The Old Brewery Bristol: Class A Fire-Rated Rooftop Paving Across a Multi-Zone Regeneration Scheme

The redevelopment of The Old Brewery in Bristol presented a technically complex rooftop paving scheme spanning 400 square metres across five distinct zones. Wallbarn was appointed by installer Afan Group to supply a complete Class A fire-rated paving system, designed to meet stringent fire regulations while accommodating varied slab formats, height ranges and surface conditions.

This regeneration project required detailed planning, adaptability and close collaboration from concept through to completion. The result is a robust, regulation-compliant rooftop system integrated seamlessly into a landmark mixed-use development.

A Multi-Zone Rooftop Challenge

The scheme incorporated both 600 × 400mm and 400 × 400mm × 50mm paving slabs, demanding precise coordination to ensure:

• Consistent structural support

• Accurate rail direction alignment

• Compatibility across changing build-up heights

• Smooth transitions between roof zones

Wallbarn supplied a complete Class A fire-rated substructure solution, including:

• MetalPad Ex adjustable pedestals

• Optional spreader plates

• I-Plus aluminium rails

• Specialised paving headpieces

Each element was selected to ensure full compliance with high-rise fire safety requirements while maintaining flexibility across the five separate rooftop areas.

Evolving Design and Flexible Adaptation

Initial engagement began in June 2024 with a virtual Teams meeting. Wallbarn received PDF plans, issued a preliminary quotation and proposed an initial layout concept.

However, the project paused for several months before resuming in December with revised drawings. These updated plans required a full reassessment of the system design, including:

• Changes to rail direction

• Adjustments to height ranges

• Refinements to suit the functional needs of each zone

A series of collaborative virtual meetings followed, during which Wallbarn worked closely with Afan Group to refine the layout and ensure seamless integration across all roof sections.

This iterative approach ensured that every component aligned with the evolving architectural and structural requirements.

On-Site Problem Solving in Constrained Conditions

Once materials were delivered to site, Wallbarn conducted a detailed site visit, attended by a technical team member and a Director. The inspection revealed several tight-space areas where standard layout configurations required localised modification.

Rather than imposing rigid solutions, Wallbarn proposed and implemented alternative approaches directly on site, ensuring:

• Optimal fit within confined sections

• Continued compliance with fire safety regulations

• Structural integrity across all zones

• Clean and consistent final finishes

This hands-on support reinforced the project team’s confidence and allowed installation to progress efficiently despite spatial constraints.

Regenerating a Historic Bristol Landmark

The Old Brewery redevelopment is part of a major regeneration of the historic Ashton Gate Brewery site, which dates back to 1829. The scheme blends new-build construction with the careful refurbishment of original brewery buildings, preserving the area’s industrial heritage while delivering modern residential and commercial spaces.

The development includes:

• 107 affordable homes

• Seven commercial units

• Sensitive restoration of historic structures

Located in Southville, an inner-city ward of Bristol, the site presented logistical challenges due to restricted access and proximity to neighbouring residential and commercial buildings. Careful coordination of deliveries and installation sequencing was essential to minimise disruption.

A Nine-Month Collaborative Journey

From initial contact to final site support, the project spanned approximately nine months. Throughout this period, Wallbarn remained actively engaged in:

• Design updates and layout revisions

• Quote adjustments reflecting specification changes

• Technical coordination meetings

• On-site inspection and problem solving

This continuous involvement ensured that the Class A fire-rated system was not only supplied correctly but integrated effectively into the broader redevelopment programme.

Delivering Structural and Safety Assurance

The completed rooftop paving system achieves full Class A compliance while accommodating complex slab formats and varying height requirements across five distinct zones.

Key performance outcomes include:

• Stable, adjustable support using MetalPad Ex pedestals

• Enhanced load distribution via optional spreader plates

• Strong and consistent alignment with I-Plus aluminium rails

• Precise slab support through specialised paving headpieces

The flexibility of the system allowed design changes to be absorbed without compromising safety or structural integrity.

Award-Winning Recognition

The quality and impact of the redevelopment have since been formally recognised. The project was awarded Best Residential Development at the Bristol Property Awards 2024 and received Highly Commended for Best New Development in the South at the First Time Buyer Magazine Readers’ Awards 2024.

These accolades reflect the success of the wider regeneration scheme — and the importance of delivering compliant, well-engineered rooftop systems that support long-term residential and commercial use.

A Proven Approach to Complex Rooftop Schemes

The Old Brewery project demonstrates how Wallbarn’s Class A fire-rated systems can be adapted to complex, multi-zone rooftop environments within sensitive regeneration sites.

Through flexible design adaptation, proactive communication and close collaboration with Afan Group, Wallbarn delivered a bespoke solution capable of supporting varied paving layouts without compromise. The project stands as a strong example of how careful planning, technical expertise and responsive on-site support combine to deliver safe, durable and award-winning outcomes.