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ACE Amsterdam is a large-scale, sustainable urban development project on the Sloterplas in Amsterdam Nieuw-West, where housing, education, sports, and amenities come together in a single integrated city block. The centerpiece is a 23-story residential tower approximately 75 meters tall, which serves as a striking vertical feature defining the silhouette of the development.
The project includes 565 homes, a sports complex, a community school, and various commercial facilities, and is being developed by VORM. To heat and cool all facilities comfortably and energy-efficiently, a hybrid thermal energy storage system (WKO) from Vattenfall is being used. The system will be connected to a total of 580 prefabricated thermal energy storage skids and shaft modules from ERA Prefab Systems. In addition, ERA is responsible for the engineering, 3D design, logistics, and installation of the horizontal distribution network for heat and cooling, which consists of several kilometers of piping. In doing so, ERA integrates both vertical and horizontal building distribution into a single, comprehensive concept.
While larger thermal energy storage distribution pipes are traditionally often welded, ERA Prefab Systems has deliberately chosen a different approach for the ACE Amsterdam project: pressing the pipes. “A method that offers clear advantages in terms of quality, reliability, and installation speed,” says Eduard Aubri, founder of ERA Prefab Systems. “In this project, we’re using the Geberit Mapress piping system. Our thermal energy storage skids are also equipped with Geberit Mapress piping and fittings, ensuring that the skid and distribution network are technically compatible.”
With ACE Amsterdam, ERA demonstrates how prefabrication principles can be extended from individual energy skids to an integrated systems concept in which engineering, prefabrication, vertical and horizontal distribution, and installation are optimally coordinated.
For twenty years, ERA Prefab Systems has been engineering, manufacturing, and installing prefabricated service shafts and service walls based on steel frames, into which piping for heating, ventilation, drainage, electrical systems, (drinking) water, and/or plumbing fixtures can be integrated. “Through high-quality engineering and extensive standardization, we make the assembly process less dependent on scarce, specialized construction site personnel,” says Aubri. “We can train people with technical insight and a knack for hands-on work in-house. This allows us to recruit local installers and also employ people who are distanced from the labor market under our guidance. In this way, we contribute to local employment and ensure the quality of our systems.”
The skids are assembled year-round under controlled working and environmental conditions at the ERA Prefab Systems factory in Almelo, where the technicians have access to precision machinery and the right tools. “This allows us to properly dimension and finish all components in a single operation, with millimeter precision. Furthermore, we can inspect and test the skids before delivery, ensuring a high and consistent level of quality.”
At the construction site, the prefabricated skids can be easily installed and connected. “This means that large-scale logistics facilities and intermediate stockpiles on the construction site are hardly necessary,” says Aubri. “The skids are delivered just-in-time and can be quickly installed by a small assembly crew. This allows us to address current challenges in the construction industry, such as the shortage of skilled workers, tight construction schedules, and cramped inner-city construction sites.” It also reduces transportation, waste, and storage on the construction site, which helps lower the environmental impact.
Prefabricated construction also has the advantage that each skid can be individually coded and enriched with relevant data, according to Aubri. “All thermal energy storage skids and shaft modules in ACE Amsterdam will receive their own identification and materials passport, in which relevant product and material information is recorded. This allows us to know which components were used and where the skid in question is located within the building. This information remains valuable even after completion for management, maintenance, reuse, and recycling.” In this way, ERA also aligns with the principles of circular construction.
The prefabricated thermal energy storage skids at ACE Amsterdam are engineered, manufactured, and assembled by ERA Prefab Systems on behalf of VORM. They are based on specially developed steel frames, designed in accordance with the technical specifications applicable to the project. The piping for heat and cold transport, along with the necessary fittings, valves, and connections for the outlet sets, are pre-assembled within the frames. “Compared to traditional on-site assembly, this allows us to reduce installation time by approximately 80%,” says Aubri. The fire-resistant system is also integrated into the prefab skid concept. “With our ERA Smart Shield concept, the fire-resistant seal is prepared and implemented as part of the overall skid system.” In doing so, ACE clearly demonstrates what ERA Prefab Systems has come to stand for. “We not only supply the prefab skid, but can handle the entire process: from engineering and 3D design to production, vertical and horizontal distribution, logistics, assembly, and quality assurance.”
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Innovative building solutions for utility and stacked construction For over 20 years, we have been a leader in Austria and Germany. We specialize in utility projects and stacked construction, such as hotels, apartment and healthcare complexes, where we lead the way in supplying installation shafts and walls. What makes us unique? We supply fully prefabricated solutions, including the piping for heating, ventilation, [...]
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