June 2020

Every element presented a new challenge with
almost none of the existing roofing features
meeting modern standard build dimensions.
“To protect and enhance the build’s features, we
also had to conform to the materials used in its
original construction, which included replicating
the use of Welsh Pink Slate.”
Removing damaged slating as carefully as
possible to ensure minimum disturbance, after
extensive research the slate was replaced with a
close Welsh natural slate match, Cwt-y-bugail,
with the DFR team installing between 20,000 –
30,000 slates across the roofing area.
The Melville building in Royal William Yard: “A big part of the job was taking the time to remove and reinstall its aging copper sheets.”
Small stuff
As with most historic buildings, Melville was built
to last, with many areas featuring bespoke lead
and copper design, as Andy explained: “Melville’s
roof was a standout architectural feat in its own
right when it was originally constructed, and the
roof was a key part of its draw with extensive
lead and copper detailing. A big part of the job
was taking the time to remove and reinstall its
aging copper sheets; with extensive fabrication
and hand-dressing required to meet the existing
build style, which also included creating doublelock
standing seams.
With lead detailing also a necessity, including the
creation of ornate cornices, rooflights and
copings, an onsite workshop was required to
ensure materials could be created and fitted to
the structure’s exacting specifications. Andy
added: “When working with an historic building
like Melville, we often have to take on the role of
designers to restore some of the build’s most
important and unique design elements, working
alongside organisations like Heritage England to
ensure we fully understood the fabric of the
building.
“When you are working with lead ranging from
code six to nine, everything takes time and
patience, and it’s often the smallest, most ornate
detailing which are the most important elements
in preserving the character of listed structures.”
Topping out
As well as undertaking a range of bespoke
detailing work, DFR Roofing also had to provide
the basics, and with no insulation included in its
original construction, the team needed to create a
warm roof which included the installation of a
Tyvek vapour control layer, liquid waterproofing
and ventilation roof insulation. Many of the
materials have also had to be individually handcut
to fit the unique build dimensions, including
the timber board, insulation and slate.
“When you are working
with lead ranging from
code six to nine,
everything takes time
and patience”
With work commencing in 2019, a large
majority of the roof is already completed,
however works are still ongoing on the
monumental structure. However, working on a
structure as historic as Melville has proved a
worthwhile challenge for the South West
contractor, as Andy explained: “Melville is a
flagship project for the region, and we have had
to undertake extensive research into historic
methods and materials to protect and respect
the heritage of its listed status.
“Close consultation has been required throughout
with various historical organisations, contractors,
architects and consultants to ensure nothing
would negatively impact the build, both
structurally and visually. We are proud to have
played a small part in ensuring that the iconic
building can be enjoyed by generations for years
to come.”
Contact DFR Roofing
01752 255616
www.dfrroofing.co.uk
@dfrroofing
JUNE 2020 TC 35