Prefabricated Halls and Maintenance: How to Keep Your Hall in Good Condition

Prefabricated halls and their maintenance are important for the long-term durability of the hall. It is necessary to keep all parts in good condition; some are required by standards for certain parts of the prefabricated hall.

Regular Maintenance of Steel Structures

The owner of a steel structure is obliged by building law to properly maintain the steel structure. In case of neglecting maintenance, the owner is co-responsible for any damages. Maintenance is governed by regulations for inspection and maintenance. Proof of maintenance is especially regular inspections according to ČSN 73 2604:2012. For load-bearing steel structures, in addition to routine maintenance, you must carry out regular inspections:

• In highly corrosive environments, inspections must be defined by the manufacturer of the structure. The owner must carry out maintenance of the structure and keep coatings in good condition.
• For structures stressed by cranes, the owner must not only carry out regular inspections of bridge cranes, which are performed 4 times a year, but also check the crane track rails according to the prescribed height and directional tolerances. In case of non-compliance, the crane track must be rectified.
• The structure must even be replaced if required by the project.

Repairs of Steel Structures and Determining the Aggressiveness of the Corrosive Environment

If you find damage or defects in the steel structure during inspection, you must first determine the cause of the damage and then propose a repair of the coating, unless it is already addressed by the structural project. If damage to the structure, coatings, corrosion losses, or significant deviations are found, a professional company will carry out repairs or renewal of coatings as part of maintenance.

The choice of anti-corrosion coating should reflect the aggressiveness of the environment in which the steel structure is located. The aggressiveness of the environment is directly addressed by the set of standards ČSN EN ISO 12944 Paints and varnishes – Corrosion protection of steel structures by protective paint systems, part 2:2018 Classification of environments according to atmospheric corrosivity. Our company usually provides a warranty on the coating for 5 years, but guarantees a minimum service life of the high (H) coating for 15 years, unless otherwise stated in the contract. Subsequently, you must check or renew the coating if damage is found; the maximum service life of the coating depends on the corrosive environment.

We usually provide a 5-year warranty on the structure including the coating from the handover of the work for environments up to C3 aggressiveness.

Maintenance of Sandwich Panels and Sheets in Prefabricated Halls

Prefabricated halls are usually clad with trapezoidal sheets, and insulated halls with sandwich panels. The owner is obliged to maintain the cladding during the warranty period and after its expiration to extend the service life of the cladding to the declared 25–35 years by the panel manufacturers, depending on the corrosive environment.

We usually provide a 5-year warranty on panels and sheets from the handover of the work for environments up to C2 aggressiveness. For other environments, the warranty is according to the panel manufacturer.

1. Removal of Snow and Dirt

When removing snow and dirt from the roof covering, you must take proper safety measures to prevent damage to the surface with tools. Every year or more often (if needed), remove fallen leaves and other debris from the roof covering. Clean gutters and downpipes at least once a year. It is strictly forbidden to leave tools and accessories unrelated to the purpose of the prefabricated hall.

2. Annual Inspections

At least once a year, thoroughly inspect the surface and grooved parts of the cladding (especially in covered areas such as gutters, panel joints and grooves, panel or sheet edges). In environments with higher corrosion aggressiveness, you should consider more frequent and detailed inspections. You must check that panel parts and gutters are properly anchored, as missing or damaged fasteners can cause leaks and dampness, which can subsequently damage coatings and result in corrosion. During the inspection, all damaged fasteners must be replaced and loose fasteners tightened.

3. Sealing

If you are designing a building that requires frequent cleaning, consider using additional sealing of the contact surfaces of panels and sheets (in addition to sealing materials and sealants applied to the joints), so that water and cleaning agents do not moisten the contact surfaces and worsen the thermal and moisture parameters of the barrier. Do not use acidic sealants (e.g., those based on acetic acid). We recommend neutral reaction sealants based on silicone, butyl, or polyurethane. Such sealants must be regularly inspected and replaced if damaged.

