Modular lightweight hall for expansions
Companies in the industrial and logistics sectors are often faced with the challenge of expanding their storage capacities in a flexible and efficient manner. A prime example of a successful solution is provided by the reference project of FRANKEN BRUNNEN, one of Germany's largest mineral water producers. Here, an existing modular lightweight construction hall was successfully expanded to meet growing requirements. This project highlights the advantages and possibilities that modern lightweight construction concepts offer industrial companies.
Challenges in the expansion of warehouses
The expansion of existing warehouses presents companies with a wide range of challenges. The first thing to do is to minimise the impact on ongoing operations. Any downtime or restrictions can lead to significant costs and delays. Smooth expansion is essential, especially in the beverage industry, where seasonal fluctuations and just-in-time deliveries are the order of the day.
Another challenge lies in the integration of new structures into existing systems. The expansion must be seamlessly linked to the existing infrastructure, whether in terms of conveyor systems, storage technology or IT connections. Aspects such as fire protection, energy efficiency and occupational safety must often be taken into account.
Last but not least, official requirements and approval procedures also play an important role. Depending on the location and type of expansion, lengthy processes may be necessary, which make flexible and rapid implementation more difficult.
When do industrial companies need to expand their warehouse capacities?
We recognise a number of different reasons and needs that lead to the need for expansion in industrial companies:
Growth and expansion: companies like FRANKEN BRUNNEN, which are experiencing constant growth, need more storage capacity to keep pace with increasing production.
New product lines: The introduction of new products or variants requires space for new product lines with their respective machines and equipment. This often requires additional storage space for raw materials, packaging materials and other products.
Optimisation of logistics processes: Modern logistics concepts such as just-in-time delivery or cross-docking can make it necessary to restructure and expand storage areas.
Technological developments: The integration of new technologies, such as automated storage systems or robotics, often requires adapted and expanded premises.
Seasonal fluctuations: In the beverage industry in particular, seasonal peaks in demand can make additional storage space necessary.
Changes in the supply chain: We are only too familiar with the effects of global events, especially after the coronavirus pandemic. They cause global shifts in supply chains and can lead to companies having to maintain larger inventories.
Compliance and regulatory requirements: New regulations, for example in the area of food safety, can make expanded or specialised storage areas necessary.
Advantages of lightweight halls over solid construction
FRANKEN BRUNNEN's decision to use a modular lightweight hall to expand its logistics capacity emphasises the numerous advantages of this construction method:
Flexibility and adaptability: Modular lightweight halls can be easily extended, reduced in size or even relocated to a different site. This enables a high level of adaptability to changing business requirements. An integrated system of different sites within a corporate structure can thus react and act even more flexibly to internal logistics shifts.
Fast realisation: The assembly time of only 32 days for the FRANKEN BRUNNEN extension impressively demonstrates how quickly lightweight halls can be erected compared to solid structures. This minimises interruptions to operations and enables rapid commissioning.
Cost efficiency: lightweight halls are generally much more cost-effective than comparable solid structures, both in terms of acquisition and maintenance.
Sustainability: The use of recyclable materials and the option of reusing the structure often makes lightweight halls more environmentally friendly than traditional construction methods.
Light permeability: many lightweight halls, such as the one at FRANKEN BRUNNEN with a thermo-tarpaulin roof, allow a high level of daylight to enter, which reduces energy costs and improves the working environment.
Lightweight: The lightweight construction often requires less elaborate foundations, which can be particularly advantageous in difficult ground conditions.
Individual customisation: Despite their modular construction, lightweight halls can be individually customised to specific requirements, as the integration of docking stations at FRANKEN BRUNNEN shows.
Special features of a goods handling centre
The extended logistics centre of FRANKEN BRUNNEN serves as a transshipment centre for goods and therefore has some special features:
Efficient use of space: with a total area of 13,950 m², the hall offers sufficient space for the storage and handling of large quantities of goods. The span of 3 x 30 m allows for flexible room division and optimal utilisation of the area.
Adjustable height: The side height of 5.20 metres is ideal for storing pallets and allows the use of efficient storage technology such as forklift trucks or shelf systems.
