Strengthening a local landmark
We reroofed Calvary Church in Cairns with cyclone-rated materials, blending durability and design while keeping the church fully operational throughout the project.
Client
undisclosed
Location
Grafton Street
Date
April 2024
Surface Area
550 m²
1. The Challenge
The existing roof suffered from advanced corrosion and had been patched repeatedly with tar paint, making flashings around AC units extremely labor-intensive to remove. Stripping the penetrations alone required two full days. Once opened, the roof could not be made fully watertight for up to two weeks, requiring meticulous planning and weather-risk management.
The project required the replacement of roof sheets, a large box gutter, parapet flashings, parapet cappings, and multiple penetration flashings. The irregular layout of AC penetrations increased potential leak points, and the lack of a proper walkway meant maintenance crews frequently damaged the old roof during servicing.
2. The Solution
We implemented a staged roofing plan balancing demolition, temporary weather breaks, and mechanical system management. AC penetrations were consolidated into a straight line, significantly reducing the flashing footprint and long-term leak risk. All drainage components—including box gutter sumps and overflow systems—were custom-fabricated from stainless steel for durability.
A permanent aluminium walkway was installed to protect the new roof during future maintenance activities. All works were completed in compliance with local building codes and cyclonic regulations.
Key strategies included:
Full replacement of roof sheets, box gutter, parapet flashings/cappings
Consolidation of AC penetrations to reduce leak points
Custom stainless steel box gutter sumps and overflow fabrication
Installation of a permanent aluminium walkway for safe access
High-precision sequencing to manage long exposure windows
3. The Result
The result is a modern, fully compliant Zincalume roofing system engineered for FNQ’s demanding conditions. The re-aligned penetrations, upgraded drainage, and new access walkway significantly improve long-term maintenance, reduce leak risk, and restore the building’s structural resilience.
The project has since become a case study in delivering premium roofing outcomes under complex, high-visibility conditions. It reaffirmed SH Metal Roofing’s position as Cairns’ go-to specialist for commercial reroofing in live environments — combining structural excellence with absolute professionalism.