4. Surface Cleaning

Surface cleaning of panels is carried out to remove all visible dirt affecting the appearance of the panel, which also negatively impacts the durability of the anti-corrosion protective coating. For equipment in the food industry, microbiological cleanliness is required. In such cases, cleaning and disinfecting agents must be used.

The specific type of cleaning agents for composite panels and sheets depends on:

• the type of panel surface and surface treatment;
• the frequency of cleaning;
• the thoroughness of cleaning.

If cleaning dirt with water is difficult, you can wash the panels with water and a cleaning agent. We recommend mild water-soluble cleaning agents with a permissible pH of 4–9. After each wash, the cleaning agent must be thoroughly rinsed off with clean water.

In special cases, if you need to use industrial and disinfecting agents due to hygiene requirements, follow the manufacturer’s recommendations. To check whether the agent damages or softens the organic coating, it is necessary to perform a washing test (on a small area).

Cleaning agents must not be left in the concentration specified by the manufacturer at the relevant intensity and temperature (maximum 30 °C) in contact with the coating for more than 30 minutes.

The pressure of clean water used for rinsing must not exceed 5 MPa (50 bar) at the nozzle outlet, and at the point of impact, the water jet pressure must not exceed 0.04 MPa (such pressure is created by a 5 MPa jet with a 15° nozzle angle at a distance of 20 to 30 cm from the wall). Rinse very carefully, starting from the top of the room, equipment, etc., to wash away all cleaning agents. Remember that the water drainage system (e.g., waste system, drains, etc.) must always be thoroughly flushed at the end.

If you use water to remove grease, its temperature must not exceed 30 °C (the temperature may exceptionally temporarily rise to 50 °C). Grease can be removed with a soft cloth and white spirit. Surfaces cleaned in this way must be immediately rinsed with clean water. Do not use organic solvents or abrasive cleaning agents.

Do not clean panels with steam. Do not rinse surfaces with water in rooms where the temperature is 0 °C or lower.

5. Painting

Before carrying out a repair or complete replacement of the coating, you must visually check the condition of the organic coating.

Maintenance of Doors in Prefabricated Halls

Sectional doors, double-leaf, fire doors, and other doors are an integral part of almost every prefabricated hall. They are often stressed and therefore require maintenance service. Service should generally be performed at least once a year, and the door manufacturer also requires it! The service is paid and is not covered by the warranty service within the warranty for the work. The door supplier will write a service report for the service.

The warranty on doors is a maximum of 2 years from the handover of the work.

Door service by the manufacturer includes:

• Lubrication of the doors,
• Adjustment of door seating,
• Sensors for fire doors,
• Inspection of cables,
• Inspection of electrical installation, etc.

However, maintenance directly by the owner of the doors is also important for the long service life of the doors. If you are unsure, it is better to pay for a professional service. Maintain the doors according to these steps:

1. Cleaning the Doors

Clean the doors on both sides. A cloth and ordinary warm water with a universal cleaning agent will suffice.

2. Cleaning the Seals and Rails

Do not forget to clean the rails and seals as well, so the doors do not jam. A dry cloth is sufficient for this; use it to wipe off dirt and dust that has accumulated.

3. Lubrication of Sectional Doors

Carefully lubricate the axles of the rollers, hinges, springs, and bearings of the garage doors, preferably with grease or oil. However, be careful not to lubricate the rails! Otherwise, dirt would stick to them and the doors could jam. Lubrication is performed by a technician during paid service once a year.

4. Inspection of Steel Cables

If your garage doors have steel cables, make sure they are not frayed, torn, or otherwise damaged.

5. Balancing the Doors

You probably open the doors more often with a remote control, but from time to time check if they are properly balanced. How to do it? Switch the doors to manual opening and then open them to a height of one meter. If they stay in place, they are well balanced. If they do not hold, even by a few centimeters, something is wrong.

6. Checking the Remote Control

Last but not least, check the remote control. Wipe off dust (including inside), make sure the controller is properly closed and the seal is tight, and of course, that it works well and the doors respond quickly.

