Home Our Approach Case Studies Warm Roof Refurbishment For West Ewell Primary

Case Study

Warm Roof Refurbishment For West Ewell Primary

Garland UK Technical Manager
Daniel Sandell

Approved Contractor
Richard Soan Roofing Services

Warm Roof Refurbishment For West Ewell Primary

Garland System

StressPly Flex Plus

Sector

Education

Size

3000 sqm

Project Cost Saving

£98,000

Waste Avoided

30 tonnes

West Ewell Primary School, part of the Bourne Education Trust, is a thriving community school and nursery in Surrey that includes a specialist centre for children with communication and interaction needs. Following years of water ingress issues at the school, Synergy Construction and Property Consultants instructed Garland UK Technical Manager, Daniel Sandell, to conduct a detailed roof survey to evaluate the overall condition and remaining life expectancy of the roof areas and make recommendations for repair or replacement.

The existing built-up bituminous membrane system had come to the end of its natural life and was in extremely poor condition, including areas of poor drainage, organic growth, and ponding water. The protective mineral slate on the membrane had washed away over the years, leaving the cap sheet brittle from unprotected sun exposure and less responsive to movement in the building.

Challenge

The detailed roof condition survey also highlighted that the roof perimeters were at the beginning stages of failure, with debonding upstands and the mortar between the coping stones severely deteriorating. The mortar was no longer keeping the large, heavy stones secure, posing major health and safety risks, where the stones could easily come loose and fall to ground level and potentially injure a staff member or student.

The existing PIR insulation was only 50mm, resulting in a thermally inefficient 0.56 U-Value for the school. The insulation, however, was dry and still useable, making it imperative that it was well protected and avoided saturation throughout the refurbishment project.

By carefully planning the roof refurbishment stages, the school could significantly mitigate material replacement costs and prevent any unnecessary waste to landfill.

Solution

Daniel Sandell identified that whilst the roof was at the end of its natural life, fortunately, it was suitable for an overlay system rather than a costly entire roof strip and replacement. To improve the drainage, the refurbished roof system would also include a tapered warm roof design around the sump outlets.

The StressPly Flex built-up membrane system (BBA-certified) was specified to overlay the 930 sqm roof to deliver a thermally efficient, fully waterproof warm roof refurbishment. StressPly Flex is a high-strength torch-on bituminous waterproofing system designed with superior tensile and tear strength for optimum waterproofing performance.

The Approved Contractor, Richard Soan Roofing Services, got to work preparing the roof by removing the hazardous existing coping stones and debris and plywood board capping the parapets. Torch Flex, a high-performance VCL, was installed, and an additional 90mm flat board and drainers were added to bring the total u-value to 0.18 W/m2K.

A Torch Flex Ultra Vent underlayment sheet was installed before finishing with the StressPly Flex 4.2mm bituminous slate finished cap sheet. The parapet walls were encapsulated with the StressPly Flex system and completed with a GRP Trim.

To complete the works, the aged and underperforming rooflights were removed and replaced for improved thermal efficiency, increasing the volume of natural sunlight for the classrooms below.

Outcome

During the works, Daniel Sandell visited the site weekly to assess the quality of the installation and provide regular progress reports to the client and school. On project completion, Sandell supplied West Ewell School with Garland’s industry-leading 25 year Single-Point Guarantee, which accepts the full liability for the design, material and quality of the installation workmanship for the project.

Utilising the existing PIR insulation and adopting an overlay waterproofing system resulted in a significant cost saving for the school, mitigating the need for a complete roof replacement and reducing the overall embodied carbon of the project.

The new roof at West Ewell School is now to standard, with a 0.18 U-Value rating, providing an immediate uplift in thermal efficiency for the building.

The technical expertise and service from Garland UK has been exceptional, and the client is extremely happy with the quality of the system and end result. Most importantly, the school now has a safe and dry learning environment for its students and staff.

Michael Wedlake

Senior Building Surveyor, Synergy Construction and Property Consultants

The early roof investigations from Garland UK meant that we were given clear and detailed information on the building’s condition so that we could make the best waterproofing decision for the school. We’re delighted with the end result; the school is warm and dry, and through Garland’s expertise, we have avoided any unnecessary costs for a full roof replacement.

Claudio Cutajar

Member of the premises team, West Ewell Primary School

Warm Roof Refurbishment For West Ewell Primary

Garland Technical Manager

Daniel Sandell

Approved Contractor

Richard Soan Roofing Services

Transformation at West Ewell Primary School, from failing waterproofing, leaky classrooms and loose coping stones to a thermally efficient 930 sqm StressPly Flex warm roof refurbishment.

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.”