Case Study

Project Overview

A complete refurbishment of the roofs to two historic WWII aircraft hangars, each measuring approximately 5,500m², giving a combined roof area of 11,000m². The objective was to restore the weatherproof integrity of the ageing roofs whilst minimising disruption and avoiding the significant cost and operational impact associated with a full roof replacement.

Following a detailed roof survey, the Rooflock Twelve System was specified to provide a seamless , long-term waterproofing solution capable of extending the service life of the existing roof structures.

The Challenge

The project presented several unique challenges.

The hangars are large-span WWII-era structures with extensive roof areas requiring careful planning and specialist access solutions. Due to the roof configuration and access restrictions, approximately 60% of the roof area could not be safely accessed using conventional methods.

To overcome this, a significant proportion of the application works had to be undertaken by specialist rope access technicians, allowing the Rooflock team to safely reach difficult areas while maintaining productivity and ensuring the coating system was applied to the required specification.

In addition, the scale of the project demanded meticulous coordination to ensure a consistent application across both buildings while maintaining the highest standards of quality and safety.

The Solution

After preparing and treating the existing roof surfaces, Rooflock applied the Rooflock Twelve System, a fully-bonded, BBA-certified liquid waterproofing solution designed to provide a seamless protective barrier against water ingress and environmental degradation.

The refurbishment included:
    •     Comprehensive roof inspection and condition assessment.
    •     Surface preparation and cleaning.
    •     Localised repairs where required.
    •     Application of the Rooflock Twelve waterproofing system.
    •     Specialist rope access operations to reach difficult and restricted areas.
    •     Quality assurance inspections throughout the project.

The combination of access specialists and experienced Rooflock technicians enabled the project to be completed efficiently while maintaining complete coating coverage across the entire roof area.

The Result

The completed refurbishment successfully restored the waterproof integrity of both WWII aircraft hangars, protecting a combined 11,000m² of roofing infrastructure.

Key project outcomes included:
    •     11,000m² of roof area fully refurbished
    •     Two WWII aircraft hangars protected from future water ingress
    •     Rooflock Twelve System installed across both buildings
    •     Approximately 60% of works completed using rope access techniques
    •     Extended roof service life without the need for costly replacement
    •     Minimal disruption to site operations

Project Summary

    Sector:    Heritage / Industrial
    Building Type:    WWII Aircraft Hangars
    Roof Area:    11,000m² (2 x 5,500m²)
    System Used:    Rooflock Twelve
    Works:    Full Roof Refurbishment & Waterproofing
    Specialist Access:    Rope Access (approximately 60% of roof area)
    Outcome:    Long-term waterproof protection and extended roof life without replacement.