Fragile Roof Repairs in Manchester
Table of Contents
Background of Case Study
RPMG Global were appointed by Bridges Worldwide, an established carriage company, to investigate and resolve ongoing roof leaks at one of their warehouse facilities. During an initial inspection, it became apparent that the existing cement fibre roof was in a significantly fragile condition, with deterioration around fixings, sheet joints, cracks, and gutter interfaces creating multiple potential points of water ingress.
Due to the fragile nature of the roof, specialist access and safety measures were required before repairs could commence. Internal safety netting, stage boards, MEWP access, and rescue provisions were implemented to ensure the works could be carried out safely and efficiently. RPMG then undertook a programme of targeted remedial repairs, including the installation of profile-matched Filon oversheets and Seamsil 400 repairs, to restore the roof’s weatherproofing performance, extend its lifespan, and provide a cost-effective alternative to full roof replacement.
Key Project Requirements
- Install internal safety netting to designated roof areas.
- Provide safe access via MEWP and rescue provision via internal scissor lift.
- Install stage boards to enable safe working on the fragile roof.
- Supply and install profile-matched Filon oversheets.
- Carry out Seamsil 400 repairs to fixings, cracks, gutter joints, and roof details.
- Work in accordance with fragile roof and working-at-height safety requirements.
- Remove and dispose of all waste materials from site.
- Deliver a best-endeavours repair solution to address identified water ingress defects.
Scope of Works
The project required the installation of internal safety netting beneath the designated work areas, complemented by stage boards across the roof surface to provide a safe working platform and prevent loading of the fragile sheets. Access and egress were achieved using a large MEWP, while an internally positioned scissor lift was maintained throughout the project as part of the site’s rescue plan. Once safe access provisions were established, RPMG supplied and installed profile-matched Filon oversheets to damaged rooflight sections and carried out targeted repairs using Seamsil 400 to seal and reinforce fixing bolts, sheet cracks, gutter joints, and associated roof details. All resulting waste materials were removed from site upon completion.
The completed repairs restored the integrity of the roof covering, significantly reducing the risk of water ingress and extending the serviceable lifespan of the existing roof without the need for extensive replacement works. The specialist sealing system improved weather resistance across vulnerable areas whilst providing a cost-effective maintenance solution for the client. Furthermore, the use of carefully planned access systems allowed RPMG to safely undertake works on the fragile roof structure whilst minimising disruption to the occupied premises.
Challenges Faced and Overcome
The project presented several operational and environmental challenges:
Roof Fragility
The existing cement fibre roof was found to be in a highly fragile condition, preventing operatives from working directly on the roof surface. RPMG overcame this challenge through the installation of internal safety netting and stage boards, creating a safe working environment whilst protecting both personnel and the building occupants below.
Identifying Water Ingress
Water ingress can often originate from several defects rather than a single failure point. Deteriorated fixings, cracked sheets, failing gutter joints, and weathered roof details all had the potential to contribute to the leaks. A systematic inspection and repair approach was adopted to identify and address each potential ingress point.
Working In An Occupied Environment
Repairs were carried out above an operational warehouse, requiring strict controls to protect personnel, equipment, and stored goods below. Safety netting and controlled work zones were implemented to mitigate the risk of falling objects.
Matching Existing Roof Components
The installation of new Filon oversheets required compatibility with the existing roof profile. Careful selection of materials ensured the replacement components integrated effectively with the existing roof structure whilst restoring natural daylight provision and weather protection.
Outcomes & Benefits
Extended Roof Lifespan
By addressing deterioration around fixings, sheet cracks, rooflights, and gutter interfaces, the remedial works helped extend the operational lifespan of the existing roof and delayed the need for a more costly replacement programme.
Reduced Risk of Water Ingress
Targeted Seamsil 400 repairs sealed multiple potential leak paths and improved the overall integrity of the roof covering, significantly reducing the likelihood of future water penetration.
Improved Weatherproofing
The combination of oversheet installations and specialist sealing works enhanced the roof's resistance to adverse weather conditions, helping to protect the warehouse and its contents from moisture-related damage.
Cost Effective Alternative to Roof Replacement
The repair strategy provided the client with a practical and economical solution, delivering significant improvements to roof performance without the disruption and capital expenditure associated with a full roof refurbishment.
Enhanced Natural Daylight
The installation of profile-matched Filon oversheets improved the condition of deteriorated rooflight areas whilst maintaining natural daylight penetration into the warehouse environment.
Maintained Business Operations
Through careful planning and the implementation of specialist access systems, the works were completed whilst allowing the facility to remain operational, minimising disruption to the client's day-to-day activities.