Maintenance of Windows and Doors in Prefabricated Halls

Usually, for basic care of windows and their frames, it is enough to degrease the window frames and sashes 1–2 times a year (ideally in spring and autumn) with a special cleaner with a degreasing effect. There are many such products in drugstores or specialized shops. Due to the accumulation of surfactants, ordinary dish soap or other dishwashing cleaners are not suitable, as the surfactants in these products layer and then create a film that attracts dust and other dirt. After the frames have dried, simply apply a care product to the frames and seals, which fills small irregularities and cracks in the topcoat, prevents moisture penetration, and restores elasticity to the seals. No other technical maintenance is necessary if the windows are in good condition; this treatment will last for half a year to a year.

We usually provide a 5-year warranty on windows from the handover of the work.

How to Care for Plastic Windows and Doors

Maintenance of plastic windows is simple and does not require much work or time. At least once a year, owners of plastic windows should check their hardware and seals. The most suitable time is after winter, as this is when the windows are most stressed. Frost, cold wind, and increased precipitation mainly affect the seals, especially in the lower part of the frame, where dirt also accumulates. Even if the window is fitted with EPDM seals, which are most resistant to unpredictable weather conditions, they still require more intensive care in winter. It is sufficient to treat the seals with a suitable product that prevents the seals from freezing to the profiles. The most suitable for this purpose are special products based on silicone resins.

Always Call a Specialist for Hardware

After winter, it is necessary to assess the condition of the window hardware. First, check if any metal part is loose or worn. If you find that the window does not close as it should, or if it has dropped slightly, you should call a specialist who will adjust the level and pressure of the frame directly on the hinges.

Maintenance and Cleaning of Windows and Doors

Your new windows (doors) do not require any special care; their maintenance is based only on occasional washing of accumulated dust.

• After construction work is completed, windows must be cleaned very carefully, especially never dry! Remnants of mortar or other hard building materials can seriously damage the hardware and seals if removed carelessly.
• For normal window cleaning, it is sufficient to wash off accumulated dust with water and detergent. Dry cleaning is unsuitable and creates static electricity.
• For heavier soiling, such as oil stains, an alcohol-based cleaner can be used. Never use abrasive materials on windows and doors! Do not use technical chemicals such as solvents (petrol, acetone), alkaline products (e.g., ammonia-based), or acidic products (sulphuric acid-based, etc.), thinners, or other aggressive substances, as these could cause irreversible damage to the profile surface. Do not use such products or application tools that could scratch the windows, such as sandpaper or wire brushes.
• Before winter, lightly coat the rubber seals with glycerin.
• Regular care of individual hardware parts will keep them running smoothly and protect them from premature wear. Protective films must be removed from plastic and aluminium profiles no later than 3 months after delivery.

Maintenance of Hardware

Lubricate the designated hardware points so that the oil does not run down the outer surfaces and soil the frame. Do not use acidic or resinous greases for lubrication. Wipe off excess lubricant with a dry cloth. Only use cleaning and care products that do not compromise corrosion protection.

Adjusting the Windows

If you find that the windows open or close poorly, they can be adjusted according to the instructions for use and maintenance, which the customer always receives with each window delivery. Abnormalities to watch for and not neglect their repair: the hardware must operate smoothly and quietly without excessive effort. If unusual noises occur, the cause is probably dirt or a foreign object. It is recommended to use a vacuum cleaner and vacuum the entire perimeter of the hardware, then treat the window frame and seals with commonly available products. Window seals must fit tightly at all points, be straight, and free of deformation. It is advisable to wash and lubricate them with a suitable product. There is a lubricant for seals in the form of a stick, which makes application easy. Glass requires only normal maintenance such as washing. When washing, check that the silicone around the glass adheres well and there are no air bubbles. If such a defect appears, its repair requires a specialist, who will come directly to the site and re-silicone the window.

A detailed manual for the maintenance of system aluminium elements is described in detail in the manual:
NÁVOD K ÚDRŽBĚ VÝROBKŮ ALUPROF.pdf

Sources:

1. Panel supplier Ruukki CZ s.r.o.
2. Door supplier PORTAPRO s.r.o.
3. Window supplier V Okno s.r.o.
4. Aluminium profile supplier Aluprof (Thermont spol. s r.o.)