The roof structure of the Applemore Leisure Centre covering 2,400m², had several issues identified during Makers Construction detailed survey.

The existing roof system consisted of a bituminous vapour control layer, 25mm PIR insulation, 13mm fireboard, 60mm PIR insulation, and a BUR system.

This topped with a cold applied liquid system. Despite previous upgrades, the roof only achieved a U-value of 0.36 W/m²K, which fell short of current energy efficiency standards. Further inspection revealed visible fibreglass matting through the coating, indicating that the coating had not been applied to the required thickness.

The fibreglass matt, being UV unstable, had deteriorated over time, compromising the integrity of the system. In addition, water ponding on certain areas of the roof had caused the coating to wear down quicker in these sections, further weakening the structure.

Additional challenges included the presence of ineffective mushroom vents installed in isolated areas by previous contractors. These vents were intended to help dry out the original roof build up but were not successful. Some areas of the roof had coatings applied directly over loose chippings, which caused cracking due to poor adhesion. Several upstands were found to be below the recommended 150mm height as per BS 6229:2018, creating a potential failure point for the waterproofing system.

Read how the full Roof Refurbishment was carried out and how U-Value was achieved…

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