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Eurobuild in Steel

Case Studies - Industrial Buildings


AIRBUS INDUSTRIAL HALL
IN TOULOUSE
Case study : Social collective residential building, Evreux
*

Steel construction industry provides efficient long span and limited weight structural frame for a huge
industrial hall that will produce the A380 Airbus airplane of next generation for intercontinental
flights.

This huge industrial building covers 200 000


m of ground occupation, is 45 m high and
provide spans of more than 115 m. Criteria to Sliding doors shall provide a 117 x 32 m
be met are, efficient space occupancy, opening. They are structural frame by
flexibility in arrangement of the internal themselves.
volume. Due to the expected change in the
industrial process after several year of This huge structure can only be erected in an
production, a reconfiguration/refurbishing economical way using steel as material,
approach design has been considered taking fabricated sections and a trussed upper beam.
count of fast financial return. Architectural and
structural appearance shall also be an attractive
sign of the company performances.

The widest module, 115 long by 250 m deep


building is equipped with the following heavy
crane material:

two parallel industrial rolling cranes, 50m


span, 22 tons load for wings lifting,

two parallel industrial rolling cranes, 35


m span, 30 tons load for fuselage
transportation,

Two dual loads 2x4 suspended cranes for


normal service.

The wing lifting cranes are rolling on ways that


are at one support suspended at the upper truss
of the structural frame of the roof and at the
other support fixed on the columns. Indoor picture of the plane montage building

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Case study : Social collective residential building, Evreux
*

Client: EADS
Architect: ADPI
Design office Cooperation : ADPI and Jaillet Rouby
Contractor: URSSA (Spain), CIMOLIA (Italy), CASTEL et
FROMAGET, JOSEPH PARIS, RICHARD DUCROS
(France), BUICK (Belgium)
Control Office SOCOTEC and VERITAS
Application Benefits Flexib ility of space organisation
Fast track construction Sustainability approach
Intensive use of steel components Structural strength

Internal view during construction. External view during erection of hall S34: 100 x 100 m.
Personage at the ground level Building on the back gives scale size.
gives scale size

Construction Details structural scaffolding, simple operation and


Roof and roof trusses: The structural roof fast construction arrangement.
trusses spans 117 m. Height of the trusses vary Joints between the truss elements and the
from 8 m on supports up to 13,50 m at mid top of the columns are pinned. This is a
span. Main roof elements are composed of two simple method that provides the following
parallel truss frames distant of 33 m and made
advantages:
of rectangular hollow steel sections. One roof
element include a pair of front and back Rapid joint operations in a critical
trusses, roof structure, roof service equipments, erection step,
fire safety network , and when completed at No welding operation during erection,
ground level is lifted and positioned at top of The truss upper flange element is
columns in one piece along the structural connected and simply resting on a short
columns. The gap between two adjacent span joint beam on top of the column.
elements is meters. Vertical deflection of any truss is limited to
Columns are rigidly fixed on ground 1/2000 of the span length due to crane
foundations and have equal slenderness operation requirements.
ratio in each direction to avoid any Elements of the truss are I shape
premature horizontal buckling constructed sections and bolted on joints.
phenomenon during lifting operations. Each column is made of two separate
Construction of the trusses on ground has constructed sections jointed by a
the advantage of safe building site, limited continuous truss web.

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SHOPPING CENTRE CACTUS
IN ESCH/ALZETTE
Case study : Shopping Centre Cactus in Esch/Alzette

This urban project in the city centre of Esch/Alzette provides a modern vision of steel structure using
curved cellular beams with glazed faade. The luminosity inside this building highlights the lightness
of visible steel structure. This visible and aesthetic steel solution was obtained due to modern fire
engineering approach.

SHOPPING CENTRE CACTUS IN ESCH/ALZETTE

General information Structure


This medium size supermarket is situated in The structure is a hall made up with portal
the city centre, of Esch/Alzette and it will frames comprising steel columns and
replace an older structure, which is situated in cambered cellular beams. The frames are
the proximate neighbourhood. The owner interconnected by means of steel roof purlins
wanted to have a non-typical hall and opted for and bracing system.
an open space with huge glassing surface in The frame is constituted one bay of 20m span.
two of the faades. The steel structure, with The ground level is at 0m, the top of the
long span curved cellular beams should column at 7,55m and the top height in middle
maintain visible . of the cambered beam is 9,13m.
Due to the location of the supermarket in a city The distance between adjacent main frames is
centre, the authorities required a fire resistance 7,50m. Frames are connected by continuous
of 90 minutes for the steel structure supporting purlins (IPE200). The roofing is made wit h a
the roof. The Natural Fire Safety Concept has steel sheet (HOESH TR44A), insulation and
been applied to calculate the evolution of the waterproofing.
fire in the supermarket. Using this concept, the The beams are Arcelor Cellular Beams build
opportunity for a building with a fully glazed from an HEB450 in S235. The height of the
faade and visible steel structure has been final beam is 590mm, the openings diameter is
retained. 400mm and the distance between the openings
Processing time: 2003 axes is 600mm. The distance between the
Total height: 9,13m edges of two consecutive openings is thus
Ground-plan: 28,51 x 48,16m 200mm.

