MAR.ZINC. – Complete replacement of industrial roofing

Manini Service has completed a industrial roofing replacement intervention of approximately 5250 sq.m. at Mar.Zinc. srl zinc-coating plant in Scarlino (GR).

The structure was produced by another prefabricator in the late 90s with a roof formed by prestressed reinforced concrete main beams supporting Y-section roof tiles that supported curved sheets of cellular fiber cement. The opaque roofing was interspersed with translucent fiberglass sheets that rhythmically created zenith skylights for the building’s internal lighting. Originally, there was also a ceiling in the building, with fiber cement false ceiling panels that were previously removed by the property owner. The choice of intervention was dictated by the widespread degradation detected on the prefabricated roof tiles: on the edges of the Y-shaped tile cups, concrete crumbling was occurring, causing some fiber cement roofing sheets to fall. The phenomenon was most likely caused by the particularly aggressive environment to which they are exposed due to the specific processes carried out inside the building.

The intervention, entirely designed by Manini, involved dismantling the sheets and all Y-shaped tiles and the subsequent positioning of new prestressed reinforced concrete wing tiles “Tegoli Ondal”, placed exclusively in correspondence with the existing pillars. In this way, a roofing system was designed with equivalent weight between the existing and the new one, increasing the distances between the tiles, maintaining the seismic behavior of the structure unchanged.

In place of the zenith skylights, micro-shed type windows were positioned, with some panels always open and protected from atmospheric agents with slats for the evacuation of production fumes: a tailor-made solution, of dimensions suitable to satisfy the aero-lighting requirement requested by our client. These support a new roof covering in straight bi-sheet, insulated panels. Particular attention was paid to the treatments of all metallic technological components present on the roof. The technological solution of the new roof, also through the installation of permanent fall protection systems, is walkable.

Synchronization between our production plant and the construction site, coordination of workers and equipment for the entire duration of the work, allowed for the success of the project. Difficulty significantly increased by the production line installations present inside the building that significantly occupied the maneuvering spaces.

The intervention was minimally invasive for the client: activities were programmed and concentrated during the summer production shutdown. With three weeks of closure in August, Manini Service dismantled the existing roof, installed the new tiles, and positioned the straight sheets of insulated metal panels, so that upon return from vacation, our client already had a building with a roof, albeit not complete, already functional and suitable to host the production activity.

The most delicate, but at the same time most spectacular phase was the handling of prefabricated elements both in the removal and then in the positioning of the new beams. The movements were carried out in an existing building with evident increase in work difficulties: operating in the presence of existing structures increases the complexity of every operation, requiring extraordinary degrees of precision possible only with know-how acquired over years of experience.

Through the synergy between company departments, technical knowledge and operational expertise, Manini Service provides interventions of the highest technological and engineering level with results of technical and aesthetic quality. Because beauty, our founding value, is reflected in what we do, shaping solutions with high engineering content into aesthetically satisfying interventions.