Progress of work on the new main BENNINGHOVEN plant
A clear commitment to Germany as a production location, to Rhineland-Palatinate, to the region and also to the town of Wittlich.
This project is the largest single investment in the history of the WIRTGEN GROUP (> 100 million euros). The new plant is a logical and necessary consequence to expand competitiveness while providing the production capacity to meet the increasing demand.
The BENNINGHOVEN construction diary
The worldwide largest and most modern factory for the production of asphalt mixing plants is built in Wittlich Wengerohr – a state-of-the-art facility. Join us, how the new BENNINGHOVEN plant is gradually taking shape.
- October 2018
- December 2017
- Topping-out ceremony
- August 2017
- June 2017
- Cornerstone Ceremony
- Foundations and ground work
- Ground-breaking ceremony
After exactly one year and eleven months, all of the around 800 BENNINGHOVEN employees moved into the new factory in Wittlich Wengerohr. A super-sized production facility – on a plot of 310,000 m2, with a production area of 46,000 m² and an administration building with 12,000 m² on five levels.
In addition to state-of-the-art production systems with lean management concepts and technologies within the Industry 4.0 context, particular emphasis was placed on workplace quality and safety.
Health and safety of all employees was the primary concern for the design of the work stations at all times. This ranges from ergonomic, air-conditioned offices and acoustic tests to modern surface technology – where paint coats used to be the standard, powder-coating is now used exclusively at the new factory. This allowed the previously used solvents to be eliminated almost completely. Another important aspect is the extraction of the hot air from the production workshop, which is then purified in a filter unit, while the energy generated from the exhaust air is returned to the air circulation.
A factory designed for durability and sustainability – “an investment into the future”.
On Tuesday, 9 October 2018, all employees of BENNINGHOVEN GmbH & Co. KG were pleased to accept the invitation from the management to the official opening of the new factory in Wittlich Wengerohr with a small ceremony. BENNINGHOVEN was particularly pleased to welcome the Chairman of John Deere, Mr Samual R. Allen, who did not want to miss this memorable moment.
The new administration building of BENNINGHOVEN – “THE FACE” of a new milestone in the history of Benninghoven – extends over 5 levels. It houses approx. 120 open-plan offices which are equipped and designed according to the latest ergonomic criteria.
The new production workshop houses the entire production chain under one roof. From pre-fabrication to shipping, everything flows through in one process – the fundamental prerequisite for faster and more efficient working. This provides optimum conditions and, in the end, is crucial for delivering improved products to our customers.
The production is structured based on the flow of materials:
Building progress - December 2017
All of the hall and office buildings are now standing, and all of the roofs should be sealed by year’s end. The interior work has begun, i.e. electrical installations, ventilation/heating and drywall, and even the first components of large machinery, such as the powder-coating system, have been pre-installed in the halls. At the moment, there are 300 employees working to ensure that we stay fully on schedule, and that the moving trucks can roll out in mid-2018. Special praise goes to the intensive and collegial teamwork among all the employees of the construction companies involved.
One of the first Benninghoven asphalt mixing plants in Ürzig, more than 30 years old and owned by the Juchem company, is actively involved in the construction of its constructor’s new plant. It is delivering asphalt for the paths, roads, parking and storage areas throughout the grounds of the new plant. Which was brought in and reinforced with WIRTGEN GROUP technology. This brings the effort full circle in road construction.
Work beneath the roof has begun, such as roof drainage. This will be followed later on by gas, water, compressed air and power installations.
Final assembly and the area of surface technology
The powder-coating plant worth EUR 9 million took up occupancy at the new plant already in early November.
With the brand new powder-coating system, for the first time we can coat components up to 13 m long, 3.3 m wide and 4 m tall and weighing up to 20 t in automatic mode. Components larger than this can be wet painted manually.
Jet housing with mounted turbines – the heart of the continuous blasting plant
In the foreground, the suction funnels of one of the powder-coating booths. In the background, work on the second powder-coating booth has progressed further.
A view of the subsequent final assembly – The roof is already completely sealed, and the skylights that which will provide sufficient light in the future have been installed. The crane runway girders are also nearly completely mounted, and laying of the concrete hall floors is complete.
One of two production management offices in final assembly has been completed.
The first asphalt works of the base layer for subsequent outdoor storage and parking areas took place under the leadership of Strabag with asphalt from the BENNINGHOVEN plants of the Juchem company, with finishers by VÖGELE and rollers by HAMM.
A plant – state-of-the-art – will soon stand here. Particular emphasis is placed on job quality. From ergonomic workstations in all areas, to modern ventilation systems, natural lighting, etc.
