Specialist Works

Bushmills Distillery – Bottling Plant Roof Refurbishment

Bushmills, Northern Ireland

Specialist Works

Date Completed

2026

Sector

Industrial

Main Contractor

Direct to Client

Project Overview

Project Brief

Thornton were appointed by Bushmills Distillery to replace an ageing, out-of-warranty roofing system across their live bottling facility.

The existing roof had deteriorated to a point where it posed a risk to ongoing operations. The client required an FM-approved and insured roofing system installed without disrupting production.

A critical constraint was the strict prohibition of naked flames. Due to the nature of the facility, the presence of alcohol and associated vapours meant any exposure to flame presented a catastrophic explosion risk. This ruled out traditional torch-applied systems and dictated a flame-free installation approach.

The works were carried out directly above an operational bottling line, within an environment that remained fully live throughout. In addition to production continuing, guided tours of the distillery were ongoing, heightening sensitivity regarding safety and presentation.

This meant:

Zero tolerance for water ingress
No contamination risk to product
No disruption to production or visitor experience
Heightened safety controls due to public access

The project therefore had to be delivered in a carefully phased and tightly controlled manner, maintaining a watertight envelope at all times.

Method

Thornton installed a Strata Waterproofing-supplied IKO Powerflex bituminous membrane system, providing an FM-approved solution with a 25-year insured warranty. The system was specifically selected for its durability, FM Approval, and suitability for flame-free installation.

The works were undertaken in sequenced roof zones, ensuring that each section was watertight before progressing. This approach removed exposure risk to the live environment below and allowed both production and public tours to continue uninterrupted.

The delivery included the controlled strip and replacement of the existing roof system, installation of upgraded insulation and U-Value, and careful detailing around rooflights, penetrations, and abutments. Interfaces with existing drainage and perimeter conditions were managed to ensure continuity of performance, while the condition of the existing substrate was continually assessed and addressed as works progressed.

Given the operational and public-facing nature of the building, quality control and supervision were critical throughout. Particular focus was placed on high-risk interfaces and detailing to ensure long-term performance and eliminate the potential for waterproofing failure.

Outcome

The project was successfully delivered with no disruption to production or visitor tours and without any water ingress incidents. The completed system meets all FM and safety requirements and provides a robust, long-term roofing solution backed by a 25-year insured warranty.

This project demonstrates Thornton’s ability to deliver complex roofing works in live, high-risk and publicly accessible environments, where sequencing, safety, and control are as critical as the installation itself.