Roof Refurbishment Works to Assist Solar Panel Installation
Table of Contents
Background of Case Study
RPMG were appointed by Thomas Halliwell, a world leading mechanical, electrical and renewable energy specialist company to assist with installing 120panel solar PV systems at a business park in Oldham. The works were essential in facilitating the implementation of renewable energy solutions across the business park, which resonates with RPMG’s dedication to the environment and finding environmentally friendly construction solutions. This project was part of a wider sustainability project for the business park and served as a critical stage in enabling the client to reduce energy costs and improve environmental performance.
The client had committed to investing in renewable energy but faced a significant obstacle. Following detailed investigations by the project team, it was established that the existing trapezoidal metal roof was unsuitable for supporting a new solar photovoltaic system. While the proposed solar PV array would provide substantial energy savings, the existing roof structure had deteriorated to a point where it could not safely support the new installation. RPMG were enlisted to assess the roof condition and develop a solution that would provide the required structural integrity and long-term performance.
Key Project Requirements
- Create a structurally sound roof suitable for solar PV loading.
- Extend the lifespan of the building envelope.
- Improve thermal performance.
- Minimal disruption to ongoing business operations.
- Deliver the works safely within a live industrial environment.
- Provide a future-proof roofing solution capable of supporting renewable technology for decades to come
Scope of Works
Working alongside the principal contractor and project design team, RPMG delivered the installation of approximately 2,156m² of Ash & Lacy AshGrid overclad roofing system across the facility.
Overcladding
The scope of works included overcladding the existing roof structure, this acts as cost effective alternative to a full roof replacement and holds several benefits including allowing the building to remain fully operational with minimal disruption to the occupants. Overcladding also means that there is little waste to dispose of, further adding to the environmental commitment of this job.
Structural Implementations
A new AshGrid roofing system was instated, which includes the installation of support bars and brackets. This assists with improving the load bearing and structural strength of the roof, making it an ideal solution for supporting solar panels. 0.7mm profiled steel roof sheets were installed, along with 240mm glass fibre insulation to significantly improve the building’s thermal efficiency and reduce heat loss. Existing rooflight outer skins were renewed with new GRP rooflights to maximise natural daylight within the workspace, helping to lower reliance on artificial lighting and reduce energy consumption.
Weatherproofing
New ridge, verge and eaves flashings were installed to create a fully weatherproof building envelope, protecting the property from water ingress and extending the service life of the roof. The project also included the installation of specialist fixings, foam fillers and weatherproofing components to enhance durability and performance in challenging weather conditions. Crucially, the roof was structurally upgraded and prepared to accommodate a new solar PV installation, providing the client with a secure, long-term platform for renewable energy generation. By refurbishing rather than replacing the roof, the solution minimised disruption to operations, reduced material waste, lowered lifecycle costs and future-proofed the facility for improved sustainability and energy savings for years to come.
Challenges Faced and Overcome
The project presented several operational and environmental challenges:
Existing Roof Unsuitable for Solar Installation
During the early stages of the project, assessments identified that the existing trapezoidal metal roof was not in a suitable condition to safely support the proposed solar PV system. The challenge was overcome through structural investigations and the installation of a new AshGrid overclad roofing system, providing a robust and compliant platform for the solar array.
Managing Roof Access and Safety
Refurbishing more than 2,000m² of roofing presented significant safety risks associated with working at height. These were mitigated through the use of scaffolding, edge protection, safety netting, MEWPs, crane lifting operations and comprehensive CDM-compliant safety procedures
Working in an Occupied Environment
Due to the works being carried out on an operational industrial facility, careful planning, coordination and phased delivery ensured minimal disruption to day-to-day activities while maintaining project progress
Balancing Structural Upgrades with Cost Efficiency
A full roof replacement would have increased costs, programme duration and waste generation. By adopting an overclad solution, the project delivered the required structural improvements, enhanced thermal performance and solar readiness while reducing disruption and improving overall value for the client
Outcomes & Benefits
RPMG successfully transformed an ageing industrial roof into a modern, energy-efficient roofing asset using an innovative overclad solution. By combining improved thermal performance, robust weatherproofing and structural readiness for solar PV technology, the project supports the client’s long-term sustainability objectives while protecting the building for decades to come.
Improved Thermal Performance
The installation of 240mm glass fibre insulation significantly enhanced the thermal efficiency of the building, helping reduce heating demand and operational energy consumption.
Reduced Waste
By overlaying the existing roof rather than undertaking a full strip-and-replace project, substantial quantities of material were diverted from landfill and embodied carbon impacts were reduced
Futureproofing for Long-Term Sustainability
The client required a roofing solution that would not only address current defects but also support future energy-generation technology. The installation of the insulated AshGrid system created a weatherproof, thermally efficient and solar-ready roof that extended the building's lifespan and enabled the successful installation of a 120-panel solar PV system.
Extended Roof Lifespan
The overclad roofing solution revitalised the existing roof without the need for complete removal, creating a robust, weather-tight building envelope that protects the underlying structure, reduces ongoing maintenance costs, and provides decades of additional service life
Improved Weatherproofing
The completed works significantly reduced the risk of water ingress, leaks and weather-related deterioration, enhancing the building's resilience against harsh environmental conditions while protecting the internal operations and assets below
Reduced Energy Consumption
The installation of 240mm glass fibre insulation and replacement GRP rooflights significantly improved the building's thermal performance and natural daylight levels. By reducing heat loss during colder months and lowering reliance on artificial lighting, the upgraded roofing system helps decrease overall energy demand, leading to lower operating costs and improved energy efficiency across the facility