The ground-breaking ceremony held in summer 2016 was followed in April of this year by the laying of the foundation stone for the world’s largest and most modern plant for the production of asphalt mixing plants. At a time when the foundations and ground work were not yet complete and building construction had just begun, a thunderbolt hit: The entire WIRTGEN GROUP was to become part of John Deere. At the same time, it was promised that construction and all the other activities would continue as planned. As a result, we were able to celebrate the topping-out ceremony on 18 October 2017 – almost a year to the day after construction began.
As the carpenters proclaimed the traditional topping-out address, the ceremonial wreath was hoisted to the top of the structure. The topping-out address is a way of thanking the architect and the developer, on the one hand, and requesting God’s blessing for the structure on the other.
Food and drinks were provided in honour of the occasion, and to thank the construction workers for their work.
Progress of work - August 2017
The construction progress has now become very easy to see. With the start of the actual building construction at the end of June 2017, the buildings have literally been sprouting out of the ground.
This progress is ensured by around 170 workers, construction managers, project managers, planners and QA employees working on the site every day. Not only the manpower, but also the hardware is impressive – 6 rotating tower cranes, a lattice boom crane on a lorry frame for assembling precast concrete units, up to 3 telescopic lorry-mounted cranes and approx. 15 working platforms are in use every day.
„We have the greatest respect for the performance of the construction companies, considering the limited workforce availability due to the summer holidays and the highly changeable weather in the past few weeks – everything from baking heat to stormy, wet and cold.“
Peter Heßler, Construction Project Manager
Foundations and ground work
Work on the rain water drainage channels and the wastewater pipes in the outside area is almost complete. Currently, the first cable ditches are being dug and underground cables are being laid as well as lines for local heating, drinking water and fire extinguishing water. At the same time, installation of the empty conduits continues.
The concrete ceilings above the 1st and 2nd floor have already been completed, while the ceiling above the 3rd floor will be completed at the end of August. The building is gaining in height, slowly but surely: a new floor every three weeks.
The working pit for the basement has been backfilled, the concrete surfaces in the basement have been made good and the painters and plumbers are already working in this area.
Production workshops and social building
In social building E (one of the social buildings), the concrete ceiling above the ground floor will soon be installed, and the precast concrete walls have also been installed up to the level of the 1st floor.
In the area of social building D (one of the social buildings), the wastewater ground pipes are currently being installed while pits, shafts and foundations are being concreted.
Almost all foundations for the workshops have been laid. The precast concrete support structure for the paint shop and final assembly were installed within 5 weeks (approx. 21,000 m² floor area!) as well as the fire wall between pre-fabrication and paint shop (approx. 1,500 m²).
Each concrete pillar weighs approx. 24 t, i.e. each had to be transported to the site individually on a lorry. Other interesting data include the pre-stressed concrete roof trusses with a weight of approx. 18 - 19 t (2 roof trusses on each lorry) and the support girders with 30 - 37 t, depending on the span (1 girder per transport).
Until today, approx. 500 precast concrete parts with a total weight of approx. 10,000 t have been installed.
The basement is currently being built.
Photo gallery - August 2017
Progress of work - June 2017
Around 140 workers, site managers, project managers, planners and QA employees are currently working tirelessly at the construction site, steadily driving the underground works and building construction.
„The good weather during the past weeks and the resulting very low accumulation of stratum water in the excavation areas has had a very positive effect on the progress of work.“
Peter Heßler, Building Project Manager
Foundations and ground work
The civil engineers were able to mostly complete the basic earth moving works including stabilising the soil for buildings and traffic routes. The excess soil will be placed into the area of the car park successively over the next months.
The good progress of the civil engineering works meant that work on the sewage system on the factory site was also started. Rainwater drainage channels, rain retention basins and wastewater channels including pump buildings as well as the drainage lines in the area of the factory site show very good progress.
Furthermore, installation of the rainwater drainage channels has started in the area of the car park, allowing installation of the rainwater retention drains underneath the parking area very soon.
The first sections of the local heating lines have been installed; heating oil and diesel tanks have been “buried” and the separator systems for the tank location and wastewater processing have been relocated.
Work on the central building continues to progress well. The concrete ceiling over the basement was recently completed. The outer insulation of the basement walls is currently being installed.
The concrete work for supports, stairwells and floor joists is currently being carried out and the first parapet walls are being mounted.
Two revolving tower cranes are currently in continuous operation for this, supported by a mobile crane during the last three weeks.
Social building and production workshops
The foundation work in the area of the paintshop and final assembly are nearly completed. The large foundations have an area of 5.20 x 5.20 m. A 4.00 m footing base provides sufficient bearing capacity. To increase compressive and tensile strength, each foundation contains approx. 1500 kg reinforcements, and 100 m3 of ready-mix concrete are used every day.
