DHL SORTING CENTRE
IN MANNHEIM

REQUIREMENT

Sorting centre for high parcel volumes and an ergonomic working environment

A sorting centre was to be built in Mannheim for Deutsche Post DHL that would reliably process very high parcel volumes every day. The facility had to be designed for up to 25,000 parcels per day - with reserves for seasonal peaks. Clearly organised material flows, short distances and a hall geometry without disruptive supports were important in order to be able to optimally integrate conveyor technology and sorting systems.

In addition to efficiency, working conditions played a central role. The building had to offer the quietest possible indoor climate, support ergonomic processes and provide sufficient space for 120 employees. In addition, the structural requirements of the DHL corporate design, a fast realisation time and implementation as a "MechZB88" type building had to be met. The technical requirements also included defined fire protection classes, high building economy and a resilient roof and wall construction for long-term, trouble-free operation.

RESULT

6,400 m² sorting centre with high performance and reduced background noise

Astron realised a 6,400 m² DHL sorting centre in Mannheim, which is designed for high parcel volumes and smooth processes. The column-free hall construction with a length of 147 metres and a width of up to 43 metres enables a flexible arrangement of the sorting technology as well as 92 loading and conveyor chutes for fast parcel flows. Around 120 employees process up to 19,000 parcels on a daily basis, and as many as 25,000 items per day at peak times.

The façade was realised in line with DHL's corporate design, with prefabricated concrete elements in the lower section and yellow sandwich panels above. The building fulfils fire resistance class F0 and could therefore be realised without additional fire protection for the steel structure. The LPR1000 roof system with 120 mm insulation ensures long-term impermeability and energy efficiency.

A major advantage is the significantly reduced background noise: The soft soffit of the LPR roof achieves over 60% sound absorption and noticeably improves the working environment. The result is a technically sophisticated, economical sorting centre that is optimised for high throughput volumes.