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At the end of 2023, our roofing client in Portugal finished a very challenging project of the renovation of the roof of Caetano Bus factory in Porto, Portugal. This project was remarkable not only because of its size (20.000 m2) but especially because of the complexity and risks involved in execution. The complexity of the roof forms, the steeply pitched circular surfaces, the presence of numerous roof penetrations such as chimneys or the posts of the metal walkways, and the type of simple corrugated sheet several decades old that was significantly brittle and even interspersed with large translucent areas, impossible to walk on.
The solution was studied and decided that the membrane would have to be bonded to the insulation previously mechanically fastened to the structure with a special fixing solution, known as a flower rivet. Large format PUR/PIR were used to ensure a solid and stable substrate for the membrane application. The membrane used was the KÖSTER TPO 1.5 F, a very robust sheet with almost 2,5 mm thickness, with a centrally embedded glass fleece reinforcement and a polyester fleece-coated underside applied with KÖSTER PUR Membrane Adhesive, to ensure a secure connection between the membrane and the insulation.
With this application, the client installed 256 solar tubes that allow natural light to illuminate the factory interior. The statements from Caetano Bus employees describe the superior comfort of the building now. The various leaks that have been eliminated, the pleasant temperature, and the brighter interior environment increase productivity.
A video of the project:
