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Pioneer House - Full Video

Pioneer House was a chance to significantly improve the performance, longevity and reliability of an ageing office roof, without the disruption and cost of a complete roof replacement.

Cambridge Roof Exchange designed and delivered a full overcladding solution for around 850m² of roof. The building now has a new, specification-backed roof system, designed around the existing structure and the building's future needs.

Rather than simply replacing the existing roof, the project focused on improving the building's overall performance, extending the life of the roof and keeping disruption to a minimum. The offices below stayed fully operational throughout the works, and the project was completed ahead of programme.

A New Approach to an Existing Roof

The existing roof was clearly showing its age. A condition survey found metal fatigue in the roof sheets and gutters, rusted fixings and paint worn back to bare metal. Earlier liquid-membrane repairs to the gutters had failed. With only 25mm of insulation beneath the steel sheets, the roof was also losing a significant amount of heat. These are classic signs that a commercial roof needs attention, and refurbishment was an important consideration for the future of the building.

Our solution was a new, design- and specification-backed overclad system installed over the existing roof. Overcladding is an effective alternative to complete roof replacement: it upgrades an existing roof while keeping much of the structure beneath.

The new system is built up in layers:

• A vapour control layer laid over the existing roof
• A galvanised steel bar-and-bracket sub-frame fixed through to the existing structure
• 280mm of A1 non-combustible glass-fibre insulation
• New 0.7mm profiled steel sheets with a Plastisol coating, secured with stainless steel fixings
• Perimeter cappings colour-matched to the existing wall cladding

The result is a modern, durable external weathering layer and a major improvement in the building's thermal performance. For the client, it meant dealing with the condition of the existing roof while investing in the long-term performance of the property. We took a similar approach on our commercial overclad in Waterbeach.

Solving Problems Uncovered on Site

As with many refurbishment projects, opening up the roof revealed issues that couldn't be fully seen at survey stage. Some of the existing gutters were so badly corroded that they had rotted through. Our team riveted galvanised steel plates into the gutters to restore their strength before the new lining went in.

The existing purlins were also more widely spaced than ideal for the new system, so we installed additional intermediate Z-bars to give the overclad the support it needed. Dealing with these issues properly during the works means the new roof is built on a sound foundation.

Improved Thermal Performance

A key objective of the project was to improve the building's thermal efficiency.

The new overclad system includes 280mm of glass-fibre insulation, taking the roof to a calculated U-value of 0.18 W/m²K, a dramatic improvement on the original 25mm insulation board. A condensation risk analysis confirmed there is no risk of mould growth within the new build-up.

For commercial properties, upgrading the roof specification can play an important part in reducing energy demand and improving a building's EPC rating. The upgrade also gives Pioneer House a more modern roofing specification, helping to future-proof the property.

A 20-Year Manufacturer's Guarantee

The completed roofing system is backed by a 20-year manufacturer's guarantee, giving the client extra confidence in the installation and the performance of the new roof.

For a commercial property owner, a roof is a significant investment. The aim is not just to complete the work and hand over a new roof, but to provide a system that offers long-term protection and reassurance.

The manufacturer inspected the works throughout the project. At the final sign-off inspection, they rated the workmanship as "excellent" and recorded no defects.

PVC Membrane Gutter Lining System

As part of the refurbishment, Cambridge Roof Exchange installed a welded PVC membrane gutter lining system. We also used liquid-applied detailing at the outlets and pipe penetrations.

Gutters are a critical part of any commercial roofing system. Even a high-quality roof can be compromised if water management isn't properly addressed. The new gutter lining provides a durable waterproofing solution that protects the building from water ingress and keeps the roof drainage working effectively alongside the new roof.

By treating the roof and gutters as one refurbishment rather than separate problems, we were able to provide a more complete solution for the building.

Complete Site Setup

A successful commercial roofing project involves far more than installing the roof itself.

At Pioneer House, Cambridge Roof Exchange provided a full site setup so the works could be carried out safely and efficiently while the offices below stayed in use. This included:

• Welfare facilities
• A secure Heras-fenced site compound
• Scaffold edge protection and debris netting
• A lockable stair tower for safe roof access
• A 14m telehandler and boom lift for materials handling
• Waste disposal
• Site management and coordination

Working on an occupied commercial building also needs careful thought about the surrounding environment. Site access, materials, waste, safety and the day-to-day running of the building all have to be managed alongside the roofing works. The project ran through a hot summer, with temperatures of 25–30°C, which the team managed with early starts and extra labour to keep the programme on track.

Our approach was to coordinate all of these requirements as part of the overall project, rather than treating them as an afterthought.

Refurbish Rather Than Replace

Pioneer House is a good example of why an ageing commercial roof does not always need a complete replacement.

An overcladding system can be a practical way to upgrade an existing roof, improve thermal performance and extend its service life without removing the entire existing roof structure. It's often a more cost-effective route too. Our article on what affects the cost of an industrial roof replacement explains the factors involved.

Every building is different, though. The right solution depends on the condition of the existing roof, the structure of the building, the thermal performance needed and the client's long-term plans for the property. That's why the design and specification stage is so important.

At Cambridge Roof Exchange, we assess the existing building before recommending a solution. Where appropriate, overcladding can be an efficient way to turn an ageing roof into a modern, higher-performing roofing system.

The Result

The finished project delivered:

• Around 850m² of ageing roof overclad with a new profiled steel system
• 280mm of A1 non-combustible insulation, taking the roof to a U-value of 0.18 W/m²K
• Corroded gutters strengthened and lined with a welded PVC membrane system
• Offices kept fully operational throughout the works
• Completion ahead of programme
• Workmanship rated "excellent" by the manufacturer, with no defects recorded
• A 20-year manufacturer's guarantee

From the initial design and specification through to installation, gutter lining and full site setup, Cambridge Roof Exchange delivered a complete commercial roofing solution designed around the building and its needs.

Is Your Commercial Roof Showing Its Age?

If your commercial roof is ageing but structurally sound, overcladding could give you a modern, energy-efficient roof without the cost and disruption of full replacement. Get in touch to discuss your options.

Book a survey today!