Rehabilitation of the EDP Headquarters Roof in Castelo de Bode

 

Some projects challenge us by their scale. Others, by their technical complexity. And then there are those that are, above all, a true privilege: to intervene in a building that forms part of a critical national infrastructure.

 

That was the case for the rehabilitation of the roof of the EDP Tejo Mondego Directorate Headquarters, adjacent to the emblematic Castelo de Bode Hydroelectric Power Plant.

 

This project was not only an engineering challenge—it was also a direct contribution to the preservation of a support building for an essential installation, where history and innovation continue to generate energy.

 

 

 

A building at the heart of Portugal’s energy network

 

The Castelo de Bode Dam, located in the municipality of Tomar, is far more than a hydroelectric infrastructure. Since its inauguration in 1951, it has stood as one of the greatest symbols of Portuguese engineering and a key element in the country’s energy and water supply system.

 

Today, it is part of the Tejo-Mondego Production Center and stands out for:

 

• Supplying electricity to more than 2 million people in the Lisbon region and surrounding municipalities
• Having a 60 km-long reservoir covering over 3,300 hectares
• Contributing to the preservation of river ecosystems by ensuring the downstream ecological flow

 

 

Panoramic view of the Castelo de Bode dam

 

 

Autonomous energy and a protected ecosystem

 

The Castelo de Bode power plant is one of the few in Portugal capable of performing a “black start”, that is, restarting the electrical grid autonomously, without relying on external sources. This process, crucial in the event of widespread power failures, proved essential, for example, during the blackout that affected the Iberian Peninsula in April 2025.

 

The operation is carried out through two small hydro generators that allow the start-up of the three main generators. In addition, these small units ensure compliance with the ecological flow: a controlled release of water that is vital for maintaining the environmental balance of the downstream rivers.

 

Generators at the Castelo de Bode power station

 

 

This ecological flow ensures:

• The preservation of river habitats
• Water quality
• The sustainability of riparian ecosystems

 

It was in this unique setting, where energy production, engineering, and environmental commitment converge, that Prudêncio stepped in.

 

 

 

The technical challenge: structural complexity at different heights

 

The building’s roof had a varied configuration and a complex structure, including areas with lightweight and solid slabs, finished with zinc over a base of lightweight screed and cork.

 

The main challenges included:

• Variable height of the shaping layer, ranging from 210 mm to 350 mm
• Numerous technical elements crossing the roof, such as skylights, walls, and irregular edges
• The need for a durable, watertight, and thermally efficient solution

 

A conventional solution was not an option. This context demanded a system fully adapted to the building’s specific characteristics.

 

 

During the execution of the project

 

 

The Prudêncio solution

 

To meet the project’s unique requirements, the following rehabilitation system was applied:

• Installation of PIR (polyisocyanurate) foam boards over EPS spacers, providing a flat, resistant base for the waterproofing and thermal insulation system.
• Mechanical fixation only of the PIR boards to the load-bearing substrate, with characteristics and dimensions adapted to the various types of concrete and existing height differences.

On top of these, a fully bonded waterproofing system was applied, consisting of:

• KÖSTER Membrane Adhesive polyurethane glue
• KÖSTER TPO 1.5 F membrane, reinforced with fiberglass mesh and a 250 g polyester backing, ensuring superior adhesion and resistance

 

Final result of roof waterproofing

 

 

In addition to the roofs, walls and other construction elements were also waterproofed, ensuring full continuity of the system for maximum watertightness.

 

To guarantee efficient natural lighting while eliminating thermal bridges and ensuring a tight seal with the waterproofing system, the old skylights were replaced with Solatube solar tubes, further improving the roof’s energy efficiency.

 

The entire system was executed continuously, safely, and under strict quality control, meeting the highest standards required for a building of this nature.

 

Installation of Solatube solar tubes

 

 

A project that honors client trust and site value

 

The work was successfully completed and received direct recognition from the client. We also had the privilege of a guided visit inside the power station, an opportunity to witness firsthand the strategic importance of this site where Prudêncio left its mark.

 

Internal tunnels / Former command post, now converted into a museum space

 

 

Today, the roof of the EDP Headquarters in Castelo de Bode is:

• 100% watertight and protected against infiltration
• Thermally efficient
• Prepared for climatic and operational challenges
• Energy-efficient and aligned with the power station’s sustainability goals

 

 

 

When rehabilitation means protecting something greater

 

This project once again demonstrated that rehabilitating a roof goes far beyond the technical aspects. It is a matter of responsibility and precision. When the building supports the national electrical grid, every detail matters.

 

At Prudêncio, we believe that waterproofing is more than protecting structures: it’s about protecting what they represent.

 

Would you like to see more examples of our work? Explore the technical solutions we apply to each project.