Fire-Damaged Structural Rafter and Industrial Roof Repair at Howard Industries
Replacing Fire-Damaged Structural Steel Without Stopping Production
Metalguard restored fire-damaged primary framing, purlins, liner panels, insulation and roofing inside Howard Industries’ approximately 2.3-million-square-foot transformer manufacturing facility in Laurel, Mississippi. Because the repair was roughly 300 feet from the nearest roof edge and production continued about 22 hours per day, Metalguard coordinated the structural engineer and scaffolding engineer while self-performing the fabrication and field work. The resulting plan combined a 12,000-square-foot engineered interior scaffold platform, independent structural shoring, an exterior scaffold stair tower, a rooftop doghouse, traveling chain hoists, custom rails and a transport cart.
Project at a Glance
The Business Problem
A fire damaged a primary structural rafter, connected purlins, interior liner/decking, insulation and the exterior metal roof. Repairing the steel was only part of the problem. The work sat deep within an enormous facility, directly above active manufacturing, and conventional crane access was not practical.
Investigate the Damage and Design the Repair Sequence
Fire damage distorted the primary rafter and affected the purlins and layered roof assembly above.
Metalguard coordinated with specialized licensed structural and scaffolding engineers to document damaged and undamaged conditions, establish the repair limits, and plan the load path during removal. Both the permanent repair and the temporary works mattered: the damaged framing had to remain supported while stored stresses were released and new sections were fitted.
Structural Engineering: Collaborative Design and Load-Path Modeling
Complex pre-engineered metal building (PEMB) structural restoration requires deeply integrated engineering and field coordination. For over 10 years, Metalguard has partnered with SMS Engineering (Katy, TX), collaborating on five to six industrial projects annually and routinely managing multiple simultaneous complex scopes. For the Howard Industries project, both Metalguard and SMS Engineering aligned their specialized corporate licensing to operate within the state of Mississippi.
The structural engineer evaluated the fire-damaged primary rafter, the connected purlins, and the remaining rigid frame components designated to stay in service. This comprehensive engineering review established:
- The exact dimensional limits of structural steel removal.
- The geometry, connection plates, and splicing requirements for the sectional replacement rafter.
- The temporary structural shoring load requirements.
- The precise sequence in which structural loads would be safely transferred.
This collaborative relationship extended directly from the design office to the production floor and the field. Leveraging a high-trust, continuous communication loop backed by real-time photo verification, the structural engineer inspected and approved Metalguard’s prefabricated steel sections at the production shop prior to deployment. Due to this long-standing relationship, routine technical questions and project updates were communicated seamlessly, frequently allowing the teams to manage two or three projects simultaneously.
During field execution, the structural engineer and the Metalguard project manager were both present on site for the initial controlled cut. This active field engineering oversight ensured that as the fire-distorted member released its locked-in thermal stress, the temporary shoring absorbed the physical movement exactly as modeled.
The replacement rafter could not be treated as an isolated steel component. Each custom-fabricated section was engineered to seamlessly interface with the retained framing, restore the pre-engineered design load path, and accept the purlin, brace, and connection attachments salvaged during demolition. Ground trial assembly, precise field measurement, final geometric adjustments, controlled hoisting, heavy bolted connections, reinstalled secondary bracing, primer, and finish paint were all systematically executed to return the rigid frame to certified service.
Scaffolding Engineering: Integrated Temporary Infrastructure
To address the temporary infrastructure, Metalguard partnered with BrandSafeway, the premier national specialty scaffolding firm. BrandSafeway’s engineering team designed and supplied an independent, approximately 12,000-square-foot elevated work platform engineered to safely support construction traffic without loading the active manufacturing floor below.
Metalguard’s internal design team facilitated a three-way coordination workflow alongside BrandSafeway’s engineers and SMS Engineering. Together, they engineered an integrated temporary framework capable of supporting two distinct structural loads simultaneously:
- Below-Roof Shoring: Supporting the building’s compromised primary framing during demolition.
- Above-Roof Logistics: Supporting the operational weight of the custom traveling rail-trolley and chain-hoist material handling systems.
