Bauder Ltd

A large derelict warehouse located in Witham has undergone major renovation to transform it into a storage centre for Essex County Council that will assist its services and benefit the local community. The refurbishment works were designed and project managed by Lambert Smith Hampton on behalf of the client, who wanted the building to act as a benchmark for sustainability with the roof playing an integral part in achieving this through the addition of solar panels.

This landmark office development in the City of London features Bauder's hot melt and extensive green roof systems and boasts an 'Excellent' BREEAM rating

The Neath Port Talbot County Borough Council wanted their new school to be fitting for the 21st century and bring them to the forefront of modern-day roofing technology. These requirements were met by BauderSOLAR’s innovative photovoltaic system, SOLfixx, which delivers significant cost and environmental benefits, as well as providing an eyecatching visual reminder of the importance of sustainability.

Barony Campus is a new build project situated in Cumnock, Scotland. The campus will incorporate a range of primary schools, learning centres and academies within the area, and is the biggest capital project undertaken by East Ayrshire Council.

Basildon and Thurrock University Hospital’s existing roof was failing in multiple areas, and 80 rooflights needed replacing. The client wanted the refurbishment to make as little impact as possible on the departments directly below which included drug refrigeration, x-ray and ultrasound clinics, patient wards and operating theatres.

The client wanted the new visitor centre building to replicate the shape of the iconic spitfire wing and to be waterproofed with a roofing system that would be aesthetically pleasing due to its high visibility. A particularly challenging element of the installation was the amount of intricate detailing requirements due to the elliptical shape and 5° pitch of the wing areas. The waterproofing system needed to incorporate insulation that would achieve a 0.16 U-value and the memorial site had to remain open throughout the works causing logistical challenges.

The impressive Belvedere Court 4-storey building, which was converted from a hotel into 16 prestigious residential apartments in 2008, recently underwent further development including extensions for additional accommodation, basement housing, a communal swimming pool, a theatre and an underground car park.

