Fire-proof floating roof for a tank and method for the production thereof

Abstract

The invention relates to a fire-proof floating roof for a tank, comprising a plurality of roof segments, wherein a roof segment has at least a lower laminate and an upper laminate and a filling compound between the laminates, and between two adjacent roof segments a joining zone is provided into which a connection element is inserted to connect two roof segments, wherein the connection element has at least a lower laminate and an upper laminate and a filling compound between the laminates, and wherein the connection element is connected to the roof segments.

Description

[0001] Fireproof floating roof for a tank and method for its manufacture

[0002] Field of the invention

[0003] The invention relates to a fire-resistant floating roof and a method for producing

[0004] State of the art

[0005] Until now, GRP floating roofs have been constructed on wooden formwork, either directly inside the tank or directly next to the tank. Floating roof tanks typically have a diameter of 10 m to over 100 m. Both options require extensive weather protection to protect against the elements. The wooden substructure served as a negative mold (shaping surface) for the construction of the floating roof. With the "directly inside the tank" construction method, the entire substructure had to be dismantled and removed via manholes after completion. The disadvantages of the approaches described are the high costs of designing and manufacturing the weather protection tent and formwork, the dependence on weather influences, and long construction phases and the associated decommissioning periods for the tank.

[0006] If the roof is constructed "directly next to the tank," it must be lifted into the tank as a complete component using a crane after completion. However, this requires a large crane to be set up next to the tank, which is not always possible due to space constraints.

[0007] Another challenge in both construction processes is maintaining a minimum temperature of 15 degrees Celsius in the tank or assembly tent during the cold season. The lamination processes require a stable ambient temperature. Achieving this minimum temperature in the weather protection tents requires an energy-intensive and costly heat supply.

[0008] Description of the invention

[0009] The object of the invention is to provide a fire-resistant floating roof and a method for producing the floating roof, which reduces the required assembly times, heating costs and thus the dependence on external weather conditions.

[0010] This object is achieved by a floating roof according to claim 1 and a method according to claim 10. Further features which develop the invention are contained in the subclaims. A fire-resistant, in particular external, floating roof for a tank according to the invention comprises a plurality of roof segments, wherein a roof segment has at least one lower laminate and one upper laminate and a filling compound between the laminates, and wherein a joining zone is provided between two adjacent roof segments, into which joining zone a connecting element for connecting two roof segments is inserted, wherein the connecting element has at least one lower laminate and one upper laminate and a filling compound between the laminates, and wherein the connecting element is connected to the roof segments, in particular glued via the filling compound.This allows the floating roof to be installed inside a tank. The factory prefabrication of individual segments and subsequent assembly within the tank significantly shortens the installation time, as no negative substructure is required. Likewise, only a much smaller crane is required to lift the individual segments into place. The laminate is preferably constructed in multiple layers, with individual glass-fiber-reinforced resin layers being laminated together, for example, by applying the resin several times in succession to a glass fiber layer, like a glass fiber cloth.

[0011] The filling material of the segment and / or the connecting element is preferably formed from at least one foam board or a honeycomb board, in particular several such boards. The foam boards are easy to process and relatively lightweight, yet stable. They are particularly well suited for the on-site production of the connecting elements.

[0012] The connecting element preferably has an identical structure to the roof segments. This makes it easier to combine the connecting element with the roof segments, as the same material layers always need to be connected.

[0013] The individual layers of the laminate and / or the filler of the roof segments are preferably designed in a stepped manner at the edges of the joining zone. This allows for a stronger connection with the connecting element during construction of the floating roof, as individual layers can be designed to overlap.

[0014] The floating roof preferably further comprises a central segment, which is particularly circular in shape, with the roof segments arranged circumferentially around the central segment. With a central segment, the connection of the individual segments in the central area can be designed and manufactured more easily. This is particularly advantageous because all roof segments converge in the central area, where connecting the segments and connecting elements is particularly difficult.

[0015] The floating roof preferably has at least one drainage hole, and the floating roof is designed to slope downwards to drain liquids toward the drainage hole. Multiple drainage holes may also be incorporated into one or more roof segments during prefabrication. In particular, the floating roof is designed to slope downwards toward a central area, and a drainage hole is provided in the central area.

[0016] Each of the laminate layers can be single- or multi-layered. This increases the strength of the laminate layers.