The temporary BrandSafeway system layout was engineered to navigate heavy process ductwork, high-voltage utilities, industrial equipment, and active plant traffic patterns without forcing a manufacturing shutdown. Furthermore, the design precisely aligned the vertical columns of the rooftop doghouse enclosure directly over the interior scaffold support columns. This critical engineering alignment ensured that all temporary live loads followed an intentional, calculated path straight down to the building substructure.
- Damaged primary rafter/beam and associated connections
- Bent and separated roof purlins
- Interior liner panel/decking and insulation
- Exterior roof panels and damaged roof curbs
- Temporary scaffold and shoring systems reviewed with specialty engineering input from SMS Engineering and BrandSafeway
Exterior Scaffold Stair Access for a Large Roof Crew
A full-height exterior scaffold stair tower provided a guarded, repeatable route between grade and the roof. With many workers moving to and from the roof, the stair system was more efficient than cycling personnel through a lift and avoided relying on ladders as the primary access method. Its landings, stairs, and guardrails also gave crews a consistent access route for daily mobilization, breaks, emergency planning, and demobilization.
Engineer Safe Access and the 12,000-Square-Foot Interior Scaffolding System
The interior scaffolding served as the foundational infrastructure for the entire Howard Industries structural restoration. It functioned as an engineered, approximately 12,000-square-foot elevated work platform meticulously constructed inside an operating transformer manufacturing plant. This specialized access design allowed structural steel and industrial roofing work to proceed overhead without occupying the active production floor with conventional material staging, falling-debris zones, cranes, or man lifts.
Multi-Entity Temporary Engineering Integration
The permanent structural repair and the temporary access infrastructure could not be planned independently. SMS Engineering modeled the damaged rigid frame, defined the structural connection specifications, and projected the physical behavior of the fire-damaged member as its locked-in thermal stress was released. BrandSafeway’s engineering team utilized these parameters to design the temporary platform grid, determine support column placements, specify load capacities, and calculate the path by which construction loads reached suitable support below.
During the multi-phase project, the BrandSafeway platform and its underlying support grid accommodated crews, plywood decking, high-intensity task lighting, plastic dust containment, fire blankets, specialized tools, heavy welding machines, demolished steel sections, replacement structural rafter pieces, secondary purlins, interior liner panels, and independent structural shoring.
The integrated temporary system logic required:
- Permanent structural design by SMS Engineering for the damaged rafter, connection splices, and rigid frame load restoration.
- Scaffold infrastructure design by BrandSafeway for the elevated work platform, high-capacity support grid, and navigation of obstacles within the occupied plant.
- Separate adjustable structural shoring to support the building’s compromised roof framing before and during demolition.
- Precise structural alignment of the vertical rooftop doghouse columns directly over the interior scaffold support columns to establish a deliberate load path down to the building’s foundation.
- Integrated hoist-support framing and traveling trolley systems coordinated with the doghouse framing, roof openings, and the interior work platform below.
- Continuous field verification and daily log documentation as construction activities, structural loads, and facility conditions changed.
Built Around an Active Production Footprint
The layout area for the scaffolding contained major physical obstructions, including large process ductwork, industrial utilities, existing building framing, heavy plant machinery, and active employee traffic patterns. The first interior scaffold sections were carefully fitted around these fixed obstacles rather than forcing manufacturing operations to relocate.
Erection, modification, and final dismantling of the scaffold were strictly sequenced around the plant’s available shutdown windows. Metalguard utilized extended shifts to accelerate the assembly process and minimize operational interference. Once fully erected, the platform established a distinct physical boundary, separating the construction environment from the factory floor and giving the field crew a stable, continuous surface across the entire fire-damaged area.
A Controlled, Layered Work Environment
To convert standard scaffold decking into a high-productivity industrial workplace, Metalguard implemented a multi-layered protective deck. Plywood was installed over the BrandSafeway deck to provide a continuous, impact-resistant surface. Heavy plastic sheeting was overlaid to trap dust, fire residue, and small construction debris. Solid perimeter controls defined the elevated boundaries, while temporary high-intensity lighting illuminated connection details and overhead framing. Fire blankets and localized welding screens were deployed across the deck during all cutting, grinding, and welding operations.
This contained setup provided double-sided benefits. It isolated the active manufacturing environment below from all construction hazards while vastly increasing field efficiency. Crews could safely stage heavy tools, store materials, inspect connections, and perform continuous cleanup directly at the repair level without repeatedly lowering equipment to the production floor.