Integrated docking stations: The four docking stations enable fast and weather-protected loading and unloading of lorries, which is particularly important for the sensitive beverage products of FRANKEN BRUNNEN.
Climate control: The insulated roof and insulated sandwich panels on the façade provide good insulation. This is crucial for maintaining the constant temperature conditions required for storing beverages.
Floor loading capacity: The floor of a transshipment hall must be particularly strong to withstand the constant traffic of forklift trucks and other transport vehicles.
Flexible door systems: In addition to the docking stations, various door systems are often integrated to ensure a smooth flow of goods. At FRANKEN BRUNNEN, for example, roller shutters were installed.
Security systems: Handling centres require special security measures such as fire protection systems, emergency exits and lighting concepts that meet the specific requirements of the stored goods and the applicable regulations.
Modular Lightweight Hall
The video impressively shows how a lightweight hall built in 2011 was quickly and easily extended to meet the customer's need for a rapid expansion of capacity..
Technical details
| Width: | 30,00 m |
| Length: | 155,00 m |
| Area: | 13.950,00 m² |
| Side height: | 5,20 m |
| Roof: | High-quality thermal roof cover |
| Facade: | ISO panels |
The FRANKEN BRUNNEN project in detail
The extension of the logistics halls at FRANKEN BRUNNEN in 2022 is a prime example of the successful implementation of a modular lightweight hall concept. The halls, originally installed in 2011, have been extended by an impressive 65 metres, which is impressive proof of the flexibility and expandability of this construction method.
The three H-LINE halls, each with a span of 30 metres, together create an impressive total width of 90 metres. The extension to 155 metres in length creates an impressive total area of 13,950 m². This generous dimensioning enables FRANKEN BRUNNEN to optimise its logistics processes and be prepared for future growth.
Particular attention was paid to the functional equipment of the halls. The integration of truck loading stations and roller shutters ensures efficient goods handling. This is particularly important for a beverage manufacturer that relies on fast and smooth logistics processes.
The roof system chosen was a thermo-insulated roof, which offers an optimal balance between light transmission and insulation. This not only contributes to energy efficiency, but also creates a pleasant working atmosphere through natural light. The façade was equipped with insulated sandwich panels, which ensure excellent thermal insulation and thus reduce energy costs.
The short realisation time of the project is also remarkable. With an assembly time of only 32 days, the extension was implemented quickly and with minimal disruption to ongoing operations. This underlines one of the main advantages of modular lightweight halls over conventional construction methods.
Future prospects and sustainability
The successful expansion at FRANKEN BRUNNEN shows how modular lightweight halls can provide a future-oriented solution for growing companies. The ability to expand existing structures flexibly without significantly disrupting ongoing operations is invaluable in today's fast-paced business world.
Furthermore, this construction method also offers advantages in terms of sustainability. The materials used are largely recyclable, and the modular design enables the halls to be reused or adapted to new requirements. This significantly reduces the consumption of resources compared to conventional construction methods.
For companies like FRANKEN BRUNNEN, which operate in a dynamic market environment, modular lightweight halls offer the flexibility needed to respond quickly to market changes and growth opportunities. The ability to expand or restructure storage capacity as needed, without having to make massive investments in rigid infrastructures, gives a clear competitive advantage.
Conclusion
The reference project of FRANKEN BRUNNEN impressively demonstrates the advantages of modular lightweight halls in modern logistics. The successful extension of the existing halls by 65 metres shows how flexibly and efficiently this construction method can respond to growing requirements. With a total area of 13,950 m², intelligent equipment with docking stations and an energy-efficient construction method, this project sets new standards in the industry.
The short realisation time of just 32 days also underlines the efficiency of this solution. For companies that need to react quickly to market changes, modular lightweight halls are therefore an ideal option for expanding their logistics capacities.
The combination of flexibility, cost efficiency and sustainability makes modular lightweight halls a forward-looking solution for the logistics industry. The FRANKEN BRUNNEN project is a prime example of how companies can benefit from this innovative construction method to strengthen their competitiveness and at the same time operate sustainably.