Most factory roofs normally span a large area and to balance the size to be covered and natural lighting requirements one would normally see factory roofs covered with IBR, Corrugated, Polycarbonate and / or fibreglass sheets. Additionally, and the focus of this article, Georgian Wired Glass Windows and Internal Box gutters / gulleys.
The combination of these elements historically combined to create a saw-tooth factory roof. Essentially the roof profile matching its namesake and creating “bays” beneath.
Over time sections of this type of roof structure would require maintenance and if neglected for too long possibly replacement.
We have previously provided some information on industrial roof maintenance and this is available at https://dampcon.com/2024/06/13/dampcon-industrial-roof-maintenance-pointers/
Vertical Windowed Sections:
These sections would have historically been covered using Georgian wired glass windows and in some applications possibly fibreglass sheeting. Todays installations are most likely to be Polycarbonate Sheeting.
Additionally sourcing Georgian wired glass in South Africa today is time consuming and expensive and more likely would need to be imported. The more practical approach may in fact be to remove the wired glass and frames and retrofit the vertical surface with polycarbonate sheets to match to roof profile. This along with the correct cover and drip flashings has proven to be a suitable long term solution in major maintenance projects.
Alternatively, one could reuse the window frames and replace the Georgian Wired Glass Panes with suitable safety glass.
Internal Box Gutters:
As the factory ages these areas become prone to leakages. This is especially true since these box gutters / gulleys carry and discharge all the water from the roof surface to the ground via downpipes.
Additionally these sections are subject to a considerable amount of moisture throughout the year, in addition to rain and hail, in terms of dew and frost.
Box Gutters normally constructed of steel corrode over time. The result is ongoing waterproofing and maintenance, the relining of the gutter or in extreme circumstances, replacement.
Noteworthy, is the span of these box gutters. Longer lengths normally are normally constructed of sheets bent to specification and welded together. The result of this is generally an undulating surface that results in sections of ponding.
Add to this, the tendency of these box gutters to fill with dust, bird dropping and tree debris which often forms a wet sludge at the base of the gutter. This continually wet sludge with the high ammonia content of bird droppings accelerates the corrosion of the metal. It is common to see this corrosion on the side walls of your box gutter where this wet sludge and atmosphere interface.
Generally the original downpipes in older structures were also steel. They corroded with age and at some stage would require retro-fitment with more modern and cost effective materials.
Lining your box gutters early on with a suitable waterproofing system combined with regular cleaning and maintenance can extend their lifespan almost indefinitely.
It is also important to note that not all leaks occurring on or around box gutters stem from the gutters themselves. Roof leaks occurring further up the line may run down either the roof truss / beam or sisalation / insulation layer where fitted and still only discharge inline with the box gutter.
And lastly, do not underestimate the importance of hail guards in regions that experience hail storms.
Asbestos Roof Sheets:
This is worth a notable mention as some older factories and warehouses are still covered by roof sheets containing asbestos. This normally takes the form of the Big 6 sheet profile. There are major health risks associated with asbestos dust and per the department of labour can only be removed and disposed of by approved and registered contractors.
In general newer fibre cement sheet manufacturers no longer make use of asbestos due to the associated long term health complications which have been well documented.
Solution:
We, at Dampcon, have the expertise to correct assess, report on and repair your factory roof using the latest material technologies to match cost effectiveness with durability. Feel free to contact us at https://dampcon.com/home/ or visit our LinkedIn profile at: https://www.linkedin.com/company/dampcon/
