Steel Construction Complex for Automotive Gasoline Production

The engineering firm conducted the design and planning of a steel construction complex for automotive gasoline production at an industrial plant in Bavaria. The steel structure serves as the central support framework for the facilities where the production process occurs - from raw material supply to gasoline filling. The planning included a detailed site survey, creation of a digital 3D model, and structural calculations of all relevant components to ensure load-bearing capacity and durability. Specific manufacturing processes were defined, along with workshop drawings for steel component production and detailed assembly plans for efficient on-site erection.

Challenges

A major challenge was meeting the stringent safety and environmental requirements for fuel production facilities, particularly due to Bavaria's strict regulations. The precise integration of the steel structure into existing infrastructure required detailed coordination with various trades and exact modeling to optimize space and load distribution. The project's scale and complexity demanded rigorous structural calculations and careful coordination of manufacturing and assembly processes to meet the tight schedule.

01.04.2021 - 01.08.2022

Structural steel weight	132	metric tons
Engineering hours	2430	hours
Total footprint	200	m²
Length	10.5	m
Width	9.5	m
Height	35	m
Process capacity	250000	liters/day
Wind load resistance	42	m/s

Adress:

Bavaria, Germany

Project phases

Requirements Analysis

This initial phase involves detailed collection and analysis of project requirements. Together with the client, target specifications are defined including capacity requirements, safety standards, and specific steel structure specifications. This analysis forms the basis for all subsequent planning phases, ensuring the project meets all technical, economic and regulatory requirements.

3D Laser Scanning Survey

Comprehensive 3D laser scanning was performed to capture the exact geometry of the terrain and existing structures. This technology enables highly precise measurements and creates a reliable foundation for the digital model used in later planning phases. The collected data captures every detail of existing conditions, facilitating exact integration of the new steel structure.

As-Built Modeling

Based on laser scan data, a digital 3D model of existing conditions was created, representing all relevant components of the existing structure and surrounding terrain. This model serves as the foundation for precise planning and is crucial for structural calculations and coordination with other trades.

Preliminary Design (LPH 3)

A preliminary design was created according to Service Phase (LPH) 3 of HOAI. The design includes fundamental planning concepts for the steel structure, including arrangement of load-bearing components, access routes, and connection points. The design was conceived to be both functionally and economically optimal for gasoline production.

Approval Planning (LPH 4)

In the approval planning phase (Service Phase 4), the design was further detailed to obtain permit approval. All required documents and verifications, including detailed structural calculations, were prepared to obtain project approval. This approval planning forms the formal basis for execution planning.

Execution Planning (LPH 5)

In the execution planning phase (Service Phase 5), the steel structure was fully detailed, including comprehensive workshop drawings and assembly plans. The workshop drawings specify manufacturing of each steel component, while assembly plans precisely describe on-site erection. These plans serve as exact instructions for contractors and project managers to ensure efficient and error-free implementation.