Ynysybwl RFC
Full Roof Replacement & Structural Works
Project at a Glance
Client: Ynysybwl Rugby Club
Contractor: Crossbuild Construction Services Ltd
Contract Role: Main Contractor
Project Type: Roof Replacement & Structural Works
Location: Ynysybwl, South Wales
Works: Structural steel, structural timber, reinforced concrete foundations and complete roof replacement
Project Overview
Crossbuild Construction Services Ltd were appointed as Main Contractor to undertake the complete replacement of the existing roof at Ynysybwl Rugby Club.
The project involved considerably more than the replacement of the roof covering. The existing roof was removed and replaced with a new structural arrangement incorporating structural steelwork, timber construction and independent reinforced concrete pad foundations. The works required detailed planning and coordination between the client, design team, structural engineer, Building Control and specialist subcontractors.
As Main Contractor, Crossbuild took responsibility for managing the project from the initial pre-construction and design coordination stages through to construction, inspection and completion.
From Design Through to Construction
One of the key aspects of the project was establishing how the new roof structure would integrate with the existing building.
Before work commenced on site, Crossbuild worked closely with the relevant consultants and structural engineer to review the proposed design and develop a practical construction sequence. This included coordinating the position of the new independent pad foundations, structural steelwork and timber roof structure, while considering access, lifting requirements, temporary stability and the safe removal of the existing roof.
Our role was not simply to build to a set of drawings. As Main Contractor, we were involved in coordinating the various elements of the project and resolving construction issues as they arose, ensuring that the design could be delivered safely and efficiently on site.
Where clarification or additional information was required, Crossbuild liaised directly with the design team and relevant consultants before progressing the works.
New Reinforced Concrete Foundations
The new roof structure required independent reinforced concrete pad foundations to provide the necessary support for the structural steelwork.
The foundation works involved accurately setting out the new positions, excavating to the required depth and preparing the foundations in accordance with the structural design. Reinforcement was installed before the concrete was placed, with the works coordinated around the existing building and other site activities.
This stage required careful planning and coordination, as the new foundations had to be positioned accurately to suit the subsequent steelwork installation and overall structural arrangement.
Structural Steelwork
Once the foundations had been completed and the required inspections undertaken, Crossbuild coordinated the installation of the new structural steelwork.
The steel frame formed a fundamental part of the new roof structure and required careful sequencing to ensure that the structure remained stable during erection and that the steelwork aligned correctly with both the foundations and the timber roof construction that followed.
Crossbuild managed the coordination of deliveries, lifting operations and installation on site, working alongside the specialist steelwork team and structural engineer where required.
Timber Roof Structure
The structural steelwork was followed by the installation of the new timber roof structure.
The timber elements were coordinated with the steel frame to create the required roof form and provide the supporting structure for the new roof construction.
Particular attention was given to the interfaces between the steelwork, timber and roofing elements to ensure that the finished construction was both structurally sound and properly detailed.
Complete Roof Replacement
With the new structural framework in place, the project progressed to the complete replacement of the existing roof.
The existing roof was carefully dismantled and removed, with the works planned around the structural sequence and the need to maintain safe working conditions throughout. Temporary protection and careful sequencing were particularly important during the transition between the old and new roof structures.
The replacement roof was then constructed, including the roof covering, associated flashings, junctions, weathering details and interfaces with the existing building.
The finished roof was designed and constructed to provide a durable, weather-tight solution while integrating successfully with the existing building.
Building Control & Design Liaison
Building Control liaison formed an important part of Crossbuild's role throughout the project.
We coordinated inspection stages with Building Control and worked with the design team to ensure that the structural and construction elements were progressed in accordance with the relevant requirements.
This included coordination around the new foundations, reinforcement and concrete works, structural steelwork, timber construction and the completed roof.
Where Building Control or the design team required additional information or clarification, Crossbuild coordinated the necessary response and ensured that any issues were addressed as part of the construction process.
This close communication helped maintain progress while ensuring that the appropriate inspection and approval processes were followed.
Managing the Project
As Main Contractor, Crossbuild were responsible for coordinating the different trades, specialist subcontractors, materials and plant required to deliver the project.
The sequencing of the works was particularly important. The foundations needed to be completed before the steelwork could be installed, the steelwork needed to be sufficiently advanced before the timber structure could progress, and the roof construction then had to be carefully coordinated to provide protection to the building.
Alongside the physical construction, Crossbuild managed the day-to-day site operations, health and safety, programme, subcontractor coordination, quality control, deliveries and communication with the client and design team.
Working Around an Existing Building
One of the main challenges of the project was carrying out significant structural alterations while working with an existing building.
The works required careful consideration of the existing structure, access and site conditions, as well as the safe removal of the existing roof before introducing the new structural arrangement.
Crossbuild's experience as a Main Contractor allowed us to coordinate these different requirements and maintain control of the project as the works progressed.
Health & Safety
The project involved a number of significant construction risks, particularly due to the roof removal, working at height, structural steel erection, lifting operations and excavation for the new foundations.
These risks were addressed through detailed planning, suitable risk assessments and method statements, site supervision and coordination between Crossbuild's site team and specialist contractors.
Safety remained a key consideration throughout the project, particularly during the transition from the existing roof to the new structural arrangement.
Quality & Completion
Quality control was maintained throughout the project, with particular attention given to the reinforced concrete foundations, structural steel connections, timber installation and roof detailing.
Crossbuild coordinated inspections and worked with the relevant consultants and Building Control to ensure that the works were completed to the required standard.
The completed project delivered a fully renewed roof structure and roof covering for Ynysybwl Rugby Club, incorporating new independent reinforced concrete foundations, structural steelwork and timber construction.
The Crossbuild Difference
This project demonstrates Crossbuild Construction Services Ltd's ability to take on complex refurbishment and structural projects where careful planning, design coordination and construction management are essential.
As Main Contractor, we provided a single point of responsibility for the delivery of the works, coordinating the client, design team, structural engineer, Building Control and specialist subcontractors throughout the project.
From the initial design and construction planning through to the final roof installation and completion, Crossbuild managed the project as a complete construction package.
The result is a substantial upgrade to the rugby club's building, providing a new structural roof solution designed to give the facility many years of continued use.
Project Summary
Crossbuild Construction Services Ltd were proud to deliver the complete roof replacement at Ynysybwl Rugby Club, combining reinforced concrete foundations, structural steelwork and timber construction as part of a fully coordinated structural and roofing solution.
From design coordination and Building Control liaison through to construction and completion, Crossbuild managed the project from start to finish as Main Contractor.
