Hidden costs to budget for
Experienced project managers always build contingency into commercial roofing budgets. Common surprises include:
- Structural deck repairs: Once the old roof is stripped, rot, corrosion, or inadequate falls are often revealed. Budget 10–15% contingency for deck repairs.
- Drainage upgrades: Current building regulations require roof drainage to be sized for 1-in-100-year rainfall events. Older drainage may need upgrading (typically £1,500–£8,000).
- Rooflights & smoke vents: If existing rooflights are at end of life, replacing them during a re-roofing project saves significant scaffold re-hire costs later. Allow £800–£3,500 per rooflight.
- Planning & permitted development: Most like-for-like commercial roof replacements do not require planning permission. However, changes to roof form, materials on listed buildings, or extensions may need consent.
- Warranty requirements: Many system warranties (e.g. Sarnafil, Firestone, Bauder) require specific detailing, certified installers, and third-party inspections. These add value but marginally increase project cost.
- Business disruption: An open roof during bad weather — even for a few hours — can damage stock, equipment, or interiors. Factor in the cost of business continuity planning or temporary covers.
