Case Study

Roof Restoration at the Old Smithy, Thorp Arch

Case Study: Roof Restoration at the Old Smithy, Thorp Arch


Project Location: Thorp Arch Estate, Boston Spa, Wetherby

The Smithy dates back to early C19 and is located on The Green in the centre of Thorp Arch, Wetherby. This building is Grade II listed for its special architectural and historic interest but in dire need of roof restoration.

Thorp Arch is known for its unique blend of high quality countryside and attractive historic village. The local Parish works hard to maintain the conservation area of the old village and sympathetically maintain the areas outside to retain the character of the Parish.

The Old Smithy is a single story property currently being used as a plumber’s store. It dates back to the early C19. and sited on the Thorp Arch estate.

Despite the property being Grade II listed, the roof the property was in a terrible state of disrepair, as can be seem in the below photographs, and in dire need of roof restoration.

 

Project Overview

The roof restoration works comprised of:

  • Carefully taking down the existing chimney stack in individual pieces and numbering these so they went back in the same positions.
  • Removing the existing slates and storing these at ground level in order of sequence.
  • Removal and disposal of the existing rooflight.
  • Removal of the existing timber rafters and the existing defective timber purlins. These were uses as templates in order to replicate a like for like timber structure.
  • Reuse of any timber purlins which were still structurally sound.
  • Levelling off the internal wall with a course of reclaimed brick and then install new timber wall plate.
  • Fixing new restraint straps internally down the internal face of the wall.
  • Reconstruction of the timber structure and new purlin as required, new rafters, new wallplate and new ridge plate.
  • Installation of new timber fascia boards
  • Installation of new cast aluminium guttering and new cast aluminium fall pipe.
  • laying new breathable felt and battens  across the roof structure.
  • Rebuilding the chimney stack with the existing stone.
  • Relaying the existing slates and source any reclaimed slate necessary.
  • Installation of new Velux conservation window
  • Installation of new lead flashings and new lead soakers around the chimney stack.
  • Re-bedding the ridge tiles and the verge ends with lime mortar.

The finished result of this roof restoration project is a testament to the skill of our roofers who have done an excellent job!

The Works

The roof restoration project involved a comprehensive sequence of carefully planned works to preserve the character of the building while upgrading its structural integrity. The process began with the meticulous dismantling of the existing chimney stack, with each stone numbered to ensure it was reconstructed exactly as before. The existing slates were carefully removed and stored in order, ready for reuse. A defective rooflight was removed and disposed of, along with the old timber rafters and purlins. These timbers were used as templates to craft a like-for-like replacement structure, reusing any purlins that remained structurally sound. The internal wall was levelled with a course of reclaimed brick, and a new timber wall plate was installed, along with internal restraint straps for added stability.

The timber structure was then rebuilt, incorporating new rafters, purlins, wall plates, and ridge plates as needed. New fascia boards were fitted, followed by the installation of cast aluminium guttering and downpipes. A breathable felt and batten system was laid across the roof, and the chimney stack was reconstructed using the original stones. The existing slates were re-laid in their original order, with additional reclaimed slates sourced where necessary. A new Velux conservation window was installed, along with new lead flashings and soakers around the chimney. Finally, the ridge tiles and verge ends were re-bedded using traditional lime mortar. The completed restoration stands as a testament to the craftsmanship and care taken by the roofing team throughout this detailed and sensitive project.

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