The Challenge

This large-scale supermarket roofing re-cover project posed many challenges, the first of which was the need for a very quick start on site following the main order placement with ourselves and the Mechanical & Electrical (M&E) contractors. This lead to some unforeseen coordination issues, particularly concerning the scope of the new refrigeration installation requirements for the store, which ultimately had a significant impact on our working timeframes and tightened our deadlines.

Unless we made some immediate changes to our working methods, these coordination issues would have meant both our system and the new refrigeration would have needed to be installed linearly, which would have resulted in the project programme not being achieved as initially planned.

In addition to these challenges, we also needed to manage the specifications of the proposed roofing system itself. The original specification proposed by the supplier included membrane fixings that did not have a locking thread at the top of the disc. This would mean that, as the roofing system was trafficked the insulation board would be compressed, which would push the fixings through the membrane — a pre-existing issue with the current roof that we did not wish to replicate with this new system.

And finally, with the building being a working supermarket, we needed to meet all of the above challenges in such a way that would avoid any water ingress during installation.

Waterproofing breaches were simply not an option, as the store needed to remain open throughout the project.

With all these challenges to work with, we needed to adapt fast and take decisive action in order to bring the project in on shifting timescales and with new, non-negotiable deadlines.

The Approach

Adopting to shifting deadlines

The best and most efficient way to accommodate the unforeseen changes surrounding the refrigeration installation schedule was with more manpower. We pulled team members off other projects at short notice

and reassigned them to this project to speed up our own schedule. In the short space of just a 6-day period, the newly-bolstered Rock Roofing team was able to re-cover half of the roof — a feat that would not have been possible on the original project scope.

This then allowed the refrigeration contractors to return to the site and continue their work with the fully-waterproofed roofing they needed to be able to carry out their installations safely and on time.

Advising on the best possible roofing specifications

To avoid the potential risk of seeing repeated issues experienced with the old roof, we advised Sika-Trocal on the design limitations of the original specification and re-proposed some improvements.

One of our main advisories was a change in fixings from the original stainless, non-locking head fixing to a carbon alternative with a locking head, which ensured that neither the fixings nor the discs on this new roof would be able to pop through the surface of the membrane as the roof is trafficked.

The Results

Despite early setbacks and very tight schedule, our flexible, adaptive approach in drafting man- power from other projects meant that the original programme was halved from 8 weeks to 4 weeks delivering results in record time and ensuring the activities of other contractors were not too heavily impacted or delayed.

Of course, time saving on its own is no measure for success if it means compromising on quality. In our case, highlighting the limitations of the original design specification and proposing changes certainly wasn’t a quick fix, but in the long run it meant the client would not see a repeat of the issues experienced with the old roofing system.

Here’s what our client, HB Projects had to say about working with us:

“Very’ impressed with the quality, ond Rock Roofing’s approach to the works on o doily basis. I would have no hesitation to use Rock Roofing on any contracts going forward.”
George Mitchell, Site Manager, HB Projects.

Do you have a complex project that requires a unique, adaptable approach?

The Rock Roofing learn is highly adaptable and resourceful, allowing us to respond to even the most difficult setbacks that will inevitably crop up in the current unpredictable climate. We work as an extension of your own team to advise on the most suitable, best-quality solutions that perfectly address the needs of even the most complex projects. Gel in touch via our contact page and tell us what you need: we’ll do the rest.