New construction of two office buildings

 

June 04, 2019

 

Building construction work with little space, time and complex components

The new building project for Roche was an exciting challenge for the teams from ERNE Structural Engineering.
Between April 2018 and June 2019, structural engineering work was carried out in Basel for two office buildings with five and eight storeys respectively for F. Hoffman-La Roche AG. The complexity of the buildings, the short construction time and the high safety requirements presented the ERNE structural engineering teams with a number of challenges. Around 31,000 m3 of concrete and 5,000 tons of reinforcement were used, with up to 70 construction workers and four cranes working on the site at times.

Demolition, dismantling and excavation of the construction pit

Back in 2017, ERNE dismantled and gutted an existing office wing with workshop. The old structure contained contaminated parts of the building, which were decontaminated and disposed of professionally. Once the buildings had been completely dismantled, the construction site for the new office buildings was ready.

The excavation for the three-storey basement, which will later connect the two office buildings, took place from mid-2017 to mid-2018. Around 70,000 m3 of gravel was excavated using a teledipper (telescopic grab), in some cases to depths of up to 15 meters. As the two new buildings will later be 4 m deep in groundwater, dewatering was necessary to protect the excavation pit from water ingress. The groundwater level was lowered using drilled filter wells. The excavation pit was supported with overlapping and disintegrated bored pile walls (with or without strand anchors), underpinning walls and vault walls (some with strand anchors), which were lined with both wood and concrete. The 1 m thick, solid floor slab for the basement could then be concreted.

Prestressed truss girders challenge the building construction teams

The structural engineering work for the two new office buildings began in April 2018. Building 008 presented a number of challenges: very high ceilings, a 35 m long and 12 m high prestressed lattice girder, a multi-sided inclined communication staircase and a demanding façade that required special formwork skills. During the construction of the buildings, several prestressed structures also had to be erected in the girder and façade area. A heavily reinforced, prestressed in-situ concrete truss girder was planned for the longitudinal façade of building 008 over two storeys. It was not possible to work with prefabricated elements, as the lattice girder had to be integrated into the façade and was prestressed. In addition, prefabricated girders with a cross-section of 70 × 75 cm would have been too heavy to move. The truss girders were formed, reinforced and concreted on site. The construction of the formwork was a challenge, as it had to sit cleanly and firmly in an inclined position during the entire process. Using a special formwork and formwork construction, it was ensured that this was achieved and the prestressed truss girder could be erected.

BIM model enables construction of a multi-sided inclined communication staircase

The architects had designed beautifully shaped staircases for the interior of the building, which would later connect the individual floors. The floor plan of the staircase differs on the various floors, is never identical and the underside is inclined on several sides. Detailed floor plans were created using a BIM model of the staircase. Together with sister company HUSNER, specific, custom-made timber formwork was produced to enable optimal work on the construction site. Around 250 individual items of reinforcement were used for each staircase. It took two ironworkers over two days to lay the reinforcement. The staircase was constructed in fair-faced concrete quality.

An exciting construction site

In addition to the technical requirements, the tight space conditions were not to be underestimated. At the Roche site, the materials had to be delivered and installed "just-in-time", as there were practically no storage areas. In addition, the transformer station that supplied the entire site with electricity was located in the middle of the construction site: it had to be carefully planned and built around.

The construction project was both very exciting and challenging for those involved. The ERNE teams are delighted that they were able to build this challenging structure.

Facts about the construction site

 

Object

New office building Roche BSN 008/011

Services

Industrial building construction, exposed concrete and reinforced concrete construction

Construction time

April 2018 - June 2019

Project participants ERNE

Site managers: Pascal Alabor, Marius Hoffmann, Foremen: Andreas Waldmeier, Daniel Obrist, Steve Eckert Waldemar Zeier, Raphael Senn, Martin Boutellier, Fabian Bader, Tomislav Nikolic