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Complex roof refurbishment at Eastbourne District General Hospital, improving insulation, drainage, and energy efficiency, all while working within a live hospital environment. Overcoming major design and logistical challenges, the project was completed to a high standard with a 20-year guarantee, showcasing expert collaboration and innovative problem-solving.
Eastbourne District General Hospital, built in 1977, has undergone several significant repairs over the years. Most recently, the aging roof required extensive attention, leading to the initiation of a major refurbishment project. The key concerns with the original roof, included its poor performance and insufficient insulation.
This project was awarded through a competitive tender process, with Veolia appointed as the main contractor. The roofing specification was expertly provided by Bauder, ensuring the technical requirements aligned with the project’s objectives for energy efficiency and environmental sustainability.
Bauderflex bituminous waterproofing was chosen as the solution for the roof refurbishment. To align with the project’s environmental goals, funded by the Carbon and Energy Fund (CEF), the refurbishment addressed the roof's lack of insulation. This was rectified with the installation of 120mm BauderPIR FA-TE flatboard insulation, delivering a U-value of 0.18.
In collaboration with Bauder, Clarke Roofing Southern Ltd and Veolia, a comprehensive plan was developed, incorporating core sampling, survey reports, U-value calculations, carbon savings analyses, detailed specifications, and solar PV designs. These elements were integral to Veolia’s successful bid to secure the project.
This project presented a series of complex design and logistical challenges that required innovative thinking to maintain functionality and minimise disruption—particularly important given the sensitive hospital environment.
A primary issue was ponding water in the gutters, which was resolved by installing tapered gutters to enhance water flow and drainage. Bespoke lead slates were also designed for breather vents penetrating the upstands, ensuring effective ventilation and preventing moisture build-up.
Areas housing plant equipment, which could not be relocated, demanded tailored design details to ensure these zones were fully integrated into the new roofing system.
During installation, unexpected complications arose. The original plan to use a de-chipper for asphalt chippings on the large roof had to be abandoned due to unacceptable noise and vibration levels that would disrupt hospital operations. The solution was to adjust the specification and lay recovery boards directly over the chippings.
Further logistical challenges included limited crane availability, which required precise scheduling and close coordination. This was especially critical for managing direct material deliveries from Germany, ensuring all components arrived in alignment with the installation timetable.
The completed roof system is backed by a comprehensive 20-year guarantee covering both product and workmanship. Quality assurance was maintained through over 30 interim inspections and regular site meetings involving Bauder, Clarke Roofing Southern Ltd, Veolia, and other stakeholders.
The new system has significantly improved the building’s thermal efficiency, reducing heating costs and cutting carbon emissions, successfully meeting the environmental targets set by the Carbon and Energy Fund (CEF).
This project stands as a strong example of effective collaboration, strategic planning, and adaptability, delivering a high-performance result with minimal disruption to hospital operations.
Read more about this project in our blog.