Roof replacements, roof repairs, waterproofing

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Waterproofing roof gutters
We were asked to assess and quote on a roof leak that many other contractors have worked on and tried to address the waterproofing problem without success. The water ingress is noticeable on the cornice.
Water damage on the cornice
Side view of cornice
Cornice in corner by brick wall
We determined that the roofing contractor's internal gutter did not work. It was quite shocking to see. They put corrugated roof sheets underneath the roof sheets as their gutter. This is very strange as, when we opened up the roof we saw that there was more than enough space for a light industrial fiberglass internal box gutter. The contractor also put a covering over the "gutter" which worsened the problem in that it trapped leaves inside and blocked up the flow of water.
Corrugated roof sheets and valley of roof
Corrugated roof sheets and chimney
Corrugated roof sheets

We established that the gutter was to blame but also could not rule out the fact that water could be coming from the header wall directly above the small PVC gutter visible in the picture above.

The scope of works was :

- To redo the header wall flashing directly above the bricked chimney area.
- To seal the roof bolts in the roof area affected.
- To flash between the lower roof section and the upper roof section.
- To redo the waterproofing of the bricked chimney.
- To reline and to widen the valley.

The specifications were to:

Header Wall flashing: (torch on)
> Strip and remove old and damaged waterproofing systems to the header wall flashing. Remove all rubble from site.
> Apply a single coat bituminous waterproofing primer.
> Apply a 4mm heat fused torch on waterproofing system to the previously primed areas allowing for 75mm overlaps, heat sealing all overlaps.
> Apply a heat/light reflectant silver aluminium paint to protect underlying waterproofing system against UV rays.

Roof Bolts
> Remove previous waterproofing around roof bolts.
> Re-secure roof bolts where necessary.
> Seal all roof bolts with a Bituseal Plastic waterproofing agent.
> Apply a heat/light reflectant silver aluminium paint to protect underlying waterproofing system against UV rays.

Flashing between the upper IBR flat roof of the house and the lower IBR flat roof of the extension.
> Strip and remove old and damaged waterproofing system between the upper IBR roof of the house and the lower IBR flat roof to the extension.
> To loosen the roof sheets of the upper roof sheets, fixing a 4mm waterproofing system to the last row of battens in the roof.
> Apply a single coat bituminous waterproofing primer to the lower IBR roof.
> Apply the 4mm heat fused torch on waterproofing system to the previously primed areas allowing for 75mm overlaps, heat sealing all overlaps.
> Apply a heat/light reflectant silver aluminium paint to protect underlying waterproofing system against UV rays.
> Fix in place the previously removed roof sheets.

Chimney (torch on)
> Strip and remove old and damaged waterproofing systems around the chimney, down to a bare underlying substrate. Remove all rubble from site.
> Conduct a thorough inspection confirming a good bondable substrate.
> Apply a single coat bituminous waterproofing primer to the substrate and allow solution to flash off.
> Apply a 4mm heat fused torch on waterproofing system to the previously primed areas, allowing for 75mm overlaps and 150mm upturns, heat sealing all overlaps.
> Counter flash, where necessary, using a self-adhesive 300mm wide uniflash waterproofing system.
> Flash off counter flashing using bitu-seal plastic.
> Apply a heat/light reflectant silver aluminium paint to protect underlying waterproofing system against UV rays.

Valley Re-lining
> Strip and remove roof sheets adjacent to valley so as to expose the existing valley.
> Lay a 4mm heat fused torch-on waterproofing system down the full length of the valley securing the waterproofing system to adjacent batons using Flathead clout nails.
> Apply a heat/light reflectant silver aluminium paint to protect underlying waterproofing system against UV rays.
> Place back the previously removed roof sheets.

So we got underway and opened up the roof and took out the corrugated "gutter".

Removing corrugated roof sheets
We inserted the new light industrial fiberglass internal box gutter and made good the waterproofing and the site was ready to withstand the Winter rains once again.
Roof valley was relined with light industrial fiberglass internal box gutter.
Flashing was done between the lower roof section and the upper roof section
 

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