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Construction of the new vitamin A plant at BASF in Ludwigshafen, Germany

State-of-the-art, BIM-based scaffold planning and innovative PERI systems were instrumental in the construction of the new vitamin A complex at BASF SE in Ludwigshafen, Germany.
At peak times, up to 1,300 t of PERI system material were in use on a daily basis.
The 30-m-high heavy-duty platforms and a bridging construction on the northern side of the building proved to be challenging aspects of the PERI scaffolding solution.
It was possible to combine PERI UP and VARIOKIT in an extremely versatile manner for a wide range of applications – for example, for forming the bridging construction with its tensioning system and its span of 12.75 m at a height of 33 m.
The metric basic grid of the PERI UP scaffolding kit ensured a high level of geometric and structural adaptability – and therefore a high degree of occupational safety.
The majority of the approximately 4,000 scaffolding units were planned using CAD and provided as 3D models over the course of the 18-month project term required to construct the complex BASF plant. In this way, it was possible to minimise conversion times, optimise scaffolding costs and implement high safety standards as early as the planning phase.
Thanks to the geometric adjustment options in the 25 cm system grid, it was possible to implement a virtually gap-free design for the PERI UP deck levels.
Trip-free corner designs and transitions using PERI UP system components ensured that the scaffold could be used safely. Protective caps in a signal colour rounded off the safety concept.
Where the modular ULS system formwork girder was used for bridging, the decks could be installed directly on the top chords, meaning the deck direction could be changed at any time.
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プロジェクト情報

ロケーション: Ludwigshafen, ドイツ

  • The new vitamin A plant is expected to increase BASF's annual production capacity for vitamin A by 1,500 t.
  • Around 600 machines and devices as well as 5,000 test points are integrated into the process control system. In addition, 250 linear metres of pipe bridges had to be constructed.
  • At peak times, around 1,300 t of PERI system material were in use at the same time on a daily basis.
     

現場でのニーズ

  • Extremely restrictive spatial conditions on account of the plant structure.
  • Stringent occupational safety requirements in the industrial environment.
  • Integration of 30-m-high heavy-duty platforms designed for 20 kN/m² as well as a bridging construction with a span of 12.75 m at a height of 33 m.
     

顧客名

Scaffold construction project management 
promaintain GmbH & Co. KG, Ingolstadt, Germany

Client
BASF SE, Ludwigshafen, Germany

お客様にとっての価値

  • All of the information was digitally retrievable: requirements data (locations, responsibilities), planning data, drawings, parts lists, static calculations, 3D models.
  • Just like in a digital scaffolding book, the current status of each scaffolding unit could be selected and retrieved: requested, in planning, planned, under construction, completed, released, deregistered, dismantled.
  • After dismantling, the handover to the controlling department for accounting purposes took place in a virtually automated manner.
  • The BIM-assisted scaffold planning process allowed subsequent users to check the scaffolding plans for usability, variability and flexibility before they were erected and to have them optimised if necessary.
  • This minimised conversion times, optimised scaffolding costs and meant that high safety standards could be implemented as early as the planning phase.
  • High level of occupational safety due to geometric and structural adaptability.
  • The virtually gap-free design of the PERI UP deck levels, the inward-opening safety swing gates and the scaffold nodes encased in protective caps in a signal colour all ensured that the scaffold could be used safely.
     
Portrait of Tino Freund, Project Manager at promaintain GmbH & Co. KG, Ingolstadt
Tino Freund
Project Manager

The spatial conditions dictated by the plant structure posed a significant challenge in this project. Thanks to the 3D pre-planning phase and the PERI UP grid dimensions of 25 cm, it was possible to erect the scaffolding safely and on schedule despite the spatial confinements of the plant. To a certain extent, new solutions and components were conceived and deployed to overcome this significant challenge, which expanded the horizons of industrial scaffolding construction. In the external areas, enormous cost and time savings were achieved for the client through the use of PERI UP Flex in combination with the VARIOKIT modular system. This has also opened up new scaffold construction possibilities.

提案内容

  • A joint project team from promaintain and PERI planned and coordinated the wide-ranging industrial scaffolding tasks.
  • BIM methodology with cross-trade 3D planning, coordination and execution provided the basis for this.
  • The on-site project team registered and managed over 4,000 scaffolding units using Autodesk's BIM 360 Field construction field management software over the course of the 18-month project term.
  • Processes were planned and documented in terms of scheduling and spatial requirements.
  • The majority of the total scaffolding quantity of around 2,000 t was planned with CAD and made available as a 3D model.
  • It was possible to combine PERI UP and VARIOKIT in an extremely versatile manner for a wide range of applications: Standing scaffolds, safety scaffolds, suspended scaffolds, shoring, stairways, material platforms and mobile working scaffolds.
  • The metric basic grid of both PERI systems, PERI UP and VARIOKIT allowed for flexible adaptation of the scaffolding solution using system components.
  • The 30-m-high heavy-duty platforms and a bridging construction on the northern side of the building involving a tensioning system proved to be challenging aspects of the PERI scaffolding solution.
     

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