GRP FLAT ROOF INSTALLATION IN DARLEY DALE
Coverclad Services were instructed to undertake a GRP flat roof installation in Darley Dale, Derbyshire. The existing felt flat roof had deteriorated past its lifespan and was suffering water ingress through multiple roof penetrations into the loading bay below.
Our task was to install a GRP flat roof over the top of the existing felt flat roof, together with a few additional works. First the existing roof was prepared, then OSB 3 boards were screw fixed to the existing roof substrate. Next, lead replacement flashings (GRP trims) were installed and then the premium 600g CSM fibre complete with resin bonded application was applied to the roof and left to cure. Finally, the grey top coats were rolled out to finish the GRP system.
Additional works included slight alterations to the existing steel and felt upstands and installing a new drainage outlet point together with new UPVC downpipe, hopper and associated gutter components.
Photos from the GRP flat roof installation in Darley Dale are below. If you are looking for GRP flat roofing installers, then please contact us on 01384 573088. Alternatively you can send us a message or contact us on 07976 726770 if you are in need of an emergency callout.
Before view of the existing felt flat roof. The upstand stops the water cascading over the side of the unit, but with only one outlet point, ponding can occur during heavy downpours.
Close-up of the only outlet point to the felt flat roof.
Close-up of the outlet showing how water exits into the gutter. The problem with this design is the water collects into the gutter and then waits to be discharged further around the gutter run. Ideally there should be a downpipe here so that during heavy downpours the water discharges quickly and does not overflow.
Also at the outlet point, there is no weather seal to the felt perimeter upstand.
View of the felt perimeter upstand to the opposite side of the roof, where an alteration and second drainage outlet point was to be created as part of our GRP flat roofing in Derbyshire.
View of the existing roof penetration and upstand detail chased into the stonework.
Progress of works with OSB 3 boards screw fixed down to the existing substrate and expansion trims in place, allowing for thermal movement in both hot and cold conditions. CSM Fibre matting also laid and some of the GRP resin also applied.
After laying the resin, our GRP installers go over the roof and check for imperfections and small pieces of debris (often gathered through foot traffic). Those areas are sanded off (white dust sections in the photo) and treated again to achieve a consistent excellent finish across the roof. Also notice the felt perimeter upstand fully encapsulated with GRP to weather seal it off.
Lead replacement flashings (GRP trims) installed, chased into the stonework with Giromax Seamsil bead along the top edge.
Glass reinforced resin (GRP) topcoat applied to the trims, prior to rolling the GRP top coats out across the roof. Notice the new dektite with box feature in the background.
Close-up of the existing outlet point, with fleece and GRP resin bonded down into and around the existing UPVC gutter so water cannot track behind. The side of the old felt perimeter upstand also fully encapsulated with GRP.
Close-up of the second outlet point created in the opposite corner of the roof. In this section, the existing perimeter upstand was taken down to the new roof substrate and OSB 3 board fitted. Then fibre mat and resin applied down into the newly installed UPVC hopper and downpipe.
Dark grey GRP top coat rolled out across the new flat roof. Roof penetration box feature in the background.
Completed view of the GRP flat roof installation in Darley Dale.