Replacing the roof on Primark’s 640,000 sq ft distribution centre in Thrapston, was the largest refurbishment of a single-ply roof undertaken in Britain in 2012 and clearly demonstrated Bauder’s status as one of the largest and most respected companies in the roofing industry.

The specification 

The BauderThermofol PVC single ply system in light grey was specified to overlay the existing system. Mechanically fastening the membrane to the deck is a safe and effective method of membrane attachment with wind uplift calculations undertaken to BS EN 1991-1-4:2005 to ensure the correct fastener density was utilised.

Project challenges

The building's exposed location proved a challenge. The previous roof suffered from extensive wind damage so Bauder’s bespoke proposal was specifically designed to cope with extreme weather conditions and a drainage specialist was brought in to ensure that the design of the roof would disperse water effectively.

The result

The distribution centre remained operational throughout the work, which added to the logistical challenge. All deliveries had to be timed to ensure they did not affect vehicles moving in and out of the warehouse and these restrictions also affected the roofers accessing the building.

Working with the main contractor, Asphaltic Contracts Ltd, Bauder took full responsibility for every element of this PVC overlay roofing project, from design and wind-lift calculations to the supply of all the components and the fit. The roof comprises five huge ridges of over 20 metres each, amounting to 56,000 sq metres in all.

BauderThermofol PVC Single-Ply Waterproofing System