Precision and Performance in Bristol: Wallbarn Delivers a Class A Fire-Rated Paving System for The Old Brewery Redevelopment

In April 2025, Wallbarn supported Afan Group in delivering a technically advanced Class A fire-rated substructure system for The Old Brewery redevelopment in Bristol. Spanning over 400 square metres and divided into five distinct roof zones, this complex project required a flexible, fully compliant paving solution capable of handling varying heights, mixed slab sizes, and tight installation conditions.

A Detailed Design for a Historic Site

The Old Brewery, originally established in 1829, is part of a wider regeneration scheme in Bristol’s Southville district — transforming the historic Ashton Gate Brewery into a new mixed-use community featuring 107 affordable homes and seven commercial units. The development combines new construction with the careful restoration of existing industrial buildings, maintaining the area’s original character while introducing modern functionality.

Working within this sensitive and highly constrained site demanded precise system design, meticulous coordination, and adaptable materials. Wallbarn’s Class A fire-rated paving solution offered the perfect foundation for success.

Supplying a Complete Class A System

Wallbarn provided a full non-combustible substructure, including:

• MetalPad Ex adjustable pedestals for secure height adjustment

• Optional spreader plates to distribute load evenly and protect insulation

• I-Plus aluminium rails for added rigidity and alignment

• Specialised paving headpieces designed for 600x400mm and 400x400mm slabs

The system ensured fire safety compliance for a structure exceeding 18 metres, meeting current Class A Specification requirements for non-combustible materials. The flexibility of Wallbarn’s modular components made it possible to accommodate differing slab formats and surface gradients across the five zones.

Collaboration from Concept to Completion

Wallbarn’s involvement began in June 2024, following an initial Teams meeting with Afan Group. After receiving PDF plans, a preliminary quotation and layout proposal were issued. The project was later paused before resuming in December, when new plans required a complete revision of the design and costings.

Our technical team worked through multiple collaborative virtual meetings with Afan Group, updating layout directions, pedestal ranges, and rail orientations to match the latest construction phases. When materials were delivered, a Wallbarn director and technical representative visited the site to review the installation in person.

This visit identified areas with restricted access and localised height challenges, prompting on-the-spot adjustments to ensure structural integrity and perfect alignment. These proactive site measures allowed the project to continue smoothly and efficiently.

Overcoming Urban Installation Challenges

The Southville location presented logistical constraints, with narrow access routes and close proximity to residential and commercial properties. Despite these challenges, the modular nature of Wallbarn’s system allowed for controlled delivery, easy handling, and precise installation — even in confined rooftop areas.

The combination of adjustable MetalPad Ex pedestals and lightweight aluminium rails meant installers could work efficiently without compromising on performance or finish. Each section of the system was tailored to suit the specific requirements of its zone, ensuring consistent support, perfect drainage, and long-term reliability.

Recognised Quality and Lasting Impact

The successful completion of The Old Brewery redevelopment underlined Wallbarn’s ability to support complex projects from early design consultation through to site-level refinement. The collaboration with Afan Group exemplified how technical expertise and close communication can deliver outstanding results, even on challenging multi-zone rooftops.

The development has since gained significant recognition, winning Best Residential Development at the Bristol Property Awards 2024 and earning a Highly Commended honour for Best New Development in the South at the First Time Buyer Magazine Readers’ Awards 2024.

Setting the Benchmark for Fire-Rated Roofing Systems

This project showcases how Wallbarn’s Class A-rated substructure systems provide more than just compliance — they deliver strength, adaptability, and architectural precision. By combining robust design with a collaborative approach, Wallbarn continues to set the standard for safe, high-performance rooftop paving solutions across the UK’s most demanding developments.