The client had recently completed construction on a brand-new commercial office facility. Unfortunately, shortly after opening, significant roofing issues became apparent. Poorly designed water drainage around roof gulleys and air vents caused severe leaks, affecting three critical areas: a warehouse, an administrative office, and a specialist cosmetics laboratory.
These leaks posed considerable health and safety risks, forcing the closure and cordoning-off of key operational areas. With limited internal expertise to tackle such complex issues, the client granted Excel Roofing full authority to assess the situation and implement appropriate, effective solutions.
Project Approach & Solution
Excel Roofing swiftly carried out a detailed site inspection, diagnosing critical design flaws leading to inadequate drainage and standing water on the roof. Recognising the urgency, Excel devised an innovative, tailored solution:
First, the existing steel roof sheets were precisely cut and modified, altering the roof’s slope and dramatically improving water flow. Flat steel sheeting was strategically installed to further facilitate drainage and prevent standing water from accumulating.
Excel then undertook an extensive waterproofing exercise, custom-moulding approximately 100 metres of robust fibreglass gutter lining to fully seal and eliminate gutter leaks. Given fibreglass moulding’s sensitivity to temperature, Excel Roofing carefully managed material handling and curing processes—successfully overcoming challenges posed by intense summer heat. Rigorous scheduling ensured fibreglass application occurred during optimal periods of the day, guaranteeing maximum effectiveness and durability.
This meticulous approach permanently solved the underlying water management issues, ensuring no recurrence of leaks.
Execution & Impact on Operations
The entire repair and waterproofing project was executed swiftly and efficiently in just three full working days, without any internal disruption. Excel’s meticulous planning and communication allowed the business inside the building to continue uninterrupted, protecting productivity and minimising financial impacts.
The immediate result was reopening all previously closed-off operational areas, quickly restoring the client’s full facility use and normal workflow.
Outcome & Benefits
The facility now benefits from a highly effective, long-term waterproofing solution. The innovative fibreglass-lined gutters and newly adjusted roofing structure guarantee leak-free performance for decades. Employees, management, and other stakeholders reported immediate improvements in operational confidence, comfort, and workplace safety, alongside the reassurance that future disruptions are highly unlikely.
Shortly after completion, the client confirmed that the new roofing solutions had passed a practical ‘real-world’ test: heavy summer rainfall confirmed the repairs were robust and effective, completely resolving all previous leaks.
Additionally, the solutions implemented by Excel have simplified roof maintenance, providing clearly defined drainage pathways and reducing future inspection complexity. The cosmetics laboratory—previously at risk due to its sensitive nature—also benefited from a secure, contamination-free environment.
Cost & Budget
The project was quoted at a fixed price and delivered precisely to budget, reflecting Excel Roofing’s accuracy, transparency, and reliability in project costing and execution. This fixed-price commitment provided clear financial predictability for the client, removing concerns of unforeseen expenditures or hidden costs.
Lessons Learned & Client Feedback
This project reinforced several important insights for Excel Roofing. Notably, the importance of precise scheduling around weather-dependent materials like fibreglass was highlighted, leading to improvements in internal planning procedures for future projects. Excel Roofing now incorporates enhanced scheduling flexibility to better respond to temperature fluctuations and other environmental variables.
Client feedback was overwhelmingly positive, with specific praise given for Excel’s proactive communication, technical creativity, efficiency, and overall professionalism. The client particularly appreciated Excel Roofing’s autonomy and decisiveness, solving complex issues independently and with minimal burden on their own resources. This allowed the client’s management team to remain focused on core business activities, confident in Excel’s capability to deliver.
The client summarised their experience positively: “We’ve had plenty of rain to test the solution—and it’s all good. We’re very happy with the result and impressed with Excel’s innovative approach.”
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