Case Study: Roof Replacement and Spray Foam Insulation Removal

Project Overview

Our team was engaged to execute a comprehensive roof replacement and spray foam insulation removal on a 120m² roof with small concrete tiles. The project involved the careful removal of both closed cell and open cell spray foam insulation directly applied to the existing tiles, followed by the installation of new roofing materials, including a breathable felt membrane, battens, and the reinstallation of existing concrete tiles. This case study outlines the full scope of the project, including challenges, solutions, and the outcomes achieved.

Scope of Work

The project consisted of the following key tasks:

1. Scaffolding and Site Preparation:
   • Erected a two-lift scaffolding to gutter height with waste chutes and tile bumpers to ensure safety during the tile removal and reinstallation process.
   • Supplied skips for the disposal of waste materials, including foam and broken tiles, managed under our waste carriers license.
2. Removal of Existing Roof Materials:
   • Carefully removed the existing small concrete tiles, stacking them neatly on the scaffolding for potential reuse. Given the age and fragility of the tiles, allowances were made for up to 25% breakages.
   • Removed and disposed of both closed-cell and open-cell spray foam insulation attached to the membrane, which required careful handling to avoid damaging the underlying roof structure.
3. Preparation of Roof Structure:
   • Scraped, sanded, and cleaned all rafters, hips, and ridge boards, preparing the roof structure for new materials.
   • Treated all exposed rafters and roof elements with a universal 5-star wood treatment to protect against wood rot and insect infestation.
4. Installation of New Roofing System:
   • Installed over fascia vent strips and felt support trays at eaves level, enhancing the roof's ventilation system.
   • Applied Marley breathable felt membrane and fitted 25/38mm treated battens to provide a solid and durable base for the reinstallation of the concrete tiles.
   • Reinstalled the existing small concrete tiles, allowing for breakages, and followed manufacturer recommendations and best practices in accordance with the code of practice for tiling and slating.
5. Lead and Valley Tray Repairs:
   • Conducted a thorough inspection of lead trays around the chimney, replacing or repairing them as required to ensure watertight integrity.
   • Replaced valley trays where necessary to improve water drainage and prevent future leaks.
6. Ridge System Installation:
   • Supplied and fitted ridge tiles to hips and apex, installing a dry ridge system to improve the durability and ventilation of the roof.
7. Insulation Upgrade:
   • Supplied and installed Knauf mineral wool insulation to a minimum depth of 270mm, ensuring compliance with local building authority regulations and enhancing the energy efficiency of the property.
8. Final Touches and Compliance:
   • Provided and installed new Velux flashing kits where required, ensuring seamless integration with the new roofing system.
   • Managed site cleanliness and safety throughout the project, performing a full site audit including before, during, and after photographs of the work carried out.
   • Liaised with local building control on behalf of the client, securing all necessary approvals and compliance certificates.

Challenges and Solutions

Outcome

The project was completed within the agreed timeframe, which included all scaffolding, labour, materials, and a 10-year insurance-backed guarantee from the Confederation of Roofers. The new roof system fully complies with all building regulations, enhancing the property's thermal efficiency and overall aesthetic.

Key Benefits to the Client:

Spray Foam Removal 

Client Testimonial:

The client expressed satisfaction with Craig Webb's professional management of the project. Webb ensured clear communication and coordination with local building control. The meticulous approach to handling the existing tiles and spray foam was particularly appreciated, as it maintained the character of the original roof while significantly upgrading its performance.

Conclusion

This project highlights our expertise in complex roof replacement and insulation removal tasks, showcasing our ability to manage delicate materials and deliver high-quality, regulation-compliant results. We are committed to leaving each site clean, safe, and with a roof that not only meets but exceeds client expectations.

Links To Some Of Our Roofing Pages

Dorset, Bournemouth, Weymouth, Dorchester, Wimborne Minster, Verwood, Ferndown, Bridport, Blandford Forum, Gillingham, West Moors, Sherborne, Corfe Mullen, Poole and Christchurch