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Case Study

BASE Innovation Hub Roof System at Manchester Science Park

Garland UK Technical Manager
Daniel Crowley

Approved Contractor
Caddick Construction

BASE Innovation Hub Roof System at Manchester Science Park

Garland System

Dura-Coat

Sector

Commercial

Client

Bruntwood SciTech

Architect

Bridge Architects

Energy Efficiency Rating

The Base building is a £21m, 91,000 sqft new build office building located in the heart of Manchester Science Park. Designed as a tech hub for Industry 4.0, computer engineering and light manufacturing businesses, Base includes several sustainability measures, including A-rated EPC, operating at Net Zero carbon across communal areas and generating its energy with PV solar power.

For the new-build project, Garland UK Technical Manager, Dan Crowley, was instructed by Colm Donaghy, Project Manager at Bruntwood SciTech, as the designated roofing specialist to specify a waterproofing system that would protect the innovation hub for the future.

From the early concept design stages, Dan Crowley worked in close collaboration with Bridge Architects to develop the roof design to ensure it was clear from the outset how the building would perform when fully operational and meet the high sustainability aspirations for the project.

Challenge

The Base building project sought to achieve an EPC A rating and include 704m2 of PV solar power to enable a hybrid heating and cooling system.

The ideal roofing system chosen for the project had to be compatible with a solar PV installation. In addition, the roof system would need to meet the waterproofing demands of the building, including the complex plant equipment that was stationed across the roof areas.

The design would also need to incorporate high-traffic areas and walkways across the roof to ensure efficient maintenance access was available once the building was operational.

During Dan’s weekly site inspections to monitor the project progress, a deflection was observed within the pre-cast concrete deck. Although structurally sound, the specification was developed to ensure that no flat spots or back falls were created in the finished waterproofing system due to deflection within the deck.

Solution

A warm roof build-up with a tapered insulation design was specified not only to meet but to exceed the thermal performance requirements of a new build office. The tapered insulation design also negated any risk of any flat spots or back falls.

Working with Approved Contractor, Caddick Construction, the roof build-up started with a vapour control layer fully bonded to the concrete deck before laying PIR insulation and applying a fully bonded carrier layer using Torch Flex Evolution carrier. For the finishing layer, Dura-Coat, a cold-applied liquid waterproofing system, was installed to provide a smooth and modern aesthetic.

A ballasted frame was installed on top of the Dura-Coat system to support the solar PV panels. This mitigated the need for any additional penetrations to the roof system to be made and did not compromise the overall waterproofing integrity of the building.

The rooftop walkways, particularly around the serviceable areas of the rooftop plant, were created using Dura-Walk. Designed for high-traffic areas, Dura-Walk’s innovative PUMA technology includes excellent crack-bridging properties to create a highly versatile and hard-wearing finish for use during future building maintenance works.

Outcome

Dan Crowley visited the project weekly to assess the installation quality and provide visual progress reports to the client. Using Garland’s RAMP (Roof Asset Management programme), Bruntwood SciTech, Bridge Architects, Caddick Construction, and other relevant parties could review the documented progress of works and ensure the project was on schedule and budget at every stage.

On project completion, Dan Crowley rigorously assessed the Base building roof project before supplying Bruntwood SciTech with Garland’s market-leading 20 year Single-Point Guarantee.

The Base building project successfully achieved an EPC A rating and provides flexible office space and meeting rooms for fast-growth science and tech businesses within Manchester Science Park, one of the UK’s most established specialist innovation clusters.

It was important for us to reduce the need for hot works during the project, and the cold-applied liquid waterproofing Dura-Coat system was the ideal solution to achieve that

Colm Donaghy

Project Manager, Bruntwood SciTech

Right from the concept stage, we were assisted with costs during the design and had support in getting the structure right. Dan was involved from the beginning to provide his roofing expertise, helping our Quantity Surveyors achieve cost certainty on the project.

Colm Donaghy

Project Manager, Bruntwood SciTech

It’s a security blanket, knowing that if there is ever an issue, we only have one person to go to to get it sorted.

Colm Donaghy

Project Manager, Bruntwood SciTech

BASE Innovation Hub Roof System at Manchester Science Park

Garland Technical Manager

Daniel Crowley

Approved Contractor

Caddick Construction

Dura-Coat cold applied liquid waterproofing system supports the high sustainability aspirations at new-build innovation hub at Manchester Science Park.

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.”