“This project represented the convergence of two critical objectives: addressing years of leak problems and escalating repair costs while facilitating the client decision to install solar power generation across the roof.

“That second objective drove the first—you can install a solar array on a deteriorating roof, so comprehensive refurbishment was essential. The existing construction presented particular challenges. The building had aluminium top sheets with an asbestos liner underneath, which meant we needed enhanced safety protocols during the removal phases. You can’t take shortcuts with asbestos—the procedures have to be rigorous, and that affects your programming and methodology.

“The operational requirement was non-negotiable: the building had to remain fully functional throughout the works. That meant we couldn't strip the entire roof and leave the client exposed. We planned and executed the project in carefully sequenced phases across six roof slopes, ensuring each section was weathertight before moving to the next. Before we could proceed with installation, we needed confidence that the structure could handle the additional loads.

“The new insulated composite panel system is heavier than the original construction, and the solar array adds further weight. We commissioned structural surveys upfront to confirm the buildings load-bearing capacity and identify any strengthening requirements. Those surveys gave us—and the client—confidence to proceed.

“The roofing solution was a high-performance insulated composite panel system from Tata Steel, installed across all six slopes in bay-by-bay sequences. We incorporated new rooflights throughout to maximise natural daylight penetration, which improves the internal environment and reduces reliance on artificial lighting.

The solar panel installation required strategic positioning to maximise energy output—we achieved coverage across 80% of the roof area, carefully coordinating with the rooflight positions and structural considerations. Managing this project required sophisticated coordination.

“We had roofing teams working in phases, solar installation specialists following behind, and the need to maintain daily operations below. Project planning was critical—we used digital management tools that provided real-time visibility of progress, challenges, and completed works. That transparency was available to all stakeholders 24 hours a day through our online portal, which the client particularly valued.

“Communication wasn’t just about technology—it was daily site updates, clear explanations of what was happening and why, and proactive management of any issues before they became problems.”