Industrial buildings need to be designed to withstand the elements. The roof on your factory or warehouse does far more than simply keep the rain out. It shelters essential equipment and inventory and protects the ongoing business operations. Industrial roofing and cladding prevents the need to conduct costly repairs or to provide a roof repair or replacement due to production delays or repairs.

The core difference between an industrial roof and a residential roof is the scale and purpose. With industrial units, there will be larger roof spans, and specific equipment will dictate the roof’s loading requirements and the need for an opening. These are not your ‘weekend roofer’ types of jobs. Industrial roofing poses commercial construction challenges that require the integration of specific structural and industrial engineering knowledge.

Cladding System Performance

While cladding and roofing construction is done separately, they need to be designed as a unit. The cladding system has a direct impact on the performance of the eaves and roof junctions. In fact, poorly installed cladding is one of the major causes of interior water leaks in industrial buildings. It creates the perception of roof leaks, causing tenants to chase issues around the building as a direct result of poor original cladding and roofing system integration.

It is easy to see why buildings in an industrial setting use Metal cladding systems for construction. They’re lightweight and quick to install. They’re also able to deal with the natural thermal movement that occurs with large structures. Newer seamless systems have improved with the reduction of leaks and maintenance points. Though there is an initial increase in expenses, time spent on smaller maintenance issues is decreased.

Recently, composite panels have also emerged. improved insulation values, and can speed up installation times. However, the fire performance requirements changed after Grenfell. Therefore, you need to check what’s actually acceptable for your building use. Not all composite panels meet current regulations for industrial premises.

Maintenance reality

Most industrial roofs are neglected until something goes wrong. This creates the need for emergency repairs instead of planned maintenance. The cost difference is significant /*reactive maintenance typically runs three to four times higher than keeping on top of things..

It is required that all flat industrial roofs are checked at the very least bi-annually. Ponding water, blocked water channels , and breaks in the membrane that may have occurred are all issues that need to be checked. Larger buildings can make access more difficult. Proper access equipment may also need to be factored into your maintenance budget.

People don’t understand issues that gutters and downspouts cause. Industrial buildings move a lot more water than residential. Improperly sized systems result in overflow that causes cladding damage and possibly other structural issues. These problems are often outside the obvious view when looking at just the roof.

Replacement Is a Better Option

After a certain point patching an ageing industrial roof is a false economy. Not only is more money being spent, but life is not being bought back on the building. There is huge variation in replacement costs due to factors like access, building height, and the need to work around other operational activities.

Expect to spend about £40 to £90 per square metre for the replacement of basic industrial roofs. This price range is for basic single-ply membrane systems and metal roofing. Be prepared to pay more for other non-standard structural work or detailed arrangements to accommodate existing industrial machines. The more complex the design and the more divisions the structures have, the faster costs will rise.

There is more to consider when it comes to timing for industrial buildings than residential. A roof replacement cannot take down the entire operation for a week, so it is important to schedule this work in. Phased installations are less operationally disruptive, however this approach increases cost and the overall timeframe, due to contractor mobilization. These considerations should be taken in the planning stage, not discovered during execution.

Components That Will Last

Most industrial applications use single-ply membranes TPO or PVC. They are simple to install and offer good thermal movement accommodation on large roofs. Sealed welded seams offer a continuous waterproof seal without the use of sealants which break down over time.

For smaller industrial buildings or complex roof shapes, GRP systems are a great option. With a liquid application, you can get a smooth and seamless finish around difficult details. GRP systems take longer to install, and unlike membranes, susceptible to the weather. Proper curing involves dry and temperate conditions.

If metal roofing systems are done right, you optimize the lifespan of the roof. Costs are higher initially, but 30-40 years can go by before you need to consider replacing the roof. This is a good choice for buildings where you are anticipating a long-term use.

No matter what system you select to use, the quality of the installation is the biggest factor. Roofs are the biggest surfaces in building, and average sized materials fitted properly will perform better than premium materials fitted poorly. Ensure that your contractor is commercially competent and review similar projects.