This new build project in the centre of Cambridge combines a Sustainable urban Drainage Solution (SuDS) with vegetation and renewable energy in a warm roof construction.The client for the Department of Civil Engineering at Cambridge University, R H Partnership, identified sustainability as being a key driver in the design of the roof, but also sought a single source supplier that could provide a guarantee for both workmanship and products. Bauder’s systems range encompasses products to meet all the sustainability objectives, and with our network of approved contractors carrying out the installation, we could offer the comprehensive guarantee that was required.Bauder Building BoardProject:Cambridge University Department of Engineering​Location:CambridgeRoof Area:1610m²Client:University of CambridgeSpecifier:RH Partnership ArchitectsMain Contractor:SDC LimitedApproved Contractor:Voland LimitedThe specificationTo meet the sustainability criteria set out by the client, the Bauder technical team designed a roof system combining an extensive blue roof, a green roof and a solar PV array. The first and most fundamental element of the roof system though is the waterproofing. Bauder Total Green Roof System (BTGRS) was selected as it provides robust and durable waterproofing with a life span in excess of 35 years, as validated by BBA Certificate 10/4744. The Plant E cap sheet has also been tested by the FLL to ensure long term root-resistance, making it ideal for use in conjunction with the BauderSOLAR G LIGHT system. The BauderSOLAR G LIGHT system is a unique way to combine rooftop vegetation with renewable solar energy. The PV panel mounting boards are held in position using the growing medium as ballast, meaning the waterproofing is not penetrated and therefore compromised. The mounting boards incorporate a water retention feature which allows a small amount of excess rainwater to be stored for short periods of time for the various plant species to feed from. The BauderSOLAR G LIGHT system’s unique mounting system lifts the panels above the vegetation allowing the plant life to grow freely and therefore qualify a greater area of the roof as biodiverse.In addition to the BauderSOLAR G LIGHT system, a blue roof was added to the build-up. Blue roofs are sustainable drainage solutions designed to manage stormwater on a flat roof to reduce water runoff rates and ease flash flooding and standing water in built up areas. The BauderBLUE Roof System attenuates water from a flat roof over a 24-hour period via a restrictive flow outlet. Calculations are carried out to determine the rate at which the water should egress the rooftop. This is determined by the local planning authority and is often set as low as 5-8 litres per second per hectare. With these calculations, Bauder can design each flow restrictorto meet the necessary runoff rate. For the Department of Civil Engineering, the main roof area of 1455.5m² required two flow restrictors, each with flow control holes to ensure the specified discharge rate of 0.77 litres per second was achieved. The maximum depth of water the roof is designed for is the H-max. When the water level reaches H-max, it will drain via the emergency overflow pipe. These overflow pipes are set at the same height as the H-max level. On this project the H-max was calculated to be 99mm. Although an unlikely scenario, this provision for a ‘once-in-a-hundred-years’ storm event will ensure that the structural integrity of the building is always preserved.Project challengesThe roof deck was constructed using a pretensioned concrete plank roof structure. Due to the large span of these planks, the dead load weight to the roof would be restricted. This being a blue roof with green landscaping and PV (a reasonably heavy build up), presented the issue of balancing the need of the roof design and the weight restriction of the supporting structure. To add to this challenging scenario, the pretensioned deck did not provide a completely flat finish. When installing a blue roof, a flat deck with no positive or negative falls is essential, as detailed in the 2018 update of BS 6229 – Flat roofs with continuously supported flexible waterproof coverings. To overcome this onsite challenge,the final deflection of the fully loaded roof was calculated and the concrete deck was screeded to give a flat finish.The resultBauder believes this project to be one of the first of its type in the UK to bring together so many rooftop systems in one space. Project management and clear communication was paramount in order to ensure a smooth installation. The Bauder project team consisted of green roof and solar PV product managers, area technical manager, technical design team, site technicians and approved installers for the waterproofing.With all the different elements being installed, green roof and solar PV product managers worked with our technical team to design the best possible PV array configuration for optimum energy generation whilst also qualifying for the maximum biodiverse area.Bauder site technicians worked closely with Bauder approved contractors, Voland Asphalte Ltd, to ensure works were kept to schedule and that a high quality of workmanship was maintained throughout.To ensure the landscaping is maintained, irrigation was installed by Access Irrigation Ltd. The system, Permadrip Pro, is a drip line irrigation system with anti-syphon design to resist clogging and pressure regulation. Due to the specialist nature of the irrigation system, Access Irrigation Ltd provided a bespoke design service.The result of this network of expertise was a multi-faceted support service for the client, specifier, main contractor and roofing and PV installers. System installed1 BauderPLANT E 42Green, 5mm torch-on root-resistant capping sheet.2 BauderTEC KSA DUOA self-adhesive, elastomeric, bitumen underlayer. This underlayer was used to ensure thorough sealing of lap joints in low temperatures when the roof was installed.3 BauderPIR FA-TETissue-faced flatboard insulation faced on both sides with aluminium foil to provide efficient thermal output.4 Bauder Super AL-ETorch-on air & vapour control layer. Once installed on the concrete pretensioned plank deck, it can act as a temporary waterproofing layer, allowing internal works to be carried out immediately which was a huge advantage on this new build project.

This new college features over 3,500m2 of Bauder's Thermofol single ply system along with PVC roof profiles to replicate the appearance of a standing seam metal roof.

As part of the £26 million refurbishment of this Grade II listed residential estate, which features a continuous block of over 600 properties, work was performed to not only repair the existing roof but to bring Byker Wall to the forefront of modern day roofing technology with the installation of a state-of-the-art photovoltaic system.

The roof area of this government office building was complex due to expansion joints, air conditioning units and intricate detailing requirements. Work hours had to be agreed with the client to keep disruption to other ongoing work at the site to a minimum.

Chelmsley Wood Shopping Centre, located in East Birmingham, was experiencing leaks with their current flat roof waterproofing system and so they needed a quick, high quality solution to remedy the situation. Although competitors had suggested the only option was to strip the roof, Bauder found a more cost-effective answer by using our in house Troxler Moisture Gauge to identify any areas of wet roof construction, removing the saturated areas and then overlaying the whole roof area.

The regeneration at Clapham Park involved the demolition of old housing stock to make way for new affordable homes. The 5-storey building with 21 dwellings incorporating the latest rooftop technology which blends a biodiverse green roof and unified solar PV array. This approach met the planning requirements and maximised the limited roof space to generate energy for the residents. The development was certified BREEAM ‘Outstanding’ due to its environmental, economic and social sustainability attributes.

