Solid Fuel Store Roof

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The Background:

The owners of a rural property use a solid fuel boiler to provide for central heating and hot water needs. Due to the remote rural location, fuel deliveries were infrequent but large and are stored onsite in modified shipping containers adjacent to the boiler.

The Problem: 

Wet fuel in the store was causing the boiler to shut down, requiring manual intervention and increased maintenance. Investigation had isolated the cause to be rain water leaking through the flat hatch opening.

The Solution: 

The client had developed a concept for a pitched roof to the store, with a large central opening that would maintain the dumper truck access for restocking of new fuel. Gestalt Group were approached to complete the detailed design of the structure, fabrication drawings & cutting lists and size and specify the hydraulic equipment.
We started by reviewing the concept and better understanding the problem, including a site visit which allowed us to define key parameters and dimensions.
With the basics known, we developed a 3D CAD model from which we could better understand the geometry, motion and masses involved and proceed with selection of the hydraulic rams and power pack.
We completed global and local stress calculations to ensure structural integrity of the moving components and provided the client with a complete specification and drawing pack for cutting of steel sections, plate work, fabrication and equipment procurement.

We also provided CAD data to, and worked with the cladding contractor as required.

The Outcome:

The new roof protects the fuel well through all seasons. Shutdowns of the boiler have ceased and maintenance costs dramatically reduced.

Original Roof
Original Roof

The existing sliding roof which leaked

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3D CAD ISO Closed
3D CAD ISO Closed
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3D CAD ISO Open
3D CAD ISO Open
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Early Fabrication
Early Fabrication
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Installing Hydraulic Rams
Installing Hydraulic Rams
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Testing of hydraulic lift
Testing of hydraulic lift
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Final Installation
Final Installation
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Final Installation Wide Open
Final Installation Wide Open
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