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Case Study: Pre-Solar Roof Overhaul & Underlay Restoration in Dunshaughlin, Co. Meath

  • Location: Dunshaughlin, County Meath
  • Project Type: Pre-Solar Inspection, Eaves Felt Replacement, Re-Battening & Ridge Repointing
  • Property Type: Two-storey detached suburban home
  • Duration: 1–2 Days
  • Primary Materials: Don & Low RoofTX® Maxi breathable underlay, pressure-treated timber battens, weather-rated high-bond roofing mortar, reinstated interlocking concrete profile tiles.

Project Overview

A homeowner in Dunshaughlin reached out to DJ Roofing ahead of a scheduled rooftop solar PV installation. Mounting solar panels involves securing heavy framing brackets directly into structural roof rafters, where they will remain undisturbed for 25 to 30 years. Installing expensive solar arrays over aging felt or compromised timber is a costly trap: if a leak develops underneath the panels later, the entire solar array has to be decommissioned and reinstalled at significant expense just to carry out a basic roof repair.

The client wanted complete peace of mind that her roofline was sound, storm-ready, and fully watertight before the solar mounting brackets were bolted down. Our team carried out a free comprehensive roof inspection, identified several localized points of decay, and completed targeted structural repairs to prepare the roof deck for solar loading.

The Inspection & Problem Diagnosis

While the main body of the concrete roof tiles remained structurally sound, our inspection uncovered key failure points that required remediation before solar panels could be fitted safely:

  1. Deteriorated Felt on Eaves and Overhangs: The original bitumen roofing felt beneath the bottom four to five tile courses had rotted, flaked, and perished with age. Water pooling near the fascia board had degraded the felt edges, leaving the attic insulation and timber wall plates vulnerable to wind-driven rain penetration.
  2. Saturated & Brittle Battens: Beneath the lower tile courses, moisture trapped by the failing felt had begun degrading the original timber battens. Rotted battens lose their structural nail-holding capability, meaning they could not reliably support roofers or solar installation crews walking across the pitch.
  3. Missing Mortar on Ridges and Valleys: Natural expansion, winter frosts, and seasonal winds had loosened and eroded the original bedding mortar along the ridge capping and valley cuts. Missing mortar gaps allowed water ingress and created points where storm-force winds could catch and lift tiles.

Materials & Technical Specifications

  • Breathable Underlay: Don & Low RoofTX® Maxi — high-performance, BBA-approved, tear-resistant vapor-permeable membrane engineered to block wind-driven rain while venting interior humidity safely to prevent attic condensation.
  • Roofing Battens: Vacuum pressure-treated timber battens and counter-battens treated with timber preservatives to resist wet rot and fungal infestation.
  • Mortar Mix: Weather-rated roofing mortar enhanced with bonding agents for durable adhesion along high-stress ridges and valley cuts.
  • Roof Tiles: Existing interlocking double-roll concrete tiles, cleaned, inspected, and securely reinstated.

Work Carried Out: Step-by-Step

1. Stripping and Stacking Lower Courses

Our crew carefully stripped back four to five courses of interlocking concrete tiles along both the front and rear roof elevations. Sound tiles were inspected, cleared of moss, and stacked safely on surrounding battens to keep the work area clear and avoid unnecessary waste.

2. Removal of Degraded Sub-Structure

All rotted bitumen felt, rusted fixing nails, and decaying timber battens were stripped down to the structural roof timbers. Rafter tails and wall-plate timbers were checked for moisture damage, dried out, and swept clear of residual debris.

3. Installing RoofTX Maxi Breathable Membrane

We measured and rolled out RoofTX Maxi vapor-permeable membrane across the exposed eaves, securing it taut with adequate horizontal laps over the sound existing felt further up the pitch. The breathable membrane was extended cleanly into the gutter line to guarantee smooth water runoff away from the timber fascia.

4. Counter-Battening & Re-Battening

New pressure-treated structural timber battens were measured, spaced to the correct tile gauge, and fixed directly into the rafters using corrosion-resistant nails. This created a secure, straight mounting frame ready to carry the weight of both the tiles and future solar panel brackets.

5. Re-Tiling & Interlock Alignment

The salvaged concrete tiles were reinstated course-by-course onto the fresh battens. Each tile was interlocked and seated flush to match the existing roofline, maintaining water drainage channels across the pitch.

6. Ridge and Valley Mortar Restoration

To complete the overhaul, our crew repaired the ridge lines and valleys. We removed loose, fractured mortar along the apex ridge caps, repointing and re-bedding them securely with weather-rated mortar to prevent wind lift. Valley cuts were likewise cleared and pointed, preventing rain from driving beneath the cut edges.

Project Outcome: Solar-Ready and Built to Last

By proactively repairing the roof before the solar installation, the homeowner avoided future leaks and avoided the high labor costs of removing solar panels down the line.

As trusted Roofers Meath homeowners rely on for honest assessments, DJ Roofing completed this project in under two days. The roof deck is now structurally sound, the underlay is completely renewed with modern breathable technology, the ridge caps are secured against storm damage, and the property is fully prepared for the solar installation team to commence mounting.

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