How the Platform Enabled the Structural Work Sequence
The engineered platform directly enabled the structural removal sequence. Adjustable temporary shoring posts were set up on the deck to brace the roof structure and take the weight of the damaged rafter. SMS Engineering and the Metalguard project manager conducted the initial cut on the fire-distorted frame from the platform surface. When the rafter separated and reacted to the release of stored stress, the independent shoring maintained total structural control. Traveling chain hoists suspended from the doghouse columns then lifted the severed steel sections up through the roof cuts and onto the rail-cart system, avoiding any material handling through the factory interior.
Secondary Framing Restoration and Project Closeout
The BrandSafeway platform remained a vital asset after the primary structural rafter was successfully replaced. Working from the stable surface, crews systematically removed and replaced approximately 2,200 linear feet of damaged secondary purlins and lifted approximately 12,000 square feet of new corrugated interior metal liner panels and decking into place. This interior work was executed in lockstep with the installation of the insulation, hat-channel subframing, and the new 87,000-square-foot exterior roof-over above.
The industrial repair generated substantial debris, including scorched insulation, warped metal decking, steel cuttings, old fasteners, and packaging. Daily vacuuming and debris consolidation were performed to maintain safety above the operating plant. Housekeeping milestones were verified in daily construction logs and reviewed during morning Job Safety Analysis meetings. Upon final structural approval of the permanent framing, the temporary shoring, containment materials, plywood decking, and BrandSafeway scaffold components were systematically dismantled and removed in a controlled sequence coordinated with plant management.
What the Interior Scaffolding Demonstrates
This was engineered temporary construction used to preserve business continuity. It converted a congested area above an active production floor into a protected structural-repair workplace and supported the project from investigation and shoring through rafter replacement, purlin work, liner-panel installation, cleanup, and demobilization.
Self-Perform Critical Fabrication
By self-performing critical fabrication, Metalguard reduced outside dependencies and maintained greater control over quality, cost, sequencing, and delivery. Fewer handoffs allowed a faster, more agile response to changing field conditions and real-time field measurements.
Shop Layout and Structural Tolerances
Metalguard fabricated both the temporary rooftop doghouse components and the permanent rigid frame replacement rafter sections prior to installation. All connection plates were precisely laid out, machined using magnetic drills, and welded within a controlled shop setting to guarantee exact structural tolerances before deployment.
Because the massive structural rafter sat deep within the active facility, a single full-length member could not be delivered across the roof deck. Metalguard engineered the replacement as a multi-part sectional assembly consisting of ten precise, five-foot sections. All fabricated rafter sections were later trial-assembled on the ground, measured, bolted together, and structurally adjusted for final fit prior to being transported to the roof staging area.
Engineer the Rooftop Doghouse, Hoists, Rails and Cart
The long doghouse frame established a protected lifting corridor directly above the fire-damaged rafter. Vertical doghouse columns passed through controlled roof openings, transferring structural weight straight down to the engineered BrandSafeway scaffold support columns below.
The doghouse structure was engineered to serve multiple integrated purposes: framing the weather-protected rooftop enclosure, supporting the active overhead traveling chain-hoist beams, and establishing a deliberate temporary load path straight to the building’s substructure. Fully enclosed with industrial metal wall panels, matching roof decks, and detailed base trims, the lifting corridor isolated the plant interior from the elements, ensuring facility operations remained dry and uninterrupted throughout the project lifecycle.
Engineering Collaboration and Shop Quality Control
The temporary rooftop enclosure and hoisting system were developed through close collaboration between Metalguard and the structural engineer. Metalguard defined the required operational functions, calculated the material handling logistics, and specified the sizing parameters for the primary rafter beams being removed and replaced.
Using this operational data, the structural engineer designed the specialized structural frame. To guarantee maximum quality control, the engineer conducted a comprehensive visual and structural inspection of all Metalguard shop welds prior to shipping the temporary components to the project site.
Field Oversight and Structural Enhancements
This active engineering collaboration extended directly into the field. While the crew was on site preparing to make the initial controlled cut on the damaged rafter framing, the structural engineer conducted an exhaustive field inspection of the temporary structures.