[0017] The filler of the connecting element is preferably flush with the filler of the roof segments, and the layer or layers of the laminates overlap. In particular, the fillers are bonded to a resin layer, which also forms the laminate layer. Flush fillers facilitate the production of the connecting elements, while overlapping laminate layers significantly improve the strength of the roof structure.

[0018] The filling compound of a roof segment and / or a connecting element can comprise several foam panels separated from each other by one or more intermediate laminate layers, particularly a single-layer laminate. This improves the flexibility of the roof segments and connecting elements while maintaining high stability.

[0019] The invention also relates to a method for producing a floating roof, comprising the steps of a) providing roof segments, b) arranging a second roof segment adjacent to a first roof segment and forming a joining zone between the roof segments, c) filling the joining zone with a connecting element by applying a lower laminate, in particular a multi-layered one, applying a filling compound to the lower laminate, and applying a particularly multi-layered upper laminate, and d) repeating steps b) and c) until the floating roof is completed. When repeating steps b) and c), the additional segment is then preferably placed next to the previously applied segment. Using such a method, the floating roof can be manufactured cost-effectively in a tank without great effort. Furthermore, in step a), one or more spacers can preferably be used to space the adjacent roof segments apart.

[0020] Preferably, in step c), the layers of the laminates of the connecting element and the laminates of the roof segments are arranged overlapping. This is achieved in particular by a surface treatment such as sanding, cleaning, and / or activating the laminates of the connecting element, so that the layers of the roof segments can bond more effectively to the connecting element. In step c), preferably when inserting the filler, a lower filler is applied to the lower laminate, followed by a middle laminate, and then an upper filler. This increases the flexibility of the floating roof while simultaneously ensuring high stability. The lower filler is preferably thicker than the upper filler, in particular more than twice as thick.

[0021] Short description of the characters

[0022] Fig. 1 shows a section of a tank in which the roof segments are placed on a substructure;

[0023] Fig. 2 shows the section of the tank from Fig. 1 , in which a weather protection cover is attached;

[0024] Fig. 3 shows an isometric view of two adjacent roof segments with spacers;

[0025] Fig. 4 shows an enlargement of a section of a joining zone between two roof segments;

[0026] Fig. 5 shows the joining zone of Fig. 4, in which a connecting element is inserted; and

[0027] Fig. 6 shows a section of the tank from Fig. 1 with the floating roof completed.

[0028] Description of the preferred embodiments

[0029] Fig. 1 shows a tank 8 in which the roof segments 12 for a floating roof 10 are shown. Here, the roof segments are already arranged next to each other, so that a joining zone 20 is formed between each two roof segments.

[0030] The floating roof 10 is circular in the embodiment shown. The shape of a tank 8 is usually circular, but other shapes such as an oval shape of the tank or a rectangular or square shape are also possible. The segments can then form a floating roof 10 shaped according to the shape of the tank. In principle, the individual segments can be designed as desired, i.e. roof segments 10 with a square cross-section can be used, in which case the edge pieces must then be adapted accordingly to the shape of the tank. However, circular segments, as shown in the figures, are preferred, particularly for a circular tank. These roof segments 10 are arranged so as to encircle a common center point of the roof segments 12. The center point is preferably formed in a central segment 14, around which the other roof segments 12 are arranged.A joining zone is then also provided between the central segment and the roof segments, in which a connecting element 30 is also inserted. Manholes 18 can be provided in individual roof segments 10 so that, when a floating roof 10 is in place, the underside of the floating roof or the interior of the tank can also be accessed. The width of the joining zone is preferably at least 35 cm, 40 cm, or 45 cm, and more preferably at most 65 cm, 60 cm, or 55 cm.

[0031] The individual roof segments 12 and the central segment 14 are manufactured in a separate process step under defined and controllable conditions in a production hall. All functional elements, such as the conductive chemical protection layer, the structural laminate, the core material, the sloped insulation, and the fire protection layers, are integrated into the segments during prefabrication, so that the prefabricated roof segments 12 meet the same high quality standards as conventionally manufactured floating roofs.

[0032] As in Fig. 1, Fig. 2 shows the substructure with the individual roof segments 12. Fig. 2 also shows a weather protection cover 19, which is stretched over the floating roof and thus protects against the weather, especially rain. The weather protection cover 19 is designed so that any water that hits it is immediately directed into a drain 17 of the floating roof 10. The drain then runs inside the tank 8 via pipes to the walls of the tank 8 and then carries the liquid contained in the drain to the outside of the tank 8.