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Case study : Shopping Centre Cactus in Esch/Alzette

Application Benefits Project Team


Column free internal space provides maximum Client: Cactus S.A
flexibility Architect Paczowski Fritsch Associs
Transparent appearance due to curved cellular
beams Structural Engineer Schroeder & Associs S.A
Architectural solution Constructor MABILUX S.A.
Unprotected ste el due to fire engineering
Fire engineering Arcelor Profil Luxembourg
approach
R&D

Top: Building during use Bottom: Building during errection

Natural Fire Safety Concept


Arcelor Profil Luxembourg Research has been completely glazed). As the maximum resulting
asked to perform the fire engineering of the steel temperatures in the columns reached up
structure. The authorities accepted to apply the to 880C, a 3-D finite element analysis was
Natural Fire Safety Concept. The fire design performed, taking into account the whole
was based on the prescriptions of EN1991-1-2 structure of the building. One complete model
(Characteristic fire load for office building: of the building in 3 dimensions was analysed.
730MJ/m) and by taking into account the All the simulations were made using the FE
active fire fighting measures (Automatic alarm software SAFIR.
& transmission to the fire brigade, smoke The result of this fire engineering approach
exhaust systems). No sprinklers were was that the whole steel beams and columns
foreseen due to the small size of the building. will remain without any passive fire protection.
The gas temperature has been calculated using
the 2 zone software Ozone and localised
temperature were calculated using Hasemi
methodology. A set of simulations has been
made to analyse the breaking of the glazed
surfaces (front and back faades are
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BILBAO EXHIBITION CENTRE
Case study : Exhibition Centre, Bilbao

BEC is the new Exhibition Centre in Bilbao, Spain. The exhibition centre has a floor area of 117 000
square metres, in 6 halls. The halls have no internal columns or supports, thanks to steel lattice girders
in the roof. Concerning fire safety, performance based rules were applied with the result that some
parts of the structures stay unprotected.

BILBAO EXHIBITION CENTRE, SPAIN

Aerial view

BEC is an initiative designed to offer the best The concrete walls are covered with a steel
possible service for exhibitors, visitors and the skin to prevent an aggressive impact of the
general public in a modern, convenient, building with the surrounding landscape
practical and highly functional trade fair
The loads are specified by the National Annex
facility.
NBE-AE-88. The magnitude of loads depends
1. Construction Details on the use of each area:
Structure - Car parks use load: 400kg/m
- Lorries accesses: 4000kg/m (national
The project consists of 111000m of exhibition
regulation: 1000kg/m)
area in 6 halls: the Arena hall (30000m) ,
- Hall areas: 4000kg/m
the medium hall (21000m) and the small
halls (4x15000m). The exhibition halls are - Pedestrian zones and accesses: 400kg/m
free of columns. 24300 tons of steel for the - Office areas: 300kg/m
structure of the halls and 19200 tons of - Restaurants: 300kg/m
- Roof (only for maintenance purposes):
corrugated steel in the foundations were used.
100kg/m
The box trussed beams of the halls are 125 to
These loads are supported in the different areas
167m long. The roof tubular spatial structure
with the following structural elements:
consists of 60 panels (37x37m).

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Case study : Exhibition Centre, Bilbao

2. Fire Safety concept


The national standard in Spain for fire
protection is the NBE-CPI-96: Condiciones
de Proteccin Contra Incendios.

The NBE CPI-96 is based on a prescriptive


approach but the characteristics of the structure
of the BEC allow an alternative study to avoid
the severe prescriptive requirements for roofs
passive fire protections thanks to low fire load,
good ventilation ,large diaphanous spaces with
high thermal dissipation, and presence of
Internal view of Hall n5 active protection measures (automatic
sprinklers)
Car park
The columns and beams of the car park are
made of reinforced concrete and the floors
consist of prefabricated concrete alveolar
plates with a compression layer of concrete.
Lorries accesses and hall floors
Prefabricated concrete alveolar plates with a
compression layer of concrete.