To ensure absolute safety during the critical stress-release phase of demolition, the engineer directed the field crew to add specialized triangular gusset bracing to specific high-stress points on the temporary frame. Characterized by the engineer’s signature “belts and suspenders” approach to structural risk management, this minor field adjustment provided immense additional load protection, ensuring the physical movement of the building frame behaved exactly as modeled during the cut.
Rooftop Logistics and Material Handling
A custom transport cart was fabricated on the roof to run on a field-built rail system. Curved twin rails were engineered and assembled on site to connect the exterior roof loading area directly to the enclosed doghouse opening. This custom track system safely transported heavy rafter sections, purlins, tools, and even commercial welding equipment across the roof deck without routing those heavy construction loads through the active manufacturing floor.
Protect Production, Weather-Tightness and Fire Safety
Maintaining a secure overhead workplace required strict environmental controls, rigorous fire prevention, and a continuous weather-sealing strategy. Because construction took place directly above an active electrical transformer manufacturing facility, protecting the plant’s interior assets, equipment, and workforce from external elements or industrial spark hazards was a primary operational requirement.
Pre-Construction Surface Preparation and Flash-Fire Prevention
Before any spark-producing work could begin, the fire-damaged steel framing and surrounding components underwent intensive cleaning. The original fire incident had vaporized sections of insulation and structural coatings, leaving behind a highly combustible layer of oily soot and carbon residue across the remaining purlins and rigid frames.
To eliminate the risk of a secondary flash fire during hot work, Metalguard implemented a comprehensive surface decontamination protocol. Crews manually scraped away heavy soot accumulations and applied commercial degreasing agents to strip the volatile film down to bare steel. This meticulous pre-cleaning ensured that slag, sparks, and molten metal generated during subsequent structural demolition would not ignite any residual surface contaminants.
Fire Containment and Hot Work Safety Controls
With the steel surfaces fully decontaminated, the elevated work deck was transformed into a highly regulated hot work containment zone. Flame-retardant welding blankets were layered across the plywood scaffolding deck to catch sparks and grinding slag. Specialized localized containment screens and plastic containment were positioned around every cutting and welding station to block stray sparks from escaping the immediate work area.
To maintain air quality on the enclosed deck during heavy cutting and welding, industrial fans combined with the open doghouse structure were utilized to supply constant fresh air and displace contaminated air. Fire watches monitored active work zones with thermal imaging tools and fire suppression equipment. Furthermore, strict daily housekeeping routines were enforced, utilizing vacuuming and manual collection to completely remove metal shavings, burned insulation, and construction debris from the active work platform at the end of every shift.
Weather-Tight Structural Enclosures and Daily Resealing
Because the structural repair required cutting through the building’s primary roof envelope to install the sectional rafter components and vertical hoist columns, preventing water infiltration was essential. Roof openings were specifically sized and cut so they could be completely and securely resealed at the end of every single day.
To handle the frequent rain events common to the region, Metalguard deployed multiple layers of temporary flashing, heavy-duty patching, and counterflashing around the active penetrations. Weather seals were systematically inspected and reinforced ahead of every projected rain event, keeping the active manufacturing floor below dry, dust-free, and operational throughout the project lifecycle.
Administrative Controls and Safety Protocols
Safety and documentation were managed through a continuous daily feedback loop:
- Task-Specific JSA: A detailed Job Safety Analysis was reviewed with the entire field crew at the start of every day to address the specific hazards of that shift’s tasks.
- Daily Progress Logs: Comprehensive logs were maintained daily, documenting the exact crew count, weather conditions, work performed, equipment utilization, field issues, and the next-day operational plan.
- Dedicated Safety Oversight: On-site safety management adapted dynamically, implementing new physical controls and personnel positioning as the project transitioned between demolition, fabrication, and structural erection.
- Hot Work Controls: Engineered fire blankets, highly controlled cutting boundaries, active mechanical ventilation, and continuous cleanup protocols were maintained across all structural modifications.
- Proactive Weather Management: Roof seams and temporary flashing layers were pressure-tested and physically reinforced prior to every forecasted storm.
Remove the Damaged Rafter Under Engineered Support
The initial separation cut on the compromised rafter was executed using a heavy-duty mechanical grinder rather than a conventional cutting torch. The structural engineer and the Metalguard project manager were both physically present on the elevated platform to oversee this critical milestone. The deliberate decision to use a grinder was driven by the need to completely eliminate concentrated heat input, preventing any further thermal distortion or unpredictable expansion of the already damaged steel.
