IKO UK

BriefA 21-acre residential development was to be built on the site of Ford’s Brentwood-based headquarters, which had been at the centre of the famous car manufacturer’s UK operations for more than 50 years. As well as the former commercial land, the development incorporated adjoining parkland. Fairview New Homes was tasked with providing a variety of high-quality residential units in addition to commercial space and the development was to act as a springboard for the regeneration of the wider area.Spread over two phases, 133 units were to be constructed, made up of a mixture of private and housing association apartments and houses as well as provision for off-street parking. On the northern (phase 1) site, Sheriff Construction installed IKO roofing systems across three apartment blocks, which ranged 4-5 storeys in height.ChallengesOne key challenge that Sheriff Construction’s operatives encountered during installation involved the soil vent pipes (SVPs). To prevent water penetration into the building, the pipes needed to be sealed at roof level. However, the SVPs designated for the project were made of PVC and so sealing around them with IKO’s hot melt system risked damage to the pipes.There were also challenges relating to distribution of materials, specifically around the logistics of safely and efficiently moving materials from the delivery vehicle to the point of installation. As the development was a live site and subject to a phased occupation, strict risk management was imperative.Clients and residents used the same access roads as tradespeople. Therefore, from a health and safety perspective, Sheriff Construction and IKO needed to ensure that delivery vehicles could access the storage area for distribution, while limiting disruption to members of the public.SolutionIKO and Sheriff Construction worked together to come up with a solution to the PVC SVP issue – a metal sleeve detail. This ensured that the pipes could be sealed, without risk of heat damage from the hot melt system.When it came to the logistical and safety issues, IKO facilitated the delivery of materials either pre-slung or on pallets to allow safe unloading of the vehicle using a forklift or crane. This meant Sheriff Construction’s operatives did not have to access the vehicles, helping to reduce occupational risk and exposure to workplace hazards.IKO also provided an accurate timescale of deliveries and met all of Fairview New Homes’ restrictions on the size and type of vehicles allowed on site, to keep project disruptions to a minimum.Sheriff Construction worked closely with IKO’s design team from the beginning, to achieve design requirements and U-values. IKO also provided extensive on-site support and in person-guidance on using the IKO Permatec system which was specified, even for non-standard designs. The hot melt system is renowned for its high resistance, low temperature flexibility and long life expectancy, making it a popular and versatile choice for a variety of roofing projects.Sheriff Construction’s experienced project team and IKO’s inspectors closely monitored and managed the workforce activities, from start to finish, supervising the roof installation process with a critical eye.Due diligence, quality assurance, excellent workmanship and effective communication meant that the project was delivered safely on time, within budget, and to the client’s satisfaction and exacting standards.

BriefAs part of the drive to revitalise Kirkby Town Centre, the local authority, Knowsley Metropolitan Borough Council, has been significantly investing in regeneration works. A redundant B&M shopping centre formed an important part of the uplift.At 36,000 sq ft, the empty precinct was the largest vacant unit in the town centre and was in need of significant repair and modernisation. Bringing the building up to date was crucial in encouraging businesses back to the area and delivering more choice of retail outlets to visitors.The project was estimated to cost £1.66million, with £450,000 allocated to the roof renovation, which was to be carried out by Paramount Roofing Systems, in association with IKO.ChallengesThe busy, central location of the shopping centre presented several challenges for the roof installation. The existing roof needed a comprehensive refurbishment, including stripping back to the metal decking and removal of all layers and outdated materials.A total of 48 redundant skylights needed to be carefully and meticulously taken out as they were no longer needed or functional. Any obsolete ventilation fans and plant equipment also had to be removed, as streamlining roof space was essential for efficiency. This all had to take place before the installation commenced.When it came to delivery of materials, there was limited laydown due to the surrounding live loading bays for neighbouring shops and this lack of space also affected the storage of the materials on-site.Inclement weather presented a significant challenge for the team. Despite operations taking place during the summer, torrential downpours were frequent. Protecting the integrity of the building was paramount to ensure the businesses below the installation could continue trading without risk of water ingress or leaks.SolutionAs this was such an expansive project, it was important that the roofing system was robust, easy to install and would stand the test of time. IKO worked with Paramount Roofing Systems to ensure the most suitable solution was specified for the replacement roof.A fully built-up bituminous felt warm roof was chosen as the best option, as it was designed to ensure effective insulation, weatherproofing and longevity for many years to come.To mitigate disruption to nearby trade, Paramount Roofing Systems effectively coordinated with local businesses for the duration of the project. The team established a robust schedule, so that construction activity was minimally affected by the town centre’s busy hours and zoned time restrictions.A telescopic forklift truck was hired specifically for the project, to handle offloading and loading more efficiently and allow the team to move more precisely within the confined space. Four operatives were trained to ensure that the forklift truck was used safely, which was imperative given the high footfall close to the site.IKO arranged for bulk materials to be delivered directly to the roof to help overcome the issue of restricted space. Materials were also stored off-ground and covered at all times with strategically placed tarpaulins to avoid water damage from the persistent rain.Despite the wet weather conditions hindering progress, the project was delivered just over the expected time frame of 8-10 weeks. The collaboration between IKO and Paramount Roofing Systems was pivotal in ensuring that the project met and exceeded requirements – contributing to an integral building that promises to give a much-needed boost to Kirkby town centre.

