The massive £4 million project saw the renovation of Marylebone’s 150-metre long station shed roof covering four of the station’s six platforms. Beginning in May 2010, the works were managed by the main contractor, Morgan Sindall, on behalf of Network Rail, and were completed in January 2011.

With their distinctive red, black and silver livery, the hoppers and downpipes at Marylebone were one of the defining details of the Grade II listed train shed. In order to meet English Heritage guidelines, these cast iron fittings had to be replaced with exact copies. Alumasc’s Heritage Cast Aluminium was specified to replicate the original cast iron system, delivering high performance and low maintenance requirements with all the benefits of modern manufacturing technology.

As one of the UK’s largest manufacturers of rainwater systems, Alumasc is renowned for its heritage ranges and ability to replicate historic components. The Heritage made-to-order range in cast aluminium met the needs of the project on every level, and involved high levels of involvement from Alumasc’s technical team who rose to the challenge of replicating the exact historic designs and RAL colours of the original system.

The historic status of the building, restricted schedule and central London location presented many challenges to the manufacturers, suppliers and installers working on it. From the outset, Alumasc liaised closely with BSS Drainage, and installers Cover Structure, in order to plan the schedule in detail, with a lot of work taking place overnight while the station was empty.

On the success of the project, Network Rail route director Jo Kaye comments: “The new roof at Marylebone has made a huge difference to the station environment and provides passengers with a lighter, brighter travelling experience. This is the first of several projects to restore and renew our London stations so it is excellent news that the work at Marylebone has been delivered on time and on budget.”

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Greenbuild Expo is the UK’s newest sustainable building and refurbishment event, providing Alumasc with the perfect platform to promote the energy-saving benefits of its EWI systems in readiness for the forthcoming Green Deal initiative.

Alumasc is a specialist in the design and development of insulated render systems for both refurbishment and new build, offering engineered solutions for residential and commercial projects of any scale and making a significant contribution to thermal efficiency and improved aesthetics.

Alumasc’s Swisslab and Swisspan External Wall Insulation systems are primarily suited to refurbishment applications, with an impressive track record in transforming poor quality housing into warm, attractive, energy efficient homes.

Swistherm and Swisrail External Wall Insulation systems are primarily suited to new build applications, with Swistherm being particularly suited for use with Cork insulation, providing the perfect solution for low carbon, sustainable developments.

Alumasc’s EWI systems are BBA accredited, offer full warranty packages and are supported by Alumasc’s unrivalled technical expertise.

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 A Derbigum warm roof system from Alumasc has been used in the roof refurbishment of Doddington Community Hospital in Cambridgeshire – a project requiring complex liaison between the contractors who were working around the demands of one of Europe’s largest ever temporary roofs throughout the installation.

The hospital roof had come to the end of its lifecycle and urgently needed replacing.  Following the consideration of a number of options, the client,  NHS Cambridgeshire, decided the entire roof should be replaced.

The versatility of Alumasc’s Derbigum system was a major contributor to the work being finished on schedule, despite the scale of the project and the complicated logistics.

The main contractor, Morgan Sindall, was asked to remove the existing waterproofing and deck and install a new plywood deck. Alumasc approved contractor, Camflat Roofing, installed 1700m² of the Derbigum warm roof system with a mineral surfaced Derbigum cap sheet, carrying a 20 year warranty. The system comprised a 4mm thick dual reinforced Derbigum membrane based on APP modified bitumen with a decorative mineral weathering surface, offering a combination of high performance protection plus speed and convenience of installation.

A huge HAKI temporary roof was used on the project to prevent any possibility of water ingress into the hospital while the roof was being replaced, enabling it to stay open to patients. Even though the temporary roof was one of the largest ever erected in Europe, it still only covered half of the space being re-roofed. All work in progress had to take place under the covered section which was moved on rails to the other end of the roof half way through the job. The work also included detailing around new windows, roof lights, and plant and courtyard areas.

Mick Smith of Camflat Roofing comments: “This job was complex in terms of the logistics and working under the temporary roof. Alumasc’s advice and support during the project was highly valuable and the speed and versatility of Derbigum was also a major factor in successfully completing the job.”

