Don Bur Bodies and Trailers Ltd
Stoke on Trent, Staffordshire
Full roof replacement and gutter refurbishment before Solar PV installation
Don-Bur is a UK-based designer and manufacturer of commercial vehicle trailers and rigid bodywork. All Don-Bur products are designed, engineered and manufactured under one roof in Stoke-on-Trent.
The manufacturing facility included a roof section originally constructed in the 1960s, featuring roof sheets and fragile Georgian wire rooflights. Over time, the roof had begun showing signs of deterioration, with weathering, cracking and ageing components indicating that the roof was approaching the end of its serviceable life.
Many of the original roof fixings had become corroded and loose, while protective washers had broken down due to prolonged exposure to the elements. This left the roof increasingly vulnerable to water ingress and reduced its ability to provide long-term protection for the building.
Roofclad Systems was appointed to deliver a complete roof replacement, providing a safe, compliant and thermally efficient roofing solution designed to extend the life of the building and support future solar PV installation.
Replacing an ageing roof over a live manufacturing facility required meticulous planning, specialist expertise and an uncompromising approach to health and safety.
The project presented several key challenges:
With manufacturing continuing below the work area, protecting both Roofclad Systems’ operatives and Don-Bur’s workforce was fundamental to the project’s success.
Roofclad Systems delivered a comprehensive roof refurbishment package, combining specialist roof sheet removal expertise with the installation of a modern insulated composite roofing system.
Health and safety were at the heart of the project delivery. Working closely with Don-Bur’s management team, Roofclad Systems developed a detailed construction methodology that prioritised the safety of both our operatives and the client’s workforce while ensuring manufacturing operations could continue safely throughout the programme.
The works included:
As part of the refurbishment, Roofclad Systems also enhanced the building’s rainwater management system to improve long-term performance.
Works included:
Despite the complexity of working above a fully operational manufacturing facility, the project was delivered safely on programme and with no interruption to Don-Bur’s day-to-day production.
Careful planning, phased working and the installation of safety netting during non-operational hours created a controlled working environment from the outset, protecting both Roofclad Systems’ operatives and Don-Bur’s employees throughout the project.
The completed refurbishment has transformed the roof into a modern, high-performance building envelope, significantly improving weather tightness, thermal efficiency and long-term durability.
By safely removing the existing roof sheets and replacing them with an insulated composite roofing system, Roofclad Systems has provided Don-Bur with a compliant, low-maintenance solution designed to protect the building asset for decades to come.
The new roof also provides a robust platform for the future installation of solar PV, supporting the client’s long-term sustainability and energy efficiency objectives.
“Roofclad Systems managed the project professionally from start to finish, working safely within our operational manufacturing facility to minimise disruption. They clearly understood the challenges of replacing a deteriorating roof and maintained high standards. The new roof offers better protection, improved insulation, and a long-term solution. We are very pleased with the quality of the installation.”
– Chris Underwood, Maintenance Manager – Don-Bur (Bodies & Trailers) Ltd
