Building Design in a Sugar Factory: Replacement of Filter Presses
Building design, structural engineering and installation concept for modifications in an existing industrial facilityFor a sugar factory, INOPCO planned the structural replacement of existing filter presses with new equipment components with significantly different geometry and mass. The focus was on load transfer in the existing structure, strengthening of level +7.00, redesign of the installation level and safe installation via temporary roof openings.
- Building design and structural engineering in an existing industrial facility
- Existing/new load comparison for the main structure, columns, foundations and connection points
- Execution planning, steel structure design, shell construction planning and bills of quantities
- Planning of temporary construction stages for installation via roof openings
Project Profile
Sugar industry
Modification of existing facility
Building and structural design
+7.00 m
Initial Situation
Several existing filter presses were to be replaced by new equipment. Since the new units differed significantly from the existing equipment in terms of geometry and mass, the load-bearing capacity of the existing main structure had to be assessed and the installation level structurally adapted.
1. Assess Existing Structure
Review of existing documentation, on-site verification and assessment of the existing reinforced concrete and steel structure.
2. Verify Loads
Existing/new load comparison for columns, foundations, steel beams, steel connections and level +7.00.
3. Plan Modification
Redesign of the installation level, new support frames, strengthening from below and an installation concept for the temporary construction stage.
Technical Planning Task
Minimal intervention in the existing structure, maximum safety for modification and installationThe new filter presses were to be installed on the existing level +7.00. The objective was to develop a solution with as few structural interventions in the existing facility as possible. Since the structural assessment of the existing platform initially did not confirm sufficient load-bearing capacity, strengthening of the level from below was incorporated into the planning.
Structural Engineering
Auditable structural calculations, continuation of the existing structural documentation, recalculation of the reinforced concrete slab and steel structure.
Steel Structure and Shell Construction
Execution drawings, shell construction drawings and workshop plans for new steel support frames and strengthening measures.
Tender Documents
Specifications and bills of quantities for shell construction, steel construction and roofing works, including quantity take-off.
Installation Stage
Verification of temporary modifications to the roof structure and coordination of an installation concept for equipment handling and structural strengthening.
Building Design
Execution planning with detailed information for strengthening level +7.00, detail and construction drawings, coordination of specialist project participants and documentation.
- Execution planning
- Detail drawings
- Bills of quantities
- Bid comparison and award recommendation
Structural Engineering
Existing structure assessment, load comparison, auditable structural calculations, redesign of new support frames and planning of steel frames for strengthening the platform.
- Existing / new load comparison
- Recalculation of existing structure
- Steel support frames and opening reinforcements
- Execution drawings for steel and shell construction
Temporary Construction Stage
Planning of temporary modifications to the existing roof structure and installation concept for removing the existing and bringing in the new filter press units.
- Roof openings for installation
- Temporary structural verifications
- Roof installation concept
- Strengthening installation concept
Planning in an Operating Production Environment
Modification planning with existing structure constraints, installation sequence and equipment interfacesThe project required close integration of building design, structural engineering and equipment planning. For the new filter presses, machine layout plans, interface forces, dynamic factors, existing structural calculations, workshop and installation drawings as well as operational information had to be taken into account.
