Cookson's Consultancy Ltd

Cookson's Consultancy Ltd Roofing industry experts backed by over 25 years experience. Specialising in flat roofing and pitched metal roofing.

The importance of core samples. Or, more specifically, knowing when not to take one.There is a lot of talk in surveying ...
18/06/2026

The importance of core samples. Or, more specifically, knowing when not to take one.

There is a lot of talk in surveying circles about core samples. And rightly so.

In most flat roof investigations, core samples are incredibly valuable. They can confirm the roof build-up, identify trapped moisture, expose hidden defects, and give the client evidence that a surface-level inspection cannot.

In many cases, I would say they are essential. But not always. And this is where experience and independence matter.

I recently inspected a two-level flat roof that, on paper, had all the ingredients for a more invasive investigation: single-ply membrane, reported woodwool deck construction, ponding water, previous concerns, questions over the build-up, and a scope that allowed for core samples.

It would have been easy to arrive on site, cut holes in the roof and say, “That’s what we were asked to do.” But that is not surveying. That is following a process without thinking.

Once on the roof, the picture was different. The single-ply membrane was generally well installed. The laps were checked and no significant delamination was found. There were no reported active leaks. The moisture mapping did not identify elevated readings to the accessible mapped areas.

The main issues were not hidden within the roof build-up. They were on the surface: blocked outlets, vegetation, debris, a gutter that could not discharge properly, a slipped downpipe partially restricting an outlet, and localised mastic and masonry defects.

In those circumstances, cutting into the roof would not have added value. It would have added risk. Every core sample is an opening through the waterproofing. Yes, it can be repaired, but it is still a deliberate breach in a roof that, based on the evidence, was performing reasonably well.

That is the bit that sometimes gets missed. Core samples are not a badge of thoroughness. They are a tool. A very useful tool, but still a tool. The skill is knowing when to use it, where to use it, and when the evidence says it is not justified.

Had this been a “free survey” from someone with a system to sell or a job to win, I suspect the answer may have been different. The ponding might have become a reason to overlay. The woodwool deck might have become a reason to strip. The blocked outlets might have been treated as a symptom of failure rather than a maintenance issue.

But the independent answer was much simpler: retain the roof, clean it, clear the outlets and gutters, carry out localised repairs, and maintain it properly.

Not every roof with ponding water needs replacing. Not every roof with a concerning build-up needs cutting open. Not every survey needs to end with the most invasive option.

Good surveying is not about doing the maximum amount of investigation possible. It is about doing the right amount of investigation, based on evidence, risk and judgement.

Sometimes that means taking core samples. Sometimes it means knowing when not to.

The client didn’t want a full roof replacement.The roof didn’t care.That was the situation on a recent high street retai...
12/06/2026

The client didn’t want a full roof replacement.

The roof didn’t care.

That was the situation on a recent high street retail property where we were asked to provide an independent flat roof assessment.

The question was simple:

Can it be repaired, refurbished, or does it need replacing?

Getting the answer was less simple.

The building was in a pedestrianised town centre location, with no suitable rear access for a MEWP. Before we could inspect the roof, we had to liaise with the local authority, arrange out-of-hours access, coordinate a cherry picker, and carry out the survey after trading hours.

That is often the unseen part of roof consultancy.

Once on the roof, the defects were familiar:

Aged built-up felt.
Poor falls.
Vegetation around outlets.
Defective perimeter details.
Failed upstands.
Ponding.
Internal evidence of water ingress.

There was also a woodwool slab deck beneath the waterproofing, which meant any recommendation had to be carefully considered.

This was not a roof where “patch the leaks” was a sensible long-term answer.

But it also was not automatically a full strip and replacement.

Core samples were dry at the locations tested, which meant the deck may still be suitable for retention.

The technically preferred solution was a warm roof overlay, subject to structural confirmation, incorporating a vapour control layer, insulation, improved falls and a new waterproofing system.

That would deal with the roof properly.

But, the client had lease constraints and needed to understand whether targeted repairs could reduce the immediate risk of water ingress in the short term.

So we prepared a targeted repair specification and pricing schedule.

Not “price some repairs”.

A defined scope:
Outlet refurbishment
New perimeter trims
Felt repairs
Upstand detailing
Gutter works
Access requirements
Caveats and exclusions

Because vague scopes lead to vague prices.

And three vague prices are almost impossible to compare.

A clear specification protects the client, helps contractors price fairly, and makes the risk visible.

That is where independent roof consultancy earns its keep.

Not by telling every client they need a new roof.

And not by pretending tired waterproofing can be magically fixed with a few patches.

