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Innovative Warm Roof Over Inverted Tray for Pāpāmoa Surf Rescue Base

The new Pāpāmoa Surf Rescue Base is a timely addition for the Pāpāmoa Surf Life Saving Club, which following population growth now services almost 30,000 people in the community. The building was made possible through community fundraising and donations from local businesses, including GJ Gardner who built a charity house, with all proceeds donated to the surf club for the build.

With such generous support behind the build, Jigsaw Architects looked to specify durable, high-performance materials which would serve the club for many years to come, while also being sensitive to budget constraints. For the 1000m² roof, a resilient system that would provide thermal performance without risk of corrosion was required.

Initially a timber framed roof with a torch-applied bitumen roof was considered, but following discussion with the Ardex team a more innovative approach was considered. Instead of using ply substrate, an inverted tray deck from Dimond Roofing was specified along with Ardex’s Firestone UltraPly TPO membrane system.

A first for the Ardex team, the inverted tray deck warm roof solution was the perfect choice for the surf club, providing the higher thermal performance that a warm roof offers at a lower overall build cost due to the substrate dramatically reducing framing requirements — from 400mm spans to 4m spans.

“The ability to move from a plywood framed roof system to a large span tray warm roof system while reducing the overall build cost forecast was a huge benefit for the design team who were facing budget constraints,” says Steve Miles, Specification Manager, Ardex. “And as a community project, it was great to see the surf club receive the benefits of a high-performance warm roof.”

“The coastal location right on the beach meant a standard metal or tin roof would have had big disadvantages in terms of thermal performance and durability,” says Steve. “The Ardex TPO system offered the benefits of a warm roof but also a membrane that resolves those corrosion issues.”

An energy-efficient membrane ideal for large roof areas, Firestone UltraPly TPO is heat reflective and resistant to shrinkage and cracking from UV radiation and ozone exposure, making it a smart choice for the beachfront build. “Firestone TPO is an incredibly reliable choice,” says Steve. “It offers superior UV resistance which is critical in such a harsh UV environment.”

The Ardex team worked closely with Jigsaw Architects and Project Lead Jason Benton to ensure accurate detailing of the roof, and provided support on site for installers Arid Technologies. “We like to be involved right through from the specification stages of the project through to completion to ensure a positive outcome for everyone,” says Steve. The high level of organisation by all parties involved meant that installation of the membrane roof went very smoothly.

Steve commends Arid Technologies for the high-quality install, “Arid Technologies are Ardex trained installers and the quality of workmanship they provide is to a very high standard,” he says. “They are a market leader for membrane installs in the bay, and have a very good reputation.”

“For us that quality and reputation are key,” he adds. “We not only supply a high-quality product but we also work with good installation businesses to ensure the success of the project.”

The longevity and reliability of the inverted tray warm roof is backed by a 20-year system warranty which covers right from the inverted metal tray deck to the TPO membrane and everything in between.

The end result is a stunning club building with an innovative warm roof system from Ardex that ensures trusted thermal performance and durability. The building was also shortlisted for a 2021 NZIA award for Public Architecture in the Waikato and Bay of Plenty region. “I’m really happy with the outcome. It looks sensational,” says Steve. “It's been a pleasing project, and as a Pāpāmoa local, one I’ve really enjoyed being involved with.”

Project credits:
Architects: Jigsaw Architects
Contractor: Naylor Love
Membrane installer: Arid Technologies

View more information on ARDEX, including contact details.
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