Coláiste an Chláirín Bauder Thermofol single ply waterproofing system with BauderROCK insulationSynopsisThe new Coláiste an Chláirín building in Athenry, Co Galway is a post primary school consisting of classrooms, a special needs unit, sports hall, general-purpose hall, staff amenities and extensive external facilities designed by Smith Kennedy Architects & Healy Partners Architects. The project was managed by JJ Rhatigan and Company and the roofing element appointed to Priority Roofing and Cladding Ltd. The roof of the main building and the gymnasium required flat roof build-ups to meet the specifications as set out in in SDG 02-05-03 (Acoustic Performance in New Primary & Post Primary School Buildings), while meeting the general performance requirements specified within TGD 021-7 2018 (Minimum Performance Standards of Roof Materials and Finishes). The chosen system had to meet an acoustic performance of 35dB indoor ambient noise level (IANL). It was decided that, despite sports halls having a slightly higher IANL threshold, the 35dB performance criteria would be applied across all areas of the school, with control of reverberation being a key consideration in the gym.Bauder Building BoardProject:Coláiste an ChláirínLocation:County GalwayProject type:New BuildRoof size:8550m²Main contractor:JJ Rhatigan & CompanyApproved contractor:Priority Roofing & Cladding LtdThe specification:The Architect specified that the insulation used in the flat roof system should be non-combustible and achieve a U-value of 0.16Wm²k which actually exceeds the thermal requirements as described in the Irish Building Regulations Technical Guidance Document L for flat roofs in schools.BauderROCK was specified to achieve the thermal and acoustic requirements of the design. As a Euroclass A2-s1,d0 non-combustible material, BauderROCK also provided the specified fire performance. This insulation could be used across all roof areas, with some adaptations for the gym which required additional acoustic performance due to the inherent nature of the space. Acoustic infills were used in the troughs of the perforated metal deck, thus combatting the reverberation of the indoor environment.  Products appliedBauder Thermofol PVCAn integrated single ply waterproofing system, featuring a lightweight, cost effective membrane which offers a pleasing aesthetic finish on a flat roof. This system holds fire classification BROOF(t4) for compliance with building regulations under TS 1187 test method 4 for external fire exposure to roofs. BauderROCKHigh density mineral wool insulation.Project challengesOne of the challenges of this project was the ambitious schedule. The use of the self-adhesive air and vapour control layer (AVCL) enabled the trades working within the building to progress quickly without being delayed by weather conditions. BauderROCK is relatively quick to install, as was the lightweight single ply waterproofing.  The resultThe project was finished to time and specification with exceptional workmanship from the fixers at Priority Roofing and Cladding and superb collaboration from all parties throughout. The membrane was finished with standing seams to create a statement look. The roof achieved a U-value of 0.15 W/m2k, exceeding the thermal target, and met or exceeded the 35db IANL requirement across the main building and the sports hall.  The thermal performance, which will hold up for decades to come, will also impart energy efficiency benefits that reduce running costs at the school in the long term. Finally, the non-combustible nature of the mineral wool insulation ensured that the build-up met the fire safety specification.  Advocacy Niall Hanley, Contracts Manager at JJ Rhatigan, the project’s main contractor, said:"Coláiste an Chláirín Athnery was a great success and in particular the use of the self-adhesive AVCL in advance of the build-up allowed works to commence immediately internally, which was critical from a programme perspective.” Kevin Ryan, Director at Priority Roofing, explained:"We found the system both practical and efficient to install. The combination of the availability of the products and the technical backup received was superior to any other system that we have worked with.”  Eoin O’Grady, Associate Director at Healy Partners Architects commented:"We are delighted with the overall delivery of the roof build-up and the performance achieved. The PE hall solution to deal with reverberation noise as well as rainfall noise was very successfully managed. We look forward to working with Bauder on future projects.” 

Constructed in 1977, Den Court is a large retirement home made up of 24 flats in the small town of Lochgelly in Fife. The regeneration of the sheltered housing by Fife Council involved the demolition of part of the building as well as replacement windows and doors, landscaping and a new car park.

During the recent regeneration in and around Birmingham, innovation has been a key factor; a theme optimised by the redevelopment of the Dunlop Tyres warehouse which has been transformed into 45,000m² of office space and a 6,000m² hotel. Practical challenges such as the reduction of noise pollution and maximising the building’s lifespan were all met by the Bauder Total Green Roof System with an extensive landscaping of sedum. The planting scheme provided instant coverage as the sedum was laid as pre-cultivated vegetation mats.

Fulham Wharf is a landmark regeneration scheme that began in 2013 and included the ecological enhancement of an abandoned jetty on the River Thames. This redevelopment was designed to provide the local community with an ecological education centre and bio-diverse wildlife reserve.

Located in Guildford, George Abbot School is a secondary education school which provides education for 2000 people aged 11 to 18. The school had a history of leaks in the DT rooms above which a profiled sheet metal roof was installed. Following many attempted repairs, Bauder was commissioned to carry out a roof survey on the 228m² profiled sheet metal roof. The report identified issues with not only the gutter area, which was originally believed to be the problematic area, but also with the adjoining profiled roof and also with the large rooflight unit.

