Roof Replacement – A Case Study

We have recently completed a project in Bromley. The project entailed a roof replacement: removing all the old tiles and replacing with a new handcrafted plain tile. In this example, we used a Sussex Blend plain tile in the Alban range from Wienerberger/Sandtoft.

First Step

Here at White and Sons Ltd, we arrange for one of our estimators to meet with you, and attend a site visit. We take photographs and measurements, and use this information to help us prepare a quote for the work. Here are some photos taken during our site visit. In this example, the tiles are starting to flake away on the rear of the property, and are mismatched on the front. This is usually a sign of tile repairs being carried out throughout the years. Once our quote has been accepted, we contact our client to let them know of an approximate start date.

The rear of the property and what appears to be flaking tiles.

Front of property with mismatched tiles.

Carrying out the work

 The first step to carrying out the work is usually to have a scaffold erected. We will only ever use reputable scaffolding companies, that have their own insurance and certification. A good scaffold also ensures that we can operate at a safe and efficient manner throughout the duration of the job.

Scaffold safely erected around the property

Once the scaffold is erected, it allows us to have a closer look at the roof. In this example, the flaking of the tiles (on the rear and side of the property) was more visible, as shown by the orange patches of tiling. Also visible are what appears to be a couple of concrete plain tiles used as a repair. 

Rear and left of property, with tiles starting to show orange.

Our next step would be to carefully remove all the old tiles, felt, and batten and place in a skip, focusing on one side at a time. It is once the roof is off that we can inspect any potential timber damage on the inside of the roof. In this case, the interior timbers (rafters) were all a good quality, so no extra work was required. We try to limit the mess caused by replacing a roof, and (in this example) we used a chute to transfer all the old tiles into a skip. Once a side or area is stripped, we provide and fit a breathable membrane/felt and the appropriate sized battens. For plain tiles, this is a 25mm x 38mm graded, treated batten, so that this complies with British Standards. 

Scaffold with chute, taken down at the end of the day to not inconvenience our client.

Mini roof mock up, showing different handcrafted plain tiles.

 

We discuss with our client the type of colour tile that they would prefer and provide samples of the tiles. Tiles can offer all sorts of different features to a roof. Handcrafted and Handmade tiles are often irregular which results in a more characteristic final product. We even have a small roof mock up that we can put the tiles onto to help differentiate the colours. We also tile a small patch of the roof so that our client can see what the tiles would look like on the roof. 

 

 

 

 

Once the roof has been completely battened with treated, graded batten,  we load the roof with the tiles, and start to lay the tiles. We tile in rows of 5 wide, and usually nail every fourth course and perimeters, depending on job specifications. We tile in the main areas, and then focus on the edges of the roof, such as the verges, valleys, and hips. In this case study, we used a hip ridge and GRP valleys, because the pitches on the roofs were all different from one another. We bed all the ridge on a sand and cement mortar, and mechanically fix the ridge down with a screw once the mortar has dried. We sometimes leave out an area of tiles 5 tiles wide, to be used as a walkway up and down the roof (as seen in the photo below).

Hip ridge being cut, with 5 tile walkway

Leadwork

This case study also had some lead work that needed to be carried out. We replaced the lead on the two chimneys, and the flat roof at the front of the house. The chimneys both have a Code 5 lead back-gutter, with Code 4 lead side flashing and front aprons. The lead code refers to the thickness of the lead and this dictates the width and length of the piece of lead. We use a mechanical angle grinder to ensure that the lead tucks into the bricks approx. 25mm, which we then seal with a sand and cement mortar. The lead flat roof required a Code 5 lead, with a wood roll used to create lead bays. We also clad the cheeks, or sides, of the front dormer in a Code 5 lead. All our leadwork is finished with a patination oil which helps to prevent it leave white staining.

Chimneys with new lead.

Finished lead flat roof

 

For this project, we arranged for a painter and decorator to paint the outside of the house to provide the house with a new lease of life. Below are some photos of the work in its various stages. Please contact us if you have a project that you would like us to carry out. Please call 01342 835181 or email sales@whiteandsonsltd.co.uk.

(All work will be carried out in accordance with the new Slating and Tiling BS5534 Codes of Practice, which includes, but is not limited to, such changes as using graded batten, increased fixing of tiles, mechanically fixing ridge and hip tiles etc.)

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