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In April 2009, the Volkswagen AG group took the decision to extend production at its location in Bratislava, Slovakia. Already in 2011, the first vehicles of a new series are to leave the production line for delivery across the world. The entire volume of investment is 308 m Euro. Here, with a yearly production capacity of 400,000 vehicles, 1,500 new jobs will also be created.
This extension included an extension to production hall 2A, where painting work takes place. Construction planning and project management were undertaken on the part of the client through an own department within Volkswagen AG construction planning, i.e. according to group-wide standards and regulations. From tendering to award, actual execution to acceptance, all project tasks were carried out bilingually, in Slovakian and German. The tendering documents and project documentation regarding approval for the construction in hall 2A were provided in August 2009 by the Slovakian general planner Coproject a.s. Here, all bills of quantities were created in two languages with support from the project and cost management software by RIB.
Production hall 2A is a four-story structure with main floor measurements of 251.0 m x 60.0 m, square span support modules of 12.0 m x 12.0 m and a construction height of approx. 24.0 m with a foundation depth of -2.2 m.
The engineering office BF partners s.r.o., Bratislava, Slovakia, conceived the load-bearing structure of the hall as a skeleton structure in in-situ concrete with facade blocks in a grid of 6.0 m. This allowed, in the first place, a uniform tendering process for the construction services required to take place through a public and fully accessible call for tender. The ceiling structure was formed from continuous supports on hinged rib supports and ceiling panels. The load-bearing roof structure was designed as a steel structure of trusses and steel purlins, completed with corrugated sheeting and further elements of classical roof construction.
Both for reasons of fire protection and to limit mutual interaction, to ensure robustness and not least to smooth the process of construction, the production hall was divided into three independent construction sections with suitable support doubling at the crossover axes. As foundations for the supports, the engineers went for point foundations, where necessary with local subsoil improvement or soil replacement at the locations of any discontinuities and faults.
The tight schedule started with project preparation, construction approval, tendering and foundation engineering during summer and autumn 2009 and planned for a rapid progression to construction in the winter months and early 2010. Parallel to the actual execution of construction, the implementation planning, including drawing up the detailed construction documentation, and other extensive client requirements, had to be fulfilled. This also included disruption-free production processes in the factory, while adhering to correspondingly high safety standards. .
The Czech company HSF system a.s. received the commission as general contractor for the creation of the production hall. For time reasons – construction had to take place while complying with the strict contractual requirements and schedule – the decision was taken to pre-fabricate the entire load-bearing structure. For this task, the GC selected the Slovakian pre-fabricated parts manufacturer Prefa Sůčany a.s. Implementation planning was taken on by the Slovakian engineering office DeBondt s.r.o., Trencin. An important role in the overall process of planning was played by the fact that a complete re-engineering of the originally planned skeleton structure to an assembled pre-fabricated construction method had to be carried out by the pre-fabricated parts manufacturer as part of its overall services. In the new planning alternative, transport of the pre-fabricated components was made by road and the assembly on site by heavy truck-mounted cranes.