Precision Cut Roofing Insulation System in Battersea

Processing and preparing bespoke stone wool insulation and fire-resistant perimeter panels for multiple roof areas delivered in installation-ready kits.

About CTF Roofing Systems

CTF Roofing Systems are a specialist supplier of high-performance tapered roofing systems and insulation for commercial construction projects across the UK. Known for delivering technically advanced roofing solutions, CTF supports contractors on complex developments where drainage performance, fire safety and installation efficiency are critical.

For a major development in Battersea, CTF required bespoke processing support to deliver a complete cut to fall tapered roofing system using dense stone wool insulation slabs. The system formed part of an inverted roof construction designed to deliver high thermal performance while maintaining strict fire safety standards.

Battersea roofing project in numbers…

900m2

roof area

900+

boards processed

900m

cut

The
Challenge

The Battersea project required a highly tailored roofing solution spanning multiple roof areas, each with its own construction specification and installation requirements. The insulation slabs needed to be precisely processed to create a complete cut to fall tapered system, ensuring effective drainage while maintaining consistent thermal performance across the roof build up.

Alongside the insulation system, the project also required Class A1 fire-resistant decking upstand boards to be produced for the roof perimeter. These elements had to be accurately cut and prepared to integrate seamlessly with the roofing system and meet strict fire safety standards.

Logistics added another layer of complexity. Materials needed to be supplied to site as collated roof area kits, allowing installation teams to work efficiently across different sections of the development. Delivery schedules were also subject to frequent change, with the main contractor adjusting timelines due to weather conditions and other site constraints.

CTF required a partner who could process materials accurately, manage bespoke requirements and maintain flexibility as installation schedules evolved.

The solution

Perudo processed the materials required for the roofing system, transforming dense stone wool insulation slabs into a complete cut-to-fall tapered system tailored to the specifications of each area.

The insulation was cut and prepared to ensure correct drainage gradients while maintaining the performance characteristics of the inverted roof system. In addition, Class A1 fire-resistant decking upstand perimeter panels were produced to support the fire safety requirements of the roof build up.

To streamline installation, materials were collated into roof specific kits, allowing contractors to access the correct components for each area of the development. Additional material packs were also prepared for on-site teams to support the installation process.

Despite changing delivery schedules driven by weather and site constraints, the materials were supplied on time and to specification.

Here’s what our
clients have to say…

Civil Engineering Client

“Thank you for your prompt and highly professional service. The items have worked well, we will certainly be in touch with any future requirements.”

Tim – Director of Bespoke

Manufacturing Client

“We were all blown away by the quality of the product you have produced. Congratulations and thank you”

Bryan – Sales Manager

Retail & Events Client

“Thank you for all the hard work. The final push on an ever-changing design ensured that everything was finished and delivered on time.”

Paul – Project Manager

See more of our work

Construction & Civil Engineering

EPS Processing for the Ashley Down Station Platform Development

Processing and preparing 300 bespoke EPS components to support the rapid installation of the Ashley Down station platform system.
Read more

Polystyrene Processing at Ashley Down Station

Processing and preparing 300 bespoke EPS polystyrene components to support the rapid installation of the Ashley Down station platform system.

About BEWI

BEWI Polystyrene is a large UK manufacturer of expanded polystyrene, supplying high-volume EPS solutions across multiple sectors. Known for producing dense, large-format polystyrene blocks, BEWI supports major construction and infrastructure projects where precision, durability and scale are critical.

For the Megatech Ashley Down station project, BEWI was tasked with supplying multiple full lorry loads of high-density EPS blocks. These were delivered in full-size moulded blocks and required processing into bespoke sizes and detailed shapes. Each individual component needed to be cut, collated and numbered to align with post production processing and on-site installation sequencing.

The project demanded significant material volumes, fast turnaround and exacting detail to support encasement in concrete and the integration of pre-formed M&E ductwork.

Ashley Down project in numbers…

900m2

area

900+

blocks processed

900m

cut

The
Challenge

The Ashley Down station development required 260 metres of expanded polystyrene platform system to be installed within a short timeframe. BEWI faced several operational pressures:

  • Large volume of high density EPS blocks to be processed into bespoke formats
  • Approximately 300 individual EPS blocks and slabs, with around 50 percent being unique variations
  • Short lead times
  • Space limitations and handling constraints
  • Strict delivery and collection schedules

The scale and complexity of the requirement meant BEWI could not internally manage the processing volume and turnaround within the required timeframe. They needed a specialist partner to transform bulk deliveries into fully prepared, installation ready components while maintaining programme certainty.

The solution

Perudo supported BEWI by processing full-size EPS blocks into precisely cut components ready for installation within the Ashley Down station platform system. Each element was shaped to accommodate drainage runs, M&E services, the station lift shaft and the pedestrian footbridge, then collated and numbered to align with the installation sequence.

Despite the logistical challenge of transporting around 300 concrete-encased EPS components from a material storage compound located one kilometre from the station, installation progressed efficiently and exceeded the minimum installation target of two linear metres per hour.

In total, 260 metres of EPS platform system were installed in just four days. The two platforms, some sections reaching up to six metres in width, were completed within eight working shifts and delivered ahead of programme.

Here’s what our
clients have to say…

Civil Engineering Client

“Thank you for your prompt and highly professional service. The items have worked well, we will certainly be in touch with any future requirements.”

Tim – Director of Bespoke

Manufacturing Client

“We were all blown away by the quality of the product you have produced. Congratulations and thank you”

Bryan – Sales Manager

Retail & Events Client

“Thank you for all the hard work. The final push on an ever-changing design ensured that everything was finished and delivered on time.”

Paul – Project Manager

See more of our work

Building Products & HVAC

Precision Cut Roofing Insulation System in Battersea

Processing and preparing bespoke stone wool insulation and fire-resistant perimeter panels for multiple roof areas delivered in installation-ready kits.
Read more