The Challenge

The Fairfield Road project presented two key challenges for the Rock Roofing team to tackle.

The first was dealing with the unscreeded camber on the hollowcore beams, which required us to pay particular attention to the way we installed the insulation layer. As the insulation layer would be tapered to create the fall of the roof, even the slightest ripple in the insulation would have led to unwanted ponding of water over time. This meant that we would need to ensure the discrepancies in the surface level would need to be addressed before we could proceed with the installation.

The hollowcore concrete beams themselves also posed a challenge for drilling. There was a risk of drilling into the hollow core, which in turn could reduce the effectiveness of the screws we needed to install. This was something we therefore needed to bear in mind when planning our approach to the project.

The second challenge tested our ability to act quickly on short notice. An unexpected shortage of joinery services on site meant there was nobody available to install the plywood top cap for the roof, which in turn threatened to delay the whole project. Fast action was needed to make sure we could all continue with the installation as planned.

The Approach

Smoothing uneven surfaces 

To tackle the small discrepancies in the concrete substrate beams, we needed to smooth out the surface before attempting to install the insulation and membrane. To do this we added a sand blinding base layer, which bridged all those high-to-low points that would have caused rippling and water ponding if left untreated.

Saving time with a last-minute joinery solution

The lack of joinery services on site, while unexpected, was luckily something the Rock Roofing team was able to step in and fix. With our very own team of trained joiners on hand to help, we were able to arrange for the plywood top cap to be installed by Rock Roofing at short notice, preventing delays to the project.

Using adjustable fixings for a faster, safer installation

Because the hollowcore beams presented a drilling risk on a tapered roof, we determined that using adjustable fixings to install the insulation and membrane would be the best approach for this particular project. If we had used traditional fixings on a tapered roof, we would have needed to drill to varying depths into the beams, which created the risk of us drilling into the hollow sections. With the adjustable fixings, on the other hand, the fixings lock into a tube that sits above the substrate, which allows us to drill to a consistent, reduced depth and avoid that risk altogether.

Saving money with value-engineered cappings

It wouldn’t be a Rock Roofing project without us spotting an opportunity to save our clients money, and this time it was for the aluminium roof cappings. The original specification called for full-width aluminium cappings, which we were prepared to install.

However, once on site we identified that it would be possible to use the same quality of capping at a third of the width, which offers the same aesthetic and the same functionality as the original spec, but for half the cost. After suggesting this to the client, we were able to install the cappings quickly and efficiently, ahead of schedule.

The Results

The key success criteria for this project centred around time efficiency and quality, and the Rock Roofing team was able to deliver on all fronts.

Our ability to react to unexpected trade gaps and substitute our own skilled team members saved the project from certain and costly delays, while our keen attention to detail ensured that the uneven nature of the substrate was properly dealt with and would not lead to a compromised final result.

What’s more, our determination to add value to the project with our more efficient, value -engineered capping solution meant significant bonus cost savings for the client.

Do you have a residential project that requires a flexible approach? Our multi-disciplined team has all the skills and services to deal with even the most unexpected and challenging of circumstances. Get in touch via our contact page and tell us what you need; we’ll do the rest.