INDUSTRIAL ROOFING IN DUDLEY - GIROMAX, OVERCLAD AND PLYGENE
This was an interesting project for our Coverclad industrial roofing experts in Dudley. The client had specified for the existing metal roof sheets over four slopes (plus associated parapet walls) to be cleaned, prepared and painted with Giromax Architectural Coating, as part of a retail unit refurbishment. Gutter re-lining works were also to be carried out. We quoted without roof access being permitted during the tendering stage and were awarded the contract.
Upon arrival to begin works the reality was quite different. During the initial roof cleaning stage the old plastisol from the metal sheets started to delaminate extensively back to the bare metal, so we consulted a Giromax representative to inspect the roof. It was discovered that the original roofing sheets colour was an offset white rather than goosewing grey (installed decades ago) and may have formed part of a faulty batch of roof sheets whereby the plastisol had not properly adhered to the metal substrate of the roof sheets (solar degradation would then have a multiply affect leading to accelerated delamination). Without roof access being permitted during the tendering stage, detecting these unforeseen problems was impossible.
Costs would have escalated for the additional labour time and chemicals needed to prepare the roof to the standard required for Giromax, which requires thorough preparation. So as industrial roofing experts we offered an alternative method of refurbishment to keep within budget, an industrial roofing overclad, which the client opted for.
Photos and further information on the roofing overclad and associated gutter refurbishment works is below. If you require industrial roofing experts, Giromax specialists or Plygene installers in Dudley or the West Midlands then please call 07976 726770. Alternatively you can send us a message.
View of the existing retail unit industrial roofing in Dudley before undertaking any works. Rubber washers on the fixings across the roof were perished and compromised to indicate possible areas of water ingress.
Close-up of the cut edge corrosion to the mid-laps and spotted delamination. Algae and lichen has also built up across the roof.
Close-up of one of the roof penetrations with historic temporary repair and possible water ingress.
On the end neighbouring unit, there were several historic repairs to the ridge flashings, which indicates that the entire roof is starting to fail in several areas.
Before view down the industrial roof slope to the valley gutter.
Before view of the front elevation slope down to the eaves, showing the parapet wall with single skin metal profile sheets. The original spec was also to clean and spray with Giromax, but again it was more efficient to replace with new metal roofing sheets.
Close-up of one of the perimeter valley gutters full of water, debris and vegetation.
Eaves fillers have perished after being pecked at by seagulls.
Close-up of the industrial roofing in Dudley after initial light blast from a distance with a jet wash (to remove the algae before the second cleaning phase). The offset white plastisol coating has clearly started to delaminate in random areas, which highlights areas of concern.
Close-up of the offset white failing plastisol, flaking and not properly adhering to the metal substrate of the roof sheets.
The small area of industrial roofing being turbo lanced following the initial cleaning phase. The plastisol is blowing off to fully expose the galvanised steel beneath.
View of the retail unit industrial roofing in Dudley during the initial general cleaning phase. The process exposed spotted areas of delamination all over the roof, so we then applied the powerful turbo lance jet wash to a small area. All of the plastisol blew off to fully expose the galvanised steel beneath. The new wall cladding sheets are for the inner side of the parapet wall.
Comparison against the neighbouring unit roof after the initial cleaning phase. Left shows the delaminating offset white plastisol coating to our roof and right shows a historic Giromax overspray to the neighbouring unit. The original specification for a Giromax overspray to our roof was to match the specification to the neighbouring roof.
On closer inspection of the Giromax overspray to the neighbouring roof, a bobbling effect had started to occur in numerous areas. The previous contractor had applied the Giromax without thorough enough preparation. If applying Giromax to an existing coating that isn’t bound to the metal substrate, as soon as the middle layer peels or bubbles anything on top will also flake off.
Installed galvanised steel gridding out system onto the existing roof ready for insulation and the new external 0.7mm plastisol coated goosewing grey metal roof sheets. Safety nets were not required for this industrial roofing overclad in Dudley because no rooflights were installed.
Eaves flashing installed onto the built-up grid system ready to allow water to pass down into the new Plygene gutter.
Eaves flashing also installed at valley gutter level, again allowing the water to pass down into the new Plygene gutter.
Our Coverclad industrial roofing experts in Dudley taking delivery of the rolls of insulation for the built-up overclad system, to be installed following agreement with the main contractor and client that Giromax was no longer feasible.
View of the internal downpipe that required industrial gutter repairs in Dudley. The rubber had perished on the collars to the joints because they hadn’t lined up fully. We took off the bottom section and installed a new joint.
Perimeter gutter first stage cleaning with rust and delamination of the cut edge corrosion at eaves level.
View along the valley gutter before the industrial gutter re-lining in Dudley commenced.
View along the valley gutter after the Plygene gutter liner has been installed.
Close-up of the retail unit valley gutter boundary dam, full of water, debris and vegetation, plus brown rust visible to the base of the gutter.
Close-up of the boundary dam between the retail units, to separate the industrial gutters. Plygene Gutter Liner in position.
Close-up of the Plygene gutter liner being installed to the valley gutter.
Completed HD Sharman Plygene Gutter Liner in Dudley. Heat welded outlet with eaves flashing to the left hand side of the gutter upstand (the dark flashing with new fixings). It’s purpose is to retain the upstand of the Plygene gutter.
Completed roof slopes with Uniclad 34/1000 profile 0.7mm plastisol coated goosewing grey metal sheets, and verge details stepping down onto the neighbouring units. Because of the delays from transpiring problems we assigned two teams to the roofing works in order to complete the job within the specified timescales.