Case Study: Roof Replacement and Insulation Upgrade on a Clay Tile Roof

Project Overview

Our team undertook a full roof replacement and insulation upgrade for a 130m² clay tile roof that had closed cell spray foam applied directly to the tiles. The project included the removal of existing spray foam insulation and tiles, installation of a new breathable membrane, new clay tiles, and upgraded loft insulation. Additionally, we provided a complete site clean-up, handled all waste disposal, and coordinated with local building control to ensure regulatory compliance.

Scope of Work

The key tasks involved in this project included:

1. Scaffolding and Site Preparation:
   • Erected two-lift scaffolding to gutter height, which allowed safe access to the roof and facilitated adjustments to the guttering and painting of soffits and fascias.
   • Installed a waste chute and tile bumper to ensure safe and efficient handling of materials.
   • Supplied skips for the disposal of removed materials, managed under our waste carriers license.
2. Removal of Existing Roof Materials:
   • Removed the original clay tiles, placing them directly in skips to clear the work area.
   • Carefully detached and disposed of the closed cell spray foam insulation attached to the roof structure, apex, and valleys.
   • Removed all battens and prepared the roof structure with scraping, sanding, and cleaning of rafters, hips, and ridge boards to ensure a pristine surface.
3. Wood Treatment and Ventilation Preparation:
   • Treated the roof structure with a 5-star universal wood treatment, protecting the rafters, hips, and ridge boards from rot and insect infestation.
   • Installed over fascia vent strips and felt support trays at the eaves level, enhancing airflow through the roof structure.
4. Installation of New Roofing System:
   • Applied Marley breathable felt membrane to create a water-resistant layer while allowing moisture to escape from within the roof.
   • Installed 25mm x 50mm treated battens, providing a strong base for the new clay tiles.
   • Supplied and fitted new clay tiles to match the existing roof profile, adhering to manufacturer recommendations and tiling and slating codes of practice.
   • Installed a dry ridge system to the hips, verge, and apex, finishing with mortar to ensure a durable, watertight seal.
5. Insulation Removal and Upgrade:
   • Removed the existing loft insulation across 60m², preparing the area for new installation.
   • Installed two layers of Knauf mineral wool loft insulation to a depth of 300mm, meeting building regulation standards and enhancing thermal efficiency.
   • Installed 75mm Celotex insulation in vaulted ceiling areas, leaving a 30mm breather gap for ventilation, covering an additional 25m².
6. Additional Maintenance and Adjustments:
   • Painted soffits and fascias in a white satin exterior gloss, providing a clean, weather-resistant finish.
   • Adjusted the guttering profile to align with the new roof, replacing broken clips and performing a full gutter clean.
7. Final Compliance and Site Clean-Up:
   • Worked closely with local building control, managing site meetings and ensuring that all regulatory requirements were met.
   • Documented the project with before, during, and after photographs for mortgage and regulatory purposes, providing a completion certificate from the Local Authority Building Control (LABC).
   • Conducted a full site clean-up, ensuring all waste was responsibly disposed of and leaving the property in pristine condition.

Challenges and Solutions

Outcome

The project was completed on time and within the quoted budget, which included all labour, materials, and a 10-year insurance-backed guarantee. The client received a high-quality, durable roof with improved thermal efficiency and aesthetic appeal, fully compliant with local building control requirements.

Key Benefits to the Client:

Roof Replacement 

Client Testimonial:

The client expressed satisfaction with the high level of professionalism and attention to detail, particularly appreciating the seamless coordination with building control and the careful treatment of the timber structure.

Conclusion

This case study demonstrates our capability to handle complex roof replacement projects involving spray foam removal, regulatory compliance, and insulation upgrades. By maintaining a meticulous and safety-focused approach, we ensured a smooth, hassle-free experience for the client and delivered a robust, energy-efficient roofing solution.

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