As the grinder severed the final section of the web and flange, the building frame reacted exactly as anticipated by the engineering models, releasing its stored internal stresses. Because the adjustable temporary shoring system had been pre-loaded to counter these specific movements, the temporary works maintained absolute control over the structural framing, preventing any dangerous shifting or load drops.
Vertical Material Extraction and Logistics
Once the rafter was completely segmented into its designed five-foot sections, the field crew initiated the overhead extraction sequence. Rather than lowering the heavy, compromised structural steel down through the interior traffic lanes of the active factory floor, the material handling path was entirely vertical.
Crews engaged the traveling chain hoists suspended from the overhead doghouse structural framing. The severed rafter sections were lifted cleanly up through the controlled roof cuts, out of the building’s interior envelope, and straight into the weather-protected doghouse enclosure. From there, the sections were securely transferred onto the custom rooftop rail transport cart, allowing the demolition debris to be safely rolled across the exterior roof deck to the designated staging area without causing a single minute of downtime for the manufacturing operations below.
The initial cut was made with a grinder to limit additional heat input into the already fire-damaged steel.
Trial-Fit and Install the Sectional Replacement Rafter
The installation of the permanent rigid frame required the same meticulous level of logistical planning as the demolition phase. Because the manufacturing facility remained operational, bringing a single, full-length structural rafter into the center of the building was physically impossible. The replacement member had to be introduced in carefully engineered segments and assembled under tight tolerances directly above the active production floor.
Ground Verification and Segmented Delivery
The permanent replacement rafter was custom-fabricated in manageable five-foot sections designed to navigate the tight transport constraints of the exterior roof deck and the vertical clearance of the doghouse lifting corridor. Before any steel was lifted to the roof, the field crew conducted a full-scale trial assembly on the ground.
The individual rafter segments were bolted together to verify overall length, flange alignment, bolt-hole registration, and final structural fit. Once exact dimensional tolerances were confirmed and minor shop adjustments were completed, the sectional assembly was disassembled and transferred systematically to the rooftop staging area.
Overhead Erection and Structural Tie-In
From the rooftop staging area, individual rafter sections were loaded onto the custom rail transport cart, rolled to the enclosed doghouse structure, and rigged to the traveling chain-hoist system. The hoists lowered the steel sections down through the controlled roof openings directly into the supported interior work zone.
Working from the stable BrandSafeway platform, the field crew aligned, fit up, and bolted the structural splices together, completing the primary rafter replacement while the independent temporary roof shoring maintained absolute control of the building’s structural load.
Secondary Framing Integration and Surface Finishing
With the primary structural rafter securely installed and connected to the main rigid frame, the crew systematically reinstalled all associated purlin clips, secondary framing connections, and lateral bracing. To ensure long-term durability and corrosion resistance, the completed structural assembly was thoroughly prepped, primed, and coated with high-performance industrial paint.
Only after the permanent framing was fully restored, coated, and structurally approved by the engineer of record did Metalguard initiate the systematic dismantling and removal of the temporary shoring systems, containment layers, and the interior work platform.
Restore Purlins, Interior Decking, Insulation and the Roof
With the primary rigid frame fully restored, the project transitioned into the systematic rebuilding of the building envelope’s secondary framing and multi-layered roof architecture. To maintain maximum efficiency and ensure continuous weather-tightness, Metalguard executed interior and exterior restoration workflows in highly coordinated parallel sequences.
Interior Secondary Framing and Liner Panel Restoration
Working from the secure, stable surface of the elevated interior platform, crews began the extensive process of replacing the secondary structural members that had been warped or weakened by the fire. The field team successfully removed and replaced approximately 2,200 linear feet of damaged secondary purlins, anchoring them directly to the newly installed rigid frame rafter.
Following the structural purlin installation, crews worked from below to lift and secure approximately 12,000 square feet of new corrugated interior metal liner panels and decking. This sub-roof deck restoration provided a clean, finished interior ceiling for the transformer plant while establishing a solid foundation for the insulation layers above.
