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In 2016, Wernesgrüner, a brewery which has been commercializing one of the most popular beers in Germany since 1436, launched a vast renovation of the roof of its loading hall. After 20 years of service, the roofing system consisting of a vapor barrier, a 100 mm thick layer of mineral wool insulation and a PVC roofing membrane had reached the end of its lifespan.
The vast loading hall, which serves as a bustling "drive-in" where 30-ton trucks are loaded with beer pallets, boasts an impressive height of 15.50 meters and spans an area of approximately 1,250 m². Its structural integrity relies on trapezoidal sheets resting on concrete beams.
UltraPly TPO 1.5 mm
For the renovation, the building owner called on roofing contractor Spenglerei Marcel Möckel. Their only requirement: that the existing PVC roofing membrane had to be replaced by a thermoplastic one. Spenglerei Marcel Möckel had been working for several years with Elevate products, mainly with the RubberGard EPDM roofing system, both for new build and renovation, so they suggested using Elevate’s UltraPly TPO thermoplastic membrane. "The installation of UltraPly TPO in this project was a first for us” said the head of Spenglerei Marcel Möckel. “Regular exchanges with the Elevate team and their support throughout the project were very reassuring," he added.
During the design phase, Elevate provided detailed calculations on the wind load, advised the replacement of the existing insulation on the eaves and proposed an extended manufacturer warranty. The support continued on site: an Elevate technician assisted the roofers during the first few days and gave them valuable practical advice on the manipulation of the membrane and its installation in the common part and around details. The regional Elevate sales manager was also present throughout the project to ensure that both roofing contractor and building owner were satisfied with the solution.
In the eaves area, the insulation had become soaked and was consequently replaced across an area of about 200 m². After installing a 60 mm thick layer of additional PIR insulation, about 1,250 m² of UltraPly TPO 1.5 mm thick membrane were mechanically fastened to the roof. Rolls of 1 m wide were used in this project, as this small dimension was favored following the calculation of the wind loads. The weldability of the joints with hot air ensured a cost-effective and fast installation, which was completed in 2 weeks.
UltraPly TPO is formulated with a specialized thermoplastic polyolefin polymer, blending polypropylene and ethylene-propylene rubber for optimal performance. Free from plasticizers, chlorine, and heavy metals, it incorporates non-halogen flame retardants to ensure its superior fire behavior.