But by giving a clear, evidence-based route forward that reflects the roof condition, construction, budget, lease position and risk.

Sometimes the answer is replacement.

Sometimes it is refurbishment.

Sometimes it is a carefully caveated interim repair strategy.

The skill is knowing which is which.

If you are responsible for a commercial roof and need independent advice before committing to major spend, Cookson’s Consultancy can help you understand your options.

Water ingress during major roof refurbishment works is not always entirely avoidable, particularly on older industrial r...
11/05/2026

Water ingress during major roof refurbishment works is not always entirely avoidable, particularly on older industrial roof systems already suffering from age-related deterioration and historic defects.

The important thing is how those issues are investigated, understood, and addressed.

As part of ongoing dilapidations works to an industrial unit in Telford, we recently carried out joint flood testing and specialist dye testing in conjunction with RPMG following reports of water ingress during rooflight replacement works.

The building was already experiencing leaks prior to the commencement of the wider remedial programme, which includes:

🔹rooflight replacement
🔹replacement fixings
🔹cut edge corrosion treatment
🔹localised roof repairs

Controlled water testing was undertaken as part of the contractor’s due diligence process to identify the precise source of ingress and to confirm whether water was tracking internally through the existing roof construction.

In one area, dyed water applied to a single defect within the roof sheet resulted in two separate internal leak points, confirming water tracking along the purlin before discharging internally.

Further investigation also identified loose fixings and localised perforations around previously deteriorated cut edge corrosion areas, allowing additional remedial works to be targeted before completion.

This is exactly why proper investigation matters on refurbishment projects. Industrial roof systems rarely fail in one simple location, and understanding the true route of water ingress is critical before repairs are finalised.

Good roofing projects are not about pretending defects never occur during complex refurbishment works. They are about identifying issues quickly, understanding the cause correctly, and implementing appropriate remedial action before completion.

Cookson’s Consultancy regularly supports landlords, contractors and surveyors with independent investigations, defect diagnosis and refurbishment advice on ageing industrial roof systems.

04/04/2026

Another roof that has well and truly earned its keep.

I was carrying out a condition survey this week on a mixed commercial and residential property ahead of a new lease. The building has two roof areas:

• A lower roof that was overlaid with a 3-layer pour-and-roll felt system
• A higher level terrace finished in mastic asphalt

The interesting part is the history you can see in the build-up.

The original construction appears to be a concrete deck with around 50 mm of cork insulation and 20 mm of asphalt. At some point, likely in the 1990s or earlier, the lower roof was overlaid with additional cork insulation and a felt system.

That tells us something important.

If the felt overlay dates from the 1990s, the original asphalt beneath it could easily be from the 1970s or even earlier. That’s decades of service from the same waterproofing system.

That’s why mastic asphalt has such a strong reputation in the industry when it’s installed properly.

Of course, time eventually catches up with every roof. On this one we’re seeing typical age-related defects, including:

Cracking and localised movement within the asphalt
Vegetation growth in surface cracks
Walkway tiles gradually sinking into softened asphalt
Moisture present throughout the roof build-up
Blistering visible in both the felt overlay and the original asphalt
Moisture mapping and core samples confirmed what the surface condition was already suggesting: the insulation layers are saturated.

The roofs have clearly delivered decades of performance, but they’ve now reached the point where a full strip and replacement is the sensible option.

Sometimes the biggest takeaway from a survey isn’t just what’s wrong with a roof today, but how long the original system actually performed before getting there.

This one certainly passed the test of time.

🎥 I’ve included a quick walkthrough video from site showing some of the defects.

28/03/2026

This is what happens when roofing is left to a general builder.

I’m on a roof in Scarborough where a GRP system has been installed directly onto a concrete deck.

That’s a fundamental mistake.

Rigid GRP systems should be installed over a timber substrate such as OSB or plywood. Installing them straight onto concrete almost guarantees problems.

And the defects are already showing.

Water ingress around rooflights.
Topcoat applied too thin with fibres visible through the surface.
Ponding water.
Edge trims lifting in the wind.
Waterproofing details not completed properly.

There’s nothing wrong with the GRP material itself. When installed to the manufacturer’s specification it performs very well.

But roofing systems are only as good as the people installing them.

This is exactly why roofing should always be carried out by competent roofing contractors, not treated as just another job for the main contractor.

24/03/2026

Not sure if aliens have landed on this roof in Manchester… or if it’s just where a man anchor has been installed.

But either way, it’s something worth paying attention to.

You can clearly see a circular mark where the coating has started to craze and crack. Small defects like this can easily go unnoticed, but over time they can compromise the integrity of the waterproofing.