[0033] Fig. 4 shows a joining zone 20 located between two adjacent roof segments 12. A roof segment has a filling compound 24 arranged between an upper laminate 26 and a lower laminate 28. The filling compound is preferably in the form of a foam board, e.g., a GRP foam board, or a PP honeycomb board, e.g., Nidaplast 8 - PP honeycomb for lamination, and the laminate is made of a resin, e.g., a reactive plastic. The laminate also preferably comprises glass fibers, which are available in various variants and can be introduced, for example, in the form of a glass fiber mat. The glass fibers are laid out for a laminate layer, and then the resin is applied to the glass fibers. In this way, multiple layers can also form a laminate. Here, for example, the upper laminate 26 and the lower laminate 28 are formed from multiple layers, preferably three (lower laminate 28) or four layers (upper laminate 26).The filler material can also be divided by one or more layers of a middle laminate 29, so that two or more filler material elements are stacked on top of each other in a roof segment. This increases the flexibility and stability of the roof segment.

[0034] At the joining zone 20, the roof segments are preferably designed in a step-like manner. This means that on one side the laminate 28 protrudes the furthest into the joining zone 20 and the adjacent layer is designed to be further back. In Figures 3 and 4 it is the lower side that protrudes the furthest, but it is also possible for the upper laminate 26 to protrude the furthest into the joining zone 20. The step-like design preferably already affects the individual layers of the laminate. Above this, the filling compound 24 is designed to be slightly offset to the rear. At the upper end, the upper laminate 26 is then flush with the filling compound 24, but can also be retracted behind it. The individual layers of the upper laminate are then also The middle laminate 29 is designed to be flush with the lower filling compound here, but can also expose part of the filling compound 24u.The upper filling mass 24o is then also provided one step behind the laminate and the lower filling mass 24u.

[0035] The joining concept provides for the prefabricated roof segments 10 to be pre-produced with a defined contour in the edge area. The individual layers and the core elements are laminated with a layer-by-layer offset of approximately 50 mm. Fig. 4 shows the basic "step" in the edge area. Thus, the lower part of the adjacent roof segments 12 is arranged closer to each other than the upper part. Figure 3 shows two adjacent roof segments 12. These are preferably placed with spacers 15 so that the joining zone 20 has an ideal width. The spacers 15 preferably have a geometry adapted to the roof segments 10, in particular a step-like design in the contact area with the roof segments 12.

[0036] One challenge in the production of the floating roof 10 is connecting the individual segments to form a completely closed GRP structure. To make this possible, the joining zone 20 is filled with a connecting element 30. Such a joining zone 20 filled with a connecting element 30 is shown in Fig. 5. For this purpose, the laminate of the connecting element (here with the lower connecting laminate 32) is laminated onto the layer of the adjacent roof segments 10 that projects furthest inwards (the lower laminate in Figures 3 and 4). The lower connecting laminate 32 can also be multi-layered. Each individual laminate layer is therefore preferably applied individually to a corresponding laminate layer of the two adjacent roof segments 10. This increases the cohesion of the laminates between the connecting element 30 and the roof segments 10.

[0037] Then, the filler compound 36 is applied to the lower connecting laminate 32. Ideally, this is done by gluing the filler compound 36, preferably in the form of a foam sheet, to the still-hot laminate. The filler compound 36 is then preferably also glued to the filler compound 24 of the adjacent roof segments, preferably with the resin used to produce the laminate. The upper connecting laminate 34 is then glued to the corresponding laminates 26 of the roof segments 10 in the same way as the lower connecting laminate 32, so that the individual laminate layers preferably overlap.

[0038] If necessary, a central connecting laminate 38 may be provided, particularly if a central laminate 29 is also present in the roof segments. The filling compound 36 of the connecting element 30 is then also divided into an upper and lower filling compound 36o, 36u. Preferably, the structure of the connecting element 30 is identical to the roof segments, so that each layer of the connecting element 30 is attached to a corresponding layer of the roof segments 10.

[0039] During assembly in the tank, the specified gap is filled with composite material (filler and laminate) by layer-by-layer lamination in the joining zone. The overlapping of the individual layers ensures optimal force transmission. Step by step, and with appropriate curing breaks during production, the joining zone 20 is filled, particularly analogous to the structure of the segments. The bond between the laminate layers is improved by appropriate surface pretreatment, e.g., sanding, cleaning, and activation. Each laminate layer fulfills a function and is partly composed of a different composite composition. Each area in the joining zone is preferably connected with a suitable material.

