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Case Study

Ambulance Station Roof Upgrade Ensures Uninterrupted Emergency Care

Garland UK Technical Manager
Tom Ferry

Approved Contractor
NRA Roofing

Ambulance Station Roof Upgrade Ensures Uninterrupted Emergency Care

Garland System

StressPly Flex Plus

Sector

Blue Light Estates

Construction Partner

Stepnall

A key ambulance station in the East Midlands was facing severe water ingress, significantly impacting its functionality and safety. The most affected areas were around the gutters and outlets, where substantial water penetration had occurred. The perimeter edge trim had also delaminated, causing further structural degradation.

Construction partner Stepnell instructed NRA Roofing to carry out the works. Tom Ferry, technical manager at Garland UK, conducted detailed roof surveys to identify the root cause of the issues and recommend a tailored waterproofing solution.

The investigation revealed that the existing bituminous waterproofing system had failed, and the insulation, with only 50-60mm of PUR and PIR materials, provided inadequate thermal performance. Standing water and debris on the metal and timber roofing deck further weakened the structure. The roof refurbishment project was tendered through the SCAPE framework to ensure best-in-class delivery partners, robust governance and value for money.

Challenge

The ambulance station refurbishment presented several key challenges, primarily related to maintaining full operational capacity throughout the project. As an essential service provider, the site needed to remain fully functional 24/7, with minimal disruption to staff and daily operations. This required precise, phased planning and close coordination with all involved parties to ensure that ongoing work did not interfere with the building’s critical services.

Additionally, it was crucial to maintain the building’s watertight integrity during the refurbishment process. Given the existing water ingress and failed membrane system, careful attention was necessary to prevent further water damage while work was being carried out. The combination of ensuring continuous operations and safeguarding the structure’s integrity made this project particularly complex and sensitive, demanding a strategic and well-executed approach.

Solution

To address the critical issues faced by the facility, a warm roof design utilising Garland’s StressPly Flex Plus system was proposed as the optimal solution. This high-performance, multi-layer roofing system was selected for its exceptional durability, weather resistance, and long-term reliability.

NRA Roofing began by removing the existing waterproofing down to the deck and installing a vapour control layer. The introduction of 180mm PIR insulation significantly improved the building’s thermal efficiency, while the StressPly Flex Plus mineral cap sheet provided robust protection against the elements.

In line with Safe2Torch guidelines, high-risk areas, such as upstands and timber decking, were identified and protected before applying torch-on membranes. Flame-free self-adhesive membranes were used in areas where open flames were unsuitable, ensuring maximum safety throughout the process.

Outcome

Thanks to the swift and efficient work by NRA Roofing and Garland UK, the ambulance station remained fully operational throughout the 4-week project, ensuring essential services continued without interruption. NRA Roofing and Stepnell worked closely to schedule the work phases with precision, minimising any impact on daily operations.

Tom Ferry conducted weekly site visits to oversee the quality of the installation, ensuring every aspect met Garland UK’s rigorous standards. He provided regular updates to stakeholders through Garland’s online Roof Asset Management Programme (RAMP), offering detailed progress reports, project images, and ongoing updates.

The roof refurbishment significantly enhanced the building’s thermal efficiency, achieving a U-value of 0.18 W/m²K, meeting regulatory standards and contributing to a reduction in energy costs. The newly implemented tapered roof design also resolved standing water issues, ensuring the building no longer suffers from water ingress or ponding water.

Upon completion, Tom Ferry provided the station with Garland’s industry-leading 25 year Single-Point Guarantee. This comprehensive guarantee covers the system design, materials, and workmanship, ensuring long-term performance and durability for years to come.

The StressPly Flex Plus system was an excellent choice for this project, not only because of its durability but also due to its ease of installation. The multi-layer system allowed us to work efficiently while ensuring a long-lasting, weather-resistant solution. The collaboration with Tom Ferry and the team at Garland UK was seamless, and their technical support throughout the process helped us complete the project smoothly and on schedule.

Harry Taylor

Contracts Manage, NRA Roofing

Ambulance Station Roof Upgrade Ensures Uninterrupted Emergency Care

Garland Technical Manager

Tom Ferry

Approved Contractor

NRA Roofing

Technical Manager Tom Ferry collaborated with construction partner Stepnell and NRA Roofing to deliver a complete roofing solution for a local ambulance station in the East Midlands.

Quick Facts

Garland System

Dura-Coat

Sector

Residential

Project Saving Cost

£900,000

The storm exposed critical weaknesses in the original roof design, which had failed to cope with the site’s wind load demands. The closure meant immediate loss of revenue, reduced access to community leisure facilities, and growing urgency to reopen.

The replacement roof required complex engineering to match the building’s 40 metre wide dual-curved structure. Standing seam sheets up to 22 metres in length had to be precision-engineered off-site, with escorted delivery, timed road closures, and careful sequencing of work.

With only a small car park as the site compound, storage, crane operations, and contractor access needed meticulous planning. Moisture protection for the exposed structure was critical throughout, with temporary coverings installed until the new system could be sealed.

Garland UK Technical Manager Rob Wall specified the R-MER LOC standing seam metal system, designed for storm resilience, thermal efficiency, and long service life in marine climates. Its penetration-free, zip-free seam design enabled faster installation and allowed for thermal movement without panel distortion.

The system was tailored to the building’s complex geometry, with 22 metre top sheet runs and 18 metre lower runs. Approved contractor, Future Roof Leeds, carried out the works, reusing the existing perforated aluminium liner where possible to reduce waste and disruption.

A high-performance, foil-lined vapour control layer was installed, along with upgraded insulation and a breather membrane suitable for coastal exposure. Acoustic infills were also integrated to maintain internal sound control, enhancing the original system’s acoustic performance.

The 1,200 sqm roofing system was completed on time and within budget, restoring full functionality to SC2 Water Park and preventing further loss of income. Garland UK’s Roof Asset Management Programme (RAMP) now provides the Council with a complete digital record of the project, including inspection reports, guarantees, and maintenance guidance, giving estates teams full visibility for ongoing asset care.

Covered by a 30 year Single-Point Guarantee for design, materials, and workmanship, the Council has complete assurance that any issues will be resolved swiftly, without dispute or additional cost.

The reopening of SC2 Water Park has reinstated a much-loved leisure venue for residents and visitors, supporting local wellbeing, tourism, and economic activity. The storm-resilient design means fewer disruptions and reduced maintenance, and reliable year-round availability, even in challenging weather.

Robin Jones, Senior Building Surveyor at Denbighshire County Council, commented,

“The level of service from Garland UK has been first-class from start to finish. Rob and the team gave us confidence at every stage, from design to handover. The quality of the roof and the management of such a tricky site exceeded our expectations.”

Rob Wall, Technical Manager at Garland UK, added,

“This was a demanding brief in a harsh environment. The combination of curved geometry, extreme sheet lengths and complex logistics called for precision planning and strong collaboration. We’re proud to have supported the Council in getting this key venue back up and running.”