D&D ROOFING

Cameron Court - Case Study 2024

CASE STUDY

Project Title: Cameron Court

Client: Owner

Location: Warrington, United Kingdom

Project Overview:

Phase 2 of the re-roofing project in Warrington involved a comprehensive survey to assess the condition of the existing roof and confirm that an overlay of the current waterproofing could be successfully applied.
Key works included:
• Installing thermal insulation to meet current building regulations
• Mechanically fastening a new single-ply membrane
• Fully encapsulating the building perimeter with the single-ply membrane
• Fitting new triple-skin polycarbonate rooflights
Thanks to exceptionally dry weather conditions, the project was completed two weeks ahead of the scheduled completion date.
Following a successful Electronic Leak Detection Test, a 20-year warranty was issued, and the project was officially handed over by Protan’s Technical Team.

Project Summary

We successfully delivered a full refurbishment of an existing flat roof to a commercial unit at Cameron Court Industrial Estate in Warrington. The project focused on upgrading the thermal performance, extending the service life of the roof, and ensuring compliance with current standards—while minimising disruption to the building occupier.

Background and Local Context

Cameron Court Industrial Estate is situated in Warrington, Cheshire—a thriving commercial and logistics hub in the North West of England. With excellent transport links via the M6, M62, and M56 motorways, Warrington has seen sustained growth in light industrial and warehousing developments, making reliable, thermally efficient building fabric a key requirement for local businesses.

The client required a refurbishment solution that would not only meet modern building regulation standards for thermal performance but also minimise operational disruption to the tenant.

Initial Roof Condition

The existing roof build-up comprised:

Metal structural deck
Vapour control layer (VCL)
50 mm PIR insulation
Built-up felt membrane system

While the existing felt system had reached the end of its serviceable life, the underlying structure remained in suitable condition for refurbishment.

Survey and Analysis

Before specifying a solution, we carried out extensive surveys to ensure our proposal would deliver the best long-term performance:

Condensation Risk Analysis: Confirmed the suitability of the new build-up and VCL strategy to prevent interstitial condensation.
U-value Calculation: Demonstrated the upgraded insulation layer would meet and exceed current Building Regulations.
Pull-Out Tests (by SFS): Verified that the existing metal deck would provide sufficient mechanical pull-out resistance for the new fixings.

This rigorous approach ensured full compliance with technical requirements while reducing risk during installation.

Specification and Solution

To avoid stripping the existing roof—which would risk water ingress and disrupt the tenant’s operations—we specified an overlay system:

Insulation: 100 mm PIR boards, mechanically fastened to the metal deck through the existing build-up.
Membrane: Protan SE 1.6 mm single-ply membrane, mechanically fastened.
Perimeters: All parapet upstands and perimeter details fully encapsulated in the new system.

This approach upgraded the thermal performance of the roof to meet current Part L standards while offering robust, long-term waterproofing.

Installation and Quality Assurance

The new system was installed with minimal disruption to the tenant’s daily operations.
All works were completed to manufacturer specifications.
The completed roof underwent electronic leak detection testing to verify watertightness.
Final inspection and sign-off were provided by Protan, securing a 20-year system guarantee for the client.

Outcome

The project delivered:

By taking a careful, survey-led approach and selecting the right overlay system, we ensured a cost-effective, high-quality solution for our client at Cameron Court Industrial Estate.

Looking for expert flat roof refurbishment?
If you’d like to discuss a similar project or need advice on the right system for your building, get in touch via our contact page.
You can also visit our dedicated Protan page to learn more about the systems we install.

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