Derbigum warm roof systems combine the proven durability of the Derbigum range, with the speed and ease of installation of a single ply system. Options are available for completely flame-free, high speed spray installation (in excess of 1000m2 per day) which is BBA accredited and fully warranted.

For more information on Alumasc’s Derbigum high performance roofing membranes, click here 

Alumasc provided a comprehensive package of high performance roofing products to the Downe Hospital in Downpatrick, Northern Ireland.

Designed by the URS / Scott Wilson Group, Downe Hospital is a £64million state-of-the-art healthcare facility, delivered by the South Eastern Health and Social Care Trust to provide a wide range of healing services to the local community.

Hydrotech MM6125 Structural Waterproofing and Derbigum Single Layer membrane were specified by the designers who had a good relationship with Alumasc’s Technical Team, following the successful use of their roofing products on a number of previous projects in Northern Ireland. The package provided a complete waterproofing solution supported by Alumasc’s unrivalled technical expertise and warranties.

13,000m² of Hydrotech MM6125 was installed by approved contractor Grainger Building Services, across various areas of the roof requiring a structural waterproofing solution. Lightweight, tough and flexible, BBA Accredited Hydrotech is ideal for protected roofs, plaza decks, green roofs, water features and access roadways. The system offers a unique formulation combined with reinforcement to guarantee lifetime performance.

9000m² of Derbigum Mineral in a light grey finish was installed on the flat roof areas. Derbigum is BBA Accredited and manufactured under ISO9000 & 14001 Quality and Environmental Management Standards. The system is available in a choice of finishes and colours including the fine mineral chippings specified for the hospital. Its many benefits include flexibility, excellent fire ratings, stronger reinforcement and suitability for all methods of application.

2000m of Alumasc’s Aluminium Skyline Copings have also provided an economical and easily installed finish to the parapets on all the flat roof areas.

For more information on Alumasc’s range of Structural Waterproofing systems, click here

A sensitive design solution by architects Isherwood and Ellis saw the redundant Grade B1 listed primary school converted into 30 self-contained apartments by building contractors Connolly and Fee Ltd for the social housing provider Connswater Homes. 

As a Grade B1 listed building, the facade could not be significantly altered, leading Isherwood and Ellis to specify Alumasc’s Heritage Cast Aluminium rainwater system with a black textured finish to replicate the school’s original cast iron system. The Heritage Cast Aluminium range is ideal for traditionally designed buildings and can be used for the direct replacement of cast iron, whilst offering all the benefits of modern aluminium casting techniques and factory finish.

The system, which was supplied by Alumasc approved supplier PFC Rainwater Systems of Newtownabbey in County Antrim, has minimal maintenance requirements and is lightweight, durable and easy to handle and fix. The moulded profile specified for Mersey Street was one of five profiles that are available in the range, alongside a choice of imperial sizes and RAL colours to suit all projects.

The Social Development Minister, Nelson McCausland opened the new £3 million development in November and added: “This really is an impressive development and good news for the people of East Belfast. Not only does this innovative project provide much needed new housing in an area of high housing need, but it rescues a much loved historic building of local importance.”

For more information about Alumasc’s Heritage Cast Aluminium rainwater systems, click here

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South Cheshire is amongst the country’s best performing FE colleges and required an innovative and contemporary facility to reflect its excellence and to embody its commitment to social and environmental responsibility. Jefferson Sheard Architects designed a new 26,500sq metre curved building based on the concept of a village street, with individual departments functioning like shop fronts.

The curved facade on the nursery section of the building demanded a first class insulation system. Alumasc worked closely with Approved Installer MIB Facades to deliver an appropriate technical solution for the project.

Rob Sharrock, director of MIB, comments: “We were appointed to install the EWI on this particular section of the building and immediately recommended the Alumasc Swistherm system using 140mm thick Lamella Board finished in 1.5mm white Silkolitt render. We had total confidence that this system would perform superbly and be straightforward to install onto the cement particle board and SFS substrate. As expected, the system has achieved the required U-value of 0.23W/m²K.”

