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Roof of Tollcross Fire Station with Bauder Thermofol PVC single ply waterproofing with Profiled PIR Infill Overlay System

Tollcross Fire Station

Bauder Thermofol PVC single ply waterproofing with Profiled PIR Infill Overlay System

Project Type:
Refurbishment
Sector:
Government
System:
Single Ply

Synopsis

Tollcross Fire Station located in Edinburgh city centre is a local authority fire station for Scotland’s Fire and Rescue Service (SFRS) that ensures the safety and wellbeing of the people of Scotland, a vital part of the city’s safety infrastructure.

A refurbishment of the building’s roof was required due to the roof of the Category B listed building suffering extensively from condensation issues. The renovation required a roof system that would eliminate the condensation and water ingress, without compromising the building's aesthetic integrity, preserving the landmark's architectural heritage.

  • Roof of Tollcross Fire Station showing completed refurbishment project
  • Old deteriorated roof of Tollcross Fire Station
  • Old deteriorated roof of Tollcross Fire Station
  • Old deteriorated roof of Tollcross Fire Station
  • Roof of Tollcross Fire Station under refurbishment
  • Roof of Tollcross Fire Station showing completed refurbishment project
  • Roof of Tollcross Fire Station showing completed refurbishment project
  • Roof of Tollcross Fire Station with Bauder Thermofol PVC single ply waterproofing with Profiled PIR Infill Overlay System
  • Roof of Tollcross Fire Station with Bauder Thermofol PVC single ply waterproofing with Profiled PIR Infill Overlay System

Bauder Building Board

Project

Tollcross Fire Station

TypeRefurbishment
Location

Edinburgh, Scotland

Roof size

1,000 m²

Waterproofing system

Bauder Single Ply Profiled PIR Infill Overlay System

Specifier and approved contractor

Insite Cladding & Roofing Ltd

Specification

Bauder’s area technical manager carried out an in-depth roof condition survey to assess the status of the existing roof covering, structural design, and thermal performance. The existing hard metal cold roof highlighted the potential for condensation. Further inspections were carried out internally that found there was insufficient cross ventilation which was causing the roof and void to condensate. The water ingress was highlighted as common in the winter months.

Upon survey, Bauder’s technical department carried out various technical tests, including condensation risk analysis and U-value calculations to determine the most suitable waterproofing system to be specified that achieved the project requirement to offset any condensation risks.

The refurbishment involved a comprehensive overlay to the existing hard metal roof and gutters. Bauder Single Ply Profiled PIR Infill Overlay System was specified to refurbish the profiled sheet metal roof. The system incorporates a PIR insulation infill that is cut to match profiled sheet metal and roof structures. The system then adds a BauderPIR FA flatboard insulation and a single ply membrane to complete the overlay solution.

Bauder also supplied an embossed walkway membrane to clearly define an access pathway with reduced potential for slips when maintenance is required. To facilitate efficient rainwater drainage, new downpipes and hoppers were installed.

Products applied

BauderPIR FA Flatboard Insulation:
Bauder’s in-house technical team utilised the results of the condensation risk analysis to calculate the amount of insulation required. To take up the depth of the standing seam roofing profile, 60mm of BauderPIR FA Flatboard Insulation was installed incorporating BauderSYN DB-PE 100 polyethylene air and vapour control layer and an additional 140mm of PIR insulation.

BauderTHERMOFOL U 15 FR PVC:
This single ply roofing membrane was applied to complete the system. It is lightweight and has a high-grade virgin polymer formulation.

Project challenges

Due to the project being landlocked and in Edinburgh city centre, there were access restrictions for the site including the time the refurbishment works could take place and the quantity of materials which could be delivered.

The deliveries had to be managed in and around a live fire station. Bauder worked closely with the contractor to organise smaller deliveries to overcome the access restrictions and continue to deliver the renovation.

Insite Cladding and Roofing had to detail in their construction phase plan where they would be working when they would be working, the duration they would be working for, and how they would overcome any emergency callouts by SRFS.

Since this refurbishment project was completed around a live fire station, keeping water ingress during construction to a minimum was imperative. Due to the project being carried out in Scotland over the winter months, Insite installers had to precisely apply the night seals each evening because they could be left for days at a time.

Throughout the project, there was strong collaboration from all Bauder and Insite Cladding and Roofing which ensured a smooth execution and adherence to high standards. Due to the nature of the refurbishment project, some instances were not forecasted at the initial survey stage. For instance, the existing gutters were not straight, therefore during the construction, a new galvanised steel angle had to be installed before the roofing installation.

The result

Hard metal roofs can experience condensation issues due to the lack of ventilation beneath the deck. Installation of Bauder Single Ply Profiled PIR Infill Overlay System is the most suitable solution for these types of failing roofs.

The refurbishment project delivered a durable, long-term waterproofing system that achieved the functional requirements for the building to ensure the continued operational effectiveness of the fire station, whilst seamlessly blending with the existing aesthetic of the Category B listed building.

The original roof system had no workmanship guarantee and had several failed attempts at repair. The installation of Bauder Single Ply Profiled PIR Infill Overlay System provided Tollcross Fire Station with a 20-year product and workmanship guarantee specific to the project requirements.

System Build Up

Bauder Profiled PIR Infill Overlay System

Bauder Profiled PIR Infill Overlay System

Bauder Profiled PIR Infill Overlay System

The system incorporates a PIR insulation infill that is cut to match profiled sheet metal and roof structures. The system then adds a BauderPIR FA flatboard insulation and a single ply membrane to complete the overlay solution.

Visit our Technical Centre for more information
Thickness (mm)1,5(-5/+10%)
Weight (kg/m2)0.25