The works comprised the replacement and renewal of lead roofing and associated weathering details to the turret roof area at Clayton Tunnel. The project intended to restore the integrity of the existing roof coverings, improve weather resistance, and extend the service life of the structure through the installation of new leadwork in accordance with current best practice.
The works included the careful removal of existing lead roof coverings and flashings from the turret roof and associated gutter details. Existing lead materials were stripped and removed back to deck.
The main roof area, approximately 40m², was recovered using new Code 7 lead sheet installed over a building paper underlay. In addition, approximately 30 linear metres of new Code 5 lead cover flashings was supplied and installed to provide a durable and weatherproof junction between roof coverings and adjacent structures.
Localised repairs to the roof substrate were undertaken where deterioration was identified. This includes the removal and replacement of approximately 20m² of damaged timber decking with new timber to match the existing construction.
A further 7 linear metres of Code 5 lead lining was installed to the gutter separating joint, incorporating a Code 5 lead expansion joint to accommodate thermal movement and maintain long-term performance.
All newly installed leadwork was treated with two coats of patination oil immediately following installation to minimise staining and ensure a uniform appearance. Flashings completed and sealed using grey lead mastic to provide a watertight finish.
All leadwork installed by experienced operatives in accordance with Lead Sheet Association guidance and recognised industry standards. Particular attention will be given to correct detailing, expansion allowances, substrate preparation, and weatherproofing to ensure the longevity and performance of the completed installation.
Upon completion, the turret roof and associated leadwork details at Clayton Tunnel now benefits from a fully renewed lead roofing system, providing enhanced weather protection, improved durability, and a high-quality finish consistent with the requirements of a heritage railway structure.