In April 2023, we completed the rehabilitation of a metal roof at Zeugma’s industrial facility in Mafra. This intervention aimed to reverse recurring leaks and improve the building’s thermal performance, while aligning the entire solution with the previously installed systems (ETICS façade) — a technical challenge that demanded precision and rigor.
Challenges and Requirements
Identify and eliminate multiple water ingress points in the metal roof.
Ensure a watertight and continuous joint between the roof and the façade already rehabilitated with the ETICS system (“cappotto”), since this connection previously lacked proper finishing, putting the façade system’s integrity at risk.
Present a lightweight solution to avoid overloading existing structures, considering the metal sandwich panel as the roof base.
Eliminate visible joints and fixings found in traditional metal finishes, ensuring aesthetic and functional continuity with added protection against leaks.
Adopted Solution
Installation of PIR (polyisocyanurate) thermal insulation boards over the existing roof to optimize thermal performance and energy efficiency.
Application of KÖSTER’s 1.5 mm TPO membrane as the final waterproofing layer, ensuring continuity, watertightness, and durability.
Integration of a continuous drip-edge flashing profile in TPO-coated rolled steel, inserted into the system in a watertight manner, eliminating joints and visible fixings of traditional finishes.
Additional adjustments and accessories to ensure compatibility with existing elements and compliance with the technical specifications.
Results and Benefits
Complete elimination of leaks in critical areas, providing long-lasting protection against water ingress.
Significant improvement of the roof’s thermal behavior, reducing heat loss and optimizing indoor comfort across seasonal cycles.
Continuous, joint-free finishes at the façade interfaces, ensuring enhanced watertightness and aesthetic integrity.
The proposed solution respected structural constraints, being lightweight and fully compatible with the existing roof, with no need for additional reinforcement.
The client appreciated the rigorous execution, system reliability, and the safety provided by the new roof.
BEFORE REHABILITATION
FINAL RESULT
This project highlights our ability to combine technical requirements, aesthetic integration, and durable solutions — every detail designed to ensure performance and longevity.
Learn more about this project here.
