ENGINEERING INNOVATION
A New Approach to Industrial Storage Tank Performance
Developed by Gunnar Zapf, the GRP full-contact floating roof combines fire-resistant performance with a corrosion-free, non-metallic construction engineered to reduce emissions, increase usable tank capacity and support long-term operational reliability.
THE CHALLENGE
Rethinking the Limits of Conventional Floating Roof Systems
Industrial storage tanks demand solutions that balance operational safety, emissions control, chemical resistance and long-term durability. Conventional metallic floating roof systems can introduce challenges associated with corrosion, maintenance and structural weight, while the available tank volume and environmental performance remain critical considerations for operators.
THE ENGINEERING SOLUTION
A Full-Contact Roof Engineered in GRP
The solution is a non-metallic GRP full-contact floating roof designed to remain in direct contact with the stored product. Its lightweight, corrosion-resistant construction provides an alternative to conventional steel systems while supporting demanding industrial operating conditions.
The design combines structural performance with chemical and environmental resistance. By minimising the vapour space above the stored product, the full-contact concept is designed to reduce evaporative emissions while allowing more efficient use of available tank capacity.
FIRE RESISTANCE
Performance Under Fire Exposure
Fire resistance formed a critical part of the development programme. The GRP full-contact floating roof was subjected to a large-scale fire test to evaluate its behaviour under severe thermal exposure.
The test shown above documents the floating roof under direct fire conditions and forms an important part of the technical validation of the concept.
ENGINEERING BENEFITS
Designed Beyond a Single Performance Metric
Reduced Emissions
Full-contact operation is designed to minimise vapour space and reduce evaporative product losses.
Fire-Resistant Performance
Engineered with fire behaviour as an integral requirement of the floating roof system.
Increased Usable Capacity
The lightweight full-contact design supports more efficient utilisation of the available storage volume.
Long Service Life
Chemical and corrosion resistance support durability and reduced maintenance requirements over the operating life.
Corrosion Resistance
Non-metallic GRP construction eliminates the corrosion behaviour associated with conventional steel roof structures.
Environmental Performance
Reduced emissions, durability and efficient material performance contribute to a more sustainable approach to industrial storage.
DEVELOPMENT
Engineering Innovation by Gunnar Zapf
The fire-resistant GRP full-contact floating roof was developed by Gunnar Zapf as a fundamentally different approach to conventional floating roof construction — combining fire performance, corrosion resistance and emissions control with an efficient prefabrication concept.
Instead of constructing the complete roof inside the tank, precisely engineered GRP segments are prefabricated at our production facility, transported to site and assembled on site using a specialised joining and laminating process developed for efficient prefabricated installation.
This approach significantly reduces construction work inside the tank and shortens the period the asset remains out of operation. For a tank of approximately 32 metres in diameter, on-site installation can be completed in approximately two months, depending on project and site conditions.
Less on-site construction also means fewer personnel inside the tank, reduced exposure to hazardous working conditions and an earlier return to productive operation.
PROVEN IN OPERATION
See the Technology in Practice
For qualified projects, we can arrange visits to selected operational installations at established customer sites — offering first-hand insight into the technology and the opportunity for direct technical exchange with experienced operators.