BriefThe Cocoa Works York project is a refurbishment of the former Rowntree’s and Nestlé factory building in York, originally built in the 1890s to manufacture chocolate and sweets.The neglected building, once responsible for making over a billion KitKats per year, was due to be restored to its former glory, providing 279 luxury apartments. A mix of studio, one-, two- and three-bedroom flats, the refurbishment of the 4,500m2 building was designed to bring back an all-important community feel to the area. With six floors, the Cocoa Works proudly sits as the tallest building in York, other than the Minster towers.One of the key features of the project is the top floor penthouse deck, which along with the rest of the building, would need to remain true to its historic design features, while delivering a contemporary living space. The iconic redevelopment also needed to have sustainability at its heart, so any materials used would have to fit with these objectives.ChallengesIt was critical to not just preserve the integrity of the building but to also protect the health and safety of the operatives. Given the age of the building and the dilapidated state that it was in before the commencement of the project, H&S was a key challenge.This was compounded by the scale and height of the building. We are acutely aware that falling from a height is a leading cause of injury and fatality in construction so it was imperative that robust risk assessment and close H&S monitoring was carried out for the duration of the project. Our number one priority was that interaction with the aged material or structure did not pose a risk to our operatives and that they could deliver the project on time but, most importantly, in a safe manner.SolutionGiven the complexities of the project, it was essential that any materials chosen would provide a lightweight roof construction. IKO Armourplan P and IKO enertherm cut to falls were specifically chosen to provide a robust membrane, without adding too much stress to the existing structure. As Armourplan P is polyester-reinforced PVC membrane, it offers enhanced mechanical properties over standard PVC membranes. Importantly, IKO Armourplan P provides an aesthetically pleasing finish, to help uphold the historic design of the Cocoa Works, without compromising performance.Meanwhile, IKO enertherm was selected for its superior thermal performance. Despite being thinner than other materials, such as EPS, XPS and mineral wool, IKO enertherm has a higher insulation value. This was crucial to make best use of the space on the roof – transforming it into a stunning penthouse apartment. At around 32 kg/m³, IKO enertherm is a lightweight insulation board with ergonomic benefits, for easier handling, too.Certa Roofing & Cladding worked seamlessly with IKO to ensure that the roofing installation was delivered on-time and on-budget. Every element was thoughtfully considered, to help future-proof the quality of this iconic building. Using the mechanically fixed IKO Armourplan system with a cut to falls insulation scheme, for example, was crucial to provide the correct drainage and reduce the risk of further maintenance further down the line. Plus, as this roof construction did not require any hot works, there was no need for any flame to be employed during the roof construction.The completed Cocoa Works York project was named winner of the Best Refurbishment Project 2023 Award at the 2024 Single Ply Roofing Association (SPRA) Awards.