Hethel Engineering Centre supports high performance engineering companies located throughout Norfolk. The original building at the centre had been operating at maximum capacity and they urgently required a new building to satisfy increasing levels of demand. The client wanted the new facility to meet a high level of sustainability, achieving a BREEAM excellent rating and using key renewable technologies, such as photovoltaics (PV), to minimise its environmental impact.

Hexagon Tower is a specialist science and technology facility located in North Manchester. The roofs of the laboratories were experiencing water ingress due to poor original detailing and aged interfaces. Whilst looking to replace the failing roof, the client also wanted to upgrade the insulation to increase the U-value and improve the appearance of the rooftop using a trusted system. Bauder was selected as the supplier due to its comprehensive service offering, which includes detailed report, bespoke specification, project advice and ongoing inspections to ensure a full system guarantee can be issued.

Completed in 1842, HMP Pentonville has remained in use since opening, experiencing many stages of refurbishment throughout the decades. In 2003, the existing asphalt deck above the kitchens was in need of a complete refit with the building having to remain in use throughout the refurbishment of the roof.

JCB’s World HQ in Rocester recently completed a major project to improve the integrity of its main office roof, and took the opportunity to reduce the company’s overall environmental impact through the addition of a state-of-the-art photovoltaic system at the same time.

The Key Theatre in Peterborough’s city centre combined Bauder’s reinforced bitumen membrane waterproofing system and sedum blanket green roof finish with a photovoltaic solution, which the council’s contract manager.

Lagg Distillery, located on the Isle of Arran in Scotland, is a new build whiskey distillery which opened its doors to the public for the first time in the autumn of 2019. The client was eager to create an iconic landmark and echo the contours of Arran with a roof scape that would blend into the environment.

The roof area was badly damaged by heavy storms, with all existing ballasted solar panels lifting off the single ply roof and destroyed beyond repair. The client needed the remedial work completed to fixed deadlines in order to comply with insurance requirements, and wanted to optimise the roof by replacing the pre-existing photovoltaic (PV) array with a solar solution that would deliver superior energy generation. The office also had to remain operational throughout the works, creating logistical challenges

Marischal Square Bauder Bakor Hot Melt structural waterproofingSynopsisMarischal square is a mixed use complex in the centre of Aberdeen based on the site of the former council headquarters building, St. Nicholas House. In 2011 Muse Developments undertook a £107m redevelopment of the site creating space for two new office buildings, seven restaurants and café bars, a 126-room hotel, a modern civic space and a new public space area in between the new buildings.Bauder Building BoardProject:Marischal SquareLocation:AberdeenRoof Area:5,400m²Client:Muse Development & Morgan SindallApproved Contractor:Briggs AmascoThe specificationWith large parts of the new roofing areas being accessible terraces and areas which will experience a significant amount of foot traffic, the Bauder hot melt structural system was a natural choice. The system was combined with hard and soft landscaping to provide the different aspects of the various terraces, stairways, podium decks and rooftops.The Bauder Hot Melt structural waterproofing system is ideally suited as a waterproofing system beneath paved or ballasted surfacing, car parks, podiums, plazas, green roofs and substructures.Project challengesA key challenge for this project was the fact that Muse Developments and Morgan Sindall, who were working jointly on the development, were looking for a single source waterproofing. Bauder proved to be the perfect fit, covering and delivering all elements of the waterproofing systems.The resultApproved contractor Briggs Amasco carried out the works on the 5,400m² of the separate roof areas, whilst expert Bauder site technicians carried out a total of 26 site visits over the duration of the project to ensure the quality of the installations. Following a final inspection, Bauder was able to issue a 20 year product and workmanship guarantee on the project.System installed1 BauderPLANT E 42Green torch-on root-resistant capping sheet.2 790-11Hot melt rubberised bitumen asphalt with a percentage of post-consumer recycled materials that infills and fully bonds to all minor deviations in the deck.3 DeckPrimed concrete.

Morris Blitz Court is a residential housing estate in Hackney that has undergone an extensive amount of refurbishment works as part of the Decent Homes Programme.

National Innovation Centre for Ageing and Data Science (NICAD) is a flagship building in Newcastle upon Tyne on the high-tech, city centre Helix Science Site where a number of building are being constructed. The client wanted an integrated PV system that didn’t compromise the integrity of the green roof solution being installed. Bauder were asked to design and supply a 30.78kWp system, generating an estimated 26,140kWh per annum.

