Emerton Roofing Contrators
Case Study:

Beeston Lodge

Back in 2018, we were called to investigate a roof leak at a detached Cheshire property. Upon investigation, we found rainwater to be penetrating a two storey slated roof slope, into an upstairs bedroom. Our contracts manager diagnosed the cause of this issue to be incorrect roof covering material, relative to the pitch of the roof. Although the slate covering was in tact, it was the case that this roof could not fully function due to an insufficient gradient – around 12 degrees. For a slate roof to function properly, the pitch needs to be at least 20 degrees, more if possible.

Subsequently, we offered our customer a range of solutions and we were delighted to instructed to remove the slate covering before supplying a new three layer built up felt roof.

The process began with the erection of a perimeter eaves level scaffold, to allow safe working access. This included hoisting equipment to safely lift materials to roof level.

One of our slating teams proceeded to remove the slates, battens and felt from the roof. These surplus materials were then segregated into waste, re-use and recyling before being carted away from site.

It was at this stage that we discovered that the roof had actually been leaking for quite some time as we found a section of the structure known as the ‘wallplate’ had become very rotten. After reporting this to our customer, our in house joiner attended site to replace this using new like for like treated timber. To do this, we had to adopt a cunning strategy as not to disturb the roof rafters and the ceiling attached to the underside.

Next, as is often the case with re-roofing projects, we installed insulation into the roof space. On this occasion, we elected to install ‘slab’ insulation between the rafters, as this was a ‘warm roof’ construction. In the process, we fixed an additional batten onto the rafter faces to lift the roof covering and allow an airspace between the insulation and the underside of the roof covering. This (vented) airspace is key in avoiding condensation issues.

We then proceeded to shape and fix a new 18mm WPB exterior grade plywood onto the roof structure, ready to receive the felt roof. As a matter of course, we prefer to use this type of decking as it is renowned for being one of the best boards for purpose, compared to the likes of Sterling/MDF type board.

It was now the turn of our flat roofing team to supply and bond a three layer felt roof system using high tensile polyester felts and hot bitumen. Although not the easiest to lay compared to other flat roof products, we consider this system to be the best on the market and have been successfully installing them across the North West for the last 50 years. On this occasion, we chose to use a mineral felt as the top layer as was the most aesthetically pleasing and also the most practical.

Following the ‘felting’, our team then completed a Code 4 Milled lead flashing over the vented top edge abutment. Painting of the fascia followed before we supplied and fixed a new UPVC eaves gutter.

Scaffold removal then brought the project to a successful conclusion.

Thank you for taking the time to read about our project at Beeston Lodge. We chose to photograph this project at each stage and created a video showing the step by step process. We hope you enjoy this below:

A video showing the process in transforming a failing slated roof to a successful built up felt roof