Kemper System’s Kemperol 2K-PUR solvent-free and odourless waterproofing membrane has been used to refurbish the 1,000m2 penthouse roof area above an oil refinery at a food processing plant in in Erith, London.
Working closely with Northfall Design Associates, the highly experienced and knowledgeable team at Kemper System helped to devise a successful conservation programme at the ADM Milling penthouse to address water ingress caused by severe deterioration of the 40-metre high roof area.
The oil refinery is housed within the ADM penthouse building and is more than 100 years old. The flat roof area which required refurbishment sits above the oil refinery with steeply pitched mansards, dormers and concrete gutters which also needed repair.
A quick yet durable waterproofing solution was required as the food milling plant was occupied and needed to remain fully functioning throughout the project.
Roofing contractors, Garhigh Southern Ltd, was able to install the Kemperol 2K-PUR system in a single, wet-on-wet process after removing, cleaning and priming the existing concrete substrate.
Concrete repairs were also required on the steep mansards and dormers prior to installation, and on the flat roof area to address disused venting outlets and to obtain optimum thickness of the concrete substrate prior to installation of the Kemperol 2K-PUR system.
The Kemperol 2K-PUR liquid waterproofing was then applied using a roller, with a reinforcement fleece laid directly into the wet resin, immediately followed by more resin on top to ensure complete saturation of the fleece. The cured solution then forms a seamless, elastomeric waterproof membrane that cannot delaminate and is UV stable – directly addressing the issues of water leaking into the building.
The works also demanded complex detailing around the disused vents, several outlets and plant on the main roof area. Because of the nature of the building, the food processing mill was still occupied during repair works, which also included a steam release from the oil refinery several times a day. This meant contractors had to work during weekend hours when the mill was closed to avoid any potential health and safety risks, as well as being flexible around the working processes of the plant. Despite this challenge, contractors were able to install Kemper System’s liquid waterproofing quickly and with ease thanks to its versatile liquid application technique.
Gary Buckman, director at Garhigh Southern Ltd, said: “Kemper System was an ideal choice on this project for many reasons. One main challenge was access to site as not only was the complex roof area 40-metres high, but the client requested for there to be no scaffolding from the ground and up the building. Therefore, we devised a plan to erect hanging scaffolding out of the dormer windows. The ease of application of Kemper System ensured installation ran as smoothly as possible.”
Gary continued: “In addition, because of the exposed location of the building, next to London’s River Thames, operatives were also faced with high winds during installation being completely exposed to the elements, and the steam released from the plant was also a potential health and safety hazard. The handling and laying of sheet membrane materials would not have been practical and increased the safety risk further for installers and employees. Therefore, Kemper System’s two-component liquid applied system was ideally suited to these conditions.”
Stuart Hicks at Kemper System added: “This project presented many design and installation challenges, yet the Kemperol 2K-PUR waterproofing solution was able to overcome these easily. The level of variation and detail of the substrates that required refurbishment showcases the versatility of the liquid applied resin, and contractors were able to safely install the system to the extremely steep mansard as well as guttering and detailing around the roof area.
“The fact that Kemper System’s waterproofing solution is eco-friendly as well as odourless was an added bonus for the client operating within the food-sector, and work was able to be carried out whilst the building was still occupied and with little disruption.”
ADM processes rapeseed into vegetable oil at its London site as well as six other facilities in England and Scotland. Kemper System was also specified to refurbish an 85-metre high food silo at the same site in 2017.