Project descriptionDixons Academies Trust is a well-established multi-academy trust that aims to challenge educational and social disadvantage in Yorkshire and the North West.The trust transforms schools into safe and high-performing learning environments, enabling students from all backgrounds to realise their potential and maximise their opportunities after school.Alpha Roofing Systems was brought in to refurbish two roof areas at Dixons Croxteth Academy in Liverpool after the existing waterproofing failed.A number of complex challenges arose from the start; after stripping back the aged and failed single ply system, Alpha identified a water-saturated bituminous roof beneath, which also overlaid the original asphalt waterproofing.The excess weight imposed on the roof from the multiple, heavily saturated waterproofing systems led to cracking and depressions in the deck, as well as rusting of reinforcement within the structure.This meant that, before installation work could even begin, many hours of labour were required to remove the top two waterproofing layers to expose the original asphalt. What’s more, this work had to be undertaken both during term time and a period of heavy rainfall.Solution and installationAfter close consultation with their IKO business manager, Mark Taylor, the Alpha team selected the IKO ULTRA Prevent 25 waterproofing system for this project.To adhere to Department of Education requirements, a 35-year durability statement was necessary, so the long-lasting, durable finish offered by the IKO ULTRA Prevent system was ideal.Challenges continued to come thick and fast throughout the project; after stripping the roof back to the asphalt waterproofing, a large expansion joint was found near the clerestory window. Tapered designs were subsequently adjusted to accommodate.30 tonnes of waste material – primarily due to the uplift of the previous failed waterproofing systems – also had to be removed from the roof over the course of a week.Furthermore, complex design variables meant that Alpha could not fully determine the existing roof falls until the roof had been sufficiently exposed. Working closely with the IKO technical team, design information and solutions were identified to keep the project on track.To complicate matters further, Alpha was also required to carry out this extensive work during active teaching time. This presented not only additional health & safety considerations but also the need to minimise disruption.With a stringent construction phase plan and regular active monitoring, the project was completed with a zero incident/accident rate and excellent feedback from the client on Alpha’s approach to safety.Despite a number of hurdles and complexities to overcome, Alpha Roofing Systems delivered the project ahead of time and within budget, providing a low maintenance, long-lasting roof for Dixons Croxteth Academy and a satisfying outcome for all involved.

BriefDorset House sits at the heart of Talbot Campus, where most of the undergraduate and postgraduate courses are delivered at Bournemouth University. It is home to the Doctoral College, providing important support to its postgraduate research community with a range of high-tech laboratory equipment, as well as the Business School’s Professional Engagement Suite.Sustainability is a top priority for Bournemouth University. In fact, the University is ranked 21st in the world and 6th in the UK for its contribution to UN Sustainable Goal 13: Climate Action for The Times Higher Education Impact Rankings 2023. As well as opening new eco-friendly buildings, Bournemouth University is carrying out major refurbishment works across its campuses, investing in a range of low or zero-carbon technologies to help minimise water and energy use.As part of this refurbishment, Dorset House was to undergo a significant transformation to help enhance the entrance area and make better use of the space. Bluestone Design & Construction Ltd was tasked with upgrading the building’s flat roofing system, in association with IKO, and the build-up include the installation of a new 80kWp solar PV system.ChallengesThere were several challenges to overcome during the project, but as the team had recently completed similar works on the nearby Poole House on campus, they could apply their extensive learnings to ensure the refurbishment of Dorset House ran seamlessly. As the project was on a busy campus, it was important that it was carried out during the holidays to avoid significant disruption to students and staff. There was, however, a short period during term-time that required more coordination, to ensure appropriate access while making sure the project ran on time.Another challenge was ensuring the material deliveries arrived on time, to minimise site storage issues and meet workforce scheduling requirements. The team managed this effectively, by ordering the materials via construction product distributor, SIG, which were then delivered as required from the local SIG depot. This meant Bluestone Design & Construction could meet programme deadlines, without needing to store materials long-term on-site.SolutionThe installation process at Dorset House involved a standard hybrid built-up roofing (BUR) system, using both self-adhesive and torch-on membranes suitable for the substrates of the project. Choosing products with a 25-year guarantee was important to the team, as the installation included solar electricity panels (also known as PV), that would need to provide reliable power output over the system’s lifespan.Bluestone Design & Construction followed a thorough process to ensure the roof area was suitable for the PV installation, following the necessary remedial works and new roof overlay. Once the systems were in place, all works were reviewed to ensure they met the specifications of an IKO technical engineer and requirements of IKO’s guarantee, without any issues. The team also worked to all the necessary health and safety standards throughout the project.Bluestone Design & Construction and IKO worked together to ensure that the Dorset House project was carried out within the programme requirements – finishing ahead of schedule, in September 2023. It was essential that the building was ready on-time and within budget, ahead of the installation of the new PV system, to ensure maximum availability for the 2024 period. With Bournemouth University’s ambitious sustainability targets in mind, the Bluestone Design & Construction team wanted the system to be fully operational as soon as possible. As the main contractor and roofing installer, Bluestone Design & Construction was able to have more control over the project and ensure the roofing segment ran smoothly as part of the wider picture.The University was extremely pleased with the installation and execution of the project. Now with its improvements made, Dorset House is another success story in the University’s plan to futureproof its campuses for many years to come.

