A historic and
archaeological treasure, the Royal Gunpowder Mills heritage site in Waltham
Abbey, Essex, has been given a new lease of life with a stunning and
sympathetic roof refurbishment.
Consisting of listed
buildings, ancient monuments and natural aspect features, the site is a
well-loved attraction. A busy hub of activity, it attracts thousands of
visitors every year, with exhibitions and a programme of hands-on activities
for school groups.
With previous roof
coverings across the site’s buildings close to derelict, a new roofing system
was needed that would both guarantee a durable solution and fit with the
aesthetic of the heritage buildings. To meet those needs, Sika Sarnafil
G410-15EL FSA Lead Grey was specified alongside Sarnavap 1000E air and vapour
control layer.
The high-quality
roofing system was chosen after the project’s main contractors Courtenay
Builders Limited were impressed with the results from similar Sika Sarnafil
projects. They also entrusted Contour Roofing with the specification and
installation after seeing its award-winning track record with Sika Sarnafil.
As a site once home
to tonnes of explosives and with visitors in throughout the refurbishment, the
project proved challenging, requiring extensive attention to health and safety.
A strict ban on naked flames and hot works meant that the plywood boards had to
be primed immediately after installation and before exposure to any wet
weather. The specification therefore considered this and the original system,
which would have needed a completely dry substrate, was switched to a loose
laid polyethylene air and vapour control layer that was more equipped for a
faster installation in the expected conditions.
Further challenges
were met due to the 45-degree pitch of the roof. Roof ladders had to be used to
allow workers access to the complex angles and achieve a seamless finish, using
Sarnafil membrane and bespoke Sarnametal flashings at abutments, changes of
angle and ridge angles.
Although time
consuming work that required the utmost skill to ensure the roofs were
completed to the highest standards, the project was kept on track. With
Contour’s contract manager making daily site visits, coupled with regular site
visits from Sika Sarnafil Technicians, the project finished a week early.
Jonathan Woods,
managing director at Contour Roofing, says: “This was a particularly
interesting roof refurbishment with unique and complex challenges due to the
nature of the site. However, by ensuring we had the right team in place with
relevant experience, and the added support from Sika, we were able to complete
the installation a week early while still providing an excellent finish that
wowed the client.”
Securing a 20-year
Sarnafil guarantee, the newly refurbished roofs have not only met the client’s
need for a stunning aesthetic, but have also provided a durable weatherproof
roofing system – upholding the heritage charity’s mission to conserve the site for
the benefit of the general public.
