Many commercial and industrial buildings use their roof space to house equipment and machinery. While maximising rooftop space can allow inside space to be put to more productive use, it is important that the roof must be appropriately specified to avoid performance issues or health and safety risks. The roofing materials must be durable, weather-resistant, and capable of bearing significant weight. Safety should also feature strongly in the design and maintenance of these roofs, ensuring the well-being of all those who work on or around them.
Generally big, bulky or noisy equipment that has been built to withstand outside use is stored on roof spaces. This includes pipes and cabling for plumbing and electrics, solar panels, heating, ventilation and air conditioning systems (HVAC) and backup power generators. Many of these share one thing in common – everything needs to be maintained, which means the space and surface needs to safely accommodate foot traffic and other work equipment.
Proper design and installation are key to ensuring the roof’s functionality and longevity, especially when storing heavy equipment.
When installing a flat roof which will eventually house machinery, it is essential to make sure it can hold the weight. Reinforced support beams or additional load-bearing structures can help manage the weight effectively. However, even the most experienced roofer is likely to need to call on the expertise of a structural engineer to analyse the roof structure, consider the static and dynamic loads that the machinery will exert over time, as well as looking at weight distribution.
As part of the planning process, consideration should be given to the equipment’s footprint, maintenance space, and pathways that maintenance engineers need to navigate safely. considered. For new builds, structural engineers are usually involved in designing and planning the roof structure to ensure it can withstand the intended loads and environmental conditions. They will assess the structural implications of the equipment and ensure the safety of the building. For renovations, or when a change of use is required (ie adding solar panels or other significant weight), a structural engineer can assess the structural implications and ensure the safety of the building.
When it comes to roofing solutions for flat roofs that accommodate heavy plant equipment like HVAC systems, durability, flexibility, and ease of maintenance are non-negotiable. These roofs are subject to frequent foot traffic, vibration, and potential punctures from tools and machinery. Polyurethane liquid roofing systems and bituminous membranes offer resilience and long-term performance.
System THX is a high-performance, cold-applied polyurethane liquid roofing system that excels in environments where heavy-duty protection is essential. One of its standout features is its seamless, elastic finish, which minimises the risk of leaks at joints or seams, a critical advantage when HVAC systems are installed. The system is also highly resistant to punctures and abrasion; it stands up well to foot traffic and the inevitable movement of tools and equipment associated with rooftop plant access. It is also easy to repair, ensuring that any accidental damage can be quickly addressed before it causes an issue.
It offers a solid solution with a base life expectancy of 25 years. For even greater durability, System THX+ adds a topcoat that extends protection up to 30 years, increasing resistance to wear and environmental exposure.
Bituminous membranes, particularly the Lancastria SYSTEM ENDURA family, are also well-suited to flat roofs housing mechanical equipment. SYSTEM ENDURA and ENDURA FR provide excellent mechanical strength, elongation, and dimensional stability, making them ideal for handling thermal movement and structural vibration caused by large HVAC units. These membranes offer life span of at least 30 years and are highly adaptable, supporting traditional torch-on application, hot air methods, or mechanical fixing depending on site requirements. The fire-rated ENDURA FR variant adds an extra layer of protection, particularly relevant in environments where fire safety is a priority.
Machinery such as HVAC systems or power generation equipment can produce significant vibrations and noise. Using resilient mounts and isolation pads can help absorb vibrations, preventing them from transferring to the building structure or damaging the membrane. However, even with these measures, it is essential to ensure that the roofing system selected can withstand vibrations and punctures.
Ensure that your flat roof design includes safe access points. Installing guardrails and non-slip surfaces can improve workers’ safety on the roof. It’s important to plan for permanent and temporary access solutions that comply with safety standards, such as ladders, stairs, scaffolding, or hoists. Safety measures should also include fall protection systems, especially when workers are required to operate machinery on the roof.
Preventing damage
Once the flat roof is in situ it is vital to protect the surface from any damage that would breach the waterproofing function. This most often likely to occur when plant and equipment is being fitted. Operatives may not be aware of the need to fully seal any drill holes or access points made in the finished surface membrane to prevent any water ingress. Specially designed cable flashings are available to make passing cables through roofing membranes quick and easy whilst the integrated flange ensures no of risk leaks or water ingress. The roofing contractor will always be happy to advise on the best solutions and ensure these are installed correctly.
Including dedicated walkways on roofs requiring regular access for plant and equipment maintenance is advised as these can prevent wear and tear to the roof surface. They also provide easy access to the roof membrane for inspection and maintenance as well as to any cables and pipes that can be routed to run underneath these raised surfaces.
Functional flat roofs must have efficient drainage systems to prevent water accumulation. As with any roof (load-bearing or not), waterproofing layers, proper slope design, and high-quality waterproof membranes (see the section on materials above) are crucial in preventing leaks and moisture. Incorporating drainage solutions such as outlets and leaf guards can protect against water damage.
Regular maintenance and inspection help to ensure that the flat roof can stand the test of time. Once installed, it’s important to establish a routine maintenance schedule to address wear and tear promptly. This proactive approach can include undertaking routine inspections to check for signs of damage, such as cracks, leaks, or sagging areas, but should also include keeping the roof clean. Accumulated debris can hinder drainage and lead to water pooling, which can damage the roof structure. In addition to taking care of the roof itself, customers should schedule regular maintenance for the installed machinery – well-maintained equipment is less likely to cause structural stress or damage the roof.
Investing in high-quality materials and proper installation can lead to long-term savings. A durable, well-maintained roof reduces repair costs and extends the roof’s lifespan. Long-term savings should also factor in the reduced risk of operational disruptions caused by roof failures.
Functional flat roofs are an excellent choice for buildings needing to accommodate plant machinery. Through careful planning and design, selecting the right materials, focusing on proper installation, and planning for maintenance, installers can ensure the flat roof is up to the task. Looking for advice on the best solutions? Speak to the Lancastria team. We’re always happy to help.
Get in touch
Lancastria Group
(main office and hoist hire)
Unit J, Woodrow Way, Irlam,
Manchester, M44 6ZQ
Lancastria
(deliveries and collections)
Unit 8, Woodrow Way
Irlam, Manchester
M44 6ZQ
For deliveries and collections please go to Unit 8. On Woodrow Way, take the first right immediately around the corner from Howdens and Andrews Tiles. Our warehouse is the second unit. If you get to our main Lancastria office, you have come too far.
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