Wallbarn Ltd

The customer wanted to build a deck on the first storey of a period building in Chicago The windows opening out on to the roof were positioned considerably higher than the rooftop itself, which meant that the structure deployed to support the deck would also need to raise it up almost a metre to meet the threshold. We recommended a number of our heavy-duty Megapads ranging from 711mm to 876mm to account for the gradual fall in the roof. The customer chose not to envelope the pedestals because he liked the industrial look created, in keeping with downtown Chicago.

A three year construction project in Knightsbridge required a temporary green roof on welfare huts. The local residents were concerned about overlooking these steel huts long-term. The solution is M-Tray® – our modular green roof system. The steel huts were wheeled into position on site on skates. They were covered with an EPDM waterproofing membrane. M-Tray® units were installed. They were easily carried up the stairs by hand and installed by hand within minutes. The modular and portable M-Tray® can just be unclicked and lifted away upon completion of the construction process.

This was a large roof terrace on a private domestic project. The area was flooded and had needed to be re-laid with waterproofing and a significant fall constructed into the deck to allow the often considerable amounts of rainwater to escape the roof deck. The contractor asked Wallbarn for a suitable but cost effective solution so we recommended Wallbarn 9mm rubber supports along with levelling shims. The area was re-waterproofed in the inverted waterproofing method, the membrane being covered with rigid insulation boards and a loose laid geotextile fabric to act as a separation layer .

Wallbarn supplied a fire-rated paving system for the rooftop areas of the Old Brewery redevelopment in South Bristol. Spanning approximately 400 square metres across five distinct zones, the project required a flexible solution capable of supporting both 600x400 mm and 400x400 mm x 50 mm paving slabs, while meeting current Class A fire performance requirements.The system comprised MetalPad Ex adjustable pedestals, I-Plus aluminium joists, and Wallbarn’s paving headpieces. Due to the variation in slab dimensions and deck heights, spreader plates were included to provide additional stability and to protect the waterproofing membrane across areas with sensitive detailing. The system was selected for its full non-combustibility, in line with building regulations for multi-unit residential developments.Wallbarn was involved from early engagement through to final installation. After an initial specification meeting in mid-2024, layout drawings and material take-offs were issued. A design update later that year required revised quotations and structural recalculations. The system layout was refined through several virtual consultations with contractor Afan Group, ensuring alignment with changes to deck heights and rail configurations across the five roof zones.Following delivery, Wallbarn attended site alongside the contractor to assess restricted installation zones. These areas required modifications to standard build-ups, which were resolved with adjusted rail spans and revised pedestal placement. The installation was completed to programme, providing a compliant and robust paving solution for this complex urban regeneration site.Located on the former Ashton Gate Brewery site, the Old Brewery development brings together new-build housing and commercial spaces, with rooftop hard landscaping designed to perform long-term under challenging site and access conditions.

The Big Chill, a bar in King’s Cross, was creating a public roof terrace on an existing structure. The deck was complicated with many changes of level and multiple objects present. A single ply membrane was installed. Paving and decking was required. Adjustable pedestals were laid directly onto the surface and their heights altered so that the upper surface of the 50mm paving slabs and the 125mm decking frame would be level. Nothing penetrated the membrane and the weight tolerance of the ASP and TD pedestals meant even very heavy traffic on a public bar was accommodated.

This was a major refurbishment and landscaping project for an office development in the City of London. A podium deck had been re-waterproofed and the area landscaped, by contractor Scotscape, with a mixture of hard surfaces, grass lawns, planters and borders. Wallbarn has a very wide range of pedestals for a variety of applications. So we were able to supply exactly the right pad to best support the 6 x 2” joists the landscaping contractor needed to hold their decking boards. The timber joists were fixed into a frame and rigid insulation placed into the cavities between the beams.

