Re-Roofing Using Brazilian Natural Slates In Carlyon Bay

We recently completed a premium re-roofing project in Carlyon Bay, St Austell, installing stunning 500x250mm Brazilian natural slates combined with a professional three-layer torch-on felt system. This project showcases our expertise in working with high-quality natural materials whilst delivering superior weatherproofing performance.

Client Requirements

The property in Carlyon Bay required a complete roof replacement. The existing roof covering had reached the end of its serviceable life, with weathering and deterioration making re-roofing necessary to protect the property from Cornwall's challenging coastal climate.

Our client wanted a roofing solution that would provide exceptional longevity whilst creating a beautiful, traditional appearance. After discussing various options, we recommended Brazilian natural slates in the larger 500x250mm format, which would deliver both outstanding durability and striking visual impact.

Why Brazilian Natural Slates?

Brazilian natural slates offer remarkable characteristics that make them an excellent choice for properties in coastal locations like Carlyon Bay. These slates are quarried from some of the world's finest slate-producing regions in Brazil, where geological conditions have created stone with exceptional density and weather resistance.

We selected the 500x250mm size for this project because larger format slates create a bold, contemporary appearance whilst reducing the number of fixing points on the roof. This larger format also means fewer slates are needed to cover the same area, which can improve the roof's overall weather resistance by minimising potential water entry points.

Natural Brazilian slate is renowned for its low water absorption rate, making it particularly suitable for Cornwall's wet climate. The material's natural composition means it won't deteriorate from freeze-thaw cycles, and its colour remains stable over decades of exposure to sunlight and salt air.

The Three-Layer Torch-On Felt System

Whilst natural slates provide the visible, weather-resistant outer layer, the performance of any roof depends equally on the underlying waterproof membrane. For this Carlyon Bay project, we installed a professional three-layer torch-on felt system beneath the slates.

This advanced underlay system provides multiple levels of protection. The first layer acts as a vapour barrier, the second layer adds structural reinforcement, and the third layer provides the primary waterproof membrane. Each layer is applied using the torch-on method, which involves carefully heating the material so it bonds seamlessly to create a completely watertight barrier.

Roof Installation Process

Planning & Preparation

Before we could begin the re-roofing work, we carried out thorough planning and preparation. We arranged for scaffolding to be erected around the property, providing safe access to all areas of the roof and protecting the property and our team throughout the project.

We carefully removed the old roof covering, taking care to prevent damage to the underlying structure. This removal process also allowed us to inspect the roof timbers and battens, checking for any signs of rot or deterioration that might need attention before the new roof could be installed.

Structural Assessment

With the old covering removed, we assessed the condition of the roof structure. We checked all timbers for soundness, replaced any damaged battens, and made sure the roof deck was properly prepared to receive the new torch-on felt system.

This structural work is crucial. Even the finest slates won't perform properly if the underlying structure isn't sound. We take the time to get these foundations right, ensuring the new roof will deliver decades of reliable service.

Installing The Torch-On Felt Layers

Our team began by applying the first layer of the torch-on felt system. We started at the eaves and worked upward, carefully measuring and cutting each section to achieve the correct overlaps. The torch-on process involves heating the underside of the felt with a specialised torch, activating the bitumen adhesive so it bonds permanently to the substrate.

We applied the second and third layers using the same meticulous technique, offsetting the joints between layers to maximise waterproofing effectiveness. Each layer was allowed to cool and set before the next was applied, making sure optimal adhesion throughout the system.

Fixing The Brazilian Natural Slates

With the waterproof membrane complete, we began fixing the 500x250mm Brazilian natural slates. We started at the eaves and worked up the roof in courses, using traditional fixing methods that have proven their reliability over centuries.

Each slate was individually fixed using multiple copper nails, positioned to provide maximum hold whilst allowing for the natural thermal movement of the material. We carefully checked the alignment of each course, making sure straight lines and even spacing across the entire roof.

The larger format of these slates meant we needed to pay particular attention to the fixing technique. The weight and size of 500x250mm slates require precise positioning and secure fixing to guarantee they remain in place through Cornwall's sometimes severe weather conditions.

Ridge, Hip & Valley Details

Professional roofing involves much more than simply laying slates in straight courses. We paid careful attention to all the ridge, hip and valley details, areas where different roof planes meet and where proper detailing is crucial for weatherproofing.

We installed appropriate ridge tiles and hip details, making sure all junctions were properly sealed and weatherproofed. These finishing details are where craftsmanship really shows, and we take pride in achieving neat, durable results that complement the beauty of the natural slates.

Final Inspection

Throughout the project, we maintained rigorous quality control, checking our work at each stage. Once the slating was complete, we conducted a thorough final inspection, examining every area of the roof to verify that our work met our exacting standards.

We checked the alignment of the slate courses, the security of all fixings, and the proper sealing of all details. We also cleared the site completely, removing all waste materials and leaving the property clean and tidy.

The Completed Roof

The finished roof has transformed the property in Carlyon Bay. The rich, natural colour and texture of the Brazilian slates create a stunning appearance that will endure for generations. The combination of premium natural slates and our professional three-layer torch-on felt system provides outstanding protection against Cornwall's coastal weather.

Our client was delighted with the results. The roof not only looks magnificent but provides complete peace of mind, knowing that the property is protected by one of the finest roofing systems available.