The five-year design and development process of Bute3® resulted in a brand new roof tile created in response to a number of market demands.
With over four decades of technical expertise, Mark Parsons, Technical Director at Russell Roof Tiles led the design and development team for the new product, as well as involvement in its manufacture on a new style of production line.
A leading expert in the industry, Mark has been heavily involved with several national trade bodies and associations during his career.
Mark explains:
The tile has evolved from discussions following on from when the Galloway roof tile was successfully launched in the market but was only seriously considered in 2014 when we could see that the process and advances in technology could be capable of manufacturing this new format of roof tile
Who was involved?
The development was a collaborative effort involving multiple teams. Internally, we had our technical department involved in the process, working in sync with production manufacturing colleagues as well as R&D. Externally, we partnered with specialist design engineers to bring our vision to life.
Aggregate, cement and admixture suppliers such as were also involved at key stages of the project. From the beginning, we engaged with them to assist in sourcing the highest-quality materials that would allow us to achieve the Wide 3 tile profile yet small Plain tile camber and strong robust design of Bute3® Regular meetings ensured that our suppliers understood our goals and were able to refine the material properties as the design evolved.
The initial concept
The initial concept for Bute3® and all its accessories underwent numerous iterations throughout their development stages. The Russell Roof Tiles’ philosophy and product quality consider both the customer’s and installers’ needs to ensure ease of use and seamless integration with fixings and accessories. This enables us to provide a quality roof covering with energy efficiency and durability at its core. The design for Bute3® started out focusing primarily on aesthetics and technical goals and quickly expanded to include advanced functional features.
Meeting customer requirements
Dedicated research and development with Roofing Contractors and Housebuilders allowed us to continue to consider the requirements of both the fixers and end users throughout the design process of Bute3®.
All aspects, from local planning authorities right through to the contractor’s work practices, usability, and site safety (including stacking and loading out tiles, to the actual fitting of the tiles), directly influenced the design refinements. For example, the weight and feel in the hand, the functionality of the nibs, nail holes in positioning of tiles on the batten, and even the simplicity of the bespoke tile clip steered us to consider subtle adjustments that enhanced both the look and usability of the product. This design formula helped to ensure that Bute3® not only met our internal standards but also more importantly aligned with our customer’s needs.
Secondly feedback from our internal teams Technical, Sales and Logistics checking early prototypes, to make key adjustments to enhance the transportation and handling with the ease of installation, ultimately leading to a product that met both our design and performance goals. Our primary goal throughout was always to make things simple and easy for our customers while delivering a cutting-edge solution.
Key developments were led by comprehensive technical knowledge and expertise, which shaped the final product. One of the major initial design choices at the outset was the decision to create a wider tile with the appearance of Three Plain Tiles to make the speed of installation quicker and easier.
The testing process
Early prototypes were made in both 2D and 3D with 4 versions being modelled. The testing phase involved close collaboration with our technical, production, and quality control teams. We utilised external testing facilities such as the BRE (Building Research Establishment), the leading global advisors who help to develop science-led solutions for built-environment challenges. We worked with them to carry out wind driven rain performance testing in a wind tunnel in conjunction with personnel from our own experienced technical department.
A comprehensive approach has ensured that Bute3® met the key industry standard BS EN 490:2011 Concrete roofing tiles and fittings for roof covering and wall cladding – Product specifications (+A1:2017) and BS EN 491:2011 Concrete roofing tiles and fittings for roof covering and wall cladding – Test methods
Balancing aesthetic and technical function
A key challenge during the development process of Bute3® was striking the balance between aesthetic and technical functionality. Achieving a thin traditional tile profile whilst ensuring structural integrity was no small feat. From the initial vision to making it a reality, we needed to push the boundaries of material technology to get the desired look without compromising on durability.
Designing a production line for a tile width that had never been made this way before was key to this process. With innovative thinking from the entire internal project team and decades of experience, we were able to create a solution to overcome this.
We evolved new production methods, with the latest vapourised curing system, which integrates technologies developed by leading European industries to achieve the optimal balance between the tiles desired look and function. Curing is an essential part of the successful manufacture of roof tiles, and this ensures maintaining high consistency of concrete mix in every tile.
New production facilities were designed specifically for the new product, at our main tile plant in Burton on Trent. The investment project, our largest to date, includes the construction of a new ground-breaking batching plant, complete with a mixer to facilitate increased concrete roof tile production.
The Ethos and journey to bring Bute3® to life contained a number of challenges, but the result is a credit to the collaborative effort of all involved, combined with the evolution in technology utilised. The development of this roof tile has been an exercise in pushing the boundaries of design, manufacturing, and technology.
We are all proud of this innovative new addition to our tile range.
Gratification of receiving the 2026 Roofing Solution of the Year at the prestigious Show home Readers’ Awards marks the first industry award win for Bute3® and acknowledges that the UK needs robust revolutionary new products to move the pitched roof sector forward.
Russell Roof Tiles has made a substantial investment with Bute3® which demonstrates its stance and commitment to the future UK-pitched roofing industry.