Building Envelope Reconstruction and Closeout
As the interior ceiling assembly neared completion, exterior crews worked on the rooftop to reconstruct the primary thermal and weather barriers. The damaged roof assembly was completely rebuilt from the deck up, starting with the installation of high-efficiency industrial insulation layers to restore the facility’s thermal performance.
New heavy-gauge exterior metal decking was then fastened down, perfectly tying the restored zone back into the plant’s massive 87,000-square-foot exterior roof-over system. This dual-sided approach allowed the building envelope to be sealed rapidly and permanently, completely neutralizing any future weather risks to the production environment below.
Once the structural integrity of both the permanent framing and the roof envelope was officially verified, Metalguard initiated the controlled, phased extraction of the temporary shoring, containment membranes, and scaffold components, successfully returning a fully restored, debris-free facility back to Howard Industries.
Rebuild Roof Curbs and Finish the Transitions
The final phase of the building envelope restoration focused on detailing the critical penetrations and material transitions across the newly installed roof system. While a roof-over provides excellent continuous protection, its long-term performance relies entirely on the engineering quality of its edge details, equipment interfaces, and penetration flashings.
Exhaust System Curb Fabrication and Integration
During the initial fire incident, several large industrial exhaust systems and process ventilation units remained structurally functional, but their surrounding roof curbs and base interfaces were severely compromised. Rather than attempting to patch the warped flashings, Metalguard systematically detached the equipment and removed the old, damaged curbs down to the structural framing.
New, high-capacity industrial roof curbs were custom-fabricated and engineered to integrate seamlessly with the profile of the new peak-to-eave metal panels. Properly executing these structural curb interfaces is one of the most critical aspects of industrial roofing; poorly designed or rushed penetrations can create years of chronic water leakage and ongoing maintenance issues, even if the surrounding roof field is entirely new. Metalguard properly flashed, sealed, and anchored each unit to ensure a permanent, watertight bond capable of withstand heavy industrial vibration and thermal movement.
Engineered Structural Transitions and Closeout
With the exhaust penetrations fully secured, crews turned their attention to the perimeter boundaries where the new 87,000-square-foot roof-over system met the plant’s existing, unmodified roof sections. Managing the elevation change and material differences between old and new roof surfaces required a precise, water-shedding transition design.
Metalguard fabricated and installed heavy-gauge custom transition trim, counterflashing, and high-performance closure strips along the entire tie-in boundary. This meticulously detailed transition established a continuous, unbroken path for stormwater runoff, preventing wind-driven rain from backing up under the panels or penetrating the expansion joints. The completion of these final transition trims officially sealed the facility envelope, delivering a fully integrated, low-maintenance structural roof system back to Howard Industries.
Document the Work and Build a Reusable Knowledge Base
The final component of the structural restoration project involved establishing a rigorous quality assurance record and an operational blueprint for the facility’s future. Because industrial manufacturing plants undergo continuous infrastructure updates, capturing the precise layout of new structural steel, customized equipment curbs, and modified framing boundaries was essential for long-term asset management.
As-Built Technical Documentation and Engineering Logs
Throughout every phase of execution, Metalguard maintained a comprehensive, day-by-day technical log. Every structural adjustment—including the precise location of the vertical doghouse support columns, the custom structural splices on the sectional rafter, and the exact routing of the 2,200 linear feet of secondary purlins—was fully mapped and recorded.
These field records were integrated into the final as-built engineering documents provided to the facility management team. Having a verified, structurally approved record ensures that future facility expansions, overhead crane modifications, or utility routing adjustments can be engineered safely without risking the structural integrity of the newly restored rigid frame.
Creating a Blueprint for Future Plant Infrastructure
The comprehensive documentation pack serves as an active, practical knowledge base for Howard Industries. It includes exact technical specifications for the 87,000-square-foot peak-to-eave roof-over system, detailing the precise gauge, profile, and fastening schedules of the metal panels, as well as the custom-engineered expansion joints along the roof transitions.
By capturing every engineering detail, material grade, and penetration flashing layout, Metalguard provided the plant operations team with a complete technical roadmap. This turn-over package completely eliminates the guesswork typically associated with maintaining specialized, fire-restored industrial structures, ensuring the facility remains fully protected, operationally secure, and highly adaptable for decades to come.
