When the canopy roof above a row of shops in Mellor, Lancashire started to visibly sag, it wasn't just an eyesore — it was becoming a genuine safety risk. The original timber structure had rotted through over the years, the boards were sagging badly, and it was only a matter of time before something gave way. The shop owners needed it sorted properly, and fast. Here's how we did it.
The finished result — new white uPVC soffits, clean and safe
This is what the finished canopy soffit looks like from below — crisp white uPVC soffit boards running the full length of the canopy, perfectly level and clean. Where there was once dark, rotting, sagging timber that posed a real danger to anyone walking underneath, there is now a smart, durable, maintenance-free finish that will last for decades. The transformation is night and day.
The completed canopy — front elevation, Mellor village
The front elevation tells the full story of the transformation. The new white uPVC fascia runs cleanly across the full width of the canopy, the EPDM rubber roof sits flat and weathertight above, and the whole structure looks exactly as a well-maintained commercial canopy should. Mellor Pharmacy and the neighbouring shops now have a safe, smart frontage they can be proud of.
The completed EPDM roof — view from above, car park side
Looking down from above, the new EPDM rubber membrane is fully bonded across the entire canopy roof — no joins, no weak points, no patches. The uPVC edge trim finishes it neatly all round. This is a roof that will perform for 20+ years without needing attention.
Completed roof — second elevation view
A second angle from above shows the full extent of the roof and the quality of the edge detail. The uPVC trims are mitred neatly at the corners and the membrane is terminated cleanly underneath — no exposed edges, no risk of water ingress at the perimeter.
Before — the dangerous sagging canopy that started it all
This is what we were dealing with when we arrived. The original timber soffit boards were visibly rotting and sagging — dark, wet, and structurally compromised. The timbers above them were in the same state. For anyone walking underneath this canopy every day, it was a genuine hazard. This needed stripping out completely, not patching.
Before — the full canopy in its original state
The full frontage before we started — the dark, tired canopy running across the full width of the shops. You can see how the original structure had lost its shape and was beginning to fail. The shops themselves are well-kept and well-used by the local community; the canopy simply hadn't been maintained and had reached the end of its serviceable life.
Stripping out — rotten timbers removed, new frame going in
Once the rotten material was stripped out, we could see the full extent of the damage — and get to work properly. We installed a completely new timber roof frame, extending the structure where needed and fixing everything with coach bolts for a solid, permanent connection. No shortcuts, no bodges — a proper structural rebuild from scratch.
New timbers and coach bolts — the extended roof frame
The new timber frame in detail — fresh, treated joists fixed with structural coach bolts throughout. The roof was extended to the correct overhang, giving the shops proper weather protection and a clean, consistent line across the full frontage. This is the foundation everything else sits on, and it's built to last.
Decking going on — OSB boards across the new frame
With the frame complete, the OSB decking boards went on across the full span — cut to fit, fixed down tight, and creating the flat, rigid surface needed for the EPDM membrane above. Every board is screwed down to the joists to prevent any movement or flex once the roof is in service.
EPDM membrane being laid — the waterproofing layer
The EPDM rubber membrane going down — fully bonded to the OSB deck with contact adhesive, laid in a single piece with no joins across the main field. EPDM is the industry-standard choice for flat roofing of this type: it's proven over 50 years, carries a 20-year guarantee, and handles the freeze-thaw cycles of a Lancashire winter without cracking or lifting.
EPDM complete — view from above before soffits
The EPDM fully bonded and the edge trims in place — the roof is now completely weathertight. At this stage the structure above is done; all that remains is the uPVC soffit and fascia work below to finish the job and give the canopy its clean, smart new appearance.
Fully installed by our own team — no subcontractors
As with every project we carry out, this Mellor canopy roof replacement was fully managed and installed by our own team from start to finish — strip-out, new timber frame, EPDM membrane, and uPVC plastics. No subcontractors, no handoffs, and a single point of accountability throughout. The shops were trading throughout the works, and we made sure the site was safe and tidy at the end of every day.
Need a flat roof or canopy replaced in Mellor or across Lancashire?
Whether it's a commercial canopy, a domestic flat roof, or anything in between, we cover Mellor, Blackburn, Preston, Chorley, Bolton, Burnley and the whole of Lancashire and the North West. If your roof is showing signs of rot, sagging, or water ingress, don't wait until it becomes dangerous — get in touch and we'll come and take a look.