Reimagining the roof

When Whiteacre Developments Ltd began planning two large, high-end homes in Dorridge, West Midlands, their goal was to create spacious, modern properties with fully usable attic rooms, without relying on a cut roof or extensive steelwork. The original architectural design included large, cranked steel beams, but the client was concerned about cost, buildability, and sustainability.

To explore a timber-based alternative, the developer contacted Ranjit Gill, Senior Designer at Wyckham Blackwell Ltd, known for solving complex roof design challenges using engineered trussed rafter systems. Ranjit was asked to assess whether the steel-dependent design could be reimagined using trusses, with the aim of eliminating as much steel as possible, without compromising internal space or ceiling heights.

About the project

The two homes are substantial three-storey properties.

Plot 1 has a 220m² footprint with a 94m² attic room, whereas Plot 2 is 215m² with a 90m² attic. The third-storey attic rooms were to be fully usable spaces, designed to accommodate a gym, home cinema, guest bedrooms and bathrooms.

A steep 55° roof pitch was used to maximise head height in the attic and avoid dormer construction, helping the homes comply with local height restrictions. The design also featured vaulted ceilings above the hallways and master bedrooms, as well as multiple rooflights across both pitched and flat roof areas to enhance natural light.

Flat roof sections were included for the placement of solar panels, hidden from view to preserve the visual character of the buildings. Plot 1 used full-span attic trusses spanning 10.56m to achieve an attic room width of 8.513m. Plot 2, with a more complex internal layout, required a combination of half-span attic trusses bearing onto a central load-bearing wall.

Technical challenges and solutions

The primary technical challenge was to remove the need for cranked steel beams and deliver a fully engineered trussed rafter solution that could preserve the architect’s original internal layouts.

To do this, Ranjit and his team designed trusses that performed dual roles, supporting the roof and forming internal stud partition walls. This allowed steel lintels at the first-floor level to be hidden within the wall build-up while enabling the attic rooms to remain clear, open, and functional.

Another issue was the cantilevered landings, where the client requested a clean, open finish without newel posts. Ranjit created a floor-depth truss with a built-in opening to support a cantilevered solid timber beam, allowing floor joists above the staircases to be supported without introducing visible supports.

One of the most complex steel elements – a large ridge beam specified for the vaulted master bedrooms was replaced with a bespoke 3-ply ‘Wolf Chord’ timber beam. This comprised 223mm and 175mm timber members plated together for a total depth of 398mm. The beam met structural and deflection requirements, was easier to install, and significantly reduced material cost.

All of this required detailed coordination between the Wyckham Blackwell design team and the site management team to ensure sequencing, load paths, and tolerances were met on-site.

Health and safety

Health and safety were embedded from the outset. Ranjit conducted a detailed site survey to check delivery access, verify structural dimensions, and ensure there were no obstacles to installing long-span trusses.

All trusses were delivered with pre-attached lifting slings so they could be craned directly from the delivery lorry to the roof. This removed the need for manual handling and significantly reduced installation risk.

For areas with vaulted ceilings, such as entrance halls, Ranjit’s team designed full-span trusses with marked sections of ceiling chord that could be safely removed on-site after installation, maintaining handling stability during lifting while meeting the design brief.

Pre-start meetings between Wyckham Blackwell, the site manager, and the erection team ensured everyone was aligned on logistics, safety procedures, and installation order.

Sustainability measures

The switch from a steel-based roof design to a timber trussed rafter solution reduced the project’s environmental impact. Trusses were manufactured using PEFC-certified timber, while wall plates, bracing, and plywood were all FSC-certified, ensuring full supply chain traceability and responsible sourcing.

By eliminating the need for large roof-level steel beams, Ranjit’s redesign cut embodied carbon and simplified the construction process. Only minor steel elements were retained at the first-floor level, where they had already been required in the original layout.

The use of prefabricated trusses reduced waste on site, improved material efficiency, and accelerated the build schedule, supporting both sustainability and cost-effectiveness.

Lessons from the project

One of the standout outcomes of this project was the success of using trusses to form both the structural roof and key internal partition walls. This reduced build time, eliminated the need for additional framing trades, and ensured smoother sequencing.

Ranjit’s early involvement with both the architect and the erection team meant that challenges were identified early, and practical solutions could be designed in, rather than applied later. This collaborative approach improved installation speed and avoided delays.

Above all, the project reinforced the value of timber solutions in high-end residential developments. Through early planning and execution, Ranjit and the Wyckham Blackwell team delivered a roof structure that was practical, cost-effective, visually clean, and sustainable, without compromising any aspect of the client’s original brief.

About the designer

Ranjit Gill has worked in the timber engineering sector for over 20 years. He began his career at Wolf Systems in 2005, gaining experience across a range of roof types and building scales. He also led technical training for customers and helped develop training materials.

At Wyckham Blackwell, Ranjit combined his technical design knowledge with practical site experience by working alongside the company’s erection team. This hands-on insight allows him to create roof designs that work both on paper and on site. He is now Senior Designer and specialises in complex, high-spec residential projects that require efficient solutions to challenging design problems.

Ranjit Gill was named winner of the Residential Project of the Year at the TRA Roofscape Design Awards 2025. The judges praised the project for its technical innovation, use of sustainable materials, and the ability to deliver complex architectural requirements using timber rather than steel.