ZAL 2
Location:
Hamburg-Finkenwerder
Build time:
August 2022 – April 2024
Client:
FAP First Aviation Property Development GmbH & Co. KG
ZAL 2
With the expansion of the Centre for Applied Aviation Research (ZAL II), Ed. ZÜBLIN AG has created a state-of-the-art research and technology hub for the aviation industry. The project creates additional capacity for innovation and strengthens Hamburg’s position as a leading aviation hub.
In Hamburg-Finkenwerder, ZAL II was built as an extension to the existing Centre for Applied Aviation Research. The new building was completed on a turnkey basis in just 21 months and seamlessly integrated into the existing building complex.
The project was carried out in close collaboration between various ZÜBLIN divisions. Thanks to model-based planning and digital processes, the stringent requirements regarding deadlines, costs and quality targets were successfully met.
With a gross floor area of approximately 8,342 m², the building offers modern workshop, laboratory, office and conference spaces. The infrastructure facilitates research into innovative aviation technologies and supports projects relating to digitalisation and climate-friendly flying.
Key features include state-of-the-art research laboratories, an MRO real-world laboratory, spaces for digital assistance systems, and the integration of an aircraft fuselage for research and validation purposes. The main users are the German Aerospace Centre (DLR), ZAL GmbH and companies from the aviation industry.
Despite the demanding schedule and the fact that work was carried out whilst operations continued, the project was completed on time. The research facilities were able to commence operations immediately following handover.
With ZAL II, Ed. ZÜBLIN AG underlines its expertise in the development of complex research, industrial and commercial properties and makes an important contribution to technological development in the aviation sector.
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Key figures
- Built-up area (BF): 2,500 m²
- Gross internal volume (GIV): 60,687 m³
- Gross floor area (GFA): 8,342 m²
- Above ground: 5 storeys
- Basement: 1 floor
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Construction period
- Structural work from November 2022 to April 2023
- Facade works from February 2023 to October 2023
- Refurbishment from June 2023 to December 2023
- Completion: first quarter of 2024
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Standard operating procedures for construction sites
- Monday to Friday, 7.00 am to 7.00 pm
- Saturday (in exceptional cases) 7.00 am to 3.00 pm
- As a rule, no work takes place on Sundays and public holidays.
Certified by the German Sustainable Building Council (DGNB)
Ed. Züblin AG is pursuing several objectives with this project: sustainable site organisation, the conservation of resources and the minimisation of emissions, responsibility for the health and wellbeing of construction workers, fostering good neighbourly relations and, of course, high-quality construction work. For this, Ed. Züblin AG was the first company to receive an award from the German Sustainable Building Council (DGNB).
You can find further information on the DGNB system for sustainable construction sites here: https://www.dgnb-system.de/de/gebaeude/baustelle/
Selected measures within the project
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Prefabricated components
The extensive use of prefabricated components (openwork ceilings, columns, beams and staircases) helps to shorten the construction period. Similarly, the volume of waste is reduced thanks to pre-assembled orders.
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Digital concrete order
To ensure the best possible coordination of concrete pouring operations, orders are placed via a digital application. Particularly in the case of large-scale concrete pouring operations, the flow rates can be tailored to the concrete pump, thereby reducing waiting times for the concrete mixers. This optimises production times and reduces noise emissions.
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Resource conservation and emissions reduction through LEAN Construction
As part of the lean approach, a production plan with call-off dates (e.g. insulation) was drawn up. Construction production planning is detailed on a weekly basis and adjusted to reflect actual production progress. Changes arising from the construction process are taken into account on an ongoing basis, enabling just-in-time deliveries to be implemented more effectively. This avoids the need for repeat or new orders resulting from subsequent changes to the plan.
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Energy management in the construction industry
Construction-related studies and comparative analyses aimed at ensuring the project is carried out in the most energy-efficient manner possible. For example, selecting a large concrete bucket to reduce the number of lifts.
| Certification contact person | Heike Mardaus-Kraka |
| Project contact | Karl Felix Wienke |
| Construction site address | Hein-Saß-Weg 22, 21129 Hamburg Tel. +49 40 20208-0 ZÜBLIN Northern Regional Office Secretariat for Turnkey Construction, Hamburg / Schleswig-Holstein |
| Download | Press release |
| Link | DGNB: Certification |