Dutch Barn
This project centred on the redevelopment of an old Dutch barn that had previously been converted for residential use, requiring a roofing solution that could retain its traditional character while meeting modern performance and planning expectations.
Synopsis
This project centred on the redevelopment of an old Dutch barn that had previously been converted for residential use, requiring a roofing solution that could retain its traditional character while meeting modern performance and planning expectations. The initial roof design proposed a warm roof with profiled metal sheeting fixed through the insulation to replicate the traditional Dutch barn appearance. However, following collaborative review of the drawings, the team achieved the required aesthetic and planning compliance by instead installing a single‑ply warm roof finished with standing‑seam profiles.
The project involved converting the structure into a private residential dwelling, requiring a roofing solution that delivered modern thermal performance while maintaining the traditional barn aesthetic. Through coordinated design development between the contractor, architect and Bauder’s technical team, the original profiled metal proposal was replaced with a Bauder single‑ply warm roof system.
Bauder building board
Project | Dutch Barn |
Location | Chelmsford, Essex |
Project type | New Build |
Roof size | 313 m2 |
Specifier | Hudson Architects |
Approved contractor | Axe Roofing Ltd |
The specification
The roof was designed as a warm roof construction over a new metal deck to deliver high thermal performance while following the curved barrel profile. A three‑layer PIR insulation build‑up was used to achieve a U‑value of 0.11 W/m²K, combined with a fully sealed vapour control layer and a BauderTHERMOFOL single‑ply membrane. The system was designed to accept standing‑seam profiling to satisfy planning and aesthetic requirements associated with the original Dutch barn form.
Project challenges
The project presented interrelated technical and logistical challenges driven by the vaulted barrel geometry, the three‑layer PIR warm‑roof build‑up, and the requirement to achieve a traditional standing‑seam appearance while meeting thermal and planning targets.
Logistics and weather exposure added complexity. The structure was an unoccupied conversion without a permanent temporary roof, so keeping the insulation and VCL dry required phased coverings and protection. Vapour control integrity was critical and had to be continuously sealed over a curved substrate and around complex junctions to prevent interstitial condensation. The barrel form required all insulation and membrane layers to follow a continuous curved profile. Bending and securing three layers of BauderPIR insulation without creating voids, compression, or thermal bridges proved challenging, so a bespoke installation sequence was developed to ensure the build‑up followed the curved roof profile.
The result
The completed roof delivers modern thermal performance while preserving the traditional appearance of a Dutch barn. The bespoke fixing strategy, combined with close collaboration between the contractor, architect and Bauder technical advisors, resulted in a watertight, durable and visually striking roof that met planning approval, budget constraints and programme requirements. The solution achieved the required U value and successfully replicated the Dutch barn aesthetic while accommodating the building’s complex vaulted barrel roof geometry. Completed to a high standard, the project fulfils its core aim of uniting traditional form with modern performance, providing a reliable, long lasting roofing solution that supports the building’s evolution into a high quality private residence.