For now, it will be reported back to the manufacturer so it’s recorded against the system warranty, and we’ll keep an eye on it during future inspections.

Another reminder that regular roof inspections are about spotting the small things before they become bigger problems.

21/03/2026

This is why roof inspections matter.

A small split in the membrane… and water already sitting underneath.

No internal leaks yet, but it’s only a matter of time before water finds its way into the building.

The likely cause? Damage during window cleaning works.

Because it’s been picked up early, the repair is simple. The manufacturer’s approved contractor can patch the membrane and keep the warranty intact.

Left unnoticed, this small defect could easily have turned into a much bigger problem.

Routine inspections catch the issues you don’t see from the ground.

Not the worst office view in Manchester today either.

14/03/2026

Another felt roof that has simply reached the end of its useful life.

This one was over a vacant retail unit in Cumbria and we were asked to assess it for an incoming tenant.

At first glance it already tells a story. The mineral surface has largely disappeared, leaving the underlying bitumen exposed to UV. In several areas the reinforcement is beginning to show through, which is a clear sign the waterproofing is approaching failure.

Core samples confirmed the construction as a metal deck with fibreboard insulation and a three-layer felt system. As is often the case with older roofs of this type, the fibreboard beneath is now saturated.

There are also several secondary defects developing:

• Splitting within the felt where movement has occurred
• Ponding water along the gutter line
• Flashband repairs around penetrations
• Metal edge cappings with holes and deterioration
• Asbestos vent pipes requiring removal as part of any refurbishment

None of this is unusual for a roof of this age. It has simply naturally deteriorated over time and is now beyond economical repair.

The appropriate solution here is a full strip and replacement rather than continued patch repairs.

This is a situation I see regularly when surveying older felt systems. Once the mineral protection is gone and moisture has reached the insulation layer, repairs rarely address the underlying problem.

Sometimes the most cost-effective decision is recognising when a roof has simply done its job.

07/03/2026

This roof hasn’t “failed”.

It’s simply reached the end of its life.

And that’s something many building owners struggle to understand.

Another flat roof survey this week looking at a very typical build-up:

• Concrete deck with screed to falls
• Original asphalt waterproofing
• A later felt overlay finished with solar reflective paint

Nothing unusual there — but time eventually catches up with every roofing system.

On inspection we could clearly see the signs of age:

Polyester reinforcement starting to show through the felt
Lap joints beginning to delaminate
Previous liquid repairs where leaks had been chased
A drainage detail discharging onto brickwork, which has led to damp masonry and even vegetation growth
None of this is dramatic failure. It’s simply a roof that has reached the end of its serviceable life.

Roofs age the same way we do — you can’t stop it.

The key is recognising when a roof has moved from maintenance territory into refurbishment territory.

In this case the sensible approach is a full refurbishment, addressing both the waterproofing and the drainage detailing so the next system performs properly.

They’ve had their money’s worth out of this one.

Time for the roof to start its next chapter.

BS 6229:2025 – a closing reflectionEvolution, not revolution.Having worked through the key changes in BS 6229:2025 over ...
12/02/2026

BS 6229:2025 – a closing reflection
Evolution, not revolution.

Having worked through the key changes in BS 6229:2025 over the last few weeks, one thing stands out more than anything else: this isn’t a radical rewrite.

The 2025 revision doesn’t reinvent flat roofing, and it doesn’t suddenly make existing roofs unacceptable. What it does do is tighten language, reduce ambiguity, and place greater emphasis on how roofs actually perform in service, rather than how they were intended to perform on paper.

Across drainage, zero and absolute zero fall, inverted and blue roofs, repairability, fire performance and surveying practice, the theme is consistent. Outcomes matter more. Assumptions are harder to rely on. And intent needs to be clearer.

For those familiar with the 2018 edition, most of the principles will feel recognisable. The difference is that BS 6229:2025 is more explicit about where compromises sit, how they should be justified, and where professional judgement needs to be applied rather than avoided.

Importantly, the revised standard remains guidance, not regulation. It isn’t a mandate to over-specify, over-design or over-react. Nor should it be used as a lever for unnecessary intervention. Understanding the building, its constraints, its use and the client’s objectives remains fundamental.

From a surveying perspective, that balance is welcome. The role hasn’t changed — but the framework for explaining performance, limitation and risk has become clearer and more robust.

If BS 6229:2025 achieves anything, it’s this:
it makes it easier to have honest conversations about flat roofs — how they behave, what can realistically be improved, and where proportionate decisions matter more than perfect ones.

That feels like progress.

Thanks to everyone who’s engaged, challenged and contributed to the discussion. The quality of debate around this update has been encouraging — and very much in the spirit of the standard itself.

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