An industrial roof doesn’t have to be falling apart before it needs attention. Quite often, we’re called out to roofs that are still doing their job but are starting to show their age. There might be a few leaks, corrosion around the sheet edges, old rooflights or gutters that are becoming a problem.
At this point, replacing the whole roof may be unnecessary. Industrial roof refurbishment gives you the option of dealing with the areas that need attention while getting more life from the roof you already have. There isn’t one standard way to refurbish a roof. What makes sense will depend on its condition, age, how the building is used and how long you intend to keep it.
What Does Industrial Roof Refurbishment Involve?
Roof refurbishment can range from carrying out several repairs at the same time through to a much larger programme of work across the whole roof. For example, a factory roof might have corrosion along the edges of the sheets, several tired rooflights and gutters that have started leaking. Rather than treating each problem separately as it gets worse, it can make more sense to deal with everything as part of one planned job.
Before deciding what needs doing, the first step is to look at the roof properly. We want to know where the problems are, what condition the rest of the roof is in and whether there are any issues that aren’t immediately obvious from ground level. If the main roof is still sound, refurbishment can often be a sensible alternative to complete replacement.
When Is a Roof Suitable for Refurbishment?
Age on its own doesn’t tell us whether a roof should be refurbished or replaced. We’ve seen older roofs that still have plenty of life left in them and newer roofs that need more attention than you would expect.
What matters is the condition. If most of the roof sheets and supporting structure are sound, but certain parts are starting to deteriorate, refurbishment may be worth looking at. The problems could include localised leaks, early corrosion, damaged sheets, old rooflights, failed fixings or gutters that are starting to cause trouble.
The situation is different when deterioration is widespread. If sheets are badly corroded across large areas, water is getting in at numerous points or previous repairs keep failing, spending more money on refurbishment might only delay the need for replacement. That’s why we’d rather look at the roof first than recommend a particular system over the phone.
Cut Edge Corrosion Treatment
Cut edge corrosion is something we regularly see on older metal roofs. It usually appears around the exposed edges of coated roof sheets and can gradually spread if it’s left untreated.
If it’s caught early enough, the affected areas can often be cleaned, prepared and treated without replacing the roof sheets. The important thing is not to leave it until corrosion has eaten further into the metal. What starts as a relatively manageable repair can become a much bigger job if water gets underneath the coating and the sheets begin to fail.
We’ve covered this separately in our guide to spotting cut edge corrosion and fixing it.
Roof Coatings
A roof coating may form part of an industrial roof refurbishment where the existing roof is suitable for it. Before any coating goes on, the roof needs to be checked and the necessary preparation and repairs carried out first. There’s little point coating over corrosion, damaged sheets or other problems and hoping they disappear underneath it.
Done for the right reasons and on the right roof, a coating system can help protect the existing sheets and extend their working life. It isn’t a way of rescuing a roof that has already gone too far, though. If the underlying roof is in poor condition, we would look at other options.
Gutters and Drainage
Not every industrial roof leak is actually coming through the roof sheets. Industrial gutters deal with a lot of water, and problems can develop around joints, outlets and areas where water is allowed to sit. Blockages can also cause water to back up and find its way into the building.
As part of a refurbishment, we’d normally look at the gutters and drainage rather than concentrating solely on the roof covering. Depending on their condition, industrial gutters may be repaired, lined or replaced.
Our guide to industrial gutter failure explains the different options in more detail.
Rooflight Replacement
Old rooflights are another area worth checking when an industrial roof is being refurbished. Over time they can become dirty, discoloured, brittle or damaged. Problems can also develop around the fixings and seals, which may eventually allow water into the building.
If the rooflights are reaching the end of their life, it can make sense to replace them while other roofing work is being carried out rather than coming back to them a year or two later. New rooflights can also make a noticeable difference to the amount of natural light getting into a factory or warehouse.
Replacing Individual Roof Sheets
A handful of damaged sheets doesn’t mean the entire roof needs replacing. If the surrounding roof is still in reasonable condition, individual sheets can often be replaced as part of the refurbishment. The same applies to damaged flashings, fixings and other localised areas.
The question is how widespread the damage has become. Replacing five problem sheets on an otherwise sound roof is very different from replacing sheets throughout the building one at a time. At some point, repeated repairs stop being the sensible option.
Could the Roof Be Overclad Instead?
Where a roof needs more substantial work but complete removal isn’t necessary, industrial roof overcladding may be another option.
This involves installing a new roofing system over the existing roof. On suitable buildings it can improve weather protection and insulation without stripping off the entire existing covering.
It can also help reduce disruption on busy sites, which is particularly useful for factories and warehouses that need to keep operating while the work takes place. Overcladding isn’t suitable for every building, so the existing roof and structure need to be checked first.
Refurbishment or Complete Replacement?
Sometimes refurbishment simply isn’t worth the money. If an industrial roof is leaking in numerous places, heavily corroded or reaching the end of its useful life, putting more money into repairs can become a false economy.
This is where we look at the bigger picture. How much would the refurbishment cost? How much extra life are you likely to get from it? What other work is likely to be needed over the next few years?
If the figures don’t stack up, replacement may be the better long-term option. Our Industrial Roof Repair or Replacement guide goes into this decision in more detail, and we’ve also put together an Industrial Roof Replacement Cost UK guide for anyone starting to budget for a larger project.
Can a Factory Stay Open During Roof Refurbishment?
In many cases, yes. We regularly work on buildings where shutting down the business simply isn’t practical. The job can often be planned in stages, taking into account what is happening inside the building as well as access, machinery, stock and vehicle movements outside.
How we approach it will depend on the site and the work being carried out. A small repair is obviously very different from refurbishing a large factory roof. The important thing is planning the work around the customer rather than expecting the customer to work around us.
If this is a concern for your site, our guide to factory roof replacement without shutting down explains how larger roofing projects can often be planned around a working site.
What About Asbestos Cement Roofs?
Older industrial and agricultural buildings can still have asbestos cement roofing, and that needs to be taken into account before any refurbishment work starts. Having asbestos in the roof does not automatically mean the whole roof has to be removed, but its condition and the work being proposed need to be properly considered.
Depending on the roof, options may include managed repairs, overcladding or complete removal and replacement. You can read more in our guide to Asbestos Cement Roofs and Your Legal Duties.
Industrial Roof Refurbishment Across the UK
Robinsons Roofing & Cladding carries out industrial roof refurbishment and repair work across the UK. Being based in the West Midlands also puts us in a good position for projects across Wolverhampton, Birmingham, Staffordshire, Shropshire, Worcestershire and the surrounding areas.
If your roof is starting to show its age, it doesn’t automatically mean you need to replace it. We can look at what’s happening, identify the areas that need attention and talk you through whether repairing, refurbishing, overcladding or replacing the roof makes the most sense.
Thinking About Refurbishing Your Industrial Roof?
If you’re considering industrial roof refurbishment, the best place to start is by understanding the condition of the existing roof. Once we know what is failing and how widespread the problems are, we can give you a clearer idea of which option is likely to give you the best value.
Speak to our industrial roofing team to discuss your roof and arrange an assessment.
