Universal Single Ply Roofing - Ford Technical Centre, Dunton, Essex

Ford Technical Centre, Dunton, Essex - Single Ply Roofing

Project Overview

Project: Ford Technical Centre, Dunton
Area: 3,500 m²
Completion Date: October 2011
Contractor: Mells Roofing Limited, Southend-on-Sea
Client: Ford of Britain
System: Icopal Universal POCB Single Ply Roofing System

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The client had been working closely with Icopal in the UK and Europe to establish a cost effective solution to the many problems that Ford had been experiencing with their flat roofs.


The original waterproofing consisted of basic traditional built-up felt membranes laid over fibreboard on a Vapour Control Layer, to a profiled metal roof deck.

With such a large building, housing 3000 engineers, and the R&D work being carried out within, the use of heat was a major factor, and Ford were insistent that there should be no naked flames used.


ICS1031-Ford-Technical-Centre-Dunton_381x266Icopal Universal POCB membrane was put forward, using the FireSmart Flame-free welding equipment. It is true to say that Fords did need convincing that a propane powered heat welder would be acceptable. Icopal’s engineer was able to successfully prove to Fords that the Firesmart welders were indeed perfectly safe.

The specification adopted for these roofs was to first prepare the existing waterproofing by removing the bedded stone chippings. An Icopal Recovery Board was then mechanically fixed through to the profiled metal deck to provide a new stable substrate.

Icopal Universal was then loose laid and mechanically fixed along the head and side laps, with all laps heat-welded with the FireSmart Flame-Free welders.

The 3500m2 contract was completed on time and to the complete satisfaction of Ford.



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