Center Parcs – Whinfell Forest

Built in 1997, the previous roof covering was a 27-year-old Sika® roof with an extensive aluminium rooflight system made of polycarbonate glazing. The roof and lights had started showing signs of significant deterioration including weather-related wear, defects, and concerns related to the integrity and thermal performance. We conducted a comprehensive drone and condition survey of the building to provide a detailed assessment.

The project involved many complexities including; working above a live swimming pool, the buildings accessibility to guests all day, the maritime climate, with high precipitation and strong winds, and the challenging roof shape, a curved design rising from six to 27 metres.

Successfully re-roofing such a sensitive building required collaboration with suppliers and stakeholders, specialist capabilities, detailed planning, and precise implementation to manage effectively.

The refurbishment involved stripping the existing rooflights, followed by the installation of 13 Marvault, Brett Martin rooflights ranging from 30m to 61m in length. The existing single-ply roof was overlaid with a seamless Sikalastic liquid cold-applied system. We also installed new lightning protection.

The project included important protective measures. For example, fall protection around the perimeter and safety netting with debris sheeting attached under the rooflights. Above the netting and debris sheets, a working platform was installed, comprising of twenty Youngerman boards. These were tied to the existing steel with plyboard covering.

Plyboard upstands were fitted to the underside of the gutters each side of the rooflight to mitigate any material entering the net. The platform allowed the team to replace up to 12m of rooflights a day. This meant the platform could be moved to the next working area through the night when the pool was closed by our rigging team.This allowed the installation team to work on the next section of the rooflight element of the project during daylight hours. Rope access technicians worked overnight to reposition the platforms for each new day.

This unique project was delivered successfully within a live, busy operational holiday environment and without disruption to the operations of Center Parcs, who now have a 20-year fully waterproofed swimming pool.

We ensured responsible procurement by sourcing roofing materials locally with Sika. Repurposed roof materials minimised waste and we raised £3,000 for three local charities, including our partner The Christie Charity.

Following the roof upgrade, Center Parcs has reduced gas heating usage by 11.14%, significantly lowering its operational/Scope 1 CO₂ emissions.

The work showcased our expertise across all areas of project delivery – risk and project management, leadership of specialist contractors, innovation, and quality workmanship.