Iplex Manufacturing Facility – 11,000m² Industrial Roof Replacement
Brendale, Queensland | Fletcher Group | Commercial & Industrial Roofing
11,000m2
Industrial roof replaced
Zero
Reported safety incidents
2 Weeks
All 11 production lines operational
Zero
Warehouse downtime
Project at a Glance
Project Detail
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Client
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Project
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Location
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Roofing Contractor
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Appointed Builder
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Roof Area
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Facility
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Pre-Construction Planning
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Critical Shutdown Window
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Safety Outcome
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Warehousing disruption
Information
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Fletcher Group
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Iplex Manufacturing Facility Re-Roof
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Brendale, Queensland
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Aurem Cladding & Roofing
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Ryza Construction
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Approximately 11,000m2
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Manufacturing Warehousing & Offices
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6 Months
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2 Weeks
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Zero Reported Incidents
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Zero Operational Downtime
The Challenge – Replacing a Deteriorated Roof Above an Industrial Production Facility
The existing galvanised Spandek roofing system had reached an advanced stage of deterioration.
Widespread rust and corrosion had compromised significant areas of roof sheeting, while redundant penetrations, deteriorated flashings and ageing drainage infrastructure were contributing to persistent water ingress.
The existing box gutter system also presented substantial deficiencies, including corroded gutter sections, inadequate sumps and insufficient overflow provisions.
Further challenges were identified within the supporting roof structure, where sections of steel purlins had experienced severe corrosion.
The original roofing assembly also lacked thermal insulation and underlying roof safety mesh.
These problems extended beyond routine building maintenance. Roof leaks during rainfall events were affecting manufacturing operations and introducing ongoing health and safety concerns within the production environment.
A complete roofing and associated building-envelope upgrade was required to provide a reliable long-term solution.
Six Months of Planning. One Critical Shutdown Window.
With 11 production lines operating beneath the roof, project planning was essential.
Pre-commencement discussions began approximately six months before works commenced, allowing Aurem, Ryza Construction and the relevant stakeholders to develop an installation strategy around Iplex's operational requirements.
Five construction staging plans were drafted and revised, with a primary focus on progressively returning manufacturing areas to operation ahead of scheduled handover milestones.
Multiple construction methodologies were also reviewed to address working at height, exposed roof areas, structural loading restrictions, crane operations, material movements and the interaction between construction crews and facility personnel.
A coordinated three-team installation strategy was selected as the most effective approach.
The Installation Methodology – Three Teams Working in Coordination
Dedicated Box Gutter Team
The first team was responsible for the replacement of deteriorated box gutters, following behind the main roofing crews as new roof areas were completed.
Main Roof Replacement Team
The second team consisted of eight installers, initially divided into two groups.
One group systematically stripped the existing roof sheeting using the planned harness-based fall-protection arrangements. Removed sheets were stacked into controlled bundles for crane removal.
The second group followed immediately behind, installing galvanised roof safety mesh across the exposed structure.
Once an approximately 11-metre-wide roof bay had been stripped and meshed, the full installation team combined to install cut-to-length Fletcher Permatuff roof insulation and new Stramit Monoclad roof sheeting.
This progressive installation sequence achieved an average output of approximately 350m² per day for the team.
Opposing Roof Replacement Team
The third team mirrored the same installation methodology on the opposing side of the warehouse.
Separating the major roofing work fronts maintained distance between exposed roof openings while allowing multiple areas to progress simultaneously.
Overcoming Structural and Logistical Constraints
One of the project's greatest technical challenges was the limited capacity of the existing roof structure to accommodate material loads.
With areas of corroded purlins identified, conventional stockpiling of roof sheeting bundles was not achievable.
A controlled crane lifting methodology was implemented, with one bundle of removed roofing material lifted down before a corresponding bundle of replacement roofing was lifted onto the structure.
Safe access was established using scaffold stair towers at the front and rear of the building, supplemented by a 45-foot stick boom lift and a 43-foot rough-terrain scissor lift for designated elevated access and material handling activities.
The facility's external yard remained active, with high volumes of trucks and forklifts servicing warehousing and distribution operations.
Careful coordination of construction zones, material deliveries, mechanical lifting and site access was essential to maintaining operational continuity.
