Galileo - Renovation of 8,000 m² Roof Surface with Sandwich Elements

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Renovation of 8,000 m² Roof Surface with Sandwich Elements

Roof Renovation of Cold Drawn Steel Production

The roof of the C33 cold drawn steel production factory at Siegen, in the company Krupp Edelstahlprofile GmbH, a company of Thyssen Krupp Steel, had to be renovated. The production of cold drawn steel, in which hot rolled bar (resistant to rust, acids and heat) is processed into high quality cold drawn steel by peeler, straightening and grinding machines, runs in this building.

Replacement of 8,000 m² WAZ by a Modern Sandwich Roof

The roof to be renovated consisted of approx. 8,000 m² of corrugated asbestos elements (WAZ), which were to be replaced by a modern sandwich roof due to their age (40 years). The dismantling of the corrugated asbestos sheets and the installation of the new sandwich elements had to take place during continuous operation and without any disruption to production. The product Hoesch isodach integral® in the 95 mm element thickness was selected.

Fast Installation and Outstanding Heat Insulation Uppermost in the Decision

The short time needed for installation (supporting shell, vapour barrier, heat insulation and draught-proofing were laid in one operation) and the outstanding heat insulation characteristics (U = 0.37 W / m² K) were uppermost in the decision for the engineers of Krupp Edelstahlprofile supervising the construction work. In addition, the advantages of the invisible fastening in the longitudinal joints of the elements were assessed very positively.

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Fig. 4.5.2 Technical data of the Hoesch isodach integral® Sandwich Element

Protection Against Corrosion

The metal Galvalume® (aluminium-zinc) coating was chosen for the inner and outer cover shell, because of the potential atmospheric strain. Corrosion protection Class III was achieved in accordance with DIN 55928-8, without additional organic coating. The alloy of 55% aluminium and 43.4% zinc achieves an exceptionally good resistance to corrosion, associated with high resistance to heat. Thanks to the high heat reflection value, the positive heat insulation value of the element is also further reinforced.

Giving the Order

The order for technical processing, delivery and complete installation was given to Hoesch Contecna Systembau GmbH (HCS), Siegen branch.

Planning and Safety Measures

Work began with drawing up the static calculation and the constructional processing. Detailed discussions about the course of installation between the participants took centre stage, in order to be able to carry out the work on the building smoothly and without disrupting production.

The safety measures were jointly discussed and established, in the light of the building’s height of 14 metres, and working while production continued to run.

Scaffolding with protective railings as protection against falling, complete planking under the roof area and safety nets in certain sections were just a part of the safety measures.

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Fig. 4.5.3 Invisible Attachment of the Sandwich Roof Element

Fig. 4.5.4 Planking Safeguards Running Production

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TRGS 519

The conditions and regulations of TRGS 519 had to be observed during work to dismantle the corrugated asbestos sheets.

Explanation: TRGS are the “Technische Regelungen für Gefährstoffe” [technical regulations for dangerous materials]. 519 concerns the “demolition for renovation or maintenance of asbestos”.

Few main points:

o The use of respiratory protective masks and protective clo
o Access to the roof area only across bridges or planking;
o Disposal of material in closed containers
o and many others besides...

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Course of Installation in Pictures