WESTFIELDS GROUP

With a total retail floorspace of over 150,000m² housing over 200 stores, Merry Hill is the eighth largest shopping complex in the UK. Developed between 1985 and 1990, in subsequent years the site has seen several expansion and renovation projects. One of these was the replacement of the 44,000m² flat roof, for which Everlast was appointed as the main contractor. 

Due to the scale of the project, it was agreed from the outset that the work would be carried out in approximately equal phases over an eight-year time frame. The shopping centre remained open throughout the works, which presented considerable logistical and Health & Safety challenges. 

Throughout the project we partnered with Tremco, suppliers of the BBA certified hi-therm dynamic roofing system used across the roof’s 44,000m². Offering superior movement and high elasticity, the products abrasion and tear resistance, impermeability, soft texture, and slip resistance created an extremely robust and durable finish. Our project design included removal of old cable containment trays and replacement with prefabricated Roof-Pro alternatives. These provide maximum stability and flexibility (allowing for future repositioning of cables) without penetrating the new roofing membrane. As part of the renovation we also coated existing gutters with a Liquid Waterproofing System (LWS).

Working in a live shopping environment called for close communication between all parties. We kept everyone informed of scheduled works and likely impacts via daily briefing meetings with the centre manager, and tenants received regular bulletins and visits from our site manager. We put extensive Health & Safety measures in place to protect customers, staff and the workforce both in and outside the centre and took steps to minimise other potential negative impacts on the retail environment. These included scheduling works that necessitated interruptions to the power supply or were noisy (such as stripping out old materials), outside opening hours.

All phases of the re-roofing works were completed in a timely and efficient manner and within the agreed eight years. A key element of our original proposal was that the material and workmanship warranty would apply from the start of phase one but the 20-year warranty period, covering the whole roof area, would begin when the final phase was complete. This in effect created an extended warranty spanning 28-years from beginning to end. 

“Merry Hill has worked with Everlast for a number of years,” commented the client’s Building Service Manager. “They provide great service at a great price, and we can rely on them to take care of everything on site and keep disruption to a minimum. They just get on with the job and know how to solve problems quickly.”

Everlast Group has worked on a variety of refurbishment and new build across all sectors