What we found on site
Multiple membrane generations had been layered over 25 years of service. Active leaks were affecting production lines below, and roof loading was approaching the structural limit for any further overlay.
Shutdown was not an option. Works had to be phased zone-by-zone with live process equipment immediately below — fire watch, hot-work permits, and dust containment had to integrate with the operator's HSE regime.
Coastal exposure, UV, and roof traffic from maintenance crews meant the new system had to combine elasticity, mechanical resistance, and a fully reinforced detail at upstands and penetrations.
From survey to handover
Survey, core sampling & load assessment
Roof cores quantified the existing build-up. A structural review confirmed the strip-back-to-deck strategy and the maximum allowable weight of the new system.
Phased strip-out
Failed membranes and saturated screed were removed in zones aligned with production schedules. Debris was collected in sealed skips routed away from intake louvres.
Screed and deck repair
Local screed reinstatement and cementitious smoothing established falls back to drainage. All upstands and penetrations were detailed before primer.
Liquid-applied PU + reinforcement
A one-component liquid PU was applied in base + intermediate + topcoat layers with a polyester reinforcement fleece embedded at the intermediate pass. All details received a double-reinforced wrap.
Flood test & handover
Each zone was flood-tested for 24 hours before reinstatement of plant penetrations and handover, with full as-built drawings and warranty documentation.
System breakdown
Liquid-applied PU membrane
Cold-applied, UV-stable polyurethane delivering a seamless, fully bonded waterproofing layer ideal for complex industrial roof geometries.
Polyester reinforcement fleece
Embedded mid-layer that absorbs substrate movement, bridges hairline cracks, and reinforces every upstand and penetration detail.
Phased delivery model
Zoned programme integrated with the operator's HSE and production schedule — no plant shutdown, full permit-to-work compliance across the 20-week window.
- Membrane
- Liquid-applied PU, 2.2 mm DFT
- Reinforcement
- Polyester fleece, embedded mid-coat
- UV resistance
- Stable, no recoat required
- Service temperature
- −30 °C to +90 °C
- Foot traffic
- Light maintenance, certified
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