Sealed Air Warehouse Facility

Sealed Air’s St Neots warehouse was a chance to transform an ageing asbestos cement roof into a modern, well-insulated and naturally lit one, without stopping a busy warehouse from working.

Cambridge Roof Exchange stripped and replaced around 5,000m² of roof. The building now has a highly insulated built-up roof system and a new rooflight layout, designed around the existing structure and the way the warehouse runs.

This was a live environment where the day-to-day business operations needed to continue with as little disruption as possible. Fork trucks and staff kept moving throughout the works, and the project was completed on programme with no accidents or incidents.

A Roof That Had Reached the End of Its Life

The existing roof was made up of asbestos cement outer sheets over insulation and plasterboard linings. It offered poor thermal performance and let very little natural light into the building. Asbestos cement sheets also become more brittle with age, which makes them harder and riskier to maintain. These are classic signs that a commercial roof needs attention.

Our solution was to remove the asbestos roof completely and replace it with a new, highly insulated built-up roof system. Removing the asbestos takes the risk away for good, rather than leaving it in place under a new covering.

The new system is built up in layers:

• A 0.7mm walkable steel liner sheet with taped laps, forming the vapour barrier
• A galvanised bar-and-bracket spacer system fixed into the existing purlins
• 240mm of mineral wool insulation, forming a warm roof construction
• A new 0.7mm profiled steel outer sheet
• Flashings pressed from the same material as the outer sheet

Working in a Live Environment

The biggest challenge on this project was not the roof itself but what was happening underneath it. Sealed Air could not close the warehouse, so goods had to keep moving and fork trucks had to keep running every day of the works.

To make this possible, we constructed tunnels within the building. These gave fork trucks and personnel clear, protected routes through the working areas, largely unhindered by the works happening above.

The strip-out and re-roofing were planned in phases around the warehouse’s operation, so each area was cleared and coordinated with the client before work began above it. Planning included:

• Detailed site surveys
• A full structural assessment
• A complete design package
• Phasing agreed with the client around their operations
• Regular inspections under CDM 2015

Safe Asbestos Removal

We carefully stripped the existing asbestos cement outer sheets, together with the old insulation and plasterboard linings. The sheets were removed in a controlled sequence so they were not broken up over the people and stock below, and all waste was disposed of in line with health and safety regulations.

Asbestos removal in an occupied building needs careful planning at every stage. Our asbestos removal work is built around keeping both our team and the client’s team safe while the building stays in use.

Improved Thermal Performance

A key objective of the project was to make the warehouse warmer and more efficient.

The new built-up system includes 240mm of mineral wool insulation, giving the roof a U-value of 0.18 W/m²K. That is a major step up from the original roof.

For commercial properties, upgrading the roof can play an important part in reducing energy demand and improving a building’s EPC rating.

More Natural Light

As part of the new roof, we set out a new rooflight pattern. It transmits far more natural light into the building and reduces the warehouse’s reliance on artificial lighting. It has made the building a much more desirable place to work.

What the Client Said

“CRE’s meticulous planning and execution ensured our operations continued smoothly throughout the refurbishment. The transformation of our warehouse is remarkable, and the enhanced natural lighting has significantly improved our work environment.”
Kevin Gaston, Sealed Air Corporation

Built on Relationships

It is through the close relationships we form with our customers that a project such as this can be carried out in harmony. That is a testament not only to our relationship with Sealed Air but to our dedicated workforce.

Sealed Air has continued to work with us since. We returned to St Neots for a phased asbestos roof replacement on another of their buildings.

The Result

The finished project delivered:

• Around 5,000m² of asbestos cement roof safely removed
• A new highly insulated built-up roof system with a U-value of 0.18 W/m²K
• A new rooflight pattern bringing far more natural light into the building
• Protective tunnels that kept fork trucks and staff moving throughout
• Warehouse operations kept running for the whole project
• Completion on programme in 12 weeks
• Zero accidents or incidents

Does Your Building Have an Asbestos Roof?

If your building has an ageing asbestos cement roof and it can’t close for the works, we can plan a safe replacement around your operations. Get in touch to discuss your options.

Book a survey today!