When the
existing flat roof above the International Departure Lounge at Gatwick
Airport’s North Terminal was failing, Kemper System’s liquid applied
waterproofing was the first port of call.
Working
closely with contractors, Mitie Tilley Roofing Ltd, to develop a sound
waterproofing solution, Kemper System’s Stratex Warm Roof system was specified
using its solvent-free Kemperol 2K-PUR liquid waterproofing as part of a full
refurbishment of the 2,500 sq. m roof area.
Severe water ingress into retail and restaurant units
below meant the project was time critical to prevent any further issues as well
as potential loss of profit for retailers. Chosen for its odourless, quick
application and versatile qualities, the
fleece-reinforced, liquid waterproofing system by Kemper System meant
contractors could adhere to the strict timescales and operational restrictions
on-site.
Mitie
Tilley Roofing Ltd first removed 250 tonnes of the existing roof ballast using
a suction excavator machine. The substrate was cleaned prior to an application
of Kempershield Type 1 Primer and Kempershield Vapour Barrier. A combination of
123mm Kempertherm FR and Kempertherm TR Tapered PIR Insulation Board was
installed onto the main roof area, including the guttering. Kempertherm TR comprises of a rigid PIR insulation board, a dense
closed cell structure with a hard-top facing providing additional reinforcement
to the top face that also provides the optimum substrate for the application of
the liquid membrane.
The polyurethane-based Kemperol 2K-PUR resin was then
applied in a single, wet-on-wet process. The roof area presented
numerous complexities and lots of detailing, including five, large air-handling
units, adjacent glazed facades and 36 separate large plinths with their own
steel work, cable trays and pipe supports.
Prior to
application, contractors also removed the existing lead skirts, cover flashings
and associated cementitious insulated upstands on each of the 36 support
plinths. The plinths, and more than 150 rain screen support steel work, were
also primed before application of the fleece reinforced Kemperol 2K-PUR resin.
The
versatility of the Kemperol system and ease of
application meant contractors could provide a watertight, seamless membrane
that fully incorporated all of the flat areas, complex details and outlets on
the roof structure.
Increased security measures also presented challenges
on-site as the 15-year old building, which was an extension of this original
airport terminal built in 1987, is at an airside location – further reinforcing
the importance of minimal possession times.
Much of the
refurbishment works were completed overnight within a four-hour working window
as the client requested no disruption to the many retailers within the North
Terminal below, which was done with ease using Kemperol.
Kemper System also developed full Inspection and Test Plans (ITP) and
Inspection and Test Records (ITR) which were updated daily by contractors, and
field technicians from Kemper System who visited the site on a weekly basis to
ensure compliance and maximum quality during installation.
Demonstrating
first-class delivery within a live airport environment, Mitie Tilley Roofing
Ltd and Kemper System won an award in the Liquid Applied Roofing and
Waterproofing category for their work on the project at the annual NFRC
(National Federation of Roofing Contractors) UK Roofing Awards (May 2017).
Warren Stuart, aviation director at Mitie
Tilley Roofing Ltd, said: “This was a challenging refurbishment as the client
demanded the highest of QHSE (Quality, Health, Safety & Environment)
standards within tight timescales. The project also required a leak free installation,
guaranteed for 25 years with zero defects and absolutely no standing water on
the roof. Installation also had to be flame free, environmentally
friendly and odour free due to the five air-handling outlets on the roof. The
timescales involved on this project were also extremely challenging, allowing
less than six months for this intricate roofing project. Kemper System ticked
all the boxes.
“Having installed Kemperol before, we knew it was quick and easy to apply as well as
versatile and durable. Its wet-on-wet application meant possession times
on-site were also decreased. We worked closely with Kemper System’s
technical team during five months of planning prior to work starting, and
throughout the project. Thanks to the highly experienced and knowledgeable
team, we were able to successfully deliver on time and within budget.
“Operational continuity was another major factor and
thanks to the speed of installation and efficient programme of works, the
airport’s retail units did not experience any ‘down time’ due to the
refurbishment. To be recognised for this project at the UK Roofing Awards is a
fantastic accomplishment and the professionalism and expertise of Kemper System
helped us to achieve this.”
Stuart
Hicks at Kemper System Ltd, added: “Kemperol
2K-PUR was specified for the project at Gatwick Airport because of its speed of
application, solvent-free and odourless qualities. The system has
also now been specified for the ongoing refurbishment works. It not only provided the benefits required to maintain the
operational integrity of the terminal and time saving, but 80% of the applied
polyols (resins) are obtained from renewable sources, adding to the green
credentials of the project.
“We were delighted to be recognised at the UK Roofing
Awards winning the Liquid Applied Roofing and Waterproofing category for this
project, which required a reliable waterproofing system and the skill of the
contractors to deliver it successfully.”
