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DHL opens one of the three largest hubs world-wide in Leipzig / Halle in 2008. On the hangar, the related workshop and the sorting center, the flat roof insulation “Durock” was installed on a roof area of approximately 90,000 m2. Besides the necessary heat protection, it also guarantees a maximum fire-protection in accordance with the industry buildings directive.

ROCKWOOL responsibles

ROCKWOOL Mineralwoll GmbH & Co. OHG
ROCKWOOL Strasse 37-41
DE-45966 Gladbeck

Telefon: +49 2043 408-0
Kontakt: Andreas Gebing

Email

Main developer

Deutsche Post World Net
Bonn

Contractors

Max Bögl GmbH
Sengenthal

From Leipzig/Halle to the rest of the world  

DHL, the express and logistics subsidiary of the Deutsche Post World Net is investing around 300 million Euros to construct their new main European hub for express goods in Leipzig/ Halle. Besides Wilmington in the USA and Hong Kong, Leipzig/Halle will become one of the three largest hubs of DHL world-wide. It will commence operation in 2008.  On the hangar, the related workshop and the sorting center, a roof area of approximately 90,000 m2 jointly received a flat roof insulation of stone wool. This ensures beside the necessary heat protection also a maximum fire-protection in accordance with the industry buildings directive.

For the region around Leipzig, the new freight airport especially signifies a clear strengthening as an economic location, because alone at DHL itself, around 3,500 new work places are supposed to be created by the year 2012.Another 7,000 places shall be created by third-parties and service providers in the surrounding area. But Leipzig/Halle does not need to shy away from the international comparison with other freight airports either. After starting up in 2008, about 50 airplanes and up to 2,000 tons of express merchandise are processed here per night. Such quantities of goods require professional logistics - not only in the air, but also on the ground. The different building complexes on the site were designed accordingly: Office rooms, an airplane hangar of around 23,000 m2, the actual distribution center of around 48,000 m2 and a company-own hangar workshop were arranged and equipped in a way to support the operational processes optimally.

Insulation thicknesses depending on the use

To insulate the large roof areas, the company responsible for the roof work, Koch Dachtechnik GmbH from the Saxon town of Meerane, reverted to a pressure-resistant roof insulation board panel made from stone wool. With it, all the fire and heat protection requirements could flexibly be fulfilled in the different building sections, explains the responsible project manager Steffen Trefzer from the company Koch Dachtechnik. "We have insulated the total area of 90,000 m2 in several construction phases. In June 2006, we initially started with the commissioning hall. With around 40,000 m2 the largest section," says Trefzer. "After concluding the work on the distribution center in November, the Hangar followed including the office building and finally the workshop, as well as various small annexes. The roof work was then finalized in May 2007."

Manifold constructions

The professionals chose different roof structures for the different building sections. On the commissioning hall for example, a PE foil (thickness 0.25 mm) was initially installed on trapezoidal sheets. This was followed by the non-combustible ROCKWOOL insulation board "Durock"with a thickness of 180 mm. The top layer is formed by a synthetic waterproofing membrane, which was mechanically connected with the insulation, and which was then hot-air welded. For roof sections with super-imposed loads, for example for footpaths, special plastic sheeting with an additional glass fleece insert was used. Other roof sections had a concrete ceiling, on which a special bitumen vapor barrier with an aluminum insert was installed. With this, a preliminary temporary sealing of the roof was achieved, so that the internal construction on all the underlying room levels could be started early.

What was of central importance for the energy balance and for the fire protection was the use of stone wool as roof insulation, according to Steffen Trefzer. "Regardless of whether on the hangar with an installed thickness of 80 mm, or on the workshop with 140 mm - with the 'Durock' boards we were always on the safe side  with regard to fire safety. The panels are non-combustible A1 per DIN EN 13501 and simultaneously have a sufficiently high point load of > 650 N. Therefore they can be walked on for the later roof maintenance."

Timely completion of construction

In order for the roof work at the new freight airport Leipzig/Halle to be concluded regardless of the difficult delivery situation in the insulation sector, is substantiated by the good teamwork between his company and Deutsche ROCKWOOL, in Steffen Trefzer's point of view. "The start of the construction was exactly at that point in time, when the demand exploded so to speak, which made the procuring continually harder, especially with regard to the insulation. We however contacted our supplier and partner Deutsche ROCKWOOL very early and informed them about the forthcoming stock. The insulation material was then delivered "just in time" according to the previously agreed on delivery plan, and was processed by us right away."