The contractor was relaying a waterproof membrane immediately above the London Aquarium and naturally the client was concerned about leaks with such precious livestock beneath. The waterproofing was torch-on bituminous felt membrane, due to be covered with road grade asphalt. Protecto-board was laid onto the waterproofing and secured with tape. It was cut to shape around the curbs cleanly and effectively without leaving vulnerable areas and without delaminating or crumbling, or leaching bitumen. It protected the waterproofing from temporary construction process damage and permanently protected it when covered with hot road grade asphalt afterwards

This residential roof deck project required a high-performance decking system within a strict height constraint. Wallbarn was approached to deliver a build-up that provided structural integrity and visual quality, all while remaining within a limited height threshold. The final system achieved an ultra-low build-up starting from just 60mm.The solution centred around Wallbarn’s Mega Balance pedestals, which are fully adjustable and feature a self-levelling headpiece, ensuring a stable base even on falls and uneven surfaces. Onto these, the aluminium Box Rail joists were installed. At just 15mm high, the Box Rail is precision-engineered from premium extruded 6063 T6 aluminium, offering outstanding strength in a slim profile. This configuration enabled the necessary clearance to be maintained beneath the decking while maximising the finished floor level.For the decking surface, Thermo Bamboo boards were selected for their durability, dimensional stability, and elegant aesthetic. These dense, compressed boards are made from steamed bamboo fibres, a process that removes sugars and moisture to eliminate fungal and bacterial activity. This method also significantly increases the material’s density and hardness, with Thermo Bamboo reaching a mass density of 1,200 kg/m³ — harder than most tropical hardwoods and exceptionally resistant to traffic damage, warping, or splitting over time.Thermo Bamboo offers long-term performance with a rich brown finish that naturally weathers to a silvery tone. The boards carry a Class Bfl-s1 fire rating and are certified “Very Durable – Class 1” under EN350 / CEN/TS 15083-2. Additional certifications include Class 0 for blue stain fungal resistance (EN152) and Class 4 for external use (EN335). These properties make it suitable for both residential and commercial applications, especially where fire safety and sustainability are key project drivers.The entire deck was installed with seamless integration around existing rooflights, thanks to the flexibility of the substructure and clean connection methods. The pedestals, aluminium joists and bamboo materials used in this system are not only rot-proof and low maintenance, but also align with sustainability goals — offering a low-carbon, environmentally responsible decking solution with a 25-year performance warranty.This project demonstrates how Wallbarn’s modular components and premium-grade materials can solve height-restricted installations without compromising on compliance, durability or finish.

Installed in April 2025, this 180m² green roof project in Ramsbury, Wiltshire, features Wallbarn’s roll-out sedum system installed on a newly constructed residential garden outhouse. The client was looking for a natural, biodiverse finish that would blend effortlessly into the rural setting and provide long-term ecological value.The full build-up comprised a protection fleece laid over the waterproofing membrane, followed by a drainage/reservoir board to manage water retention and discharge. A geotextile filter layer was then installed to prevent fine particles from migrating, topped with a specialist extensive substrate to support plant growth. Finally, Wallbarn’s pre-cultivated sedum blanket was rolled out as the top layer, offering instant green coverage and aesthetic impact.Lightweight and easy to install, the system was ideally suited to the timber-framed structure. In addition to visual appeal, it now supports pollinators and wildlife, delivers rainwater attenuation, and contributes to the building’s thermal performance—all with minimal ongoing maintenance.

We were approached by a porcelain tile supplier who needed to elevate porcelain tiles around a new build property in Wales. Initially concrete was used to create a base. However the weight of the concrete bent the lintels. The installation proved very challenging due to such a dramtic fall over such a short distance, creating a severe 5% slope. Fortunately our ‘Balance’ self-leveling range of adjustable pedestals provided the answer. Our service team are on call to advise and support installing contractors throughout their project, including site visits.

