Bauder Building Board

Specification

Bauder’s area technical manager carried out an in-depth roof condition survey to assess the status of the existing roof covering, structural design, and thermal performance. The existing hard metal cold roof highlighted the potential for condensation. Further inspections were carried out internally that found there was insufficient cross ventilation which was causing the roof and void to condensate. The water ingress was highlighted as common in the winter months.
 
Upon survey, Bauder’s technical department carried out various technical tests, including condensation risk analysis and U-value calculations to determine the most suitable waterproofing system to be specified that achieved the project requirement to offset any condensation risks.
 
The refurbishment involved a comprehensive overlay to the existing hard metal roof and gutters. Bauder Single Ply Profiled PIR Infill Overlay System was specified to refurbish the profiled sheet metal roof. The system incorporates a PIR insulation infill that is cut to match profiled sheet metal and roof structures. The system then adds a BauderPIR FA flatboard insulation and a single ply membrane to complete the overlay solution.
 
Bauder also supplied an embossed walkway membrane to clearly define an access pathway with reduced potential for slips when maintenance is required. To facilitate efficient rainwater drainage, new downpipes and hoppers were installed.
 

Products applied

BauderPIR FA Flatboard Insulation
Bauder’s in-house technical team utilised the results of the condensation risk analysis to calculate the amount of insulation required. To take up the depth of the standing seam roofing profile, 60mm of BauderPIR FA Flatboard Insulation was installed incorporating BauderSYN DB-PE 100 polyethylene air and vapour control layer and an additional 140mm of PIR insulation.
 
BauderTHERMOFOL U 15 FR PVC
This single ply roofing membrane was applied to complete the system. It is lightweight and has a high-grade virgin polymer formulation.
 

Project challenges

Due to the project being landlocked and in Edinburgh city centre, there were access restrictions for the site including the time the refurbishment works could take place and the quantity of materials which could be delivered.
 
The deliveries had to be managed in and around a live fire station. Bauder worked closely with the contractor to organise smaller deliveries to overcome the access restrictions and continue to deliver the renovation.
 
Insite Cladding and Roofing had to detail in their construction phase plan where they would be working, when they would be working, the duration they would be working for, and how they would overcome any emergency callouts by SRFS.
 
Since this refurbishment project was completed around a live fire station, keeping water ingress during construction to a minimum was imperative. Due to the project being carried out in Scotland over the winter months, Insite installers had to precisely apply the night seals each evening because they could be left for days at a time.
 
Throughout the project, there was strong collaboration from all Bauder and Insite Cladding and Roofing which ensured a smooth execution and adherence to high standards. Due to the nature of the refurbishment project, there were instances that were not forecasted at the initial survey stage. For instance, the existing gutters were not straight, therefore during the construction, a new galvanised steel angle had to be installed prior to the roofing installation.
 

The result

Hard metal roofs can experience condensation issues due to the lack of ventilation beneath the deck. Installation of Bauder Single Ply Profiled PIR Infill Overlay System is the most suitable solution for these types of failing roofs.
 
The refurbishment project delivered a durable, long-term waterproofing system that achieved the functional requirements for the building to ensure the continued operational effectiveness of the fire station, whilst seamlessly blending with the existing aesthetic of the Category B listed building.
 
The original roof system had no workmanship guarantee and had several failed attempts at repair. The installation of Bauder Single Ply Profiled PIR Infill Overlay System provided Tollcross Fire Station with a 20-year product and workmanship guarantee specific to the project requirements.
 

System installed

Bauder Profiled PIR Infill Overlay System