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Roof Refurbishment for Aston Martin's Headquarters

As described by Aston Martin Lagonda Ltd, "Gaydon [headquarters] combines cutting-edge technology with hand-craftsmanship and traditional techniques, providing an infrastructure ideally suited to innovation, creativity and advanced engineering. Providing a tailor-made space for our world-leading design team, the Gaydon Design Studio has enabled Aston Martin to tightly integrate its renowned design capability with engineering and production processes." It comes as no surprise then, that when the roof started leaking, they wasted no time finding the right high-performance and rapid solution for this problem.

After carefully considering the options available for refurbishing the roof, the client elected to use Polyroof's advanced liquid roofing systems as the optimum solution for the job. As a company passionate about UK manufacturing, Aston Martin's choice to work with Polyroof - the only independent UK manufacturer of cold-applied liquid systems - was a natural one.

A number of key criteria for the roofing works were set out by the client. The new roofing system had to be cold-applied to eliminate the risk of accidental fire during installation and new insulation was desirable to further improve the thermal performance of the roof. It was essential to reduce disruption to the operations of the facility, meaning any new system must be rapid to install with the existing roof predominantly being kept in place.

After initial consultations with the client, Polyroof Technical Services conducted a detailed roof survey to put together a comprehensive set of recommendations that met every aspect of Aston Martin's stringent performance criteria.

The Polyroof Solution

The findings of Polyroof's survey were presented to Aston Martin in the form of a bespoke specification, where the Protec Warm Roof System was the recommended solution. Core tests taken during the inspection had revealed that despite the leaking through the existing PVC single-ply membrane, the existing build-up of 60mm PIR insulation was found to be dry and in sound enough condition to be retained as the base for the new roofing system.

It was also identified during these tests that the current insulated roof configuration was missing a Vapour Control Layer, meaning the roof was at risk of condensation issues. This problem was designed out by the installation of 120mm Polyroof RES Insulation above the existing single-ply membrane, which was made good to form an effective vapour control layer. By creating a "hybrid" roof with double the insulation above the vapour barrier than below, the risk of condensation was eliminated and this was demonstrated by analysis conducted on the proposed build-up.

The roof had also been suffering from standing water issues which the client wanted to eliminate. This was achieved through the formation of sumps around the existing outlets, greatly improving their drainage capacity, and offering a highly cost-effective solution when compared to the need to alter the falls of the roof

The roofing works were carried out by Polyroof Approved Contractor Mars Construct Ltd to an extremely high standard that was worthy of such a prestigious client. After removing the existing chippings from site, the single-ply membrane was made good and cleaned and the claddings around the perimeters were temporarily released to accommodate the new insulation. 120mm Polyroof RES Insulation was bonded to the existing coverings using Polyroof's high-performance twin pack PU adhesive, a process which is extremely rapid and offers superior wind-uplift resistance.

Once the insulation was in place, the board joints were locally reinforced with Protec resin and a 450g/m2 fibreglass bandage to strengthen these details. Next, the first layer of Protec was applied direct to the insulation, incorporated Polymat 450 reinforcement. After only 30-60 minutes after application, the second coat of Protec resin can be applied to complete the system.

The finished roof provided a seamless and extra-tough waterproof membrane that was supported by the trusted Polyroof Accredited System Guarantee, with a separate insurance-backing scheme provided at no cost to the client. Aston Martin Lagonda now have the peace of mind that the roof above this landmark facility will be leak-free for decades to come.

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