By David Starr on Monday, 20 May 2024
Category: Case Studies

Case Study - Roof Replacement & Spray Foam Removal

Countrywide Coatings was commissioned to undertake an extensive roof restoration project for a historic home, encompassing approximately 120m². The original roof featured small clay tiles with closed cell rigid spray foam applied directly to the tiles. Our task was to carefully remove the existing foam and tiles, prepare the roof structure, and install new materials that match the existing design while ensuring durability and aesthetic continuity. The project concluded with a 10-year insurance-backed guarantee.

 Project Details

Client: Private Homeowner
Location: Residence, Coventry, West Midlands
Project Duration: 4 weeks
Area: 120m²

Scope of Work

  1. Initial Assessment and Planning
    • Conducted a thorough site inspection and roof assessment.
    • Planned the removal and replacement strategy, ensuring minimal disruption to the client's daily life.
  2. Removal of Existing Materials
    • Carefully removed the original clay tiles, which had spray foam applied directly to them.
    • Safely extracted and disposed of the closed cell spray foam insulation using our licensed waste carriers.
    • Provided two lift scaffolding up to gutter height, including a waste chute for efficient debris removal.
  3. Roof Structure Preparation
    • Scraped and cleaned all rafters, hips, and the ridge board to remove any residual foam and debris.
    • Sanded all structural elements to ensure a smooth surface for treatment.
    • Applied a universal 5* wood treatment to all exposed rafters, hips, and ridge boards to protect against wood decay and pests.
  4. Installation of New Roof Materials
    • Installed over fascia vent strips and felt support trays at eaves level to improve ventilation.
    • Laid Marley breathable felt membrane for enhanced moisture control and insulation.
    • Fixed 25/38mm treated battens securely to the roof structure.
    • Carefully loaded out the roof, preparing it for the new tiles.
  5. Tile Replacement and Finishing Touches
    • Supplied and fitted reclaimed small clay tiles, matching the original design and ensuring adherence to the manufacturer's recommendations and the code of practice for tiling and slating.
    • Inspected and repaired lead trays around the chimney to prevent leaks.
    • Replaced valley trays where necessary to ensure optimal water drainage.
    • Installed ridge and bonnet tiles to the hips and apex for a cohesive finish.
    • Mortar bedded verge tiles with Remix roofing mortar for added stability.
  6. Waste Management and Site Clean-Up
    • Ensured the safe disposal of all waste materials, with a copy of our Waste Carriers Licence provided.
    • Conducted a comprehensive site audit, including before, during, and after photographs, documenting the work carried out.
  7. Final Inspection and Guarantee
    • Provided a 10-year insurance-backed guarantee through the Confederation of Roofing Contractors.
    • Ensured the site was left clean and tidy, ready for the client's immediate use.

 Results and Client Feedback


The project was completed within the stipulated time frame, with the new roof seamlessly integrating with the historic aesthetic of the home. The client was highly satisfied with the meticulous attention to detail and the quality of craftsmanship. The 10-year insurance-backed guarantee provided peace of mind, ensuring the durability and longevity of the new roof.


Side Profile

​Supplied and fitted reclaimed small clay tiles, matching the original design and ensuring adherence to the manufacturer's recommendations and the code of practice for tiling and slating.


Clay Work

​Supplied and fitted reclaimed small clay tiles, matching the original design and ensuring adherence to the manufacturer's recommendations and the code of practice for tiling and slating.


Side Profile

​Supplied and fitted reclaimed small clay tiles, matching the original design and ensuring adherence to the manufacturer's recommendations and the code of practice for tiling and slating.

 Contact Us

For more information about our roofing solutions and how we can help restore and protect your property, please contact Countrywide Coatings at 0808 134 2352 

Areas We Cover

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