[0040] The joining zones to the central segment 14 are filled with a connecting element 30 in the same way. After the laminate layers have cured, final cover layers, such as a conductive chemical protection layer, are applied. The result is shown in Fig. 6. Such a floating roof is externally identical to conventional variants and also has the same properties.

[0041] 8 tanks

[0042] 10 Floating roof

[0043] 12 roof segment

[0044] 14 Central segment

[0045] 15 spacers

[0046] 16 Support frame 7 Drain hole

[0047] 18 Manhole

[0048] 19 Weather protection cover

[0049] 20 joining zone

[0050] 24 filling compound

[0051] 24o upper filling mass 24u lower filling mass

[0052] 26 upper laminate

[0053] 28 lower laminate

[0054] 29 middle laminate 30 connecting element

[0055] 32 lower connecting laminate

[0056] 34 upper connecting laminate

[0057] 36 filling compound

[0058] 36o upper filling mass 36u lower filling mass

[0059] 38 middle connecting laminate

Claims

Patent claims 1. A fire-resistant floating roof (10) for a tank (8), comprising a plurality of roof segments (12), wherein a roof segment (12) has at least one lower laminate (28) and one upper laminate (26) and a filling compound (24) between the laminates; and between two adjacent roof segments (12) a joining zone (20) is provided, into which a connecting element (30) for connecting two roof segments (12) is inserted, wherein the connecting element (30) has at least one lower laminate (32) and one upper laminate (34) and a filling compound (36) between the laminates, and wherein the connecting element (30) is connected to the roof segments (12).

2. Fire-resistant floating roof (10) according to claim 1, wherein the filling material (24) is formed from at least one foam plate or honeycomb plate.

3. Fire-resistant floating roof (10) according to one of the preceding claims, wherein the connecting element (30) has an identical structure to the roof segments (12); 4. Fire-resistant floating roof (10) according to one of the preceding claims, wherein the individual layers of the laminate (26, 28) and / or the filling compound (24, 36) of the roof segments (12) are formed in a stepped manner at the edges to the joining zone (20).

5. Fire-resistant floating roof (10) according to one of the preceding claims, further comprising a central segment (14), which is in particular circular in shape, wherein the roof segments (12) are arranged circumferentially around the central segment (14).

6. Fire-resistant floating roof (10) according to one of the preceding claims, wherein the floating roof (10) has at least one drainage hole (17) and the floating roof (10) is designed to slope downwards for draining liquids in the direction of the drainage hole (17).

7. Fire-resistant floating roof (10) according to one of the preceding claims, wherein the laminate (26, 28, 32, 34) is multi-layered.

8. Fire-resistant floating roof (10) according to one of the preceding claims, wherein the filling compound (36) of the connecting element (30) is flush with the filling compound of the roof segments (24) and the layer or layers of the laminates (26, 28, 32, 34) overlap.

9. Fire-resistant floating roof (10) according to one of the preceding claims, wherein the filling compound (24, 36) of a roof segment (12) and / or a connecting element (30) several filling masses (24o, 24u, 36o, 36u) which are separated from one another by a central laminate (29).

10. A method for producing a floating roof (10), comprising the steps: a) providing roof segments (12); b) arranging a second roof segment (12) adjacent to a first roof segment (12) and forming a joining zone (20) between the roof segments (12); c) filling the joining zone (20) with a connecting element (30) by applying a lower laminate (28), in particular a multi-layered one, inserting a filling compound (36) onto the lower laminate (28) and applying a particularly multi-layered upper laminate (26); and d) repeating steps b) and c) until the floating roof (10) is completed.

11. The method according to claim 10, wherein in step c) the layers of the laminates (32, 34) of the connecting element (30) and the laminates (26, 28) of the roof segments (12) are arranged overlapping.

12. The method according to claim 10 or 11, wherein in step c) during insertion of the filling compound (36) a lower filling compound (36u), then a middle laminate (29) and then an upper filling compound (36o) are applied to the lower laminate (28).

13. The method according to claim 12, wherein the lower filling mass (36u) is thicker than the upper filling mass (36o), in particular twice as thick.

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