Millers Quay

Synopsis

Millers Quay is a landmark residential development within Wirral Waters and exemplifies transformative urban regeneration. It is the UK’s largest regeneration scheme. Developed by Peel Waters in collaboration with Homes England, Wirral Council, and GRAHAM, this £130 million waterfront scheme delivers 500 thoughtfully designed one- and two-bedroom apartments, including 100 affordable homes. With private gyms in each tower and stunning south-facing views across to Liverpool, Millers Quay sets a new benchmark for urban waterfront living.

Designed by Howells Architects, the development comprises six tower blocks, drawing inspiration from the historic flour mill buildings that once occupied the site. The two outermost towers, blocks one and six, feature standard flat roofs, while the four central tower blocks boast a distinctive "roof within a roof" design. Here, a pitched roof elegantly overlays a flat roof beneath, maintaining architectural harmony with the area’s industrial heritage. Spanning over 50,000 m², the flat roofs serve as the primary waterproofing system, incorporating an innovative water management feature that directs rainwater through the building’s core rather than its exterior. 

Millers Quay is more than a housing development. It’s a catalyst for change, redefining the Wirral waterfront while fostering growth, opportunity, and a renewed sense of vibrancy for the local area.

Bauder building board

The specification

As part of the UK’s largest brownfield redevelopment, the roofing solution was meticulously designed to meet stringent building requirements while prioritising sustainability. All six flat roof structures incorporate the high-performance Bauderflex bituminous system, with a tapered insulation scheme specified across the apartment blocks to optimise drainage falls.

Each roof features a premium Bauder three-layer felt system with 440 mm of non-combustible BauderROCK mineral wool, delivering outstanding thermal insulation and acoustic performance. Additionally, a perimeter drainage gutter for the pitched roofs channels water to internal sumps on the flat roof, ensuring an efficient and sustainable drainage solution.

Sustainability has remained a key focus for Primeseal throughout this landmark regeneration project, particularly in the flat roof designs. The system’s robust construction has been engineered for maximum efficiency, enhancing insulation, soundproofing, and, most importantly, rainwater management.

Project challenges

This project presented unique challenges due to its combination of flat and pitched roof designs. Blocks one and six featured standard flat roofs, while the remaining four blocks required intricate pitched roof designs with integrated drainage solutions.

Originally planned as screed-to-fall roofs, the design was revised to a warm roof tapered solution on Bauder's recommendation. This change significantly reduced weight expedited installation by eliminating screed drying time, and lowered costs by approximately £300k. The design also centralised drainage within the building, avoiding external outlets and ensuring future maintenance would not disrupt residents.

Playing tag team with FK Roofers, Primeseal expertly coordinated its work to ensure only one roof was worked on at a time across the six blocks. While the pitched roofs were initially planned for completion before Primeseal’s arrival, both teams worked in tandem, alternating between blocks to maintain progress. To address health and safety concerns, Primeseal ensured its team operated on separate blocks from FK to mitigate risks associated with working directly beneath another team. Coordination extended to managing shared resources, with synchronised schedules allowing efficient use of the hoist for transporting materials to roof level.

The installation process required meticulous planning and collaboration. Bauder’s site technicians conducted 23 inspections, providing hands-on support and detailed reports to maintain quality. Their expertise addressed intricate detailing, ensuring the final roofing system was watertight, functional, and met the highest craftsmanship standards.

By overcoming design, logistical, and safety challenges through teamwork and innovation, the project exemplified excellence in modern roofing solutions.

Project management

The principal driving factor for GRAHAM Construction’s engagement with Primeseal was their readiness to embrace the challenge of designing, supplying, and installing Bauder Bituminous systems across six residential blocks and a pavilion, all built simultaneously. Their skill in managing complex on-site interface demands was essential to the project’s success.

The design incorporated intricate BauderROCK tapered insulation schemes, with the roofs of Blocks 2 to 5 overlaid with secondary metal pitched roofs. This required a range of innovative solutions to ensure the integrity of the flat roofs beneath while ensuring effective drainage from the metal roofs above.

Primeseal and Bauder ensured that all blocks would receive the highest standard of installation and rigorous quality inspection regimes. Their meticulous approach instilled confidence in both the client and end users from the outset.

Managing one of the largest construction sites in the North of England and potentially further afield required precise planning and logistics. A robust traffic management plan and the operation of three tower cranes enabled smooth coordination and delivery. This strategic approach significantly enhanced productivity and streamlined operations, underscoring the project’s overall success.

Health, safety, and environmental management

The early pre-construction collaboration between GRAHAM, Primeseal, and Bauder proved instrumental in ensuring that flat roofing specifications were tailored to each block. This proactive engagement played a critical role in achieving the health, safety, and environmental objectives agreed upon by all parties.

Located at East Float Dock, the site faced coastal challenges, including strong winds and heavy rainfall. To address these conditions, extensive calculations were undertaken for thermal performance, wind uplift, and rainwater management. These analyses informed the Bauder roofing systems, considering building heights, complex detailing, secondary roofs, and M&E services. By involving supply chain early in the process, it enabled a seamless transition from planning to on-site delivery.

Installing flat roofing on Blocks 2 to 5 was further complicated by tight schedules. The simultaneous installation of bituminous roofing with primary steelwork, purlins, and metal roofing required precision and collaboration across multiple trades to maintain safety and efficiency.

The result

The drainage system is designed for efficiency. A perimeter drainage gutter channels rainwater from the pitched roof onto the flat roof below, where it is directed through an internal gutter system. This system then feeds water into sumps created by the tapered insulation. Unlike a standard tapered system, this design guides water from the edges to central outlets, ensuring effective drainage.

Architect Cristina Rubio González noted that outlets were placed in communal corridor risers rather than apartments to minimise future disruptions. In case of drainage issues, no apartment interiors would be affected.

Primeseal’s roofs come with a 20-year guarantee as standard, but the team anticipates the lifespan of the roofs with pitched covers to far exceed this. The pitched roofs protect the flat surfaces from weather exposure, reducing wear and maintenance. Primeseal’s Design and Procurement Coordinator, Callum MacWilliam remarked that the team is keen to observe how the protected roofs will fare compared to the fully exposed block over the coming years, particularly after five to ten years of environmental exposure.