When your flat-roofed extensions were built, they probably seemed an appealing proposition. Now, you’re likely dealing with leaks, extreme heat, and an all-around uncomfortable space during the majority of the year. Switching to a different roof system can convert the room from hardly usable to an area you will want to spend time in.

A classic case is the kitchen or dining room extension with an old flat roof that has had better years. Water collects after serious rain and the room is an ice box in winter with the heating full blast. Afternoon summer heat is unbearable. You’ve gone to the trouble of patching the roof and the problem just keeps re-occurring.

What Conversion Actually Means

When most people talk about converting a flat roof, they mean changing from the old traditional felt type or asphalt system to a modern single ply membrane system, or in some cases all the way to a pitched roof. Each of these options can solve certain issues, but they can all add to costs and complications.

Choosing a higher-grade single-ply membrane for the flat roof will keep the flat roof profile, while also giving appropriate waterproofing and insulation. This is the least disruptive option. It will only be a few days of work, minimal impacts on the inside of the room, and will be reasonably priced. It will cost anywhere from £60 to £100 per square metre for a decent job, with the cost covering an upgrade to the insulation as well.

Changing to a pitched roof will be more work. It will completely change the character of the space, and you will need to consider obtaining planning permission, as well as building regulations, and how it will aesthetically fit with the rest of your house. This will take longer and cost more, but will provide you with a room that is fully insulated and functions like the rest of your home.

Regulatory Burdens of Conversion that are Universally Dreaded

Both conversions are subject to building regulations. No matter which option you choose, your roof must comply with the most up-to-date insulation standards. Building control inspectors will ensure regulations have been followed.

Gaining planning permissions often poses a headache. Planning permission for pitch roofs especially needs consideration with respect to height increases, with the exception of pitched roofs in a conservation area. Flat to flat conversions, however, usually do not need planning permission. However, in all cases it is best to check with the local authority first. Doing work only to have to undo it for not obtaining proper permission leads to unnecessary costs.

It is key to have a proper assessment of the structure. This is important to ascertain if the existing walls were built to hold the required additional weight of the pitched roof. Strength reinforcing structure to support the pitched roofs extension will be an additional cost. This is another reason instructions from the engineer should be prioritized.

Enduring the Disruptions

Disruptions will happen. Replacing membranes will render the extension unusable for several days. Converting to pitched roofs will have an even bigger impact on the house for a longer time as it will not happen until the weather is dry and the time is sufficient. This means the time to complete the conversion is weather dependent.

Roofing work is severely weather dependent with the exception of the cold and rainy day. Under colder conditions the work will take longer as there will be fewer working days. While the contractor will be busy in the spring and autumn. During these periods the contractor will be less reactive to your needs as they will be busy, so it is best to have the work scheduled as soon as possible. Otherwise there may be long waits in the in the spring and early autumn months.

The mess factor differs for each type of work done. Membrane replacement usually happens on top of the roof, so the work is done rather clean. However, pitched roof conversions can be very disruptive, especially since they tend to involve structural work that affect the ceilings below. So, expect some dust and noise, as well as your extension being fully out of use.

What about the final results of the conversion?

Your temperature issues could very well be solved with proper insulation and ventilation, so your energy bills should drop as well. Most people are able to see the conversion “pay for itself” in energy costs in 8-12 years. The room finally being usable means the improvement is likely magnitudes better than that.

The aesthetics of your extension are improved, which is especially good for the overall value of your property. The presentation of your property is impacted in either direction, so the improvement may help when you finally decide to sell the property, especially when you choose a nice patch roof to go with a modern membrane.

Issues caused by flat roof conversions getting worse over time, so a flat roof conversion gives a permanent solution to an ongoing problem. Take time to figure what needs to come out of the space, consider getting some proper estimating quotes from contractors, and set a budget to do it only once, even if it means spending more money.