Rob Wall, Garland UK Technical Manager

AS PART OF its strategic estate and asset management planning, the South Bank Multi Academy Trust worked closely with Garland UK’s technical manager, Rob Wall, to refurbish the roof and reduce electricity bills at Carr Junior School, safeguarding the site from future energy cost hikes.

A detailed roof condition survey revealed various issues with the existing build-up, including signs of cut-edge corrosion that had severely diminished the composite steel roof panels. In some cases, the protective coating was non-existent in large sections, exposing bare steel to the elements.

In its current condition, Rob Wall advised that the existing roof was unsuitable for supporting a solar PV system without substantial refurbishment. Installing solar panels on a deteriorating roof would lead to high costs and operational downtime for future repairs, as the panels would need to be removed and reinstalled.

Metal & Solar Solution

An initial Solar Yield Analysis revealed that by installing 70 PV modules using Garland’s Solarise PV system, Carr Junior School would realise a 28.7 kWp system, generating 26,287 kWh a year and providing £5,840 in first-year energy savings.

The optimum solution for the roof refurbishment was an overlay, utilising the hardy yet lightweight R-MER CLAD system. The steel-profiled metal sheet cladding was designed to retrofit over the existing roof, mitigating the need to remove and replace the roof structure and sending any unnecessary waste to landfill.

Before works commenced, a structural engineer reviewed the site and confirmed the project’s viability. Rob Wall assisted the Trust with the tendering process, and Garland UK Approved Contractors, Future Roof, was appointed to carry out the quality R-MER CLAD installation works.

A vapour control layer was installed, followed by 2mm galvanised steel top-hat profiles, and a bar and bracket system with adjusted bracket height, to accommodate the 150mm additional insulation. Finally, the R-MER CLAD metal profile was installed to seal and securely waterproof the site from the elements.

Once the R-MER CLAD system was in place, the Approved Installer, ERS, installed the custom Solarise system, which comprised 70 Solarwatt Classic 2.0 Photovoltaic panels at a 15° inclination across the southeast and northwest roof orientations. The lightweight Solarwatt panels deliver high energy yields, even in challenging weather conditions.

A bespoke mounting system was used to fit the unique profiles of the R-MER CLAD system. This ensured the solar panels were firmly anchored while distributing the load evenly, preventing damage to the roof sheets. A Solis inverter was chosen for its excellent conversion efficiency and robust monitoring capabilities, offering high reliability and service life for the school.

Long-term Sustainability Goals

Rob Wall was the client’s single point of contact throughout the project, providing weekly site visits throughout the roof refurbishment and solar installation and supplying detailed progress reports to all parties via Garlands’ cloud-based RAMP (Roof Asset Management Programme) system.

The roof refurbishment saw Carr Junior School significantly improve its overall thermal efficiency, achieving a 0.18 U-value. In addition, with the Solarise PV system in place, the school has successfully reduced its carbon footprint and is expected to negate up to 12 tonnes of CO2 emissions yearly.

Specifying the R-MER CLAD system saw significant environmental savings for the Trust, where the encapsulation process (rather than complete removal) mitigated 4.7 tonnes of waste to landfill. The metal R-MER CLAD system is 100% recyclable, meaning that when the roof reaches the end of its natural life, the school has another opportunity to recycle the panels and avoid further unnecessary waste in landfills.

Roof Refurbishment

On completion, Garland UK supplied the South Bank Multi Academy Trust with the industry-leading 20 year Single-Point Guarantee for the R-MER CLAD system and a 15 year product and 20 year performance guarantee for the Solarise system.

The Trust will see a return on investment for the solar installation in just over four years. Oliver Johnson, Director of Estates at the South Bank Multi Academy Trust, is delighted with the end result and adds, “The team at Garland UK did a fantastic job! The school is already seeing the benefits of the improved roof and solar panels, and we’re confident this project will achieve the Trust’s long-term sustainability and cost savings goals.”

For more information, visit the Garland UK website.

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