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Eight roofs appraised across a film studio complex, spans to 50 metres

Eight roofs across a film studio complex were appraised for a proposed solar PV installation, from ancillary buildings at 14 metres span to sound stages clear-spanning more than 50 metres at 20 metres to apex.

Sector Film and mediaLocation Pencoed, BridgendPeriod 2024
The brief

What the project needed.

A studio complex is not one building and its roofs are not one problem. Five sound stages and three ancillary buildings sat on the same site with entirely different geometry: clear spans from 14 metres to over 50 metres, eaves from 6 metres to nearly 19 metres, and framing set out at completely different centres. A single assessment covering the site would have been quick and useless. Each roof was taken on its own geometry.

Work carried out

  • Non-intrusive visual survey of the property, inside and out
  • Aerial drone survey of all eight roof areas
  • Structural roof loading appraisal of each roof separately
  • Roof geometry, span, eaves and apex heights recorded per roof
  • Purlin and bay spacing recorded where accessible
  • Wind and snow loading assessment
  • Justification of panels for gravity loading
  • Justification of panels for uplift loading
The engineering

What dragon studios, pencoed actually involves.

The sound stages are the reason this site is unusual. S5 clear-spans 50.55 metres over a length of 50.78 metres with purlins at 1.66 metre centres and bays at 6 metres, and S2 spans 42.05 metres with an apex at 20.278 metres. A structure carrying that span has very little spare capacity by definition, because the section sizes were driven by the span rather than by the roof loading, and the margin left over for anything added later is correspondingly small.

The ancillary buildings sit at the opposite end of the range. A5 spans 19.646 metres over 80 metres of length with frames at 8.010 metre centres, and A6 and A7 span 14 metres with frames at 7.710 metres. Same site, same client, same proposed installation, and a completely different structural question.

The survey was non-intrusive, inside and out, with particular attention to the roof and its supporting framework. The primary structure was found in good condition for its age with no significant degradation or deflection, and the coverings sound for the building's continued commercial use.

Panel fixings were explicitly excluded and flagged as a design by others. Whether a fixing can be made into a given covering is a different question from whether the frame beneath it has capacity, and reports that blur the two are how responsibility falls into the gap between consultants.

From the project record

On site.

The complex from the air. Five sound stages and three ancillary buildings, each roof appraised on its own geometry.

Project record

Dragon Studios, Pencoed

Structural roof loading appraisal covering eight roof areas, with wind and snow loading appendices, aerial drone coverage and record photography.

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