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Case Study

£900k Saved in Critical Hospital Roof Upgrade

Garland UK Technical Manager
Alex Kitis

Approved Contractor
Evolution Contracts

£900k Saved in Critical Hospital Roof Upgrade

Garland System

Dura-Coat

Sector

Healthcare

Project Cost Saving

£900,000

Located in Enfield, the Cavell Hospital is a key facility for Circle Health Group. Spanning over 1,000 square metres, the building’s existing mastic asphalt roof had reached a critical state of disrepair, causing water ingress and internal damage. Faced with a significant refurbishment challenge, Circle Health Group turned to its long-term partner, Garland UK, to deliver a durable and cost-effective hospital roof upgrade that aligned with stringent budget constraints and compliance standards.

Challenge

The existing warm roof system, composed of mastic asphalt over mineral wool insulation, exhibited widespread failure. Thermal shock had caused surface shrinkage and cracking, particularly around internal gutters and service penetrations. Water ingress was widespread, and several plant installations penetrated the waterproofing system, further complicating refurbishment efforts.

Initial projections feared the replacement of roof-mounted plant equipment could increase the total cost of the project by up to £1 million. With these logistical and financial barriers in place, the client needed a creative approach to achieve refurbishment without incurring excessive cost or operational disruption.

Solution

Garland UK’s technical team, led by Technical Manager Alex Kitis, implemented a service-led approach starting with a detailed roof condition survey that provided clear and accurate data for targeted specification. A comprehensive moisture scan was conducted, precisely mapping areas of saturation. This revealed that only 20% of the roof required full strip and replacement, while under 50% of the existing substrate could be retained under building control repair rules, avoiding a full thermal upgrade.

Crucially, this survey enabled the project to proceed with minimal disturbance to the plant equipment. Instead of a full removal, which would have added approximately £1 million to the budget, strategic isolation of plant units allowed for works to proceed with only minor relocation. This reduced plant-related costs to under £100,000, a saving of over 90%. These savings were made possible by the Dura-Coat system’s ability to be easily applied under and around complex plant penetrations without the need for disassembly, making it ideal for intricate roof layouts with heavy detailing.

The Garland-specified Dura-Coat PUMA liquid waterproofing system was the ideal solution for overlaying the remaining sections of the existing roof, thanks to its effective crack-bridging properties and rapid 30-minute curing time. For stripped areas, a new build-up incorporating a vapour barrier and 120mm PIR infill insulation with tapered insulation to the gutters was installed to promote water runoff through the congested internal gutters.

Installed by Approved Contractor, Evolution Contracts, the system provided a seamless, high-performance waterproofing layer with superior flexibility and durability, perfectly suited to the busy hospital environment. All works were fully monitored under Garland UK’s rigorous quality assurance program, with twice-weekly site inspections and full digital reporting via the RAMP (Roof Asset Management Programme) portal.

For balconies and communal walkways, Garland UK specified the Dura-Walk system. Approximately 1,500 m² of walkways and balconies were refurbished. Adhesion testing was carried out prior to installation due to previous low-level liquid applications showing early signs of failure. The new Dura-Walk system delivered a durable, anti-slip finish suitable for both private balconies and high-traffic communal areas.

Outcome

The completed project delivered a watertight, compliant roofing system on time and on budget. Through expert diagnostics, collaborative planning, and a high-performance Garland system, Circle Health Group ensured the hospital could remain fully operational throughout the works, avoided significant cost escalations, reduced risk, and secured the long-term performance of a vital clinical building.

By using Dura-Coat’s detail-friendly application, Garland UK helped Circle Health avoid the full removal and reinstatement of critical plant services, delivering the same functional outcome at under 10% of the projected cost. The result was a future-proof roofing solution backed by Garland UK’s comprehensive 20 year Single-Point Guarantee, ensuring peace of mind for Circle Health Group and setting a new benchmark for cost-efficient asset management in the healthcare sector.

This was a complex and highly constrained project, where every decision needed to balance clinical operational needs, structural performance, and financial limits. Our goal was to develop a solution that delivered maximum value for the client, not just for today, but for the life of the building. We’re proud to have supported Circle Health Group in achieving the best possible outcome for both the building and their business.

Alex Kitis

Technical Manager, Garland UK

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£900k Saved in Critical Hospital Roof Upgrade

Garland Technical Manager

Alex Kitis

Approved Contractor

Evolution Contracts

Quick Facts

Garland System

Dura-Coat

Sector

Residential

Project Saving Cost

£900,000

The storm exposed critical weaknesses in the original roof design, which had failed to cope with the site’s wind load demands. The closure meant immediate loss of revenue, reduced access to community leisure facilities, and growing urgency to reopen.

The replacement roof required complex engineering to match the building’s 40 metre wide dual-curved structure. Standing seam sheets up to 22 metres in length had to be precision-engineered off-site, with escorted delivery, timed road closures, and careful sequencing of work.

With only a small car park as the site compound, storage, crane operations, and contractor access needed meticulous planning. Moisture protection for the exposed structure was critical throughout, with temporary coverings installed until the new system could be sealed.

Garland UK Technical Manager Rob Wall specified the R-MER LOC standing seam metal system, designed for storm resilience, thermal efficiency, and long service life in marine climates. Its penetration-free, zip-free seam design enabled faster installation and allowed for thermal movement without panel distortion.

The system was tailored to the building’s complex geometry, with 22 metre top sheet runs and 18 metre lower runs. Approved contractor, Future Roof Leeds, carried out the works, reusing the existing perforated aluminium liner where possible to reduce waste and disruption.

A high-performance, foil-lined vapour control layer was installed, along with upgraded insulation and a breather membrane suitable for coastal exposure. Acoustic infills were also integrated to maintain internal sound control, enhancing the original system’s acoustic performance.

The 1,200 sqm roofing system was completed on time and within budget, restoring full functionality to SC2 Water Park and preventing further loss of income. Garland UK’s Roof Asset Management Programme (RAMP) now provides the Council with a complete digital record of the project, including inspection reports, guarantees, and maintenance guidance, giving estates teams full visibility for ongoing asset care.

Covered by a 30 year Single-Point Guarantee for design, materials, and workmanship, the Council has complete assurance that any issues will be resolved swiftly, without dispute or additional cost.

The reopening of SC2 Water Park has reinstated a much-loved leisure venue for residents and visitors, supporting local wellbeing, tourism, and economic activity. The storm-resilient design means fewer disruptions and reduced maintenance, and reliable year-round availability, even in challenging weather.

Robin Jones, Senior Building Surveyor at Denbighshire County Council, commented,

“The level of service from Garland UK has been first-class from start to finish. Rob and the team gave us confidence at every stage, from design to handover. The quality of the roof and the management of such a tricky site exceeded our expectations.”

Rob Wall, Technical Manager at Garland UK, added,

“This was a demanding brief in a harsh environment. The combination of curved geometry, extreme sheet lengths and complex logistics called for precision planning and strong collaboration. We’re proud to have supported the Council in getting this key venue back up and running.”