Photo courtesy of Sarnafil Waterproofing Systems (Shanghai) Ltd., Shanghai, China
Guangzhou Honda's second manufacturing plant is located in the Xintang section of Zengcheng, Guangzhou City, China, about 19 miles from its original plant. Before building the 1.9-million-square-foot building, which now manufactures Honda cars, careful planning was involved and choosing a satisfactory roofing contractor was important.
Sarnafil Waterproofing Systems (Shanghai) Ltd., Shanghai, China—now part of Sika AG, Baar, Switzerland—learned about the project through the Dongfeng Design Institute Co. Ltd. Southern Co., Guangzhou City, the architect for the project, and Sarnafil Waterproofing Systems (Shanghai) bid the project and was chosen to install the new building's roof system.
Climate control
Sarnafil Waterproofing Systems (Shanghai) was asked to install a PVC roof system on the building, which included thermal insulation.
Using a mobile crane to transport materials to the roof, the company installed a 0.8-mm-thick galvanized steel deck, 0.3-mm-thick polyethylene vapor retarder layer, 40-mm-thick extruded polystyrene insulation and Sarnafil Waterproofing Systems (Shanghai) Ltd.1.2-mm-thick PVC membrane.
"The PVC membrane was reinforced with polyester scrim," says Ge Zhao, manager of product management for Sarnafil Waterproofing Systems (Shanghai). "The insulation board was mechanically fastened, and the PVC membrane was fastened to the deck base with special fasteners and washers."
The project experienced some delays during installation when changes in the steel structures were required.
Working within a tight schedule, the roof system had to be installed during a heat wave, with temperatures averaging about 95 F (122 F in the sun). Sarnafil Waterproofing Systems (Shanghai) also faced the challenges of working and coordinating with subcontractors used by the general contractor; installing flashing at 1,260 skylights and various other penetrations; and site management for several large operation areas.
However, the company worked hard to overcome these obstacles.
"We employed site management and coordination for parallel installation applications," Zhao says. "We also worked during mornings and evenings to avoid installation at midday when heat was the worst.
"In addition, we trained and designated workers according to different operations, followed the Sarnafil Application Manual and designated an inspector for quality-control purposes," he continues.
Various safety precautions were used during the project.
"Job-site safety education was provided for workers, and scaffolding was used to access the roof," Zhao says. "We also used safety nets at the roof openings, set alert sign boards and lines at the roof edge, and coordinated with the general contractor with regard to skylight installation. Sarnafil Waterproofing Systems (Shanghai) offered suggestions about skylight installation so the skylights also could be flashed properly."
Communication
Details and management were unique aspects of the project, Zhao says.
"The project involved high-temperature ventilators on the roof and a lightning-protection system," Zhao says. "Because car production in the plant produces heat, many ventilators were needed, which required special flashing details. Coordination and communication with other subcontractors was key."
Car production now has begun at the new manufacturing plant, which features various workshops, including a coating workshop, welding workshop, resin workshop and stamping workshop.
Performing work for such a large-scale project and tackling the project's obstacles were satisfying.
"We overcame leak issues, which are common for traditional steel structures," Zhao says. "It was rewarding to install such a large roof system."
Krista Reisdorf is managing editor of Professional Roofing magazine.
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