A primary school extension in Ulverston needed its aging asphalt flat roof replaced during the summer holidays with minimal disruption. Our Lava20 roofing team applied this advanced liquid waterproofing membrane directly over the prepared existing roof, completing the entire 120m² project in just 5 working days — no hot works, no fumes, and no disruption to the school.
This Ulverston primary school has a single-storey classroom block added in the 1980s with a 120m² mastic asphalt flat roof. The asphalt had crazed and cracked across much of its surface after 40+ years of UV exposure and thermal cycling. Several areas had developed alligator-pattern cracking that allowed rainwater to slowly penetrate through to the concrete deck below. Water staining was visible on the classroom ceilings, and portable buckets were being deployed during heavy rain — a situation the headteacher described as unacceptable for a working school environment. Traditional re-roofing options presented challenges: torch-on felt and GRP require hot works (naked flames and catalysed resins respectively) which are prohibited on occupied school buildings under health and safety regulations. Even during summer holidays, after-school clubs and maintenance staff were on site. The school needed a cold-applied, fume-free system that could be completed entirely within the six-week summer break.
Lava20 was the perfect solution for this school project. It is a cold-applied, water-based liquid membrane that requires no heat, produces no fumes, and is completely safe to apply on occupied buildings. After pressure-washing the existing asphalt and allowing it to dry, we applied a primer coat designed specifically for aged asphalt surfaces. The Lava20 system was then applied in three coats with reinforcing polyester fleece embedded in the first coat for tensile strength. Each coat was applied by roller and brush — exactly like painting — and cures by water evaporation to form a seamless, fully bonded rubber membrane. The system was dressed up all parapet walls, over all existing lead flashings, and around the two roof-mounted HVAC units using formed details. New drainage outlets were installed with Lava20 bonded directly to the outlet flanges, creating watertight connections without mechanical fixings. The entire 120m² roof was completed in 5 working days, well within the summer holiday window.
The school returned for the autumn term with a completely waterproof roof and no signs of the previous leaking. The Lava20 membrane has performed flawlessly through the first full academic year, with the school reporting zero water ingress even during heavy autumn and winter storms. The seamless, fully bonded membrane has no joints or seams across the entire 120m² area, and the reinforcing fleece provides the tensile strength to bridge any future thermal cracking in the asphalt substrate below. The school's facilities manager was particularly pleased with the quiet, fume-free installation process that caused zero disruption to the summer activities programme. We provided a 20-year guarantee on the Lava20 system.
Lava20 is an advanced water-based liquid waterproofing system that cures by evaporation to form a seamless EPDM rubber membrane. Unlike traditional EPDM sheet, Lava20 is applied in liquid form — rolled on like paint — which means it conforms perfectly to complex roof details, penetrations, and upstands without joints or seams. The cured membrane has all the properties of sheet EPDM — permanent flexibility, UV resistance, and 50+ year durability — but with the additional advantage of being fully bonded to the substrate at every point. For school and commercial applications, its cold-applied, fume-free nature is a crucial safety advantage.
A non-woven polyester fleece is embedded in the first coat of Lava20, providing tensile strength that bridges cracks in the substrate below. This is critical when overlaying aged asphalt, as thermal movement will continue to cause cracking in the old surface. The reinforced membrane accommodates this movement without transmitting cracks through to the waterproof layer above.
The specialist primer chemically activates the surface of aged asphalt, creating a receptive layer that the Lava20 membrane bonds to permanently. Without proper priming, the natural oils in asphalt can prevent adhesion. The primer also seals the asphalt's surface pores, preventing air bubbles from forming in the membrane during curing.
New stainless steel drain outlets were installed with wide flanges that the Lava20 membrane bonds directly to, creating seamless waterproof connections. The outlets incorporate leaf guards and connect to the existing internal downpipe system.
Our Lava20 roofing team provides advanced liquid membrane solutions for schools, commercial buildings, and residential properties throughout Ulverston and South Cumbria. Safe, fast, and fume-free — ideal for occupied buildings. Contact us for a free survey and quotation.
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