Modular roof system makes engineering challenge simple

Smartroof, a provider of offsite manufactured, modular ‘room-in-roof’ systems, has completed its largest and most complex single house project to date as part of a new property in Northamptonshire. Specify & Build reports. 

Located in a picturesque Northamptonshire parkland setting, this arts-and-crafts styled home presented unique engineering challenges and logistical site issues that complicated the roofing requirements from the start. This included complex design requirements, limited site access, and proximity to an airfield that meant any crane use had to be pre-approved. 

The project, carried out for developer Clayson Country Homes, was designed by architects LMR Designs and included several architectural features. Smartroof’s solution centred on the collaborative effort between its design team, the architect and developer, and structural engineer Simply Structural Engineering.  

A distinctive feature of the roof was the integration of multiple working chimneys which, along with custom-designed steel beams supporting the roof cassettes, designed by Smartroof, added complexity to the manufacturing and installation of this hybrid roofing system. 

Adding drama with a vaulted ceiling 

Each roof section and cassette were unique, requiring precision in manufacturing, transport, and synchronised installation. The intricate design involved multiple levels, styles and stages incorporated in the build. The vaulted ceilings, which included a dramatic full height vaulted ceiling reaching 4.8 metres in height, necessitated roofing sections with in-lay valleys and hidden box gutters. 

Throughout the project, close collaboration was crucial between Smartroof, the developer, and the site engineers. Regular meetings and site visits were conducted to verify measurements, discuss emerging challenges and ensure the solutions were fit for purpose. This ongoing communication and flexible approach to design and manufacturing allowed Smartroof to adapt to any unforeseen issues and keep this ambitious project on track. 

All project components were designed by Smartroof and manufactured in its state-of-the-art production facility in Derbyshire. The offsite manufacturing process offered significant advantages including enhanced precision and quality control, improved health and safety, and the minimisation of material waste. By prefabricating as much as possible, the Smartroof system significantly reduced on-site construction time and improved overall safety during installation. The efficient use of the limited site space was essential, with close monitoring of the crane placement and layout by all teams making the installation smoother. 

“This was one of our most ambitious housing projects to date,” said Smartroof’s Head of Contracts, Jamie Bremner. “The complexity of this site demanded proactive communication between engineers, designers and site managers. With the limited availability of cranes, our design approach provided an effective solution, ensuring the project remained on schedule without compromising on quality. This collaboration demonstrated the expertise and adaptability of team Smartroof, delivering exceptional results under challenging circumstances.”  

The completed project exemplifies Smartroof’s capabilities in delivering complex challenges through innovation, collaboration, and expertise, providing a bespoke solution that addressed multiple architectural and logistical challenges. 

www.smartroof.co.uk