Lutosa continues to renovate at the Hainaut site
Lutosa continues to renovate the site in Leuze-en-Hainaut to optimize and expand production. This time, two specialty lines and a fries line were upgraded. Where possible, existing structures were preserved, while others were reinforced or replaced.
In an earlier article, we mentioned our role as a sparring partner for Lutosa since 2012. As a result, we continuously collaborate on new plans, designs, and implementations. Recently, a new production line for potato specialties was installed in an existing building at the Hainaut site. The walls and roof remained untouched, while platforms were added inside, and we designed foundations for robots, pedestals for machines, and new floors. A new spiral freezer was also installed. In an adjacent warehouse, small rooms and steel structures were added, all tailored to the new production line.
Roof Suspended from Piperack
For specialty line 9, the changes were more drastic. Only the framework of the old production hall—foundations, exterior walls, and roof trusses—was preserved. The floor was removed, and the roof covering was taken off.
As the number of pipelines required for modern production processes has increased exponentially compared to the past, there was insufficient space to accommodate them under the roof. That’s why we thought literally ‘out of the box.’ New micro-pile foundations were installed, with columns extending straight through the roof. On the exterior, a new piperack structure was built. This not only provides additional capacity for future needs but also serves a second function: the existing roof structure is suspended from it, allowing it to bear more load than before, including a fire-resistant ceiling and sprinklers.
Largest Tower Crane
Just like with the other specialty line, this building will also have additional platforms installed, pedestals cast, floors renewed, and a new freezer constructed. In early April, the installation of the piperacks will begin. These will be preassembled in modules and placed on the supports we have provided. However, this building is located at the heart of production, in an area that is inaccessible to a standard assembly crane. To solve this, we designed a concrete pedestal in an adjacent building to support a tower crane that extends straight through the roof. With a height of 80 meters and a jib length of 85 meters—capable of lifting over 5 tons even at 80 meters—this is the largest tower crane ever used in one of our projects.
Extending the Lifespan
Finally, modifications are also being made to the building housing Fries Line 2. Due to the age of the building and the humid production environment, corrosion had developed on the steel columns and roof trusses. During an analysis two years ago, we identified several beams that needed replacement. A new analysis this year revealed that some beams had completely rusted through, prompting us to install temporary supports with braces. Since new beams can only be installed during the annual two-week production shutdown, the work must be meticulously planned to ensure everything is completed in a single operation.
Because the trusses are made of square hollow sections, it was not possible to visually assess the extent of the corrosion. Therefore, a laboratory was commissioned to conduct thickness measurements. Based on the findings, some trusses will be repaired, and a ventilation system will be installed to reduce moisture levels in the space. However, this system adds extra weight. To manage the additional load, we are grouping the weight distribution and reinforcing specific areas, allowing us to avoid replacing all the trusses while still extending the lifespan of both the building and the production line.
(Annual) Risk Analysis
By preserving existing structures as much as possible, Lutosa is making a clear commitment to sustainability and circularity. However, it is crucial to monitor the wear and tear of these structures over time. For this reason, Lutosa asked us to conduct a risk analysis to assess the potential consequences of taking no action or delaying intervention for several years. In the building housing Fries Line 2, we will carry out annual inspections and update the risk analysis accordingly until the time comes for the building to be completely replaced with a new one.
Construction Partners:
- Lutosa – client
- skald engineering – structural engineering
