IKO Mach One Flat Roofing Project
This existing roof was well past its life expectancy however after surveying and core samples taking it was found the decking was also rotten. The customer decided to go with our recommendation and after receiving the full survey report from IKO, the customer felt confident in us knowing exactly what was required to hand over to the customer a valid 20-year warranty for IKO Mach One flat roofing.
Commercial Flat Roofing
Roof Condition Assessment and Survey Findings
The existing roof had significantly exceeded its expected service life and was showing clear signs of failure. Visible deterioration, recurring water ingress risks, and general material fatigue indicated that remedial repairs would no longer provide a reliable long-term solution. As with all major roofing decisions, DVC Roofing conducted a detailed roof survey supported by intrusive core sampling to accurately assess the condition of the full roof build-up.
While ageing waterproofing systems are common on older buildings, the survey revealed a more serious issue. In addition to the failed roof covering, sections of the structural decking beneath had deteriorated and were found to be rotten. This type of hidden structural damage can pose substantial risks if left unresolved, including compromised load-bearing performance and further moisture penetration.
Following a full review of the findings, we presented the client with a comprehensive survey report outlining the condition of the roof and the most appropriate course of action. Based on both technical requirements and long-term value considerations, a complete commercial roof replacement was recommended rather than isolated repairs.
To ensure full compliance with manufacturer standards and warranty eligibility, a detailed specification was obtained from IKO. After reviewing the independent survey documentation and technical proposal, the client was confident that the recommended solution would deliver both performance reliability and a valid 20-year warranty under the IKO Mach One system.
Commercial Flat Roofing Solution
Given the extent of deterioration identified, the roofing strategy centred on delivering a modern, high-performance Commercial Flat Roofing system designed for durability, energy efficiency, and long-term waterproofing protection.
A critical upgrade involved improving the thermal performance of the roof. Insulation levels were increased to 120mm to ensure full compliance with current Building Regulations and to enhance the building’s energy efficiency. Correct insulation specification is an essential component of modern commercial roofing services, contributing not only to regulatory compliance but also to reduced heat loss and improved internal comfort.
Once the new insulation was installed, the IKO Mach One Single Ply Roofing System was laid in strict accordance with manufacturer guidelines. The system was mechanically adhered at 300mm centres to the newly installed insulation, ensuring structural stability and consistent performance across the entire roof area.
All perimeter detailing incorporated a self-adhesive underlay, enabling a completely flame-free installation process. Flame-free systems are increasingly preferred across both commercial roofing contractors and industrial roofing contractors due to their enhanced safety profile, particularly on occupied or sensitive sites.
Precision Installation and Detailing
Installation quality plays a decisive role in determining the lifespan of any flat roofing system. For this project, all membrane welds were completed using controlled hot air welding techniques. Hot air welding ensures precise seam formation, creating a continuous, watertight barrier without the risks associated with open flame applications.
Drainage and outlet detailing were also fully upgraded. Existing outlets were replaced with IKO refurbishment outlets specifically designed for compatibility with the Mach One system. Proper outlet integration is vital in preventing ponding, managing rainwater effectively, and safeguarding long-term waterproofing performance.
Every element of the roof — from substrate preparation through to final detailing — was completed in accordance with IKO’s technical standards. This disciplined approach ensures not only immediate weatherproofing reliability but also long-term warranty validity.
Long-Term Protection and Warranty Assurance
The completed roof system now provides a robust, high-performance waterproofing solution supported by a 20-year warranty issued directly by IKO Mach One waterproofing system manufacturers. Manufacturer-backed warranties offer clients valuable assurance, confirming that materials, design, and installation meet strict performance criteria.
By combining modern insulation standards, precision installation techniques, and a proven single ply membrane system, the project delivers:
- Reliable long-term waterproofing protection
- Improved thermal efficiency
- Reduced maintenance risk
- Enhanced installation safety through flame-free methods
Partner with DVC Commercial Roofing Contractors
DVC Commercial Roofing Contractors is a family-run Roofing Company established in 1995, specialising in high-quality flat roofing and waterproofing solutions. Over nearly three decades, we have built a strong reputation for reliability, technical expertise, and consistent project delivery.
We are proud to have achieved CHAS Elite accreditation, reflecting our unwavering commitment to maintaining the highest standards of health and safety across all operations. Safety, compliance, and workmanship remain central to every commercial roofing service and industrial roofing services project we undertake.
With operational offices in Newcastle and Manchester, DVC Roofing maintains the capacity to deliver projects of all sizes throughout the United Kingdom. Our experienced team of commercial roofing contractors provides dependable solutions tailored to both refurbishment and new construction requirements.
For professional guidance on your next roofing project, please do not hesitate to contact our team.
