Case Study: Roof Replacement and Spray Foam Removal – 130m²

Project Overview

Our team was commissioned to remove approximately 130m² of rigid closed-cell spray foam insulation that had been applied directly to the roofing membrane and structure. Following the removal, we carried out a full roof replacement to restore structural integrity, improve ventilation, and bring the property in line with building regulations. The project also included a loft insulation upgrade, ensuring compliance with current energy efficiency standards.

Scope of Work

Scaffolding and Site Preparation

• Supplied and erected a two-lift scaffold to gutter height for safe access.
• Installed debris netting where required to protect neighbouring properties from spray foam debris.
• Supplied weatherproof tarpaulins and driveway protection to safeguard the property.
• Provided skips and waste chutes for efficient disposal, using our licensed waste carriers.

Roof Strip and Spray Foam Removal

• Carefully removed existing roof tiles, storing reusable tiles securely on the scaffold.
• Removed one aerial to allow access, leaving one aerial in place to maintain the television signal.
• Stripped existing battens with foam attached and disposed of them responsibly.
• Removed rigid closed-cell spray foam from the roof structure.
• Thoroughly scraped and cleaned all rafters, ridge boards, hips, and apex to fully expose the timber.
• Prepared the roof structure with universal 5-star wood treatment where required.

New Roof Installation

• Supplied and fitted over fascia vent strips, felt support trays at eaves level, and a Marley breathable felt membrane.
• Installed new 25mm x 38mm treated timber battens.
• Reinstalled existing roof tiles, supplying replacements where necessary to complete the covering.
• Installed a vented dry ridge and hip system to enhance roof ventilation.
• Inspected leadwork, noting contingency requirements for replacement if necessary.

Insulation Upgrade

• Removed old loft insulation where required and installed Knauf mineral wool loft insulation to a depth of 300mm.
• Overlaid insulation in boarded areas to ensure compliance with building regulations.
• Provided scaffold board working platforms in the loft to protect ceilings and allow safe access.

Final Preparations and Clean-up

• Conducted a complete gutter clean and a comprehensive site tidy.
• The roof was signed off by our lead roofer to confirm workmanship and quality standards.
• Liaised with local building control throughout, securing the LABC completion certificate.
• Provided a mortgage approval certificate, including before, during, and after photographic evidence of the works.
• Issued a 10-year Confederation of Roofers insurance-backed guarantee.
• Supplied copies of public liability insurance and waste carrier licence for client assurance.

Challenges and Solutions

Rigid Spray Foam Removal

The removal of rigid closed-cell spray foam, adhered directly to the membrane, required controlled techniques to protect the roof timbers. Our team successfully achieved complete removal while safeguarding the structural elements of the roof.

Leadwork Inspection
As with many roof replacements, leadwork could not be fully assessed until the strip-out stage. We highlighted this contingency to the client in advance and addressed any issues promptly once identified.

Conclusion

This project was delivered on time and to a high professional standard. The roof now benefits from a breathable membrane system, improved ventilation, and upgraded insulation. With all certifications and guarantees in place, the property is fully compliant, mortgageable, and prepared for long-term performance.

Key Benefits to the Client:

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.

Before - During - After Photos