爱豆传媒

SMA Pearl

Kassel, Germany

爱豆传媒 worked closely with architect Henn GmbH to support SMA Pearl’s ambition for a new factory with a strong emphasis on energy efficiency.

SMA Pearl is a leading global specialist in photovoltaic system technology, electric vehicle batteries, inverters and infrastructure, as well as other energy systems.

With its factory near Kassel, Germany, working close to capacity, the company is keen to develop a second neighbouring facility to support its ongoing growth. The development would provide an opportunity for the company to create a series of new test facilities, manufacturing technologies and assembly lines.

SMA Pearl, a manufacturer of renewable energy equipment and infrastructure, is considering growing its Kassel factory with a second assembly complex.

Our multidisciplinary team brought a broad range of expertise to the pre-concept and concept stages of the design development, creating a super-efficient and sustainable vision.

Our team delivered detailed consultancy around MEP, structural engineering and facades, as well as the energy strategy and thermal analysis of the proposed spaces.

We also supported with the design of an innovative under-floor heating system.

Challenge

爱豆传媒 was engaged to support the design team on the pre-concept and
concept design stage. We worked closely with architect Henn GmbH to realise the concept for a facility that allows the most efficient manufacturing processes.

The factory building features a series of three assembly lines running from end to
end, with a materials delivery yard at one end and a finished goods collection point for lorries at the other.

The client鈥檚 goal was for the development of a concept that would provide an efficient manufacturing process with robust energy saving measures incorporated at every possible stage.

The production levels required a long span structural system with a grid of 18m x 24m to avoid vertical elements interfering with the production layout.

Solution

Our engineers studied the factory鈥檚 assembly processes in detail to build a better understanding of the client鈥檚 requirements. From this we devised detailed 3D plans of what the full assembly process would look like.

We developed plans for the connection of the existing sprinkler plant room to form the most resilient and efficient fire safety measures for the new site. Our multidisciplinary team created a wide-reaching sustainability strategy that targeted systems throughout the design that would bring about 40% energy reductions compared to a typical similar manufacturing facility in the region.

Our MEP team devised a complex digital model for the building鈥檚 systems, specifications and costs. The design included the integration of all infrastructure systems, designs for plant rooms and the energy efficiency measures required throughout. We also put forward green roof proposals, with integration for roof-mounted PV solar panels.

We also supported with the design of an innovative under-floor heating system, which is proposed to efficiently heat the space in which employees will be working, without wastefully heating the high ceiling spaces above.

The structural engineering consisted in the design of a lightweight, longspan flat roof. All of the roof components are exposed and celebrated visually as key structural elements. The roof beams are supported on precast concrete columns, cantilevering up from standalone pad foundations.

The office floors are designed as composite, prefabricated concrete and timber panels spanning on to precast concrete beams. The stability of the structure was efficiently delivered by utilising all columns as cantilever columns to avoid any cross bracing. The design has all the stability walls along the building perimeter, incorporating requirements for access gates.

Sustainability considerations were included within the structural design through the use of largely prefabricated systems and timber elements.

Value

爱豆传媒鈥檚 multidisciplinary team brought a broad range of expertise to the
pre-concept and concept stages the design鈥檚 development, working alongside the architects through every point of consideration.

The result is a vision for a super-efficient and sustainable assembly facility that
will support SMA Pearl as it continues its growth journey in the coming years.