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This project involves the construction of a new plant within an existing production unit on the premises of Monsanto Europe. The limited space and assembly on an active production site determined the method of construction. As far as possible, a construction with modules pre-assembled elsewhere was chosen. The steel structure consists of three parts: reactor structure, production modules and piperacks. The reactor structure is built on site because of its weight. The other structures are pre-assembled elsewhere including equipment. These parts are then assembled on site using heavy cranes and coupled together.
The choice of hot-dip galvanizing was obvious: it is an excellent surface treatment that is barely affected by the ravages of time, and it significantly reduces the risk of damage during construction.
Fire-resistant paint on hot-dip galvanized substrate: durable and safe
The primary profiles of the reactor structure had to be coated with a fire-resistant paint. With this treatment, a primer is normally applied first and then the fire-resistant layer. Very special about this structure is that the robustness of hot-dip galvanizing was chosen here as well, even the parts that were finished with a fire-resistant paint layer.
For the pre-assembled modules, the robustness of hot-dip galvanizing is a big plus. The structure is moved several times with large cranes, which increases the risk of damage. Moreover, equipment and piping are pushed into the structures with all the risks that entails. Practice has shown in this project that the proportion of retouching has been reduced to zero thanks to the choice of hot-dip galvanizing. The other items such as floor gratings and handrails were also galvanized. For safety reasons, the handrails were given an additional typical signal yellow color.
The end result is a unique combination of silver (zinc) gray towers rising above the original painted structures. And contrary to what the project name suggests, the towers stand beautifully dead straight …