A Complete Roof and Building-Envelope Upgrade
The project scope extended well beyond the replacement of existing roof sheeting, incorporating a comprehensive range of roofing, cladding and drainage improvements.
New Roof Sheeting
The original galvanised Spandek roof was replaced with 0.48mm Stramit Monoclad Zincalume sheeting, providing a renewed primary roof covering.
Custom Roof Flashings
New 0.55mm custom-folded Zincalume flashings were installed to accommodate the building's roof junctions, transitions and termination details.
Wall Cladding and Weatherproofing
New 0.48mm Monoclad wall cladding in Zincalume and Pale Eucalypt finishes was incorporated, with sarking barriers installed behind the cladding to provide an additional layer of weather protection.
Roof Drainage Upgrades
The project included new 0.8mm Zincalume box gutters, replacement eaves gutters, improved sumps, rainheads, expansion joints and associated rainwater drainage components.
New 150mm PVC spreaders and downpipes were also incorporated into the rainwater discharge system.
Roof Ventilation
Approximately 140 linear metres of vented ridge were installed, introducing dedicated roof-level ventilation pathways.
Roof Safety Mesh
Galvanised roof safety mesh was incorporated into the new roofing system, addressing the absence of mesh beneath the original roof.
Thermal Insulation
Fletcher Permatuff R1.3, 55mm MD building blanket was installed beneath the new roof sheeting, improving the roof assembly's thermal resistance compared with the original uninsulated system.
The Result – Early Production Handover and Zero Warehouse Downtime
The success of the Iplex project was measured not only by the extensive roofing upgrade but by the ability to deliver the works around the facility's operational requirements.
Through careful planning and coordinated execution, approximately half of the manufacturing lines were returned to operation within the first week of the scheduled shutdown.
By the end of the second week, all 11 manufacturing lines were back in operation.
Importantly, warehousing and distribution activities continued without operational downtime throughout the roofing project.
The works were delivered ahead of planned program milestones, with zero reported health and safety incidents.
The completed roof and building-envelope upgrade provided several important improvements:
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Elimination of recurring leaks: The deteriorated roofing system was replaced, addressing persistent water ingress issues affecting production.
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Improved thermal performance: New roof insulation increased the thermal resistance of the building envelope.
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Enhanced weather protection: New roofing, custom flashings and wall cladding sarking barriers improved the building's resistance to water ingress.
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Upgraded stormwater management: Replacement gutters, sumps, rainheads, expansion joints and drainage components improved roof water collection and discharge arrangements.
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Renewed building infrastructure: New roofing, wall cladding and associated systems replaced ageing and severely deteriorated components.
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Warranty-backed workmanship: The completed roofing works were supported by Aurem's installation warranty.
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The project also demonstrated the value of collaboration between Aurem Cladding & Roofing, Ryza Construction and Iplex's operational stakeholders.
Ryza Construction's effective management and coordination contributed to the successful delivery of the project within a demanding manufacturing environment.
Delivering Complex Commercial Roofing Projects With Confidence
The Iplex manufacturing facility reroof stands as a significant example of Aurem Cladding & Roofing's capability to deliver large-scale commercial and industrial roof replacement projects.
Combining 11,000m² of roofing works with complex structural constraints, intensive construction staging, ongoing industrial logistics and critical manufacturing shutdown requirements, the project demanded far more than standard roof installation expertise.
The outcome reflects the importance of detailed pre-construction planning, disciplined project execution and close collaboration between contractors, builders and facility operators.
For Fletcher Group and Iplex, the completed project delivered a renewed, warranty-backed roofing system designed to support the long-term operation of the facility.
Commercial & Industrial Reroofing Specialists – Queensland
Is your warehouse, factory or commercial facility experiencing persistent roof leaks, deteriorated roofing or inadequate drainage?
Aurem Cladding & Roofing specialises in large-scale commercial and industrial roofing solutions throughout South East Queensland.
We understand that replacing a roof on an operational building requires careful planning, safe construction methodology and a commitment to minimising disruption.
From initial assessment and construction planning through to installation and project handover, Aurem delivers commercial roofing solutions tailored to the demands of your facility.
Contact Aurem Cladding & Roofing to discuss your commercial or industrial roof replacement project.