PROJECT OVERVIEW

A Complete Industrial Metal Roof Overcladding Transformation

Young & Company completed an extensive industrial metal roof overcladding and refurbishment project at Bifold Rotork in Middleton, Greater Manchester.

The existing building incorporated a large traditional profiled metal built-up roofing system covering an extensive commercial and industrial premises.

The existing roof required a comprehensive refurbishment solution to upgrade its external weathering, insulation and associated roofing components.

Rather than completely stripping and replacing the original roof system, Young & Co undertook an over-roofing project, installing a new profiled metal roof covering above the existing roof construction.

The refurbishment incorporated Steadman AS30 profiled metal roofing sheets in 0.7mm thickness, together with an upgrade to the existing roof insulation.

New Brett Martin GRP rooflights were installed to suit the replacement AS30 roof profile, providing natural daylight across the substantial industrial roof areas.

The project also involved replacement of the existing external eaves gutters with Young & Co Highline gutters and the installation of purpose-made fabricated flashings and associated weathering details.

By coordinating the new external roof covering, insulation upgrade, rooflight replacement and rainwater drainage improvements, Young & Co delivered a comprehensive refurbishment of the existing industrial roof.

The completed project demonstrates the advantages of metal roof overcladding as a practical long-term refurbishment solution for suitable ageing commercial and industrial buildings.

THE EXISTING BUILDING

Ageing Profiled Metal Built-Up Roofing System

Before refurbishment, the Bifold Rotork premises featured an extensive pitched roof constructed using a traditional profiled metal built-up roofing system.

The original roofing incorporated multiple rooflight runs distributed across the roof slopes, providing natural daylight within the industrial building.

Like many commercial and industrial buildings constructed during the latter part of the twentieth century, traditional profiled metal roof systems may require refurbishment as the original coverings, fixings, insulation and associated weathering details age.

Common issues associated with ageing metal roofing can include coating degradation, cut-edge corrosion, deteriorating fixings, rooflight failure, poor insulation and recurring maintenance requirements.

At Bifold Rotork, the project involved upgrading the existing roofing system through a comprehensive metal roof overcladding package rather than undertaking a complete roof strip and replacement.

The scale of the building required a coordinated refurbishment approach, incorporating the main roof covering, rooflight arrangements, insulation and external rainwater drainage details.

The existing roof structure and geometry provided the basis for the new metal overcladding design.

METAL ROOF OVERCLADDING

Refurbishing the Existing Roof Without Complete Removal

Metal roof overcladding is a specialist refurbishment method involving the installation of a new roofing system above an existing profiled metal roof covering.

Where the condition of the existing roof and supporting structure is suitable, this approach can provide an alternative to complete roof removal and replacement.

The existing roofing system is retained beneath the new external covering, with the new roof construction designed to accommodate the existing building geometry and required performance improvements.

At Bifold Rotork, Young & Co installed a new insulated metal roofing system over the existing profiled metal built-up roof.

This approach provided an opportunity to improve the building’s weather protection, thermal performance and overall appearance while retaining the original roof construction.

Potential advantages of this refurbishment method include:

• Retention of suitable existing roof components.
• Reduced disruption compared with complete roof stripping.
• Improved external weather protection.
• The opportunity to upgrade thermal insulation.
• Replacement of ageing rooflights.
• Integration of new rainwater drainage details.
• A modern and coordinated roof finish.
• A practical long-term alternative to repeated maintenance.

The suitability of metal roof overcladding depends on the condition of the original roof, supporting structure, structural loading, moisture performance and project-specific design requirements.

The Bifold Rotork project demonstrates the use of an insulated metal overcladding system to modernise a substantial industrial roofing installation.

STEADMAN AS30 METAL ROOF OVERCLADDING SYSTEM

New 0.7mm Profiled Metal Roof Covering

The new external roof covering was installed using Steadman AS30 profiled metal roofing sheets in 0.7mm thickness.

The new profiled metal roofing provided a modern external weathering surface above the original built-up roof construction.

The AS30 profile was incorporated across the extensive roof slopes, creating a clean and coordinated appearance over the complete roof area.

The new roofing system also accommodated replacement GRP rooflights, purpose-made flashings, ridge and verge details, eaves weathering and the replacement external guttering.

The completed system provided a consistent profiled metal roof finish, substantially improving the external appearance of the building.

Steadman AS30 formed the principal external roof covering within the refurbished insulated over-roofing system.

The aerial photographs clearly demonstrate the scale of the new roof covering and the coordinated layout of the rooflights across the completed industrial building.

INDUSTRIAL ROOF INSULATION UPGRADE

Improving Thermal Performance Through Roof Overcladding

An important part of the Bifold Rotork refurbishment was the upgrade to the existing roof insulation.

Older profiled metal built-up roofing systems may no longer provide the level of insulation performance expected from modern commercial and industrial buildings.

A metal roof overcladding project presents an opportunity to introduce additional insulation within a suitable new roof build-up, helping improve the thermal performance of the existing building envelope.

At Bifold Rotork, the roof refurbishment incorporated an insulation upgrade alongside the new Steadman AS30 profiled metal roof covering.

This allowed both external weather protection and insulation improvements to be addressed within the same refurbishment project.

