Radiused Aluminium Verge Flashings at Coychurch Crematorium

The brief 

Coychurch Crematorium holds huge importance for the community of Bridgend in Wales – a special location to hold cremation and funeral services to mark the passing of loved ones. Since its initial opening in 1970, the crematorium has allowed countless families and friends to hold special services and celebrations of life for the deceased. 

To add an extra special touch to the services and allow congregations to exit the chapel more easily, the crematorium embarked on a new project to build a state-of-the-art flower court. The court was designed to respect and complement the unique character and history of the Grade-II listed building, while its roof was to be made up of a series of radial arches to provide a decorative, modern touch. 

The new extension required aluminium verge flashings that matched the curved design on the building, while weatherproofing the structure and creating a neat and aesthetically pleasing finish.

Our challenge 

The client initially found it challenging to commission the work, having approached multiple metalworkers and been turned down due to the complex nature of the project. Not only did the verge flashings need to be high quality and innovative to complement the extension’s prestigious modern appearance, but the project posed several other challenges. 

While aluminium typically works well for straight parts and components, it cannot be easily shaped into curves using standard methods. The finished solution had to be precise and immaculate. Any warping at welded joints or visible fixings would compromise desired flawless finish. 

With no ‘off-the-shelf’ solutions available and other metalworkers unwilling to attempt the job, the client discovered Volund and appreciated the team’s enthusiastic can-do approach to bespoke and custom metalwork projects. 

Excited to showcase our expertise and help make the crematorium’s special vision a reality, we got to work.

Our solution 

Putting our extensive experience in metalworking and engineering to the test, we embarked on a long process of research and development to meet the project’s needs. This included: 

Prototyping:

We made test sections to study distortion and refine welding methods, and built custom jigs to hold parts in place during welding to ensure accuracy and a smooth finish.

Welding innovations:

The team designed 2.5-metre fully welded sections to handle the thin aluminium sheet construction with unsupported surfaces. These sections were subject to severe distortion, as shown, requiring innovative trial-and-error methods to solve warping issues. The team tested different joint designs and finishing techniques to achieve a flawless finish.

Joining:

With the design requiring on-site joining, we developed an internal joint system using a ceramic tile spacing tool and adhesive. The bonded joints were tested for integrity and sections of the structure were offered up to try on-site to confirm the fit and fixing arrangement. 

Improvements:

Determined to achieve the best possible dimensional and aesthetic integrity, we continued to experiment and adjust designs and methods based on lessons learned during development. This included increasing material thickness to reduce warping.

The finished product

The finished product exceeded the expectations of the client and architects, with the parts crafted to the highest standards and perfectly matching the intended aesthetic. The radiused aluminium verge flashings are visually and structurally perfect as per the client’s exacting demands, with no visible fixings, joints or distortions. 

Not only did the research and development process achieve the desired outcome for this particular project, but the documented process and designs can now be used to guide similar projects in future.

Malcolm Pearce​​​​, Founder and Senior Engineer of Volund & Customised Sheet Metal commented: “This project is a testament to the hard work, creativity and precision of the Volund team. Together we can overcome challenging projects to deliver outstanding results. 

“Not only has it allowed us to showcase our technical skills and cement our reputation as a leader in handling complex, high-profile projects, but it has also allowed us to fulfil the vision for this incredibly special project in the Bridgend community. We look forward to helping the crematorium with its next phase of work and vision for the future.”