ENGINEERING INNOVATION
A New Approach to Industrial Storage Tank Performance
Originally conceived and technically developed by Gunnar Zapf during his tenure as Head of Engineering, the GRP full-contact floating roof represents a significant part of his engineering work in advanced storage systems. The solution combines fire-resistant performance with a corrosion-resistant, non-metallic construction designed to reduce emissions, increase usable tank capacity and support long-term operational reliability.
ENGINEERING ORIGIN
A New Approach to Industrial Storage Tank Performance
During his former professional role as Head of Engineering, Gunnar Zapf was involved in the engineering development of the prefabricated GRP full contact floating roof concept and contributed technical expertise to its development and practical implementation in industrial storage applications.
His work during this period encompassed engineering approaches relating to non metallic GRP construction, full contact floating roof configurations, fire performance, corrosion resistance and the efficient utilisation of available tank capacity.
This section reflects Gunnar Zapf’s professional engineering experience and technical involvement during that period. References to his involvement do not imply ownership, exclusivity or the current status of intellectual property rights associated with the technologies described.
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 may present 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 contribute to reduced 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 behaviour of the floating roof under direct fire exposure and formed an important part of the technical evaluation of the concept.
ENGINEERING BENEFITS
Designed Beyond a Single Performance Metric
Reduced Emissions
Full-contact operation is designed to minimise vapour space and thereby contribute to reducing evaporative product losses.
Fire-Resistant Performance
Fire behaviour was considered as an integral part of the engineering concept and evaluated through large-scale fire testing.
Increased Usable Capacity
The lightweight full-contact design supports more efficient utilisation of the available storage volume.
Designed for Long-Term Operation
Chemical and corrosion resistance are intended to support durability and lower susceptibility to corrosion-related maintenance over the operating life of the system.
Corrosion Resistance
Non-metallic GRP construction avoids the corrosion mechanisms typically associated with conventional carbon-steel roof structures.
Environmental Performance
The full-contact concept is designed to reduce vapour space, while corrosion-resistant construction and long-term material performance can contribute to more resource-efficient industrial storage solutions.
DEVELOPMENT
Engineering Innovation by Gunnar Zapf
During his former professional role as Head of Engineering, Gunnar Zapf was involved in the engineering development of the GRP full-contact floating roof concept and contributed technical expertise to its development and practical implementation.
The engineering concept combines a non-metallic GRP construction with a full-contact floating roof configuration and a prefabricated segment approach. GRP segments can be prefabricated off-site, transported to the project location and subsequently assembled within the tank.
This description reflects Gunnar Zapf’s personal professional and engineering experience gained during that period. It does not constitute a statement regarding the ownership, transfer or current status of any intellectual property rights associated with the technology.
The prefabricated segment approach is intended to reduce the amount of assembly work required inside the tank compared with construction methods involving more extensive on-site fabrication. Depending on the individual project, tank geometry, site conditions and operational requirements, this approach may contribute to shorter on-site installation periods.
Based on documented project experience, an installation for a tank of approximately 32 metres in diameter was completed within an on-site installation period of approximately two months. Project durations vary and depend on factors including tank geometry, project scope, site conditions and operational requirements.
Reducing the extent of work performed inside the tank may also reduce the time personnel are required to work within the tank environment. Actual installation schedules, personnel requirements and operational outcomes remain dependent on the specific project and site conditions.
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.
