Smurfit Westrock
This project has been announced as a finalist in the forthcoming National Federation of Roofing Contractors (NFRC) 2026 UK Roofing Awards taking place in London on May 8th, submitted by Liquid Roofing Ltd.
The Smurfit Westrock’s balehouse roof replacement demonstrates how complex refurbishment works can be delivered safely within a live industrial environment.
Synopsis
The Smurfit Westrock’s balehouse roof replacement demonstrates how complex refurbishment works can be delivered safely within a live industrial environment.
Smurfit Westrock’s manufacturing facility in Stalybridge is a key UK production site for corrugated packaging. Within the site, the balehouse plays a central operational role, compacting and processing packaging products and waste materials, with continuous operations taking place beneath the roof.
Bauder building board
Project | Smurfit Westrock |
Location | Stalybridge, Greater Manchester |
Project type | Refurbishment |
Roof size | 576 m2 |
Specifier | Knight Frank |
Approved contractor | Liquid Roofing Ltd t/a LRL Roofing Solutions Ltd |
Project challenges
The existing balehouse roof had deteriorated due to historic overlays and long‑term wear, becoming thermally inefficient and prone to leaks. Multiple layers had concealed deterioration to the deck, joists and steelwork, with condensation forming around M&E services. While the building remained operational, the condition of the roof meant full replacement was unavoidable.
The balehouse could not be taken out of service and contains highly combustible cardboard materials, combining fire risk, structural concerns, and restricted access within a live project.
Any replacement solution therefore needed to be delivered safely above continuous manufacturing operations, while maintaining weathertightness throughout the programme.
Solutions
To address these constraints, Bauder specified a solution that eliminated construction‑phase fire risk and supported phased installation over a live environment. The roof was stripped back in sections to maintain protection to the area below, with defective timbers replaced, steelwork treated and a new plywood deck installed. A Bauder Airtech reinforced bitumen membrane system was installed using self‑adhesive layers and hot‑air welding rather than naked flame application, enabling safe installation directly above ongoing operations.
The completed roof provides a durable, thermally efficient and low‑risk solution over a critical operational area. It supports long‑term performance while protecting day‑to‑day manufacturing activities. The quality of workmanship, detailing and safe delivery within a complex live environment led to the project being shortlisted for an NFRC award, recognising the high standard achieved across both technical execution and site management.
