Premier Foods
30,000m² Commercial Roof Refurbishment
A major phased roof refurbishment delivered across an operational food production facility, resolving existing water ingress while keeping disruption to the client’s operations to a minimum.
Client Overview
Premier Foods operates a major food production facility in Carlton, Barnsley. Thermolast Roofing was appointed to undertake the complete refurbishment of the site's main factory roof, covering an area of more than 30,000 square metres.
Due to the scale of the facility, the project was carefully delivered across four continuous phases over a two-year programme.
Client: Premier Foods
Location: Carlton, Barnsley
Roof Area: 30,000+ m²
Project: Commercial Flat Roof Refurbishment
Programme: Four phases over two years
Roofing System: IKO Mach Two Elastomeric Roofing System
Guarantee: 20-Year Manufacturer-Backed Single-Point Guarantee
The Challenge
Premier Foods was experiencing water ingress across areas of the existing factory roof, requiring a long-term refurbishment solution for more than 30,000m² of roofing.
A key requirement was that the facility remained operational throughout the works. With production continuing below, the refurbishment needed to be carefully planned and delivered in phases to minimise disruption while maintaining safe access and a watertight building.
The scale and complexity of the factory also meant existing roof construction, changes in roof level, perimeter safety and access requirements all had to be considered as the project progressed.
As with many large-scale refurbishment projects, additional defects were identified once works were underway. Thermolast coordinated the necessary specialist works alongside the roofing programme, allowing the wider refurbishment to continue effectively.
Thermolast Solution
Following assessment of the existing roof construction, the roof was partially stripped back to the original mechanically fixed insulation board.
A new multi-layer roofing system was then installed, comprising:
Heat-activated underlay
Additional insulation
IKO Mach Two 5mm elastomeric roofing membrane
This approach allowed the existing roof construction to be incorporated where appropriate while providing the factory with a completely renewed waterproofing system.
Works were divided into four continuous phases, enabling a project of significant scale to be systematically managed and completed over the two-year programme.
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More Than a Roof Refurbishment
The project extended considerably beyond the installation of the new roof covering.
Thermolast also delivered and coordinated a substantial package of roof access and safety improvements across the facility.
These works included:
37 new roof access hatches with hydraulically operated insulated solid lids
New access stairs between changes in roof level
New roof-to-ground emergency escape ladder
New roof-mounted guardrails around the perimeter of the roof
Associated detailing for a new lightning conductor system
Together, these improvements provided safer and more practical access to the roof for future inspection and maintenance.
Responding to Challenges on Site
Large refurbishment projects can reveal issues that aren't apparent until work begins.
During installation of new perimeter edge details, deterioration was identified in sections of the existing brick ties at high level.
Thermolast sourced and coordinated a reputable specialist contractor to carry out the necessary remedial brick tie works to affected sections of masonry at roof level before the surrounding works were completed.
Being able to identify, manage and resolve issues such as these formed an important part of delivering the wider refurbishment programme.
Testing & Quality Assurance
Watertightness was a critical requirement for a roofing project of this scale.
Following completion, all four phases were electronically integrity tested to verify the performance of the newly installed waterproofing system.
The completed roof was handed over to Premier Foods with a manufacturer-backed Single-Point 20-year guarantee, covering the completed roofing system.
The Outcome
Thermolast successfully refurbished more than 30,000m² of the main factory roof while the Premier Foods facility remained operational throughout the two-year programme.
The completed works resolved the existing waterproofing issues and provided a renewed roofing system that was electronically integrity tested across all four phases and backed by a 20-year manufacturer Single-Point guarantee.
The project also delivered substantial improvements to roof access and safety infrastructure, including 37 new access hatches, new stairs, emergency access and perimeter guardrails.
Delivered across four continuous phases, the project demonstrates Thermolast Roofing's ability to manage complex, large-scale commercial and industrial roof refurbishments while working around the operational requirements of the client.
Project at a Glance
30,000+ m²
Commercial factory roof refurbished
4 Phases
Delivered across a two-year programme
37 Roof Hatches
New hydraulically operated insulated access hatches
IKO Mach Two
5mm elastomeric waterproofing membrane
Electronic Integrity Testing
Completed across all four phases
20-Year Guarantee
Manufacturer-backed Single-Point guarantee
Planning a Commercial Roof Refurbishment?
Whether you're dealing with an ageing roofing system, persistent water ingress or planning a large-scale refurbishment programme, Thermolast can help determine the most appropriate solution for your building.
Our commercial roof surveys can assess the condition of existing roofing systems and help identify repair, refurbishment and replacement options based on the requirements of your property.
Discuss your project with our team on 0114 243 1633