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.

For a full overview of the project, you can view the official Class A fire-rated substructure project in Bristol case study.

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 paving slabs
• 400 × 400mm × 50mm paving slabs

This required 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 fire-rated pedestals
• Optional spreader plates
• I-Plus aluminium rail system
• Specialised paving headpieces

Each element was selected to ensure:

• Full compliance with high-rise fire safety regulations
• Structural reliability across all five zones
• Flexibility to accommodate varying site conditions

Evolving Design and Flexible Adaptation

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

Following a pause in the project, revised drawings were issued in December, requiring a full reassessment of the system design. Key changes included:

• Adjustments to rail direction
• Revised height requirements
• Layout refinements across individual zones

A series of collaborative meetings followed, with Wallbarn working closely alongside Afan Group to refine the system using solutions such as the Class A1 rail substructure system, ensuring:

• Seamless integration across all roof areas
• Alignment with structural and architectural requirements
• Continued compliance with fire regulations

This iterative approach allowed the system to evolve alongside the design.

On-Site Problem Solving in Constrained Conditions

Once materials were delivered, Wallbarn conducted a detailed site visit involving both a technical specialist and a Director. Several constrained areas were identified where standard layouts required adjustment.

Wallbarn responded by:

• Proposing alternative layout configurations
• Adapting pedestal and rail positioning
• Providing real-time technical guidance

This ensured:

• Optimal fit within tight spaces
• Continued compliance with fire safety standards
• Structural consistency across all zones
• Clean and uniform finishes

The flexibility of systems such as the I-Plus aluminium rail framework and MetalPad Ex pedestals was key to overcoming these challenges.

Regenerating a Historic Bristol Landmark

The Old Brewery redevelopment forms part of a wider regeneration of the Ashton Gate Brewery site, dating back to 1829. The project blends heritage preservation with modern construction.

The development includes:

• 107 affordable homes
• Seven commercial units
• Restoration of historic brewery structures

Located in Southville, the site presented logistical challenges, including:

• Restricted access
• Proximity to residential and commercial buildings
• Careful coordination of deliveries

A structured approach to sequencing and system installation ensured minimal disruption throughout the build.

A Nine-Month Collaborative Journey

From initial consultation through to completion, the project spanned approximately nine months. During this period, Wallbarn remained actively involved in:

• Design revisions and layout optimisation
• Quote updates reflecting specification changes
• Ongoing technical coordination
• On-site inspections and problem solving

This continuous engagement ensured the effective integration of systems such as:

• MetalPad Ex pedestals
• I-Plus aluminium rails
• Class A1 rail substructure solutions

Delivering Structural and Safety Assurance

The completed system delivers full Class A fire compliance while accommodating varied slab formats and height differences across five zones.

Key performance outcomes include:

• Stable and adjustable support using MetalPad Ex pedestals
• Improved load distribution with spreader plates
• Strong alignment through the I-Plus aluminium rail system
• Enhanced flexibility using the Class A1 rail substructure system
• Precise slab support via specialist paving headpieces

This flexibility allowed the system to absorb design changes without compromising safety or performance.

Award-Winning Recognition

The redevelopment has received significant industry recognition, including:

• Best Residential Development – Bristol Property Awards 2024
• Highly Commended – Best New Development in the South – First Time Buyer Magazine Readers’ Awards 2024

These awards highlight the success of the overall scheme and the importance of delivering compliant, high-quality rooftop systems.

A Proven Approach to Complex Rooftop Schemes

The Old Brewery project demonstrates how Wallbarn’s Class A fire-rated systems can be successfully adapted to:

• Complex, multi-zone rooftop layouts
• Sensitive regeneration sites
• Varying structural and design requirements

Through:

• Flexible system design
• Proactive communication
• Hands-on technical support

Wallbarn delivered a bespoke solution capable of supporting diverse paving layouts without compromise.

To explore the full project in detail, visit the Bristol fire-rated substructure case study.

Conclusion

This project stands as a strong example of how:

• Advanced fire-rated systems
• Precision-engineered substructures
• Collaborative project delivery

can combine to produce safe, durable and award-winning outcomes.

By integrating solutions such as the I-Plus aluminium rail system, Class A1 rail substructures and MetalPad Ex pedestals, Wallbarn continues to set the standard for compliant and high-performance rooftop installations.