Case Study: Roof Replacement and Spray Foam Removal – 55m²
Project Overview
Our team was contracted to provide a complete new roof solution and insulation upgrade for a residential property where approximately 55m² of closed-cell spray foam insulation had been applied directly to the roof tiles. The scope of work included the safe removal of the existing roof covering and insulation, installation of new roofing materials, and an insulation upgrade to ensure compliance with building regulations.
Scope of Work
Scaffolding and Site Preparation
- Supplied and erected a two-lift scaffold to gutter height for safe access.
- Installed debris netting and tile bumpers to protect the site and neighbouring properties.
- Supplied and positioned waste chutes to ensure efficient transfer of removed materials into skips.
- Provided skips with licensed waste carriers for the responsible disposal of spray foam and roof debris.
- Used protective tarpaulins and driveway protection to safeguard the property throughout the works.
- Carefully removed the existing roof tiles with closed-cell spray foam adhered, placing waste directly into skips.
- Stripped out existing battens and foam, ensuring all contaminated materials were disposed of responsibly.
- Fully exposed rafters, hips, and ridge boards, carefully scraping and cleaning them to prepare for new installation.
- Supplied and fitted over fascia vent strips, felt support trays, and a Marley breathable felt membrane.
- Installed new 25mm x 38mm treated roofing battens to provide a strong base for tiling.
- Supplied and fitted new large concrete plain tiles matching the existing roof profile, following manufacturer recommendations and the code of practice for tiling and slating.
- Installed a vented ridge system and a vented verge system to improve airflow and roof ventilation.
- Inspected leadwork and advised on contingencies where replacement may be required.
- Installed Knauf mineral wool loft insulation to a minimum depth of 300mm, ensuring compliance with current building regulations.
- Provided scaffold boards in loft areas to allow safe working zones.
- Prepared the roof structure for a universal 5-star roof treatment where required.
- Conducted a full gutter clean and a comprehensive site tidy.
- Liaised with the local authority to obtain the LABC completion certificate.
- Supplied mortgage approval documentation, including before, during, and after photographs for evidence.
- Issued a 10-year Confederation of Roofers insurance-backed guarantee.
Challenges and Solutions
The rigid nature of closed-cell spray foam, bonded directly to concrete tiles, posed significant challenges during removal. Our team utilised controlled scraping and cleaning techniques to protect the roof structure while ensuring complete removal of the foam.
Close coordination with building control officers was required to ensure the new roofing and insulation works met all regulatory standards. Certification was secured on completion of the project.
Conclusion
This project was successfully delivered to the highest standards, with all waste removed responsibly and full compliance with building control achieved. The new roof covering and upgraded insulation not only improved the energy efficiency of the property but also provided the client with peace of mind, mortgage approval documentation, and a robust guarantee.
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
Before
During
After
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