and reduces the risk of the existing ceiling becoming dislodged during installation.
This robust roof deck preparation provides long-term stability and ensures the new waterproofing membrane performs to its full potential.
Installing the IKO Armourplan Roofing System
For this project, DVC Commercial Roofing Contractors specified the IKO Armourplan mechanically fixed roofing system, one of the most trusted flat roof waterproofing solutions available today.
IKO Armourplan is a high-performance PVC roofing membrane designed for durability, flexibility, and long-term weather resistance. It is particularly suitable for commercial roofing projects where reliability and longevity are essential.
The installation process began by carefully positioning the membrane across the prepared roof deck. The membrane was loose laid before being mechanically fixed along one edge at manufacturer-specified centres, typically around 200mm apart.
Subsequent sheets of membrane were then laid with the correct overlap and professionally heat welded together. Heat welding creates a permanent bond between membrane sheets, ensuring complete waterproof integrity throughout the roof system.
This process was repeated across the entire roof area to create a seamless waterproof barrier capable of withstanding the demanding UK climate.
Attention to Detail at Roof Perimeters
Perimeter detailing is one of the most important aspects of any flat roof installation. Poor edge detailing can result in membrane movement, water ingress, and premature system failure.
To ensure maximum performance, all perimeter edge details on this project were secured using approved IKO perimeter bars and drip trims. These components were mechanically fixed at the correct centres in accordance with manufacturer specifications.
This detailing method helps prevent the roofing membrane from pulling away from roof edges during thermal expansion and contraction. By allowing the system to move as designed while maintaining secure perimeter restraint, the roof can continue to perform effectively throughout its lifespan.
The result is a professional, durable, and fully waterproof flat roofing system capable of delivering long-term protection for the building.
The Benefits of IKO Armourplan
The IKO Armourplan roofing system offers a range of benefits that make it a preferred choice for commercial roof replacement projects:
- Excellent long-term waterproofing performance
- High resistance to UV exposure and weathering
- Strong, durable membrane construction
- Heat-welded seams for superior waterproof integrity
- Low maintenance requirements
- Suitable for a wide range of commercial buildings
- Manufacturer-backed warranty protection
For building owners seeking a reliable flat roof refurbishment solution, IKO Armourplan delivers exceptional value and peace of mind.
Comprehensive 20-Year Warranty
One of the key advantages of choosing an IKO Armourplan roofing system is the comprehensive warranty available through approved installers.
As accredited IKO installers, DVC Commercial Roofing Contractors can provide a 20-year labour and materials warranty directly from IKO PLC, one of the world’s largest waterproofing manufacturers.
This warranty gives clients complete confidence that their investment is protected by both the manufacturer and the installation contractor.
Why Choose DVC Commercial Roofing Contractors?
Founded in 1995, DVC Commercial Roofing Contractors has built a strong reputation for delivering high-quality commercial roofing services across the United Kingdom.
As a family-run roofing company, we combine traditional values with modern roofing expertise to provide dependable roofing solutions for projects of all sizes. Our commitment to quality workmanship, customer service, and health and safety has enabled us to become one of the UK’s trusted commercial roofing contractors.
We are proud to hold CHAS Elite accreditation, demonstrating our ongoing commitment to maintaining the highest health and safety standards across all operations.
With offices in Newcastle and Manchester, our team has the capability to deliver commercial roofing projects nationwide, from flat roof replacements and roof refurbishments to complete waterproofing installations.
For over 30 years, we have been handing over watertight buildings to satisfied clients, building long-term relationships based on reliability, professionalism, and value.
Need a Felt Roof Replacement?
If your existing felt roof is showing signs of deterioration, water ingress, or general ageing, DVC Commercial Roofing Contractors can help. Our experienced team can assess your roof and recommend the most suitable flat roof waterproofing solution for your building.
Contact DVC Commercial Roofing Contractors today to discuss your felt roofing requirements and discover how our professional flat roof replacement services can provide long-lasting protection for your property.
