Case Study: Roof Replacement and Spray Foam Insulation Removal on a Slate Roof

Project Overview

This project involved the removal of closed cell ridged spray foam insulation from approximately 23m² of roof space, where the foam had been directly applied to slate tiles. Our task was to carefully remove the foam and tiles, inspect and clean the roof structure, and install new roofing materials, including a breathable Marley felt membrane, battens, and matching slate tiles. The project also required liaising with local building control to ensure compliance with building regulations, including upgrading the loft insulation to meet the current standards.

Scope of Work

The key tasks for this project included:

1. Scaffolding and Initial Setup:
   • Erected a single lift scaffolding to gutter height, ensuring safe and efficient access to the roof area.
   • Supplied skips for waste management, aligning with our waste carriers license to ensure environmentally responsible disposal of materials.
2. Removal of Existing Roof Materials:
   • Carefully removed the existing slate tiles and battens, with the spray foam insulation still attached. This process required meticulous handling to prevent damage to the rafters and underlying roof structure.
   • Scraped, sanded, and cleaned all rafters, hips, and ridge boards to prepare the roof for new materials.
3. Installation of New Roofing System:
   • Supplied and installed over fascia vent strips and felt support trays at eaves level to enhance ventilation.
   • Laid Marley breathable felt membrane and 25mm x 50mm treated battens, ensuring a stable base for the new slate tiles.
   • Installed new slate tiles to match the existing roof profile, following manufacturer guidelines and adhering to the code of practice for tiling.
   • Supplied and fitted Code 3 lead soakers and Code 4 lead flashings at wall and chimney abutments, cleaning with patination oil per Lead Sheet Association specifications to prevent staining and corrosion.
4. Additional Repairs and Adjustments:
   • During the roof inspection, we uncovered rotten rafters within the stone wall. These were replaced with new rafters, and due to the height difference between old and new rafters, we counter-battened the roof to maintain a level surface.
   • Removal of the old roof covering caused some damage to the rendered verge, which will require repair.
5. Insulation Upgrade:
   • Supplied and installed Knauf mineral wool loft insulation to a depth of 150-300mm, ensuring compliance with building regulation standards and improving the thermal efficiency of the property.
6. Final Touches and Compliance:
   • Installed a vented ridge system, with ridge tiles fixed according to the manufacturer's recommendations.
   • Mortar bedded any required leadwork or flaunching around chimneys and abutments, with additional costs applied if leadwork was found perished.
   • Ensured a thorough site clean-up, leaving the property tidy and with full exposure of rafters, hips, and ridge board for sales and documentation purposes.

Challenges and Solutions

Outcome

The project was completed with a high level of craftsmanship and adherence to all relevant building standards. Our coordination with local building control ensured that all modifications were approved and compliant, resulting in the issuance of a completion certificate. The upgraded roof not only matched the existing slate aesthetic but also provided improved insulation and ventilation, enhancing the overall energy efficiency of the property.

Key Benefits to the Client:

Spray Foam Removal 

Client Testimonial:

The client was pleased with the quality of the work and the clear communication throughout the project, particularly appreciating the proactive approach taken to replace the rotten rafters and address unexpected challenges.

Conclusion

This case study demonstrates our commitment to delivering comprehensive roofing solutions that meet and exceed client expectations. By carefully managing every aspect of the project from start to finish, we ensure that our clients receive a durable, compliant, and aesthetically pleasing roof fully backed by industry-standard guarantees.

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