Hall structure
The columns are of reinforced concrete. The
box beams are composed of four trussed beams
Plan drawing of BEC
and are made of structural steel.
Construction Time:
Initiation : September 2001
Inauguration: April 2004

Hall structure during erection

Application Benefits Project Team

Column free internal space Client : Basque Government (47,7%),


Bizkaia Regional Gov. (47,7%), &
Maximum flexibility concerning the others
use
Architect : Csar Azcarate (IDOM) ; Esteban
Modern fire engineering Rodrguez (SENER)
Good working conditions through Structural Engineer : SENER & IDOM
transparent structure
Executive company : Companies cooperating in temporal
venture:
- Balzola S.A.
- Dragados
- Eraiker 2000
- Ferrovial Agroman
- URSSA

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GIRA PRODUCTION HALL
RADEVORMWALD
Case study : GIRA Industrial Building, Radevormwald
*

Concept and realisation of this architecturally appealing production building allows the integration of
the complex services as well as the manufacturing technology under consideration of maximum flexi-
bility.

GIRA PRODUCTION HALL, RADEVORMWALD

As a design-conscious manufacturer of electri- The design of these two of four possible, three-
cal components, the GIRA company makes storey halls was based on a comprehensive
high demands on technology and design as analysis of production processes, flow of
well as the architecture. In the course of the goods and general logistics. The existing pro-
development plan of their premises they real- duction buildings are tied on ground level. The
ised the first two of four possible production production concept can be successively
units with a floor space of approx. 20,000 m changed, adapted and expanded.
in total.
The basements offer break rooms, energy sup-
The new production and office development ply, buildings services, computing department
comprises two virtually identical halls each and a storage for tools. The ground floors con-
71.5 x 22.5 m on plan and linked on their long tain the production unit; open-plan bureaus,
faces by two staircases. The design of a glazed single offices, laboratories, tool production as
factory called for a clearly articulated, sle n- well as technical assets are located in the upper
derly dimensioned structure in which complex storeys. This concept provides closely linked
mechanical services and production plant workplaces of equal quality in all departments.
including lifting equipment, fork-lift trucks and
An ingenious concept for the mechanical ser-
unmanned transport systems had to be flexi-
vices allows natural ventilation via the facades
bly integrated. With their curved roofs, raking
and exploits excess energy from the production
facades and rounded glazed eaves, the build-
process.
ings have a distinctive form that makes its own
contribution to the firms strongly advocated
concept of corporate identity.

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Case study : GIRA Industrial Building, Radevormwald
*

Application Benefits Project Team


Column free internal space provides Client: GIRA Giersiepen GmbH & Co. KG
maximum flexibility
Minimisation of primary energy con- Architects: Ingenhoven Architekten, Dsseldorf
sumption
Transparent appearance for high- Structural Engineer: Werner Sobek Ing. GmbH & Co. KG
quality working enviroment KKK Ingenieurges. mbH
Innovative servicing strategy Steel Construction: Epesta Stahlbau GmbH
Mero GmbH & Co. KG
Combination of structure and facade Services: PGH Becker-Huke -Hoffmann
Service integration opportunities Building Physics: DS-Plan GmbH

Office level under construction Office level completed Production level

Construction details
The static and constructive optimisation of the beams by tension rods. Diverse crane tracks
concept led to an inner structure as composite are directly connected; for buildings services
construction with an encasing outer curved numerous openings in the beams are provided.
structure for the building envelope. The use of Fire protection
two structures has multiple advantages: On the The holistic fire protection concept follows the
one hand the curved outer structure is kept buildings functions: in the basement R120 to
slender and ele gant due to its interaction with protect the precious for m-storage; the ground
the inner one; this is also a benefit for the ap- level R90 by applying concrete filled sections;
pearance of the hall in the surrounding land- in the upper storey a R30-coating for the steel
scape. On the other hand the outer structure, frames. In addition to that sprinklers are pro-
besides being a load-bearing element, is fa- vided for the whole building.
ade, roof, ventilation and water-bearing ele-
Faade and building services
ment.
Maximum transparency, efficient sun-shading,
Outer structure in steel natural ventilation of offices and production
The outer load bearing structure which sup- units and a highly economical form of con-
ports the roof and the faade consists of dou- struction were the conditions for the faade
ble-hinged frames with rigidly linked columns design. The size of the RHS profiles are kept to
and rails. The frames are made of welded hol- a minimum, thereby accentuating the impres-
low sections with overlying purlins as rolled I- sion of transparency. The central aspect of the
sections and roofing made of profiled sheeting. design for GIRA was the minimisation of pr i-
The structure is stiffened by the frames as well mary energy consumption. The energy recov-
as concrete cores. erable from the production can help to achieve
Inner structure as composite construction a 60% saving of heating energy costs. All areas
For the inner structure supporting the upper are primarily ventilated naturally and a com-
storey a composite construction was chosen, bined heating and cooling system was devel-
consisting of rocker columns and hinged sin- oped into which the existing thermal potential
gle-span beams. The ground floor is a slender could be fed.
slimfloor slab; the upper floor is made of partly Pictures: H. G. Esch, Hennef
precast planks as a composite construction in
combination with welded I-beams (1060 x 300
mm) and hot-rolled HEB 400 columns. Inter-
mediate floors are attached to the composite
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