BriefEpping Gate is an impressive development of 1, 2 and 3-bedroom apartments in Essex. It is located close to the Epping Forest Spread, within the desirable ‘Golden Triangle’ of Loughton, Buckhurst Hill and Chigwell. Spread over three blocks measuring between 3-5 storeys, the development was designed to accommodate 97 private and 42 housing association units, a podium garden and undercroft and surface car parking.The buildings were constructed using traditional masonry, precast floors and roof planks. Developer, Fairview New Homes, instructed Sheriff Construction to work on the roofing elements of the project, in collaboration with IKO and ABG Blue Roofing.The installation was a huge undertaking, with the project size totalling 12,400m2.ChallengesIKO and Sheriff Construction worked together to come up with a solution to the meltable plastic SVPs. This came in the form of a metal SVP sleeve detail that offered higher resistance to heat and therefore protected the pipes.They also collaboratively found an answer to the podium’s water ingress problem – applying hot melt waterproofing behind the cavity to the CP board or internal block-work. This quickly resolved the associated issues and avoided years of maintenance defect calls and costly repairs.When dealing with delivery challenges, IKO ensured that materials could be ordered in bulk and deliveries were brought forward to suit changes in the programme. Sheriff Construction and IKO also worked closely to ensure that the weight and size of the materials delivered was optimised, so that they could be carefully transported by forklift or crane to the weight restricted loading bays and then onto the roof, without issue.The IKO Permatec system was ideal for this large scale and intensive project. It not only highly resistant and durable but offers low temperature flexibility and rapid setting, ensuring maximum efficiency and minimal delays due to adverse weather conditions.Both Sheriff Construction’s experienced project team and IKO’s inspectors closely monitored the roof installation process from start to finish. This ensured that the project was delivered safely, on time and within budget. IKO’s technical support in particular proved invaluable to the success of the expansive project, helping to speed up production and save time, resulting in a professional clean-line finish and highly satisfied client.SolutionIKO and Sheriff Construction worked together to come up with a solution to the PVC SVP issue – a metal sleeve detail. This ensured that the pipes could be sealed, without risk of heat damage from the hot melt system.When it came to the logistical and safety issues, IKO facilitated the delivery of materials either pre-slung or on pallets to allow safe unloading of the vehicle using a forklift or crane. This meant Sheriff Construction’s operatives did not have to access the vehicles, helping to reduce occupational risk and exposure to workplace hazards.IKO also provided an accurate timescale of deliveries and met all of Fairview New Homes’ restrictions on the size and type of vehicles allowed on site, to keep project disruptions to a minimum.Sheriff Construction worked closely with IKO’s design team from the beginning, to achieve design requirements and U-values. IKO also provided extensive on-site support and in person-guidance on using the IKO Permatec system which was specified, even for non-standard designs. The hot melt system is renowned for its high resistance, low temperature flexibility and long life expectancy, making it a popular and versatile choice for a variety of roofing projects.Sheriff Construction’s experienced project team and IKO’s inspectors closely monitored and managed the workforce activities, from start to finish, supervising the roof installation process with a critical eye.Due diligence, quality assurance, excellent workmanship and effective communication meant that the project was delivered safely on time, within budget, and to the client’s satisfaction and exacting standards.

