Hurst Castle, Kayhaven – IKO Permaphalt

Project description

Hurst Castle, situated in the Solent, originated in the 15th century and has undergone many additions and alterations up to its last defensive role in WW2. Over 5000m2 of Mastic Asphalt roofing was scheduled by English Heritage/Historic England for an extensive overhaul.

Throughout the project there was very close consultation with all agencies, local and national suppliers to achieve like for like replacement of the original makeup, adjusting plans at short notice as variations were uncovered.

The work included a complete strip up and reinstatement of the East wing with concrete repairs to structural cracks and 150 tonne of sand and cement screed under 300 tonne of IKO Permaphalt.

The West wing underwent extensive asphalt repairs throughout. The majority of work was carried out on a significant fall from 10%-20% on the gun emplacements, the asphalt detailing included upstands, down stands, vertical, capping, drips and gutters.

The solution

Challenges on this project came about due to the unique position of the castle, materials and waste were transported along a 1.5 mile gravel spit by tractor and were lifted on and off the roof by telehandler, including the three 2 tonne asphalt cookers which were used to prepare the IKO Permaphalt.

Personnel took the 20 minute ferry crossing to and from site daily and the castle remained open to visitors throughout the project adding an extra planning element to the safe execution of this 6 month project.

The site was well managed, and an excellent H&S record maintained by the crew based there in liaison with the site agent. Due to the exposed nature of the site, weather conditions, including wind, rain, hail and extreme heat, were influential in progress and completion of the works.

We are proud to say our works were completed safely, on time to a very high standard and to the delight of all parties concerned.

Photo of the Hurst Castle, Kayhaven IKO Permaphalt system