Extension and Modernization of a Building for Furnace and Process Equipment

OBJECT: Production Building.
THE SERVICES:
Feasibility Study
Design for construction permit.
Application according to Federal Noise Protection Legislation.
Architectural Design.
Structural Design.
Technical Equipment.
(a.o. ventilation, cranes).
Site supervision.
Project Coordination.

CLIENT: Gerresheimer Lohr GmbH, Lohr.

The company Gerresheimer Lohr GmbH, part of the Gerresheimer AG who are well-known producers of glass products for the pharmaceutical and cosmetics industries and the beverage and food industries, intended to modernize their pro-duction site in Lohr on the river Main.
Considerable construction work on the existing buildings was required for the exchange of an old furnace against a more effective furnace, as much as for the required reduction of noise emissions caused by the production process whereas the production process had to be kept up during construction works. The construction works were split into the following construction phases:

Construction Phase 1:
Extension of the basement on the Eastern side of the building of pans and machinery with a surface of length x width = abt. 49,00 m x 8,30 m by means of a reinforced concrete construction of floor slabs, walls, bearers and ceiling tiles for the installation of a regenerating chamber of the new furnace. The height of the cellar in the extension area is between 3,70 and 7,00 m. The building pit sheeting work was carried out via high-pressure injection which was in the same time partially acting as underpinning of existing chimney bases. Furthermore the ground-water level was lowered by means of well drillings for the purposes of extending the cellar.
Construction Phase 2:
Construction of foundations (foundation pads and continuous foundation) in the basement of the existing production building.
Construction Phase 3:
Building a new housing over the existing production building with a new construction with the dimensions length x width x height = approx. 60,00 m x 48,50 m x 17,50 m / 26,00m (eaves height on ridge side), made from structural steel. The steel structure is existing mostly of a one-sided framework which exists of roof truss girders (span/height: approx. 48,50 m / 8,00 m) with ridge roof shaped pitch roof and tension bar as well as girder columns respectively hinged columns. The structural stabilization is ensured by roof and wall bracings as wells as beams and portals in the external walls. The roof covering profile sheets are supported by steel purlins which are located the top flanges of the truss girders.
Construction Phase 4:
Arrangement of a new noise-protected roof covering with thermal insulation (cavity insulated construction made from trapezoidal steel profiles) and wall covering (panelled wall covering) and installation of a new exhaust air equipment with noise absorbing devices in the area of the building ridge.
Construction Phase 5:
Demolition of the existing production building inside the new building structure including protection of the ongoing pro-duction process.
Construction Phase 6:
Partial renewal of the new production level within the new building construction as reinforced concrete composite flooring and of the basementfloor including construction of a foundation for the new furnace and construction of a transformator station on the production level in the area of the external building wall.
the services
In 2007 the KOCKS engineers were contracted to find a concept for the reconstruction/modernization of the production building, and also with estimations for investment and the layout. It took until the mid of 2008 for design for all phases up to the preparation of construction permit documents according to Federal Emission Protection Laws, the structural de-sign, the construction drawings, elaboration of the tendering documents for the required construction works and assis-tance during the award of construction works. The construction works carried out from September 2008 until June 2009 were supervised by KOCKS Engineers on site.
A very challenging task was the integration of existing buildings into the new building construction respectively the demolition of building parts which were not required any longer under ongoing production conditions.