Overview:

The roofing work, by Nevson Roofing, has seen the refurbishment of the old King’s School library and lodge house, which will now become six unique homes. The work forms part of a larger development, by PJ Livesey, which has seen the redevelopment of the former King’s School into 36 homes and a further 45 newly built homes and apartments.

Nevson Roofing undertook the complex restoration of the slate roof which, as a result of many extensions to the building, had a complex interconnected layout. This included a centrepiece, three extension wings, turrets, pediments and a bell tower all with changing pitches, differing roof heights and angles. The tight interweaving roof spaces created many challenges for the roofing contractors including working in a space only big enough for one person and slating vertically up a bell tower.

The contractors worked alongside AccuRoof, part of SIG Roofing, to source historically appropriate materials. Over 40,000 SIGA 32 slates were hand-laid using specialist hooks and copper nails to accommodate steep pitches and high wind exposure.

The result is a visually stunning and structurally robust roof that honours the building’s Gothic origins while meeting modern regulations. The craftsmanship and attention to detail exceeded client expectations, making the library a standout feature in the Kingsgate development.

Roofing product choice:

The Kingsgate Library project used:

• SIGA 32 slates, 500x250mm, 5mm thick, holed at 90mm – approx. 40,000 slates across 2,000m² of roof
• Code 5 and Code 6 lead for all box gutters, DPCs and detailing
• Timber for structural repairs, new wall plates and rafter foot replacements
• Rockwool insulation
• Proctor Roofshield felt
• Treated ply for strengthening steep-pitch areas
• Specialist copper nails, hooks and fixings for vertical and mitred slating
• 5000m2 SR Timber Premium Gold graded roofing battens 25x50mm

The original hall, which features a louvered bell-tower with spire rising from a slated shaft in the centre, and the headmasters lodge are both Grade II listed buildings. The protected nature of the building required products chosen to respect the building’s historic character while meeting modern performance standards, including fire, thermal and weatherproofing compliance. As a result, any work in the area must meet a high-quality of design and workmanship as required by Central Macclesfield conservation requirements.

The roofing contractors worked closely with Accuroof to choose a product which would match the original slates but also echo the heritage of the building. The decision was made to go with SIGA 32 which is suited for conservation areas due to its match to Welsh slate and its rustic-appearance which would enable the slate to blend in with the building as opposed to a completely flat slate.

The SIG Roofing branch in Liverpool supplied the materials including 5,000m2 of SR Timber PREMIUM GOLD® Roofing Battens and counter battens. These battens meet the specifications outlined in BS 8417:2011+A1:2014 (preservation of timber) and is graded according to BS 5534:2014+A2:2018. It is also one of the few battens that has passed assessment by the Code for Construction Product Information (CCPI).

Other materials on the roof included Proctor Roofshield, Code 5 and 6 lead to replace the box gutters, damp proof courses and detailing around turrets. Rockwool insulation was put underneath all the party walls.

Installation:

Due to difficult access and complex layout of the roof slating had to proceed from the top down, with slate-laying carefully coordinated around copings, windows, and abutments.

The team first tackled the turret. As with the rest of the building, the roof – comprising of fragile F1 felt and century-old battens – had to be stripped cautiously due to its age, its steep pitch and the difficult access. This required the team to remove the slates one at a time using cat ladders and safety harnesses. Once stripped the team covered it in tarpaulin before starting work on the timber repairs. Once the roof was battened, a breathable membrane and insulation was installed before the team started working on the slates.

The vertical pitch of the roof required a hook-and-nail fixing for the slates due to exposure to high winds. Fishtail soakers were used for mitred corners, with precise angle-cutting required to achieve tight joins. To finish the roof the team painted the wood fascia and installed the lead work detailing.

Once the turret was finished, the team could remove the scaffolding and then start on the main roof. To meet the conditions for this listed building, the roofing contractors replaced the box gutters with Code 5 and 6 lead. The walls, which had intricate kneelers, had to have lead Damp Proof Courses (DPC) which required the team to first remove all the coping stones. Their lead specialists then had to weld up and put the DPC into place before laying the slate.

The roof was finished with decorative ridge features and flush detailing to complete this exceptional restoration

Challenges:

Although accessing the main site wasn’t a problem, getting the contractors on to the individual sections of the roof were a key challenge.

The complex, interconnected layout of the roof included a centrepiece, three extension wings, turrets and pediments all with changing pitches, differing roof heights and angles. Before work started, the roofing contractors need to take a measured and planned approach to their slating work.

Due to the steep pitch of some of the roof areas, long rafter lengths and little room for material stacking, the slates had to be walked from the loading bays to the roof areas. A job that would normally only take 3 contractors, instead required a team of 10 – all working in a chain to remove the old materials and get the new materials onto the roof.

To ensure safety for the team, all the workforce had toolbox talks, on the dangers of the job and correct working methods. This was particularly important due to how the roof spaces interweave – it would only take a slate to be dropped from height to pierce and potentially cause serious harm.

Work began in November 2023 Nevson Roofing maintained a steady programme of progress, thanks to effective sequencing and a well-managed team of up to 10 operatives.

Budget management was achieved by sourcing all roofing components from SIG Roofing, allowing bulk purchasing under a single warranty and minimising procurement delays or compatibility risks.

Feedback from PJ Livesey highlighted the craftsmanship and attention to detail, exceeding the client’s expectations. The library now stands as a statement building within the wider redevelopment. Its roof is both authentic to its 1856 Gothic Revival origins and structurally robust to modern standards.

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