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Case Study

Industrial Estate Metal Roof Replacement | Fire Damage

Garland UK Technical Manager
Jordan Thomas

Approved Contractor
Bilton & Johnson Building Co, CladRight Industrial Roofing & Cladding

Industrial Estate Metal Roof Replacement | Fire Damage

Garland System

R-MER CLAD

Sector

Industrial

A busy recycling centre in Coedcae Industrial Estate, Pontyclun South Wales, suffered from a crippling fire that destroyed one-third of the building leaving the rest in severe disrepair from fire damage. Garland Technical Manager, Dale Thomas, was instructed by long-term partner Cushman Wakefield to assess the extent of the damage and secure the optimum waterproofing system to get the warehouse unit returned to its former glory as a hive of activity for the local area.

Dale conducted a thorough condition survey and supplied a detailed written report to the client, highlighting the severity of the building damage and the poor condition of the existing roof sections and walls. Approximately 2,000 sqm were either damaged beyond repair or had fallen into a state of disrepair, meaning that a full refurbishment of all roof and wall sections was required before the optimum waterproofing system could be implemented.

Challenge

Coedcae Industrial Estate was a unique project, with many technical and structural hurdles to overcome, so it was an essential requirement for the client that the Garland UK specification was only carried out by a specialist contractor. Following a short tender process, contractors Bilton & Johnson Building Co were appointed to oversee the project and Garland approved contractor CladRight Industrial Roofing & Cladding for the waterproofing system installation.

Before any works could commence, the immediate challenge was the efficient handling of the damaged roof and wall sections, which had to be completely stripped back and removed safely, leaving behind the original steel frame structure. With many of the structural steel supports and purlins suffering from severe damage in the fire, they had to be replaced before work could commence.

It was also an important requirement to ensure that both the bituminous membrane for the entrance porch and metal profile waterproofing system for the roof and cladding elements of the project were readily accessible, to ensure the project did not suffer from any materials delays.

Solution

The client did not have to use multiple suppliers on the project, thanks to Garland UK’s diverse waterproofing system offering. With high-performance metal profile, R-MER, and bituminous membrane, StressPly, systems in the range, it meant the project could continue to run smoothly and efficiently without delay.

Once all the existing roofing and cladding had been removed, work commenced on installing the new steel supports ready for the new metal R-MER CLAD system. R-MER CLAD is a profiled metal roofing and cladding system, that is both lightweight and fast to install, available in a wide range of durable, waterproof finishes. New gutters were also installed as part of the rebuild to ensure the system had the best rainwater management and was completely waterproof.

Due to the complexity of the project, Dale was on-site at least twice a week to oversee the project and ensure that all roofing and cladding works were being installed to the correct specification.

It was essential for extra measures to be taken to ensure that the green roof was protected as much as possible from the weather elements. The new-build apartments were beach facing and susceptible to strong offshore winds, so to protect the edges of the green roof system from any potential uplift, a natural solution in the form of large pebbles were hand-laid, to secure the vegetation as much as possible.

Outcome

On completion, Coedcae Industrial Estate had been completely transformed, turning the charred skeleton of the warehouse unit into a prominent and permanent building.

A 30-year Single-Point Guarantee was issued, to provide complete peace of mind to the client, knowing that the new system was protected for design, system quality and installation workmanship for years to come.

The clients were delighted with the end result, where Garland UK was the right choice to provide the best waterproofing solution and deliver a useable and rentable building once more.

Industrial Estate Metal Roof Replacement | Fire Damage

Garland Technical Manager

Jordan Thomas

Approved Contractor

Bilton & Johnson Building Co, CladRight Industrial Roofing & Cladding

Modern metal tile roof refurbishment at Ynystawe Primary School, with R-MER TILE ST, retaining the traditional aesthetics of the building whilst providing superior long-term durability.

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.”