The same discipline applied to debris. Damaged steel, purlins, decking, insulation and packaging were staged and removed daily so the customer could continue operations.
Results and Differentiators
A Specialty Industrial Metal-Building Repair Contractor
The Howard Industries project demonstrates how Metalguard approaches a repair that cannot be solved with a conventional crane pick or a standard roofing detail. Structural repair, temporary works, access, fabrication, lifting, logistics, weather protection and production continuity were designed as one integrated system.
- Major structural replacement above an operating manufacturing floor
- Temporary access and shoring engineered around existing equipment and production flow
- Off-site and on-site fabrication self-performed for control of fit, quality and sequencing
- Custom doghouse, traveling chain-hoist system, rooftop rails and transport cart
- Approximately 2,200 linear feet of purlins and 12,000 square feet of interior liner/decking restored
- Approximately 87,000 square feet of compatible roof-over installed because the original profile was discontinued
- Daily logs, live JSAs, weather protection, fire controls and housekeeping documented throughout the work
Frequently Asked Questions
Can major structural steel be replaced while a manufacturing plant remains operational?
Often, yes. The contractor must first understand production flow and then engineer access, shoring, containment, logistics and work sequencing around the operation. At Howard Industries, production continued about 22 hours per day.
What if a crane cannot reach the damaged framing?
A custom material-handling system may be required. Metalguard used an exterior scaffold stair tower, rooftop staging, a protected doghouse, traveling chain hoists, curved rails, a transport cart and an elevated interior scaffold platform.
Why was the replacement rafter fabricated in sections?
The repair was about 300 feet from the roof edge and a full-length member could not be delivered conventionally. Manageable sections could be trial-assembled, transported by rail, lowered through the doghouse and connected in the supported work zone.
Why use a grinder instead of a torch to cut the damaged rafter?
The team wanted to limit concentrated heat input into steel that had already been affected by fire. The engineer and project manager were present, and the rafter was supported by engineered shoring during the controlled cut.
How was rain kept out around the temporary doghouse posts?
Roof openings were controlled and resealable. Layered temporary flashing, patching and secondary metal protection were installed and checked throughout the work, including during frequent rain events.
What happens when the original metal roof panel is discontinued?
The replacement must be redesigned as a compatible system. At Howard, Metalguard installed hat-channel subframing, insulation and an approximately 87,000-square-foot peak-to-eave roof-over in the damaged area.
Why are roof curbs important?
Curbs and flashing manage water around exhausts and other roof penetrations. Accurate fabrication and integration with the roof profile reduce long-term leakage and maintenance risk.
How do daily logs and JSAs help?
Daily logs preserve the project record, while activity-specific JSAs identify the day’s hazards and controls. Together they support management visibility, customer communication, accountability and lessons for future work.
Why does Metalguard self-perform fabrication?
Self-performance can reduce outside dependencies and improve control of quality, cost, sequencing and delivery. It also allows the field team to respond quickly when final measurements or fit conditions change.
Were engineers involved in the temporary systems as well as the permanent repair?
Yes. The work involved both structural engineering and scaffold/temporary-work engineering. Names and sealed design records should be added only if Metalguard and the engineers approve public attribution.
What did the structural engineer do on the Howard Industries repair?
The structural engineer evaluated the damaged rafter and retained framing, defined the permanent replacement and connections, established the removal and load-transfer sequence, and participated in critical field operations such as the initial controlled cut. Metalguard coordinated that engineering with fabrication, shoring, hoisting and installation.
What did the scaffolding engineer design or review?
The scaffolding engineer addressed the approximately 12,000-square-foot elevated interior work platform, its support grid and capacity, its fit around operating equipment and obstructions, and its interfaces with temporary shoring and doghouse support columns. The scaffold was temporary construction infrastructure, not merely a way for workers to reach the repair.
How did the interior scaffolding help Howard Industries remain in production?
The elevated platform moved the structural-repair workplace above the operating floor. Plywood, plastic containment, perimeter controls, lighting, fire blankets and daily housekeeping helped separate construction from production while providing a continuous surface for shoring, cutting, welding, material staging, purlin replacement and liner-panel installation.
Planning a difficult repair in an operating facility?
Contact Metalguard to evaluate the damage, define the temporary-work and access requirements, and develop a repair sequence around your operation.