Installation of the prefabricated concrete framework for the workshops in this area will start at the end of June.
The CORNERSTONE CEREMONY AT BENNINGHOVEN
BENNINGHOVEN celebrated the laying of the cornerstone for the new factory in Wittlich Wengerohr on 11 April 2017. This starts work for the second construction phase – the actual building. Despite the poor weather during the first months of 2017, BENNINGHOVEN is sticking to the completion date in the summer of 2018.
Current status at the construction site
70 per cent of the underground work has been completed. An essential part of this was to create level, strong surfaces for the 60,000 m² production and logistics workshop, the 12,000 m² central building with offices and the traffic routes. The plot was completely remodelled for this.
The height difference had initially been 9 m. To even this out, around 400,000 m³ of soil had to be removed in one area and re-introduced in other locations. Currently, work on the foundation for the central building has already begun. The first building sections will become visible in the next months.
The perfect basis
The new Benninghoven factory in Wittlich Wengerohr rests on a solid foundation, provided by Wirtgen soil stabilisers and road rollers from Hamm.
„The exceptional project is a complex and challenging task, but everyone at the factory knows: the objective is worth the effort.“
Heinrich Plein, Plant Engineer at Benninghoven
The main task of the civil engineers was to create a level, strong surface for the 60,000 m² production and logistics workshop, the 12,000 m² central building with offices and the traffic routes. The plot was completely remodelled and stabilised for this. “The height difference had initially been up to 9 metres.
Groundwork with quality
BENNINGHOVEN builds new main plant in Wittlich Wengerohr
After barely a year of planning, BENNINGHOVEN GmbH & Co. KG has started on the construction of a new main plant. The asphalt mixing plant construction specialist will move into the new production site in Wittlich in early 2018.
This project is the largest single investment in the history of the WIRTGEN GROUP (>100 million euros) and is a clear commitment to Germany as a production location, to Rhineland-Palatinate, to the region and also to the town of Wittlich. The new plant is a logical and necessary step in strengthening the company’s competitive position at a global level. The current production capacity is no longer able to meet the growing demand.
BENNINGHOVEN's integration into the Wirtgen Group sales and service network has been successfully accomplished in Europe and Australia, and over the next few years the company will actively continue to gradually tap into other international markets. More than ever before, all the signs point to growth.
The WIRTGEN GROUP is investing in a completely new plant at the Wittlich site to cope with the increasing volume of orders, with the long-term perspective and objective of making Benninghoven one of the world's leading companies.
BENNINGHOVEN, which has developed over time, currently manufactures mobile, transportable and stationary asphalt mixing plants, mastic asphalt mixers and granulators at two production sites in Mülheim an der Mosel and Wittlich. Plants for the production of rolled and mastic asphalt, and technologies for the recycling of old road surfaces. The goal is to merge these sites in the new building. The geographical characteristics at both old locations offered no opportunities for expansion. Concentrating the entire production chain in one place – from pre-fabrication to final assembly – guarantees optimised production processes.
Another key factor to the choice of location was its proximity to the existing plants. Not only does the company intend to retain the jobs of its highly skilled staff, it also plans to create new jobs in the future, expecting the number of employees to increase to 1,000 in the medium and long term.
The aim is to establish a state-of-the-art factory, i.e. starting with the very latest production systems, featuring lean management concepts and technologies within the context of Industry 4.0, with particular emphasis the quality of the workplace, ranging from the installation of ergonomic workstations in all areas to modern ventilation systems, natural light, and many other aspects.
A 46,000 m² production facility and a 12,000 m² administrative building on five floors are being built on the 330,000 m² site. The generous capacities of the new main factory perfectly accommodate the component dimensions of the asphalt mixing plants, which are up to 50 m tall. The growth-oriented company has already included possible expansion phases in the planning.
BENNINGHOVEN has been a specialist for the manufacturing of asphalt mixing plants for over 50 years. The manufacturer with a long tradition sets great store by quality and innovation. Whether standard designs or individual customer requests – BENNINGHOVEN can offer a suitable plant solution for any market requirement.
With unique innovations in the field of asphalt mixing and combustion technology, BENNINGHOVEN has always been regarded as an industry pioneer. The actions of the company are still characterised by pioneering spirit and tradition in combination with forward-looking technologies and highly specialised employees. From steel construction to the development of complex control systems – BENNINGHOVEN develops and manufactures all core components in-house.
Today's ground-breaking ceremony marks the start of the civil engineering work, i.e. over 400,000 m³ of earth will be moved, followed by the building construction early in the new year, so that the moving lorries can be on the road early in 2018. From the spring of 2018, the first asphalt mixing plants in Wittlich Wengerohr will then be manufactured.
Mülheim/ Wittlich 31st August 2016