The briefHatton Hall is a sheltered housing complex built in 1980, comprising of 21 flats. The building had to be re-roofed without disturbing the occupants who would remain in their home while the work took place.The Hatton Hall project was to refurbish the roof, improve the drainage and insulation, and bring it up to current building control standards.A thermographic survey of the roof was carried out by IKO, which confirmed that it was sound enough to have an overlay of the IKO ULTRA Life 30 bituminous membrane rather than stripping it back and rebuilding.IKO ULTRA Life 30 was primarily chosen by the client for the 30 year guarantee. One section of the roof to be repaired was on top of dormers. Flame-free IKO ULTRA Life 30 membranes were used because of the potential fire risk of the abutting pitched tiled roof.The challengesThe IKO survey identified that the existing roof drainage falls directed water away from the outlet locations, leading to severe ponding.In addition, one of the main causes of the leaks occurring in the building related to the parapet walls. The parapet concrete coping was allowing some water penetration through the open coping stone joints, so the existing ‘chase and flashing parapet detail’ needed attention. Other leaks related to poor detailing at pipe penetrations.The existing modular rooflights did not meet current standards for thermal performance and fragility, so it was advised that these items should also be replaced.All remedial work had to be carried out while the Hatton Hall occupants – all over 60 – occupied the building, so disruption had to be kept to a minimum.The solutionsA new tapered insulation scheme was designed to compensate for the fact that existing falls were directing water away from the drainage outlets.Also, the existing ‘chase and flashing parapet detail’ was re-designed to carry the waterproofing up and over the parapet wall, eliminating the leakage that had stained the façade of the building.The coping stones were removed and the new waterproofing membrane was dressed up and over the parapet walls, finishing in a GRP edge trim. The existing fragile and thermally inefficient rooflights were replaced by IKO Superlite Rooflights.The IKO ULTRA Life 30 torch-on system, which was installed by IKO-approved contractor Breyor Group PLC, provided a new granular finish with improved adhesion and better coverage, meaning less foot-marking.It is a two-layer roofing system guaranteed for 30 years against faulty design, materials, and workmanship – a factor which was key to the client’s choice.IKO ULTRA Life 30 torch-on is designed to allow rapid installation of the built-up system, while the warm roof build-up allows an option for the system to be installed up to the underlay without the need for hot works.Fire safety was also a vital factor, both during construction and in operation, as the building was occupied throughout. IKO ULTRA Life 30 roofing membranes contain IKO Prevent Graphite Technology (halogen-free), achieving the highest levels of fire performance in both UK and European fire tests. This allows unrestricted use under current UK Building Regulations.

Project descriptionTouchwood Shopping Centre in Solihull, Birmingham is an award-winning, 650,000 square-foot shopping and entertainment complex, which opened its doors in September 2001.Touchwood has become a blueprint for in-town development due to its innovative design, easy access to the M42, and 1,700 car parking spaces. It is home to more than 80 stores, 20 bars and restaurants, and a 9-screen cinema.The centre has successfully improved neighbouring facilities with malls, a retail offering, and civic gardens, providing green spaces for the local community.Rio Asphalt and Paving Co Ltd worked closely with the shopping centre management team to offer a replacement waterproofing and paving element for the 900m2 service deck area.Solution and installationThe focus was on delivering a solution that worked for both client and the tenants and ensured a smooth and seamless experience.IKO Permapark – a specially formulated mastic asphalt surfacing and waterproofing system for car parks and elevated vehicle decks – and the fast-curing IKO flexia metatech liquid waterproofing were chosen as the most suitable solutions for the project, given their durability and rapid installation capabilities.Certain areas were prioritised by the management team and project works were phased. The deck was split into manageable sections, which helped to minimise disruption and limit the impact on those occupying and visiting the site during the project period.Particular attention was given to the mechanical and electrical (M&E) services, which remained operational throughout the works. As areas were inaccessible for mastic asphalt, a compatible cold applied system was used instead.This enabled the works to dovetail into a small number of inaccessible areas, refurbishing what would have either been left or required substantial financial outlay and risk.The service deck area, which remained in use during the project, operated a one-way system for all vehicles. Rio also took measures to maintain road access around the centre and provided temporary delivery areas to assist with the distribution of goods to the stores.