Factory Roof Refurbishment Systems
Extend the life of your factory roof without production shutdown. Spray-applied liquid rubber, EPDM membranes and specialist coatings — installed around shift patterns with process contamination protection.
Factory Roofing Challenges
Production Continuity
Manufacturing operations cannot tolerate extended shutdowns. Refurbishment must coordinate with shift patterns and production schedules
Process Contamination
Oil mist, steam, chemical vapours and particulate contamination degrade roof membranes faster than standard commercial environments
Heat & Humidity
Manufacturing processes generate elevated temperatures and humidity levels that accelerate membrane deterioration and insulation breakdown
Complex Penetrations
Extract ducts, flues, ventilation systems, electrical conduits and process pipework create numerous potential leak points requiring specialist detailing
Production Continuity Planning
Factory roof refurbishment requires detailed coordination with production schedules. Unlike warehouse or storage facilities, manufacturing operations face significant costs from downtime — making phased installation essential.
Shift-Based Working
Installation during shift changes, weekends or planned maintenance windows
Phased Installation
Roof completed in sections while production continues in unaffected areas
Process Protection
Containment barriers and protective sheeting prevent contamination of production areas
Hygiene Protocols
Food manufacturing and pharmaceutical facilities require specialist hygiene procedures
Downtime Cost vs Refurbishment Savings
Production disruption can affect output, labour and orders. Compare refurbishment and replacement using the same access, shutdown, phasing, preparation, warranty and whole-life maintenance assumptions.
Refurbishment
Days to complete, phased around production
Full Replacement
Weeks to complete, major disruption
Start with a Professional Survey
Every factory roof is different. A professional survey identifies root causes of failure, assesses substrate condition, evaluates process contamination impact and determines whether refurbishment is viable or replacement is necessary.
Condition Assessment
Substrate viability, membrane condition, contamination assessment
System Recommendation
SprayGrade, EPDM, polyurethane or hybrid solution for your process
Production Plan
Phased installation schedule coordinated with shift patterns
Factory Roofing Systems
System selection depends on existing substrate, roof condition, process environment and production constraints. All options below are suitable for factory applications when correctly specified.
Spray-Applied Liquid Rubber
Large flat roofs, seamless coverage, minimal disruption to production
- Approximately 600m² per day under suitable conditions
- Seamless membrane with no joints
- Resistant to process contamination
- Can be applied in phases around production
EPDM Single-Ply Membrane
New installations or complete strip-and-replace projects
- 20–30 year lifespan
- Mechanically fixed or ballasted
- Resistant to UV and weathering
- Wide contractor availability
Polyurethane Coatings (Metal Roofs)
Metal profile factory roofs with cut edge corrosion
- Corrosion inhibition
- Colour retention (RAL options)
- Eliminates sheet replacement
- Fast application between shifts
Liquid Detailing & Repairs
Penetrations, upstands, complex details and patch repairs
- Brush/roller application
- Seals around ducts and pipework
- Used with spray systems
- Fast cure time
System selection depends on substrate condition, process environment and production constraints. Our technical team provides specification support — call 01254 433987 or request a survey for system recommendations.
Penetrations & Complex Details
Factory roofs typically have far more penetrations than warehouse or office roofs. Each penetration represents a potential leak point requiring specialist detailing.
Extract ducts and flues
Ventilation louvres
Electrical conduits
Sprinkler system penetrations
Process pipework
Gas supply lines
Compressed air lines
HVAC plant connections
Smoke vents
Roof access hatches
Lighting conduits
Data cabling penetrations
Penetration detailing is critical in factory environments. Liquid rubber systems excel at sealing complex details — our technical team can assess your specific penetration schedule and recommend appropriate detailing methods.
Refurbishment vs Full Replacement?
Not every factory roof needs full replacement. Where survey evidence supports retention, compare a documented refurbishment scope with replacement, including wet materials, production constraints, access, written warranty terms and planned maintenance.
Refurbishment is viable when:
- • Structure is sound
- • Insulation is dry
- • Membrane failure is superficial
- • Production continuity is critical
Replacement may be needed when:
- • Structural movement present
- • Widespread insulation failure
- • Multiple failed refurbishments
- • Building lifespan >25 years
Factory Refurbishment Process
Survey
Condition assessment and production constraints review
Specification
Technical specification and method statement
Production Plan
Phased installation schedule coordinated with shifts
Application
System installation with process protection measures
Certification
Final inspection and warranty documentation
Factory Types We Support
Food manufacturing facilities
Chemical processing plants
Pharmaceutical production
Automotive manufacturing
Textile production
Paper and packaging facilities
Metal fabrication units
Electronics manufacturing
Beverage production
Plastics manufacturing
Print works
Assembly facilities
Frequently Asked Questions
Factory Specialist
Discuss Your Factory Roof Project
Call 01254 433987 or send your project details for specification support, system recommendations and production continuity planning. Forti Nova provides factory roof surveys, system supply and approved contractor access across the North West.
Get Expert Advice
Our technical team can assess your factory roof condition, recommend appropriate systems and provide production continuity planning throughout your project.
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