Gloucester Project

Client

Gloucester Project

Location

Gloucester

Specification of Work

Overcladding to improve thermal performance and gutter refurbishment, ensuring effective wastewater management

Project Overview

Home to some of the UK’s best-known ice-cream brands, the Gloucester project site required a major roofing refurbishment to protect its large-scale food production operations. Roofclad Systems was appointed to deliver a comprehensive overcladding solution to modernise the building envelope, improve insulation performance, enhance weather protection, and upgrade the site’s water management system. All work was undertaken while maintaining strict safety and compliance standards throughout this operational facility.

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Client Challenges

A detailed inspection highlighted several issues across the existing roof:

Roof sheets were showing widespread weathering, cracking and deterioration, signalling the end of their serviceable life.
Many roof fixings were heavily rusted, corroded, or loose when tested.
The existing gutters were in poor condition and allowed rainwater ingress, creating a risk to the building fabric and operations.

Our Solution

Main Roof Areas – Overcladding

To restore performance and extend the building’s lifespan, Roofclad Systems delivered a full overcladding installation:

Supplied and installed new Z rails, secured through the existing cladding and into the purlins for long-term structural stability.
Installed a 60 mm A-rated fire insulation layer between the old and new roof sheets to significantly improve the building’s thermal performance.
Installed new 0.7 mm profiled single-skin metal sheets featuring a robust side lap detail for added rigidity. These sheets are manufactured from hot-dipped galvanised steel with a 0.2 mm PVC plastisol outer coating for enhanced durability.

Guttering

To resolve the significant water ingress issues, Roofclad Systems carried out:

Thorough industrial-standard cleaning of the existing gutters.
Supplied and installed 1,004 linear metres of new PVC Plygene waterproof gutter lining. This pre-formed, rubberised, seamless system is precision-cut to fit the existing gutter profile and comes with a 25-year manufacturer’s guarantee, assuring long-term protection.

Engineering Assurance

Due to the additional load created by the new overcladding system, an independent structural engineer was engaged to validate that roof loadings remained within safe, allowable limits. This ensured full assurance of structural integrity before and after installation.

Outcome

The project was completed safely, on schedule, and in full compliance with all applicable regulations, including:

Health and Safety at Work Act 1974
Management of Health and Safety at Work Regulations 1999
Construction (Design & Management) Regulations 2015
Work at Height Regulations 2005

The Gloucester site now benefits from a high-performance roofing system offering improved thermal efficiency, enhanced durability and significantly upgraded drainage. The refurbishment has strengthened the building envelope and future-proofed the site for years to come.