This rooftop redevelopment in central London required a fire-rated decking system suitable for use on an inverted warm roof. The project brief called for a solution that would provide the necessary ballast for the waterproofing system while delivering a sleek, low-maintenance finish for a high-traffic terrace. Working in collaboration with Fire Deck and ISW UK Ltd, Wallbarn supplied its fully Class A fire-rated substructure to support ExaDeck ceramic porcelain boards across the space.To ensure inverted roof requirements, the build-up had to meet a minimum weight of 85kg per square metre. This was achieved by integrating 450 x 450 x 50 mm concrete slabs between the I-Plus aluminium joists. The bottom ledge of the joist allowed these slabs to be securely seated without making contact with the waterproofing insulation and without requiring mechanical fixings. This provided sufficient ballast while also mitigating the risk of wind uplift, a critical consideration given the building’s height and exposure.Spreader plates were also used beneath each MetalPad Ex pedestal to distribute the load evenly and protect the insulation layer. ExaDeck’s wood-effect porcelain boards deliver a warm, natural aesthetic alongside long-term durability. Their double-rectified construction ensures consistent dimensions and a perfectly flat base, allowing them to sit flush on Wallbarn’s aluminium joists. This contributes to their quiet, solid feel underfoot. The boards also offer excellent resistance to stains, scratches and slips, making them ideal for heavy foot traffic and public-facing terraces.With a 25-year limited warranty and a projected lifespan of over 50 years, the system ensures long-term performance with minimal maintenance. This project demonstrates how modern Class A systems can achieve both technical compliance and architectural quality.

As part of a major new-build school development in South West London, Wallbarn supplied over 1,500m² of M-Tray® wildflower green roof. This large-scale installation marked a shift from the smaller domestic and retrofit applications commonly associated with modular green roof systems, showcasing M-Tray®’s performance on complex new-build schemes.The roof consisted of multiple levels with a variety of obstructions, including plant services, ducts, and angled parapets. Wallbarn collaborated closely with main contractor Bowmer & Kirkland and landscaping contractor Kingston Landscapes to develop a solution that provided both protection for the single ply waterproofing membrane and a range of environmental benefits in line with BREEAM considerations. The green roof was also designed to serve as a potential outdoor learning space for pupils.The M-Tray® wildflower system was chosen for its maturity, ease of installation, and ability to deliver a finished, healthy green roof under tight programme constraints. Delivered on pallets in pre-grown modules, each articulated load of over 600m² was offloaded and positioned for hoisting onto the roof in a matter of hours using a large cherry picker and heavy-duty forklift. The modular format meant that installation could begin immediately, reducing the time the vegetation spent stacked and ensuring optimum plant health on delivery.Each 500 x 500 mm tray clicks into place to create a seamless surface of sedum, herbs, and native wildflowers. Even during the late-season installation, flowering plants attracted pollinators to the roof. PV panels were also incorporated into the design, with M-Trays installed around the base of the units to improve the building’s overall sustainability. The modular format made it easy to access panel wiring or services when required—an advantage over traditional roll-out green roofs.By spring 2022, the green roof had matured into a lush, self-sustaining ecosystem, softening what would otherwise have been a large expanse of exposed roofing. The system now provides thermal protection, acoustic benefits, biodiversity value, and a striking visual contrast to the surrounding urban environment. Feedback from the contractor, landscaping team, and the school’s leadership has been overwhelmingly positive—and the roof is now a key feature of this forward-thinking educational facility.

This 1,200m² green roof installation in Crumlin was delivered in partnership with Polyroof / Roberts Manufacturing. Initially specified as a rollout system, the architect revised the specification in favour of Wallbarn’s M-Tray® modular green roof after concerns were raised regarding fire compliance. M-Tray® is physically tested and certified to B Roof(t4), ensuring compliance with fire safety requirements for flat and pitched roofs.Key benefits of the M-Tray® system included faster installation times and futureproofing: trays can be lifted individually for maintenance without disturbing the surrounding area. These features were particularly important given the scale and complexity of the pitched roof.To manage structural loading, Wallbarn advised the use of parapet walls and horizontal battens to prevent slumping or stress at the roof edges. These details were incorporated and sealed using Polyroof’s Protec liquid-applied waterproofing system, preserving the membrane’s integrity.With no dedicated loading bay and restricted access on site, delivery logistics were a critical part of project planning. Over 5,000 M-Tray® units were delivered across four weeks, with batches of 640 trays transported three times a week. Wallbarn’s logistics team worked closely with Haran Roofing, Polyroof and transport providers to ensure seamless, staged deliveries.This project demonstrated the versatility and reliability of the M-Tray® system, meeting structural, environmental and regulatory demands while delivering a high-quality finish. It has since been nominated for multiple industry awards.