Wallbarn’s M-Tray® Green Roof Project in Crumlin Earns NFRC Roofing Awards Nomination

Wallbarn’s innovative approach to green roofing has once again been recognised at the highest level, with its M-Tray® modular system earning a nomination at the NFRC Roofing Awards. This recognition stems from a standout project in Crumlin, Caerphilly, South Wales, where a large-scale industrial roof has been transformed into a visually striking, environmentally conscious space.

This project not only highlights the growing demand for sustainable roofing solutions but also demonstrates how advanced systems like M-Tray® can deliver both performance and aesthetic value on complex builds.

A Landmark Green Roof Installation in South Wales

The Crumlin project is a significant achievement in modern roofing, covering more than 1,200m² of pitched roof space. Delivered in partnership with Polyroof and installed by Haran Roofing, the scheme required a solution that could meet strict performance standards while enhancing the visual integration of the building within its natural surroundings.

Originally, the project was specified as a rollout green roof. However, concerns were raised around fire performance and long-term reliability. This led to a reassessment of the specification, ultimately resulting in the selection of Wallbarn’s M-Tray® system.

You can explore the full details of the installation here:
👉 View the Crumlin Caerphilly Case Study

Why M-Tray® Was Selected for the Project

The decision to move to M-Tray® was driven by several key advantages that made it ideally suited to this large, technically demanding roof.

First and foremost, the system’s fire performance was a critical factor. M-Tray® has undergone physical testing and meets the B Roof(t4) fire classification, providing confidence that it complies with current safety regulations.

Beyond compliance, the modular nature of the system offered clear practical benefits:

• Faster installation compared to traditional rollout systems
• Futureproofing, as individual trays can be removed for maintenance without disturbing the entire roof
• Consistency in finish, thanks to pre-grown vegetation

These features made M-Tray® not just a suitable alternative, but a superior solution for the project’s requirements.

If you’d like to learn more about the system itself, you can explore the product here:
👉 Discover Wallbarn’s M-Tray® Green Roof System

Overcoming the Challenges of a Pitched Industrial Roof

Large-scale pitched roofs present unique challenges, particularly when incorporating green roofing systems. Without careful planning, issues such as slippage, uneven weight distribution, and membrane stress can arise over time.

To address this, Wallbarn recommended the integration of horizontal battens and structural parapets to stabilise the system. These elements were seamlessly incorporated into the Polyroof Protec waterproofing system, ensuring that the structural integrity of the roof was maintained throughout.

This level of technical planning was essential to achieving a long-lasting, high-performing installation that could withstand environmental pressures while maintaining its visual appeal.

Logistics and Coordination at Scale

Delivering a project of this size required precise logistical planning. The site, located within a busy industrial estate, presented access limitations with no dedicated loading bays or road closures available.

More than 5,000 M-Tray® units were required to complete the installation, and these were delivered over a carefully managed four-week schedule. Trays were supplied in batches of 640, multiple times per week, ensuring a steady workflow without overwhelming the site.

Close coordination between Wallbarn’s logistics team, Haran Roofing, and Polyroof ensured that every stage of the delivery and installation process ran smoothly. This collaborative approach played a crucial role in the project’s success.

Aesthetic Impact: Blending Architecture with Nature

One of the standout aspects of the Crumlin project is its visual transformation. The finished green roof creates a natural, textured surface that blends seamlessly into the surrounding hillside.

This is a key advantage of modular green roofing systems like M-Tray®. Because the vegetation is pre-grown—often achieving high levels of coverage before installation—it delivers an immediate, established appearance.

The result is not just a functional roofing solution, but a design feature that enhances the overall character of the building while contributing to the surrounding landscape.

Sustainability and Long-Term Performance

Green roofs are increasingly recognised for their environmental benefits, from supporting biodiversity to helping regulate building temperatures. M-Tray® plays a key role in this movement, offering a practical and scalable solution for both commercial and industrial applications.

The modular system supports long-term sustainability in several ways:

• Reduced disruption during installation
• Easier maintenance and inspection over time
• Durable construction designed for long-term performance

These benefits align with the wider industry shift towards greener, more responsible construction practices.

Industry Recognition: NFRC Roofing Awards Nomination

The nomination for the NFRC Roofing Awards is a testament to the quality, innovation, and execution of the Crumlin project. It reflects not only the performance of the M-Tray® system but also the collaborative efforts of all parties involved.

Being recognised on such a large-scale industrial project highlights the growing importance of green roofing solutions within the construction sector. It also reinforces Wallbarn’s position as a leader in delivering high-quality, sustainable roofing systems.

With the awards set to take place in May, there is great anticipation around the outcome—and strong optimism that this project will receive the recognition it deserves.

A Forward-Thinking Approach to Roofing

The Crumlin installation demonstrates what can be achieved when innovation, collaboration, and sustainability come together. By choosing M-Tray®, the project team delivered a solution that meets technical requirements, enhances visual appeal, and supports environmental goals.

As demand for green roofing continues to grow, projects like this set the benchmark for what is possible on modern industrial and commercial buildings.

For architects, contractors, and developers looking to explore similar solutions, Wallbarn’s M-Tray® offers a proven, award-nominated system that delivers on every level.

👉 Explore the Full Case Study Here
👉 Learn More About M-Tray®