Major Roof Refurbishment underway at Applemore Health & Leisure Centre
Makers Construction is currently carrying out an extensive roof refurbishment at Applemore Health and Leisure Centre in Hampshire, on behalf of New Forest District Council. The project, which began in early 2025, aims to enhance the building’s thermal performance, resolve long standing roof issues, and ensure the sustainability of the facility. This important work is being conducted while the leisure centre remains fully operational, ensuring minimal disruption to the public.
The roof structure of Applemore Health and Leisure Centre, covering 2,400m², had several issues identified during our detailed survey. The existing roof system consisted of a bituminous vapour control layer, 25mm PIR insulation, 13mm fireboard, 60mm PIR insulation, and a BUR system. This topped with a cold applied liquid system. Despite previous upgrades, the roof only achieved a U-value of 0.36 W/m²K, which fell short of current energy efficiency standards. Further inspection revealed visible fibreglass matting through the coating, indicating that the coating had not been applied to the required thickness. The fibreglass matt, being UV unstable, had deteriorated over time, compromising the integrity of the system. In addition, water ponding on certain areas of the roof had caused the coating to wear down quicker in these sections, further weakening the structure.
Additional challenges included the presence of ineffective mushroom vents installed in isolated areas by previous contractors. These vents were intended to help dry out the original roof build up but were not successful. Some areas of the roof had coatings applied directly over loose chippings, which caused cracking due to poor adhesion. Several upstands were found to be below the recommended 150mm height as per BS 6229:2018, creating a potential failure point for the waterproofing system.
To remedy these issues, Makers Construction has developed and is now implementing a comprehensive refurbishment plan designed to deliver a high-performance roof system that meets modern standards. The current roof system is being stripped back to the steel deck and replaced with 160mm PIR insulation across the primary field area and CTF insulation in the gutter zones. The CTF insulation in the gutter areas will create a gradual slope, ensuring that water flows efficiently towards drainage points, significantly reducing the potential for ponding. With this upgrade, the roof will achieve an impressive U-value of 0.15 W/m²K, greatly improving the building’s thermal efficiency.
The new roof system being installed incorporates a BROOF(t4)-rated multi-layered BUR felt system at the Leisure Centre. This cutting-edge solution that offers superior fire resistance and meets the highest performance classification for external fire exposure as per BS EN 13501-5. The BROOF(t4) system is specifically designed to withstand external fire risks while providing a robust and durable waterproofing solution for commercial roofs. This roofing solution is designed to provide enhanced durability and long-term performance. The system is backed by a comprehensive 20-year warranty, ensuring reliable protection and longevity for the facility
The removal of the existing roof structure is being carried out with careful attention to safety and logistical coordination. The existing waterproofing is being removed in sections and hoisted to the rear of the building using a designated hoist, ensuring that the debris is kept away from the public. The existing material is safely moved to a private, secured compound at the rear of the building, ensuring that it does not interfere with the public car park or the regular deliveries to the centre. Makers Construction worked closely with the management team at Applemore Health and Leisure Centre to determine the ideal locations for material storage and waste management to avoid any disruption to the day-to-day operations.
A significant part of the refurbishment is focused on improving the roof’s detailing, particularly the upstands to comply with modern best practices. Several upstands were found to be below the 150mm height recommended in BS 6229:2018. Makers is increasing the height of these upstands to ensure that the waterproofing system is properly sealed and protected. In addition, new trims, flashings, and edge details are being installed to ensure that water does not accumulate and cause further damage over time.
The project doesn’t just address the roof’s immediate structural issues, but is in line with New Forest District Council’s sustainability goals. The completed roof will serve as a platform for solar panels to be installed later in 2025. This is an exciting development as the existing roof structure was not suitable for the addition of solar panels due to its age and condition. With the newly installed high-performance roof, the centre will be able to take full advantage of renewable energy, reducing its carbon footprint and improving the centre’s long-term environmental sustainability. The solar panel installation will also support the energy needs of the centre, reducing its operational costs and increasing the building’s energy efficiency.
Makers on-site Management provides a wealth of experience in delivering complex roofing projects on live sites. The team is supported by Makers Senior Management ensuring that the work is being carried out to the highest standards. With their combined expertise, the project is progressing smoothly and is on track to meet all safety, quality, and operational goals.
The refurbishment project is being closely monitored for safety and quality throughout its duration. The Makers team are committed to maintaining high standards, with regular quality inspections carried out by the Roofing Team and Health & Safety Department to ensure that safety protocols are strictly adhered to with monthly audits and a focus on safe working practices, including working at height, material management, and dust and noise control.
“This refurbishment is about more than just fixing a roof, it’s about future-proofing a community facility that many people rely on,” said Simon Hollier. “By addressing long-standing issues and delivering a high-performance, BROOF(t4)-rated roofing system, we’re ensuring that Applemore Health and Leisure Centre remains safe, dry, and energy-efficient for years to come. The installation of solar panels later this year will further support the sustainability goals of the centre and help reduce its environmental impact.”
Working closely with New Forest District Council, Makers Construction is proud to contribute to the ongoing development and sustainability of Applemore Health and Leisure Centre. The project is progressing smoothly and remains on track for completion later in 2025 completion later in 2025