In less than four months, three companies working collaboratively successfully completed a 48,000m2 fast track roofing project for one of the biggest online grocery centres in the world.
This incredibly tight programme minimised material waste and time on site, thanks to a number of innovations developed specifically for the project by the three businesses working collaboratively: SIG Design & Technology, IKO Polymeric and FK Group.
The new fulfilment centre for premium British online supermarket, Ocado is based in Erith Kent, and will be operational in 2017. It will handle 200,000 orders a week and represents £185 million of investment in the locality. The roofing project completed in December 2015.
Fast Track Roofing – Innovations
IKO Polymeric, the UK’s only single ply manufacturer, developed several innovative solutions to complete the job while minimising waste of roofing products, both in manufacture and on site.
Steve Hall, Managing Director of full building envelope contractor, FK Group, comments:
“IKO Polymeric demonstrated its usual proactive approach with innovations such as the manufacture of bespoke roll lengths and specific membrane overlap positioning which allowed significant efficiencies to be achieved on site.”
Standard length membrane is typically 20 linear metres which then has to be cut or extended (by fixing on additional sections) to fit the required dimensions. IKO Polymeric manufactured its Armourplan PVC single ply membrane in bespoke rolls of 22.35, 19.20 and 8.00 linear metres to reduce both waste and installation time for this project.
Another first was manufacturing half of the rolls with the membrane overlap positioned on the opposite side to the other half of the rolls. This 50/50 split meant the contractor could deploy two teams to work simultaneously on either side of the ridge, each rolling the membrane out in the same direction. Standard practice is for one team to work on one side at a time.
New Installation Technique
The FK Group also developed a new technique for the project, welding eight rolls together to create a large (320m2) membrane ‘blanket’. Half were then rolled back and then adhesive was applied to the area, instead of installing one roll at a time. This sequence was only possible because IKO’s Polymeric’s PU adhesive can be exposed for up to 25 minutes.
These innovative manufacturing and installation methods enabled approximately 5,500m2 to be installed each week.
Dave Schofield, Commercial Manager for SIG Design & Technology explains the importance of confidence in supply, one of our 8 Steps to a Perfect Roof:
“To ensure the smooth and efficient delivery of the roofing system, we organised a bespoke trailer for each load. Goods were collected in the afternoon and hauled overnight to arrive on site between 8:00am and 9:00am the following day. Roofing materials were unloaded within a ninety minute window and because pre-arranged signature securities were in place, all the goods were accounted for. The Design & Technology logistics team provided a slick and professional service working closely with our hauliers, IKO and FK. A great team effort.”
Steve Hall adds: “Working alongside FK Group, IKO and SIG Design & Technology made a significant contribution to the success of this job. As a key part of our supply chain, they helped us to develop and deliver a bespoke solution to our client in impressive time.”
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4 comments
who were the roofing companys?????
This fast track roofing project is a fantastic achievement. Installing 5,500m2 of membrane a week is incredibly time efficient. Of course, flat roofing can be problematic, being more likely to leak, but provided the roof is maintained and the waterproof membranes replaced regularly, this architectural triumph will undoubtedly have a long lifespan. Huge congratulations to SIG Design & Technology, IKO Polymeric and FK Group.
I agree, it’s a great project, which why it won the innovation category at the SPRA Awards 2016.
If flat roofs were ‘more likely to leak’, insurers and major stakeholders would avoid them, which is patently not the case. Roofs of any kind rarely leak due to product issues; in-service performance-based certification (mandatory in SPRA) has seen to that and claims on product warranties are extremely rare. As insurers will attest regarding pitched roofs, weak design and poor installation are frequent causes. That’s why we engage with architects and – uniquely in roofing – retain mandatory off-site training and manufacturer inspection within our constitution.