The insulation arrangement must be designed to suit the existing roof structure, condensation-control requirements, roof loading and target thermal performance.

The completed works provided a modernised insulated roofing arrangement without requiring complete removal of the existing built-up metal roof system.

INDUSTRIAL ROOFLIGHT REPLACEMENT

Brett Martin GRP Rooflights – Steadman AS30 Profile

The replacement of the existing industrial rooflights formed another important element of the refurbishment.

The original metal roofing system incorporated multiple rooflight runs across the roof slopes.

As part of the overcladding project, Young & Co installed replacement Brett Martin GRP rooflights manufactured to suit the new Steadman AS30 profiled metal roofing system.

The rooflights were incorporated into the new external roof covering, providing a coordinated installation with the surrounding profiled metal sheets.

Replacement rooflights can offer improvements in natural daylight provision, roof weather protection and the overall performance of an ageing roofing system.

By incorporating rooflight replacement within the main overcladding works, the new roof covering and rooflight interfaces could be designed and installed together.

The completed aerial photographs demonstrate the regular arrangement of the new rooflights across the extensive refurbished roof slopes.

The combination of the new Steadman metal roofing and Brett Martin GRP rooflights provided a clean, consistent and modern roof finish.

INDUSTRIAL GUTTER REPLACEMENT

Young & Co Highline Eaves Gutters

The Bifold Rotork refurbishment also incorporated replacement of the existing external eaves guttering.

Effective rainwater drainage is an essential component of industrial roof refurbishment, particularly where a new external roof covering is installed above an existing roofing system.

The new roof covering requires suitable eaves and perimeter details to coordinate the roof weathering arrangement with the rainwater drainage system.

At Bifold Rotork, Young & Co installed replacement Highline-type eaves gutters to suit the new roof construction.

The gutters were integrated with the Steadman AS30 profiled metal roofing system, new eaves details and associated fabricated flashings.

The replacement guttering formed part of the comprehensive roofing refurbishment rather than being treated as a separate maintenance item.

This approach allowed the roof covering, gutters and associated weathering details to be installed as one coordinated system.

IN-HOUSE FABRICATION

Young & Co Purpose-Made Fabricated Flashings

An important element of the Bifold Rotork refurbishment was the manufacture and installation of purpose-made fabricated flashings and associated metal roofing details.

Young & Co operate their own in-house fabrication facilities, allowing metal components to be manufactured to suit the individual requirements of existing commercial and industrial buildings.

For metal roof overcladding projects, accurately manufactured flashings and trims are particularly important because the new roof covering must interface with the existing roof geometry and building structure.

The fabrication package incorporated associated details for:

• Ridge and verge weathering.
• Eaves and gutter interfaces.
• Roof perimeter details.
• Rooflight and profiled sheet interfaces.
• Junctions with existing building elements.
• Associated trims and weathering components.

The in-house fabrication process provides greater control over component production, site coordination, quality and the completed appearance of the roofing package.

At Bifold Rotork, these purpose-made details helped provide a consistent finish across the extensive refurbished roof.

A COORDINATED INDUSTRIAL ROOF REFURBISHMENT

Roof Covering, Insulation, Rooflights and Gutters – One Project

The Bifold Rotork project demonstrates the benefits of coordinating multiple roof refurbishment elements within one comprehensive package.

Rather than treating the existing roof covering, rooflights, insulation and gutters as separate maintenance requirements, Young & Co undertook a complete metal roof overcladding refurbishment.

The works incorporated a new external profiled metal roof covering, upgraded insulation, replacement rooflights and new guttering, together with the necessary purpose-made fabricated details.

This approach allowed the different roofing components to be coordinated within the overall roof refurbishment design.

For commercial property owners and industrial building operators, a complete metal roof overcladding project can provide a practical alternative where an existing roof requires significant upgrading but remains suitable for retention beneath a new roofing system.

The completed works delivered a coordinated roof finish and a long-term refurbishment solution for the industrial premises.

THE COMPLETED REFURBISHMENT

Transforming a Large Industrial Metal Roof

The completed Bifold Rotork project demonstrates how a substantial commercial and industrial roofing system can be modernised using insulated metal roof overcladding.

The existing profiled metal built-up roof was retained beneath a new profiled metal weathering system, while the insulation, rooflights, gutters and associated roof details were upgraded.

The project delivered:

• Overcladding of the existing profiled metal built-up roof.
• Installation of Steadman AS30 0.7mm profiled metal roofing.
• Upgraded roof insulation.
• Replacement Brett Martin GRP rooflights.
• New Young & Co Highline eaves gutters.
• Purpose-made fabricated flashings and trims.
• Coordinated ridge, verge, eaves and weathering details.
• Improved external weather protection.
• Improved insulation provision.
• A modern, uniform external roof appearance.
• A comprehensive industrial roof refurbishment solution.

The completed aerial photographs demonstrate the scale of the transformation, with the extensive roof slopes finished in a consistent profiled metal covering and replacement rooflights.

The Bifold Rotork project highlights Young & Co’s experience in large-scale commercial and industrial metal roof overcladding, insulated roof refurbishment, rooflight replacement and guttering upgrades across Greater Manchester and the North West.

Get In touch with Young & Co

Telephone: 0161 339 9637
Email: enquiries@clonshall.co.uk