STRUCTURAL SYSTEM FOR EXTREME LOADS

REQUIREMENT

Structural solution for extreme loads in an earthquake zone

The German building materials manufacturer Knauf planned to build its third plasterboard plant in Uzbekistan, in the Fergana Valley. The industrial project, with an investment volume of around 17.2 million euros, was intended to meet the region’s growing demand for building materials directly on site in future and to significantly reduce transport distances.

The industrial site, covering an area of around 12,500 m², was to comprise production and storage halls, a mixing tower approximately 28 metres high, and an integrated administration building. Hall spans of up to 40 metres and building lengths of more than 150 metres had to be taken into account, as did high structural loads from production facilities, raw material silos and overhead travelling cranes with load-bearing capacities of up to 8 tonnes.

Additional requirements arose from the site’s climatic and geological conditions. The structural framework had to be designed in accordance with the Uzbek building code to withstand earthquakes of up to MSK 9 intensity, whilst also safely withstanding high wind and snow loads. All structural components had to be precisely tailored to the production processes and the tight schedule of the overall project.

RESULT

Precise structural design to meet the highest safety requirements

Astron constructed the entire steel structure for the new plasterboard plant and developed the appropriate structural solution for each area of the building. Large-scale production and storage halls provide flexible production and logistics space, whilst the multi-storey mixing tower safely transfers high vertical loads from raw material silos and process plant to the foundations.

Robust wind and seismic bracing systems stabilise the load-bearing structure, which is up to 28 metres high, and ensure the necessary structural stability at all times, even under high horizontal loads. At the same time, crane runway beams, production equipment and all structural connections are precisely integrated into the overall design.

Astron’s engineering team developed all structural components, including the bracing systems, crane runway beams and connections for the various building areas. Right from the structural design stage, seismic, wind, snow, crane and plant loads were considered together and designed as a structurally coordinated overall system. Engineering, workshop planning, fabrication and assembly interlocked seamlessly, laying the foundations for the safe and cost-effective implementation even under the most demanding conditions.