Roof Refurbishment at Van Leeuwen: Middlesbrough
Delivering a Multi-Building Roof Refurbishment
Project Overview:
DVC Commercial Roofing was initially called to Van Leeuwen’s manufacturing facility Middlesbrough, to investigate and resolve a leaking gutter that was causing ongoing maintenance concerns. While attending site, our team identified the opportunity to undertake a more detailed roof assessment of the wider roofing infrastructure to establish the full extent of the issues affecting the property.
Using advanced drone survey technology, DVC Roofing carried out a comprehensive roof inspection of the facility’s roof systems, pipework, gutters, and associated structures. The survey provided detailed imagery and condition reports without disrupting the client’s operations, allowing us to identify several areas that required immediate attention alongside longer-term refurbishment works.
Following the roof inspection, DVC Roofing developed a complete roofing solution tailored to the site’s operational requirements. The project involved refurbishing multiple buildings across the facility, each presenting its own technical challenges.
Acting as Principal Contractor, DVC Roofing managed every stage of the works, ensuring the project was delivered safely, efficiently, and with minimal disruption to the client’s live manufacturing environment.
The Challenge:
The Van Leeuwen facility remained fully operational throughout the project, making careful planning and coordination essential. The commercial roof refurbishment involved a combination of flat roofing, industrial metal roofing, rooflight replacement, structural alterations, and gutter waterproofing across several buildings.
Working above an active manufacturing facility required strict health and safety procedures, detailed programming, and close collaboration with the client to ensure production activities could continue uninterrupted. In addition, one of the warehouse roofs was found to be structurally incapable of supporting the proposed new roofing system, requiring a bespoke structural solution before refurbishment could proceed.
The project demanded technical expertise, effective project management, and the flexibility to deliver multiple specialist roofing solutions within a single programme.
Our Solution:
Office Block Roof Refurbishment
The office buildings required a complete renewal of their ageing flat roofing system. DVC Roofing carried out a full strip of approximately 600m² of existing roofing back to the joists before installing a new high-performance built-up felt roofing system designed to provide long-term weather protection and durability.
As part of the refurbishment, new rooflights were also installed, improving natural daylight within the building while enhancing the overall performance of the roof.
Main Manufacturing Facility
The largest phase of the project involved extensive refurbishment works to the main manufacturing roof. Approximately 2,300m² of rooflights were carefully removed and replaced over the live factory environment.
Given the nature of the works, comprehensive safety netting was installed throughout the project to protect both DVC Roofing operatives and the client’s workforce below. Every stage of the installation was carefully planned to minimise disruption while maintaining the highest health and safety standards.
Alongside the rooflight replacement programme, DVC Roofing installed approximately 2,000 linear metres of new ridge details and flashings to improve the roof’s weather resistance and overall integrity.
The project also included the preparation and installation of 800 linear metres of liquid waterproofing to the site’s existing failed metal gutters. This specialist system restored the performance of the gutters without requiring complete replacement, providing a cost-effective and long-lasting waterproofing solution.
Energy Warehouse Refurbishment
The Energy Warehouse presented one of the project’s most technically demanding challenges. The building featured approximately 1,800m² of ageing Galbestos roofing, which required careful treatment due to the presence of asbestos-containing materials.
Rather than removing the existing roof, DVC Roofing implemented a controlled encapsulation process to safely seal the asbestos before overcladding the roof with a new metal roofing system. This approach significantly reduced disruption while providing a modern, durable roofing solution.
During the design phase, structural assessments confirmed that the existing roof framework could not safely support the additional weight of the new roof system. Working alongside structural specialists, DVC Roofing designed and introduced additional steelwork to strengthen the building and ensure it could safely accommodate the overcladding installation.
The warehouse refurbishment also included a further 200 linear metres of liquid waterproofing to the existing metal gutters, extending their service life and improving the building’s overall weather protection.
Project Delivery:
DVC Roofing assumed full responsibility for planning, coordination, health and safety management, and programme delivery. Operating with a fully self-sufficient workforce enabled the project to progress efficiently while allowing Van Leeuwen to continue normal manufacturing operations throughout the refurbishment.
Maintaining business continuity was a key priority, and through careful sequencing of works, rigorous safety procedures, and proactive communication with the client, the project was completed with minimal operational impact.
The Outcome:
The completed roof refurbishment has significantly enhanced the performance, safety, and longevity of the roofing systems across the Van Leeuwen site. By combining drone surveying, structural engineering, specialist waterproofing systems, and high-quality roofing installations, DVC Roofing delivered a comprehensive solution tailored to the client’s operational needs.
The project demonstrates DVC Roofing’s ability to manage complex industrial roofing programmes across live manufacturing environments. Through technical expertise, innovative problem-solving, and effective project management, we delivered a durable roofing solution that will provide long-term protection for the facility while supporting the client’s continued business operations for years to come.
