American shoe brand sets foot in Dordrecht

With this sustainable, expansive property, the well-known American shoe brand is taking an important step toward its ultimate goal: making the world comfortable.

The new building has an area of about 50,000 square meters and is Crocs' largest distribution center in Europe. The producer of shoes, sandals and clogs will use the building for storage for its online store, supplying store branches and handling returns.

Turnkey builder

Crocs deliberately chose to have the distribution center developed and built by Hercuton. "About three years ago, we realized a distribution center for Boon Food Group a little further on the Distripark," explains Hercuton's contractor Ruud van Haaften. "Crocs was charmed by this and wanted a similar building. We picked up the development from then on. We realize the distribution center as a turnkey builder. This means that we take care of the realization completely, from the preparation of the land to the finishing, the building installations, the plumbing and the construction of the outdoor area."

Rapid growth

The distribution center consists of two large halls and four separate units. Initially, Crocs was to rent only the two large halls. Because of continued, rapid growth in Europe, the shoe manufacturer eventually opted to use the entire building. "This meant we had to include the units with the halls," says Van Haaften. "We do this in such a way that the halls and units can easily be separated again in the event of any changing needs in the future." In addition to the halls and units, the distribution center has some 3,100 square meters of office space and four loading pits. The outdoor area will have 366 parking spaces, with a 2,400 cubic meter water storage basement underneath. This, along with a 1,000-cubic-meter retention pond, acts as a water buffer to relieve the pumping station.

BREEAM 'Very Good'

With its transparent entrance, laminated wood beams and various windows, the building looks friendly. Moreover, the partially wooden facade demonstrates its sustainable character. Van Haaften: "The distribution center will soon comply with sustainability label 'Very Good'. The fact that we are building with sustainable materials such as wood also contributes to this. Moreover, the building is all-electric." As a natural gas-free business park, Distripark Dordrecht fits in seamlessly with Crocs' sustainability ambition. The site has a hydrogen facility point, four wind turbines and a solar park.

Concrete, wood and steel

On June 3, 2020, the first pile went into the ground. Van Haaften explains the construction method: "The distribution center is founded on 11,500 vibro-SD piles and will be built with a total of 323 concrete columns. Around these we are placing concrete facade elements of 3 meters high. At the docks they have a height of 4.5 meters. Sandwich cladding will be placed above the concrete plinth. In accordance with the wishes of the municipality of Dordrecht, we install the sandwich elements horizontally. The roof structure is made of wood and on the roof will be steel roof panels with PVC roofing." 

Two phases

In execution, Hercuton distinguishes two phases. The first phase consists of the two original large halls. For this, the columns have been placed and the roof construction realized. The roofing is currently being installed. Phase 2 comprises the portion of the original units. For this, Hercuton is now driving the final vibro-SD piles into the ground.

Modular construction

Asked where the biggest challenge lies, Van Haaften replied, "The schedule is quite tight. By the end of March 2021, we have to deliver phases 1 and 2 turnkey so Crocs can install the warehouse racks. Thanks in part to our modular construction method with precast concrete, that schedule is achievable. We can plan and prepare the construction process right down to the day. On site, it is "just" a matter of assembly. And because we work with permanent teams, our own people and our own equipment, we have complete control over the planning and quality. What I personally like very much is that the client is also closely involved in the process. Including a weekly visit to the construction site, he closely follows the creation of his new distribution center."  

Project info

Top sport in pouring floors

Commissioned by Hercuton, Twintec is realizing all the floors in and around the new European distribution center of the American shoe manufacturer Crocs. In total, according to Jeroen Boers of Twintec, it involves an area of 60,000 m² of industrial concrete floors, of which approximately 40,000 m² are 'superflat' in accordance with DIN 15.185. It requires a top sports mentality.

"For us, the project includes a great diversity of floors, both in terms of quality and flatness," says Boers. "In the preliminary stage, we were approached by Hercuton to come up with the most economical and high-quality design possible. We are responsible for the complete picture from the engineering of the floors and the piling (installing 12,000 VSD piles under the floors) to the pouring of the floors. The warehouse and expedition are executed in a hybrid floor with steel fiber reinforcement, all other floors are designed with traditional reinforcement."

A total of 10,000 m³ of concrete is involved. Boers: "The biggest challenge is meeting the flatness requirements of the enormous warehouse floor, which is assessed and checked afterwards by an independent agency. The tolerances are so low that our employees put in top performances every day, given the large number of square meters poured every day. Truly a team effort."

Construction Info

Client Crocs Europe B.V., Rotterdam

Design and realization Hercuton, Nieuwkuijk