The Halcyon Factory Roof Replacement project was a high-stakes, fast-paced industrial initiative, requiring the safe removal and replacement of a working factory roof and purlin structure within just one week. The project presented additional complexity due to its highly corrosive internal environment, necessitating materials capable of long-term durability and corrosion resistance. The project required a roof/ceiling system that could withstand these harsh conditions while also delivering strong acoustic performance and meeting strict health and safety parameters required by the food industry. Durra Panel ceiling systems were specified as a sustainable, high-performance solution capable of addressing these technical and environmental challenges.
The primary challenge of this project was executing a major structural roof/purlin replacement with minimum disruption to the factory’s daily operations. The brief required the removal and replacement of the complete roofing structure in large modules directly above an active food manufacturing workspace, all within a strict one-week timeframe. Compounding this challenge was the facility’s highly corrosive internal environment, where exposure to corrosive acids placed significant demands on material durability and longevity. The ceiling system needed to deliver both acoustic performance and long-term resistance to corrosion, while meeting stringent health and safety and operational requirements.
To meet the project’s challenges, the team implemented a two-phase lifting strategy using specialised lifting frames designed for distinct stages of the work. The first phase employed a custom Durra lifting frame with a trafficable platform, allowing crews to safely dismantle the old roof while maintaining secure access above the operational factory floor. Once the old roof structure was removed, the second lifting frame was deployed to precisely raise and position each new 110m2 roof/ceiling module, ensuring a seamless and safe installation over a live industrial environment.
Durra Panel ceiling systems were selected for their unique material properties, which made them ideally suited to the corrosive food manufacturing environment. Durra Panel is naturally inert and does not react with corrosive substances, ensuring long-term stability and durability. This was complemented by Durra Panel steel purlin sections coated with a zinc-rich paint finish, providing long life corrosion protection. In addition to their durability, Durra Panels delivered the required acoustic performance, contributing to a safer and more controlled working environment. This integrated system ensured compliance with health and safety parameters while maintaining performance, longevity, and installation efficiency.
The Halcyon project successfully delivered a full 800m2 roof removal and replacement within a single week, with minimal disruption to ongoing factory operations. The specialised lifting strategy and carefully selected material system ensured safe installation within a corrosive industrial environment, while meeting all acoustic, durability, and safety requirements. Durra Panel’s naturally inert composition and corrosion-resistant purlin system provided a long-term solution suited to the harsh conditions of food manufacturing. The project received positive feedback from all stakeholders for its precision, speed, safety, operational efficiency, and its ability to perform reliably within a highly corrosive environment.
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