KUS Industrial Estate, Flintshire

Client

KUS Industrial Estate

Location

Flintshire

Specification of Work

Asbestos roof removal, full roof replacement, improved thermal performance, new rooflight installation, and gutter refurbishment

Project Overview

Roofclad was appointed to undertake a full pitched roof refurbishment at KUS Industrial Estate in Flintshire. The existing roof had reached the end of its serviceable life, with widespread deterioration leading to water ingress, fixing failure and ongoing maintenance challenges.

The project required the safe removal of asbestos cement roof sheeting and rooflights, followed by the installation of a modern, insulated roofing system designed to improve weather performance, thermal efficiency and long-term durability.

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KUS Industrial Estate, Flintshire before — Before

KUS Industrial Estate, Flintshire after — After

Client Challenges

Our surveys identified several issues affecting both the performance and the integrity of the existing roof:

Holes were present in several areas of the asbestos sheeting, with visible water ingress staining internally
Delamination of asbestos sheets caused by foot traffic and historic repair and cleaning attempts
Corroded and loose roof fixings, with degraded protective washers no longer providing a weather seal
Rooflights severely degraded by ultraviolet exposure, leading to warping, gaps at perimeters and increased brittleness
Valley and perimeter guttering showing signs of failure, contributing to water management issues

These combined defects made ongoing repair uneconomical and increased the risk of further deterioration.

Our Solution

All works were carried out in strict compliance with the Control of Asbestos Regulations 2012, with safety, containment and monitoring forming a critical part of the project delivery.

The scope included:

Careful strip-off and removal of approximately 11,685m² of asbestos cement roof sheeting, including rooflights
Continuous air monitoring throughout the works to confirm airborne asbestos fibre levels remained within permitted limits for work with asbestos cement
Installation of a new profiled composite Kingspan roofing system with 0.4mm plastisol-coated steel for long-term corrosion resistance and a 120mm insulated foam core to achieve an energy-efficient U-Value rating of 0.16W/m2K.
The new roof panels were fixed to the existing purlins using stainless steel self-drilling fixings with integrated self-sealing washers, ensuring weather tightness.
Supply and installation of bespoke plastisol-coated ridges, eaves and barge flashings
Incorporation of factory-assembled GRP double-skin rooflights, providing improved durability and performance
- Inner liner achieving Class 1 fire rating
- External sheet achieving Class 3 fire rating

Guttering & Rainwater Management

As part of the refurbishment, all defective guttering was removed and replaced to ensure effective long-term rainwater control.

Works included:

Replacement of valley guttering with plastisol-coated pressed steel gutters
Installation of new running outlets, joint clips, stop ends and downpipes
Installation of a Plygene seamless rubberised gutter lining system, factory-cut and creased to suit existing gutter dimensions
Total gutter length of 380 linear metres
System backed by a 25-year manufacturer’s guarantee

Outcome

The completed refurbishment has delivered a modern, insulated roofing solution that significantly improves weather tightness, thermal performance and durability across the roof.

By safely removing the asbestos roof and replacing it with a high-performance composite system, Roofclad has provided the client with a compliant, low-maintenance solution designed to protect the building asset for decades to come.

Client Testimonial

“Roofclad Systems delivered the project with a high level of professionalism from start to finish. The team managed the removal of the asbestos roof safely and efficiently, keeping us well informed throughout the works. The new roofing and guttering systems have significantly improved the performance of the building, and the site was left clean and well organised. We were particularly impressed with Roofclad’s attention to compliance, quality of workmanship and overall project management.”
– Ben Still, Estate Manager, KUS Industrial Estate