Project Merlin

Project Name: Project Merlin Location: High Peak, Derbyshire Products: IKO Armourplan Roofing Contractor: Pochin Construction Architect: Fletcher Rae Architects

Waveform roof structure blends with High Peak’s rolling scenery

Armourplan PVC and Recticel Insulation by SIG Design Technology were selected for a 12,000 m2 roof to a bottling plant in a rural location on the outskirts of an historical Derbyshire spa town, known as Project Merlin.  The FMCG company chose to build the new facility away from the site of the natural spring, piping the water some two miles out of town to this green field bottling and distribution site.

To ensure the roof at Project Merlin blended seamlessly with the breathtaking High Peak scenery, local planners choose a membrane finish to be manufactured in a special order-only colour:  bottle green.

They also suggested the product could be locally manufactured and chose Armourplan PVC as it is produced by IKO near the town made famous for its twisted spire, Chesterfield, in the north of the county.

The project was constructed on a Design & Build basis by Pochin Construction of Middlewich, Cheshire. Designed by Fletcher Rae Architects of Manchester, the elegant roof form comprises a series of four barrel vaulted roofs which create a ‘waveform’ effect with a sleek finish.

Each of the roofs was constructed independently by building envelope contractors GM Services of Stockport. There is a perimeter zone to all of the barrel vaults and the roof construction is joined at the three gutters between.

The roof build-up comprises a metal deck with vapour control layer and Recticel foil-faced insulation boards. Lamella boards were used at the top and bottom of the curves and the building is waterproofed in Armourplan Premium PVC single ply membrane.

Armourplan ‘P’ incorporates UV-stability on both upper and lower surfaces, enhancing mechanical properties and performance characteristics. Superior functionality allows the use of wider membranes where required, reducing the number of fixings and enabling rapid installation.

Armourplan is the only UK produced single ply, and is solely distributed through SIG Design & Technology.

Project Merlin case study