At Henrietta Street in Chippendale, years of weather exposure had left the existing metal roof sheets rusted through. Water was consistently leaking into the tenancy below, creating ongoing damage and disruption. The original box gutters were also undersized, causing frequent overflow that pushed water into internal areas of the building.

This project wasn’t just about replacing sheets of metal — it was about redesigning a roof system to finally make it watertight, durable, and functional.

The Challenge

• Severe corrosion across roof sheets created widespread leaks.
• Undersized box gutters couldn’t handle heavy rainfall, causing overflow into internal areas.
• Tenant disruption from water ingress meant the roof had to be addressed quickly and effectively.

Approach

The solution combined direct replacement with system improvements to address both the leaks and the water management issues:

• Full removal of rusted-out roof sheets.
• Upsizing of box gutters to provide greater stormwater capacity.
• Installation of new flashings and cappings to seal vulnerable junctions.

Every element was installed with an emphasis on long-term durability and prevention of future water ingress.

Execution

1. Removal & Preparation
   • Careful strip-out of all corroded roof sheets.
   • Inspection of substrate and supporting members.
2. Installation of New Roof Sheets
   • High-grade metal sheeting installed with precision fixings.
   • Alignment and sealing to ensure weather-tight performance.
3. Upsizing of Box Gutters
   • New, larger-capacity gutters designed to handle rainfall loads.
   • Correct falls established to eliminate ponding and backflow.
4. Flashings & Cappings
   • All junctions sealed with new flashings.
   • Cappings installed to ensure water is directed safely away from internal areas.

Outcome

• Watertight Roof – The tenancy below is now protected from leaks.
• Improved Drainage – Upsized gutters handle rain without overflow.
• Longevity Restored – The new roofing system is built for decades of service.

Project Significance

Henrietta Street demonstrates how roof replacement projects often require more than just sheet replacement. By addressing gutter capacity and improving flashings, the building now has a complete system that manages water effectively, reduces maintenance risk, and safeguards the tenancy below.

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