On behalf of GlaxoSmithKline, better known as GSK, Stadsbader NV was allowed to build an extension on their site in Wavre. GSK is a British science-led company that researches, develops, and manufactures innovative medicines, vaccines, and consumer healthcare products worldwide.
GSK is the largest producer of vaccines, delivering vaccines that help protect people of every age in 160 countries. In Belgium, GSK represents the largest pharmaceutical company with 9.000 employees. The vaccine manufacturing site in Wavre is the size of seventy soccer fields, making it the world’s largest site.
This design-build project covers an area of 23000 m² spread over seven floors. The extension was built next to an existing basement and over an existing tunnel.
The complex structure was a challenge. The structure consists of a precast concrete frame mixed with 267 tons of steel structure. The superstructure is supported by 97 foundation pits and 130 lm secant pile walls.
The assembly process was no easy task. It involved heavy cantilever prestressed concrete beams, where the heaviest beam weighs 36 T. The cores were raised in 5500 m² hollow walls. Two of the floor layers were built exclusively of steel, which was hanging on the concrete structure of the floor above. The other floors are covered with hollow-core slabs.
The roof consists of a steel structure and wooden laminated beams, both covered by steel deck. The structure was enclosed by 5000 m² of facade cassettes. It was a challenging project where the client was very demanding regarding safety and quality and conducted daily inspections.
Stadsbader NV engineered the building and drew the execution plans using a BIM approach due to the project's complexity.
All existing structures around the building were schematically processed in the Tekla model, based on the surveyors’ measurements. All structures, accounting for 3360 m³ of concrete and the secant pile walls, were drawn in 3D.
The entire superstructure, including all individual precast elements, was modeled in Tekla. Assembly plans and production drawings were extracted for use on our production site, Van Maercke NV, from the Tekla model.
Invoicing was based on PXML, Unitechniks, BBS files, production planning, and post-production. The 3D models could be consulted in the office and on the construction site using Trimble Connect. Furthermore, with the in-house developed planning tool, the status of each element in the ERP package (drawn, scheduled, produced, or assembled) could be visualized in Trimble Connect at any time.
This way, everyone involved on the site could see the status of each precast element at any time and adjust plans when necessary.
Finally, Trimble Connect was very important in coordinating the subcontractors. Many subcontractors assembled the coordination model, resulting in ± 40 IFC models, which were all coordinated with each other.
