Polyroof and LRL Roofing Solutions were approached to refurbish the flat roof area at Harraby Community Campus in Carlisle. The existing single-ply membrane waterproofing system was in poor condition, resulting in numerous leaks reported in the interior of the building. The client requested a new high-performance waterproofing system to provide long-term protection against leaks.
Polyroof proposed the use of the BBA-approved Protec 20-year system in conjunction with new thermal insulation for the refurbishment. The goal was to provide a reliable and durable waterproofing that would improve thermal performance and reduce energy costs.
The main challenge faced in this project was the poor condition of the existing single-ply membrane and the leaks it caused. In the technical specification, Polyroof Technical Services outlined specific requirements and procedures for the project. The team proposed the encapsulation of the existing metal parapet capping, allowing the Protec system to be applied to the inner face of the parapet. A large ladder present on the roof was raised to provide a minimum 150mm upstand height to match the new roof level.
LRL Roofing Solutions also addressed the relocation of loose-lying M&E (mechanical and electrical) plant details to facilitate the application of the new waterproofing system. These details were later reinstalled on suitable support pads or plinths. Outlets were inspected, and any unsuitable ones were replaced with new ones to ensure proper functionality.
To prepare for the installation of the new waterproofing system, LRL thoroughly inspected the existing build-up, making necessary repairs and addressing any defects. All areas to be treated were cleaned, removing dirt, debris, surface lying water, mold growth, and moss. Areas with fungal growth or moss were treated with our Polykill “W” Anti-Fungal Wash. Wet or saturated substrates were dried out before any products were applied. Metal surfaces were mechanically abraded to remove loose paint and rust, while PVC protrusions were abraded and wiped with acetone. The existing single-ply membrane was made good and retained as an air and vapor control layer where the new Polyroof cut-to-falls insulation would be installed. Any cut-to-falls insulation was bonded to the vapor control layer using Polyroof Twin Pack Insulation Adhesive. Surface priming requirements were determined through adhesion tests.
During the construction phase, Technical Services emphasised the need to protect the warm roof construction from excessive moisture. If the roof construction became wet due to temporary protection failure, our team was available to provide advice on the requirement for temporary roof vents.
Once the insulation was in place, it was primed with Polyroof SA Primer, ensuring proper adhesion. The self-adhesive Polyroof SA Carrier Layer was then applied to the insulation, following our manufacturer’s recommendations.
Again,Technical Services provided detailed instructions for the primer coat application, specifying different primers for various surfaces. These included SP Primer for single-ply membranes, Polyroof Metal Detailing Primer for metal surfaces, and specific primers as per the Protec Manual for other surfaces.
The Protec Resin and Polymat 450 were applied in two coats, ensuring minimum coverage rates were met. LRL also installed Polyroof Pre-Formed GRP Drip Trims and Fillet Trims to enhance the system’s performance and aesthetics.
All roof termination details were carefully addressed to ensure a minimum 150mm upstand height and proper weatherproofing. Redundant roof details were removed, and the area underneath was made good to match the surrounding roof build-up.
Additionally, Polyroof’s ProGrip System was used to further enhance the safety and functionality of the refurbished flat roof area at Harraby Community Campus. The hybrid MMA anti-slip coating was used to create specific areas of demarcation, which served as visual markers and significantly improved safety measures.
With its catalyst-controlled and rapid curing properties, the coating dried in just 30-40 minutes, allowing the contractor to proceed with other tasks promptly.
Furthermore, ProGrip’s highly resistant nature ensured that the demarcation areas will maintain their appearance and functionality over time without any signs of discoloration.
In conclusion, the refurbishment of the flat roof area at Harraby Community Campus was successfully carried out using the Protec System. The new waterproofing solution, combined with the thermal insulation, provided the desired long-term protection against leaks. The project was completed according to our technical specification, and our 20-year guarantee provided the client with confidence in the durability and performance of the system.
