A major flat roof refurbishment at the Bede Museum in Jarrow has delivered a long-term solution to persistent water ingress issues on a complex, multi-level roof, while keeping the landmark venue fully operational throughout the works.

Completed in 2001, the museum forms part of the wider Jarrow Hall complex on the south bank of the River Tyne. Designed in a classical architectural style, the building includes a flat roof arrangement with multiple levels, an impluvium designed to collect rainwater, and numerous rooflights. By the 2010s, the roof had begun to fail in several locations, prompting South Tyneside Council to commission a full condition survey and replacement strategy.

Following the securing of Arts Council funding, works began towards the end of 2024 on what would prove to be a technically demanding refurbishment carried out on a live public site.

Survey and early challenges

The existing roof was an inverted single ply system incorporating 80mm XPS insulation and between 30mm and 75mm of river-washed pebble ballast. According to AccuRoof specification manager Martin Quigley, the extent of the ballast created early design challenges.

“It was clearly in need of a complete replacement, but with so much ballast it was difficult to design the replacement before the ballast was stripped off,” he said.

An initial tapered insulation design and budget estimate were prepared with contingency allowances. Structural advice indicated that removal of the ballast could result in roof movement, meaning final levels would need to be confirmed once the deck was exposed.

Drainage presented a further complication. The roof discharged through 20 outlets concealed within both internal and external walls, many of which were already leaking. Opening up the structure to replace them would have required intrusive and costly works. AccuRoof’s technical team worked with the council to develop an alternative drainage strategy, diverting rainwater externally and connecting into existing underground drainage runs.

Live site delivery

The strip-out and replacement works were delivered by AccuRoof registered contractor John Flowers Flat & Industrial Roofing Ltd, operating under South Tyneside Council’s flat roofing framework. The contractor was already familiar with the constraints of the site, which required continued access for school groups and visitors throughout the programme.

Contracts manager Gavin Hunt said the specification and support were key factors.

“The specification was from a reputable manufacturer, SIG AccuRoof, who are well established in the region. We knew we could rely on them for technical support,” he said.

The confined site ruled out large mechanical handling equipment, requiring around 400 cubic metres of river pebble ballast to be removed manually. A full perimeter scaffold, ramp and waste chute were installed, and additional local labour was brought in to maintain progress.

Oliver Wilson, building surveyor at South Tyneside Council, praised the site team’s approach.

“The team on site were fantastic. Because the site didn’t allow for any larger machinery, they had to shovel and wheelbarrow the pebbles into eight-yard skips day after day until it was removed.”

Roofing system and detailing

Once the roof deck was exposed, levels were remeasured and the tapered insulation layout revised. The replacement build-up comprised a SIGnature 25 torch-on reinforced bitumen warm roof system, incorporating the revised drainage design.

New rooflights were installed throughout, including triple-skin insulated domes to improve thermal performance. Existing stone copings were retained and encapsulated with bespoke aluminium flashings, providing a durable edge detail while maintaining the building’s appearance.

AccuRoof provided ongoing technical support during the installation, with weekly progress meetings and regular site visits from field technician Billy Lavender to assist with detailing queries and inspections.

Project outcome

Despite the complexity of the roof and the number of unknowns at the outset, the project was completed close to the original tender value and without disruption to the museum’s operation.

Reflecting on the works, Oliver Wilson said collaboration was critical.

“Don’t be overwhelmed. If you have a good team of people, you can work together and come up with solutions. It might take longer, but the outcome will be better.

“There were a lot of unknowns, but we came up with a plan and it hasn’t made much difference to the overall cost outcome, which is close to the tender returns. That’s a much better outcome for us.”

He added:
“Health and Safety were surprised we didn’t have any problems, which is a great sign, and I’m over the moon with the result. The building looks much better than it did previously. The perimeter cappings look almost to a military standard. It’s an amazing transformation.”