Single Ply Flat Roof Replacement for National Bakery Operator
After a detailed survey, it was clear the existing roofing system had reached the end of its serviceable life. A commercial single ply flat roof replacement was specified to provide a long-term, fully waterproof solution.
Project Details
- Client: National Bakery Operator
- Location: Scotland
- Project Type: Single Ply Flat Roof Replacement
- System Installed: Sika Single Ply (Fully Self-Adhered)
- Warranty: 20-Year Manufacturer Guarantee
- Scope: Strip-out, structural deck replacement, insulation upgrade, full system installation
- Programme: Delivered on time and within budget
- Operational Impact: Business remained fully operational
The Challenge
The client had been experiencing:
- Persistent roof leaks and water ingress
- Multiple historic patch repairs
- Failed flat roof membrane and ponding water
- Rising maintenance costs
A professional inspection confirmed that continued repairs would not resolve the root issues. A full single ply flat roof replacement was identified as the most cost-effective long-term solution.
Survey & Findings
A joint inspection with the system manufacturer revealed:
- Widespread membrane failure
- Saturated and underperforming insulation
- Structural timber deck deterioration
During strip-out, significant rot was discovered in the deck — requiring full replacement to support the new single ply roofing system.
The Single Ply Flat Roof Replacement Solution
A complete new roofing system was installed, including:
- Removal of all existing roofing materials
- Replacement of structural deck with marine-grade plywood
- Installation of a bituminous AVCL (air and vapour control layer)
- New high-performance insulation
- Installation of Sika single ply fully adhered membrane
- New outlets, trims, and perimeter detailing
- Full waterproofing and wind-tight system completion
The selected single ply flat roof system provides excellent durability, flexibility, and long-term weather resistance — ideal for commercial and industrial buildings.
Why Single Ply Flat Roof Replacement?
Single ply systems are widely used in commercial roofing due to:
- Lightweight design for large-span buildings
- High resistance to weathering and UV exposure
- Fast and efficient installation
- Long service life (20–30+ years)
- Minimal maintenance requirements
For this project, a fully adhered system was chosen to eliminate the need for mechanical fixings and reduce disruption.
Working on a Live Commercial Environment
A key requirement was ensuring the bakery remained operational.
To achieve this:
- A self-adhered single ply membrane was used (no hot works)
- Noise and disruption were minimised
- Works were carefully phased
- Temporary protection ensured continuous operation
The client’s business continued running throughout the entire roof replacement.
Quality Assurance & Warranty
Strict quality control procedures ensured a compliant installation:
- Manufacturer involvement and inspection
- Installation verified at each stage
- Digital project tracking and documentation
- Full system sign-off and certification
The completed single ply flat roof replacement is backed by a 20-year manufacturer guarantee.
The Result
The new roofing system delivers:
- A fully waterproof, high-performance roof
- Improved thermal efficiency with upgraded insulation
- Elimination of recurring leak issues
- Reduced long-term maintenance costs
- A long-term, reliable roofing solution
The client now benefits from a durable single ply flat roof system, designed to perform for decades.
Key Takeaway
When flat roofs reach the point of widespread failure, repairs often become a short-term fix.
In this case, a single ply flat roof replacement:
- Resolved structural and waterproofing issues
- Delivered a long-term, cost-effective solution
- Allowed the building to remain operational
Correct system selection and professional installation are critical to long-term performance.
Need a Single Ply Flat Roof Replacement?
If your roof is failing or nearing the end of its lifespan, a professional assessment is essential.
Book a flat roof survey today.
Get expert advice on the right single ply roofing system.