Dilapidated skylights Shipbuilding shed tackled and improved with care 

Between January 2023 and February 2024 the monumental Scheepsbouwloods in Rotterdam was carefully redeveloped and made suitable for a new future. But while maintaining its special, cultural-historical value. Part of the work included the renovation of the existing skylights, retaining existing materials as much as possible. Few companies dared to take on this challenge, says Marcel Greuel, manager of renovation and transformation at Kingspan Light + Air. "But we tackled this project with both hands. Commissioned by the Port of Rotterdam Authority and mindful of the activities in the Shipbuilding shed, we made the existing skylights fail-safe and watertight."

Kingspan Light + Air is no stranger to the Rotterdamsche Droogdok Maatschappij (RDM) shipyard. "On behalf of the Port of Rotterdam Authority, we regularly carry out inspection and maintenance work. Especially on the existing smoke heat exhaust systems (RWA systems) and skylights," says Greuel. "Among other things, we inspect the skylights for water tightness, damage windows and leaks, making repair and improvement proposals if necessary. In addition, we have performed work on the Submarine Wharf in the past, for which we provided all the skylights and fire safety solutions as a preferred supplier. From this relationship, the redevelopment of the Shipbuilding Wharf also came our way."

Tamper-proof and waterproof

The oldest parts of the Scheepsbouwloods date back to 1922, and that raises special issues. Also with regard to the skylights, which had to be made fall-proof, says Greuel. For example, to guarantee safe maintenance in the future. In addition, various adjustments had to be made to ensure the watertightness of the skylights. "Our assignment started with an extensive inspection, which showed that the skylights were suffering from the necessary leaks and sagging glass. Moreover, the windows were not fall-through resistant. In collaboration with our R&D department, we drew up an improvement plan, retaining as many existing materials as possible and keeping color differences and other aesthetic deviations to a minimum. As a result, quality and safety come together nicely."

An important part of the work was the installation of new glass hooks to hold the glazing in place, he says. "We replaced several damaged windows and damaged plastic sheets and made detail improvements for waterproofing. All skylights that were not fail-safe were fitted with special tube profiles so that the roof can now be accessed safely from anywhere. Our R&D department has hereby demonstrated that the skylights are fall-through-safe after the renovation."

Working safely at height

In total, Kingspan Light + Air tackled no less than 26 glass skylights and two plastic skylights. "Because the skylights were not yet fall-through-safe, we performed all the work safely leashed and secured," says Greuel. "This involved the use of a harness and special 'shootlines,' which were secured to a structure on the roof."

Minimal inconvenience

An additional challenge was that the building had to remain accessible to its users, such as an ROC school and a shipbuilding company. "We planned and coordinated our work so that inconvenience was kept to a minimum," said Greuel. "This allowed us to work energetically both on and under the roof." 

The renovation work was completed in February 2023. Meanwhile, Kingspan Light + Air is responsible for the inspection, monitoring and maintenance of the skylights. "We have also recently carried out an inspection on a higher roof section of the Shipbuilding shed, where an extensive renovation is likely to start soon. This gives the renovation of the skylights a nice continuation."