The Main Contractor at South Cheshire College was BAM Construction.

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 The unique four-part calculator offers the following:

- Foul Drainage Calculator

- Internal Rainwater Drainage Calculator

- Flat Roof Calculator

- Rainwater Gutter Calculator

The new software can be downloaded here free of charge, it will then be saved on the users PC with an easy access direct from the Desktop Icon. Users will also benefit from quick NBS Specification generation which links directly from the from the calculator results.

Firestone RubberGard® not only met Caterpillar’s stringent environmental and insurance criteria, but was also installed to a tight time schedule during harsh winter conditions and without any disruption to business.

The Caterpillar facility comprises several buildings housing both warehouse operations and administrative offices over a total of 1.8 million square feet, providing comprehensive logistics services to a wide range of clients and distributes materials worldwide.
38,000m2 of Firestone RubberGard® was installed by Alumasc’s Approved Contractor Modern Roofs of Leicester.

The system specification will help to increase the roof’s insulation performance and improve heat retention whilst its ‘Enviro-ready’ design offers the potential to cope with any subsequent installation of green systems i.e green roofs or photovoltaic systems.

Now complete, the roof is already delivering tangible benefits in terms of an improved working environment inside the building.

Firestone RubberGard® EPDM membranes offer a unique combination of features and benefits which have been demonstrated on countless commercial, industrial and residential rooftops around the world. They comprise a fully cured membrane composed of EPDM polymer and carbon black offering unmatched resistance to ozone and UV radiation. As the membrane is inert and does not contain any plasticizers, its characteristics remain stable and unchanged over time thus providing a sustainable roofing solution offering Caterpillar the additional benefits of low life-cycle costs and minimal maintenance requirements.

Located in the town centre of Witney, Marriotts Walk incorporates flagship stores, a cinema, restaurants and 143 new homes. The scheme was designed and built by Simons Group and has recently won the prestigious ‘Sustainable Communities’ Award from the Royal Town Planning Institute South East Region.

Alumasc worked closely with Simons on the design of the rainwater system which needed to suit the character of the historic town centre whilst offering the performance demanded by a contemporary build project.

Carried out by Alumasc’s approved installer Northants Rainwater Systems Ltd, the resulting installation was a combination of Heritage Cast Aluminium, to complement existing architecture in the traditional areas, with Aqualine and Flushjoint for the newly built, more modern areas.

The package at Marriotts Walk also included Harmer Drainage Outlets and the Harmer SML soil and waste system which were supplied in the public facilities across the scheme.

For more information on Alumasc’s range of rainwater products click here.

For more information on Alumasc drainage products click here.

Hydrotech MM6125 Structural Waterproofing from Alumasc has been used on the Titanic Belfast Building - the world’s largest Titanic visitor attraction.

Specified in favour of four competing systems, Hydrotech offered an innovative and practical waterproofing solution for the intricately shaped podium roof on Titanic Belfast, created by Civic Arts/Eric R. Kuhne & Associates and Todd Architects. The distinctive design of the building and surrounding podium roof, situated above an underground car park, presented a number of challenges to Alumasc and their Approved Installer Grainger Roofing which demanded a unique configuration of waterproofing system and expansion joint.

At specification stage, Alumasc demonstrated to the construction and design team how the waterproofing and expansion joint would work together to accommodate the changes of direction and elevation presented by the podium expansion gap.

Hydrotech is the ideal solution for podiums and highly detailed waterproofing schemes such as Titanic Belfast. The high performance bituminous rubber blend allows fast and simple installation at low temperatures, even over complex roof details. The robust system enables details such as up stands to be completed first allowing other trades to proceed. Highly site trafficked areas can be left until last to avoid the need for protection or the possibility of damage.

Opening in March 2012, the 14,000m2 Titanic Belfast building tells the story of RMS Titanic, and houses Northern Ireland’s largest dedicated banqueting facility. The project, built by Harcourt Construction (NI) Ltd, is jointly funded by the Northern Ireland Executive, Belfast City Council, Belfast Harbour and Titanic Quarter Ltd.

For further details on Hydrotech MM6125 please click here.