Large Industrial Roof — SprayGrade Cold-Spray Refurbishment

Project Context

A large industrial manufacturing facility (10,000m² roof) with a profiled metal roof system that is aging — fastener corrosion, metal panel deterioration, water ingress at overlaps and lapped seams. The existing roof is asbestos-containing material (ACM) — identified via pre-inspection survey in accordance with HSE Control of Asbestos Regulations 2012.

Production cannot be interrupted; the facility operates 24/7. A traditional roof replacement would require strip-out of ACM panels with specialist licensed removal contractors, temporary weather protection, extended programme time and major disruption. The client requires a fast, non-invasive overlay solution that avoids ACM handling.

ACM Protocol & Safety

As the existing roof contains asbestos-containing material, an ACM survey is completed before any works:

• • Notifiable Asbestos Contractor engaged to survey and confirm ACM presence and condition.
• • Risk assessment completed confirming the ACM panels are non-friable and non-damaged.
• • Management plan implemented under CAWR 2012 — the ACM is left in situ and encapsulated by SprayGrade overlay.
• • SprayGrade application creates an effective encapsulation layer, sealing the ACM from environmental exposure.
• • No removal or disturbance of ACM panels during application — only surface cleaning of metal.

This approach is compliant with HSE guidance and eliminates the cost and programme delay of licensed ACM removal.

System Selection: SprayGrade

SprayGrade cold-spray liquid rubber is specified for this large-area industrial application because:

• Overlay capability: applied directly over profiled metal ACM panels — no removal or disturbance.
• High-output spray: 600m²+ per day. The 10,000m² roof is completed in 16–18 days.
• Seamless coverage: spray reaches all overlaps, seams and fastener penetrations, eliminating water ingress paths.
• Cold application: no heat or flames — safe for ACM encapsulation; compliant with HSE protocols.
• Profiled surface bond: liquid rubber conforms to the metal profile, creating a durable weatherproof seal.
• Minimal disruption: works around production schedule; no shut-downs required.

Programme & Logistics

The 10,000m² roof is divided into sectors:

• • Week 1: Sector A (2,500m²) — full metal surface cleaning, primer application, two-coat SprayGrade.
• • Week 2: Sector B (2,500m²) — repeat cleaning, priming and spray application.
• • Week 3: Sector C (2,500m²) — repeat process.
• • Week 4: Sector D (2,500m²) — final application and defect inspection.

Each sector is fully completed before the next is started. The spraying team operates with fall protection, mobile elevated work platforms (MEWPs) and full H&S protocols. Production operations on the ground continue uninterrupted; the overlay work happens during off-peak or around production schedules.

Warranty & Long-Life Outcome

Upon completion, a 20-year manufacturer warranty is issued covering material, application and the encapsulation of ACM. The warranty is contingent on:

• • Annual inspections (visual assessment for damage or wear).
• • Prompt repair of any isolated damage using SprayGrade patch system.
• • Maintenance of gutters and drainage to prevent standing water.
• • ACM management plan compliance as required by HSE.