The award winning Noah’s Ark Children’s Hospice currently supports over 160 children who are seriously unwell, 230 of their siblings and 350 of their parents/guardians by providing holistic, bespoke care. To facilitate the care of even more children and their families and care givers, a new building was needed. Main build partners, 8build, undertake one charitable build project every year and were therefore recommended for the Ark project. Their unique collaborative approach and utilisation of supply chain relationships kept project costs low with these costs savings directly benefitting the hospice as they could then be spent on care for the children. The project won the "Roof Gardens/ Living Wall Installations - Commercial Roof Garden or Podium Landscaping - Under £500k" award in the BALI National Landscape Awards 2020.

The architectural vision for this new build was to create a modern learning environment that would add value to the local community. The building consists of eight roof areas on a variety of different pitches totalling 3,400m². Aesthetics were also important to the client as most of the roof areas are pitched at a 20° slope making them highly visible, particularly from the central courtyard area.

Paxman Avenue Secondary SchoolBauderflex bituminous waterproofing system with Euroglaze rooflightsSynopsisPaxman Avenue Secondary School is a new build project situated in Colchester, Essex. The school opened its doors for the first time in September 2019 welcoming 180 year 7 students. It is expected that the school will eventually hold 900 pupils by 2023.Bauder Building BoardProject: Paxman Avenue Secondary SchoolLocation: Colchester, EssexProject type: New buildRoof size: 2500m²Architect: Concertus Design & Property ConsultantsMain contractor: Barnes ConstructionApproved contractor: G.R.M Roofing Company LtdThe specificationThe main contractor, Barnes Construction, was looking for a durable, cost effective roof with longevity, and wanted a waterproofing system which included a comprehensive guarantee with great service and full support from the supplier, and so Bauder’s bituminous system, Bauderflex, was specified. Rooflights were also specified to increase natural light into the building.Bauder’s Rainwater Calculation Software was also used to perform calculations in accordance with BS EN 12056-3:2000 based upon provided data relating to the building’s dimensions, geographical location and the flow rate performance of the selected Bauder rainwater outlet product. This helped to determine the total number of outlets needed for the roof.Products appliedBauderflexA reinforced bituminous membrane system with a choice of self-adhesive and torch-applied membranes that are resistant to high levels of structural and thermal movement. Bauder Euroglaze rooflightsThese rooflights are made to order and the size can therefore be tailor made to fit any roof aperture, with many ventilation and glazing options are available to meet the demands of any type of project.The resultThe client was supported by the Bauder Area Technical Manager, Andy Leggett, from start to finish with help being provided on the design element of the project, and the Bauder approved contractors, G.R.M Roofing Company Ltd, were supported by Bauder site technicians throughout the installation.

Replacing the roof on Primark’s 640,000 sq ft distribution centre in Thrapston, was the largest refurbishment of a single-ply roof undertaken in Britain in 2012 and clearly demonstrated Bauder’s status as one of the largest and most respected companies in the roofing industry.

River Street Tower Bauder Bakor Hot Melt structural waterproofing system with mixed landscapingSynopsisRiver Street Tower is a 32 storey, luxury student accommodation situated in Manchester.Bauder Building BoardProject: River Street TowerProject type: New buildLocation: River Street, ManchesterWaterproofing: Hot MeltRoof size: 1774m²Specifier: Simpson Haugh and PartnersApproved contractor:LRL Roofing Solutions

Robert Bloomfield Academy is a middle school situated in Shefford, Bedfordshire that has approximately 800 pupils aged from 9 to 13 years old. Having recently had a Bauder roof installed, the school was keen to add a photovoltaic (PV) system to the building to meet their high sustainability aspirations. As a result of discussions with Bauder and funding specialist Evogreen, the school identified this as a perfect opportunity to have a no capital outlay PV solution fitted that would not compromise the existing 20 year roof guarantee.

ROM Ltd is a specialist manufacturer of reinforcement solutions that has facilities located throughout the UK and Ireland. The waterproofing on the roof of their Sheffield manufacturing facility had exceeded its serviceable life and the main-substructure was extremely corroded leaving it unstable and requiring urgent remedial work.

A number of the building’s roofs at Roundwood Park School needed refurbishing to prevent further water ingress entering the classrooms below. The client wanted the new waterproofing system to be of high quality and provide falls to the roof to help mitigate ponding water. A no capital outlay PV solution and new rooflights were also desired as part of the works to optimise the roofs functionality. The school remained open throughout the project creating logistical challenges.