Durable aluminum facade elements for new construction DC UTR06

On a brownfield site on the Amsterdam-Rijnkanaal, on the Lage Weide industrial estate in Utrecht, DC UTR06 is under construction. This project by Intospace includes the realization of three warehouses and a four-story parking garage on one plot, totaling approximately 59,752 m2. During the design and construction of the DC, sustainability was a key focus. The starting point is the BREEAM-NL label 'Excellent'. The use of recycled end-of-lifecycle aluminum facade elements contributes significantly to this. The aluminum curtain walls and frames for DC UTR06 are manufactured from the aluminum profile systems of SAPA, which, like WICONA, is part of Hydro Building Systems. Kozijn Garant is responsible for the production, delivery and assembly of the systems.

"Commissioned by contractor Wouters Schijndel and based on Quadrant4's aesthetic 3D/BIM design, we provided the architectural drawing work for all aluminum curtain walls, frames, windows and doors. Including associated architectural details," says Rudy Heijligers, owner of Kozijn Garant. "The work planners at Wouters Schijndel checked our drawings and provided feedback where necessary, after which a few more optimizations were made. After approval by the contractor, we immediately started our production."

Trusted partners

Wouters Schijndel is a trusted client for Kozijn Garant, says Heijligers. "In the past, we have also been allowed to provide the distribution centers for Zalando (Bleijswijk), H&M (Nieuwegein), fonQ (Utrecht), Kuehne + Nagel (Utrecht), Picnic (Utrecht) and Albert Heijn (Zaandam) with aluminum facade elements, based on Hydro CIRCAL recycled aluminum. The same applies to various distribution centers for Mainfreight in Zaltbommel and 's Heerenberg, Kelders and Holland Food Service in Wijchen and Tesla in Tilburg. The experience we have gained in this process is extremely useful in this project. The result is a beautiful and orderly construction process."

Hydro CIRCAL is one of the most sustainable aluminum alloys in the world, says Marc van den Nieuwenhof, Area Manager at Hydro Building Systems Netherlands. "Hydro CIRCAL is top quality aluminum that consists of at least 75% of recycled end-of-lifecycle aluminum (post-consumer scrap), recovered from windows and facades of existing buildings. The higher the recycled content, the smaller the carbon footprint. As much as 100% Hydro CIRCAL 75R will be used in this project!"

Lowest carbon footprint

Smelting aluminum for new applications consumes only 5% of the energy needed to produce primary aluminum, Van den Nieuwenhof emphasizes. "So: the higher the content of recycled post-consumer scrap, the better for our cities and the environment. Moreover, aluminum is infinitely recyclable, without loss of quality and material properties. In the meantime, our production in the Benelux has been scaled up to such an extent that we only use Hydro CIRCAL for the SAPA profile systems in the Benelux. The production process is fully traceable and the product is certified by an independent body (DNV-GL). Hydro CIRCAL has the lowest carbon footprint in the world: about 2.3 kg CO2 per kilogram of aluminum. This is 86% lower than the world average (16.7 kg CO2) for primary extraction. With this we guarantee project developers, architects and investors that their projects meet all the requirements for sustainable building certifications such as BREEAM, LEED and DGNB and contribute to a better world."

Minimal residual pieces

All profiles for DC UTR06 are color-coated (RAL 9011), supplied in lengths of 6.5 and 7 meters and in manageable crates at Kozijn Garant's plant in Cuijk, says Heijligers.
"Upon arrival, all profiles are extensively checked. A sawing machine then cuts the products to size, with a saw list ensuring correct dimensions. All profiles are sawn as efficiently as possible, reducing residual pieces and waste to a minimum."

The machining department includes drilling holes, milling locks/drainage and other preparatory work. "Then all the profiles are put together with ridge corners and the rubbers and hardware products are applied. The windows and doors are also hung here," Heijligers said. "In warehouses B and C, automatic sliding doors are installed in addition to standard doors. All products are collected by us and - in close consultation with the supervisors and planners - transported just-in-time to the construction site, where we take care of the assembly."

LARGE VOLUME, HIGH CONSTRUCTION SPEED

The challenge in this project is particularly the volume, combined with the high speed of construction, he says, "In total we produce, supply and assemble 2,500 m2 of curtain walling about 12 meters high and in sections of 1 meter wide, as well as 550m2 of window frames. We also supply the expanded material for the parking garage and the storm-proof screen awnings for the offices. For the latter, we have engaged an awning partner, who supplies and assembles on the basis of our measurements.