Project Stats
Project Brief
GI Sykes Ltd was appointed to undertake essential roofing refurbishment works at the Fibercill manufacturing facility in Brierley Hill. The site, a long established MDF mouldings production plant, was experiencing ongoing issues with its zinc sheet roof, including historic cut edge corrosion, failing repairs, and general weathering. A long lasting protective solution was required to safeguard the building envelope and prevent further deterioration.
A comprehensive site survey undertaken by TOR Coatings confirmed that although the roof sheets were aged, they remained structurally sound. However, numerous historic edge repairs were beginning to fail, and corrosion was particularly evident around areas adjacent to extraction vents.
To restore performance and provide a ten year protective guarantee, the TOR Unicover S roof coating system, paired with Unicover EdgeProtect for cut edge corrosion was specified as the optimal refurbishment solution.
What we did
Power Washing & Roof Preparation
The project began with a full pressure‑washing of all roofing surfaces, including skylights, to remove accumulated grime, debris and contaminants. This ensured optimum adhesion for the specialist coating system to follow.
All corrosion was removed from exposed metal areas, with sheet edges cleaned using appropriate solvents as per TOR specification. The team utilised controlled cleaning methods to prevent debris spreading to neighbouring industrial units.
Rooflight Replacement & Translucent Refurbishment
In accordance Safe Methods of Work, GI Sykes replaced defective rooflights and refurbished remaining units using a translucent coating system where replacement was not required. These works were undertaken with robust fall‑arrest measures, safety netting, and harness systems due to the fragile nature of rooflights.
All hazardous materials, including removed rooflights, were disposed of safely in line with COSHH and CAR 2012 regulations.
Application of TOR Unicover S Protective Coating System
Once cleaned and prepared, the full roof area received a complete TOR protective coating system as follows:
- Priming with Raincoat APA: An anti‑corrosive primer promoting adhesion to aged zinc roof sheets.
- Edge Treatment Using Unicover EdgeProtect:
- Elastaseal Z primer applied to exposed edges
- Elastascrim BT tape to reinforce joints
- Elastaseal Fibretex applied over prepared edge areas
- Full Roof Coating in Unicover S: A high‑performance, 10‑year protective topcoat designed for industrial roofing environments.
Wet Film Thickness gauges were used throughout the works to verify the application met TOR’s strict specification requirements.
Health & Safety & Project Management
The facility remained in operation during the works. A site‑specific Construction Phase Health and Safety Plan ensured works were completed safely and al risks were considered. These included:
- Working-at-height controls and scaffolding inspections
- Safety netting to protect against fragile surfaces
- Traffic management for shared access routes
- Daily coordination between site management and subcontractors
- Full CDM 2015 compliance
Outcome
The refurbishment programme delivered a fully restored roofing system, including:
- Cleaned and rejuvenated roof sheets
- Replaced and refurbished skylights improving natural daylight
- Full application of the TOR Unicover S system with a 10‑year performance guarantee
- Enhanced waterproofing and corrosion resistance
- Improved long‑term resilience of the building envelope
The project has significantly extended the operational lifespan of the roof, reduced maintenance requirements, and provided Fibercill with a robust, future‑proof solution tailored to the needs of a manufacturing environment.
We are registered and approved with:
