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Roger & Roger Expands (Internally and Outwardly) at Production Site in Mouscron

Roger & Roger, the potato chip producer, is constructing a fully automated storage warehouse and a front building with logistics and social functions at its site in Mouscron. The storage warehouse is being built on the location of an existing building and adjoins another existing structure, which made the “puzzle” of fitting everything together quite complex. Since we had previously been involved in various large and small projects at this site, we were able to optimize the design of the connection between the two buildings, making it both more sustainable and economically advantageous.

 

 

Roger & Roger is best known for Croky chips, but mainly produces for private-label clients in the broader retail sector. The site on Industrielaan in Mouscron is now almost completely built up, making infill development necessary to enable further growth. The new front building, which has two floors, stretches across the full width of both the new warehouse and the building to its right. It provides additional loading docks, creates a logistics zone with order picking between the warehouse and the trucks, and offers new social facilities, including canteens, meeting rooms, locker rooms, and restrooms. The high-bay warehouse behind it is made of concrete, has a footprint of 45 by 84 meters, and reaches a height of 24 meters. Part of the old industrial building of the former Euromot had to be demolished to make room for the new construction.  

 

 

Separate or Connected?

The initial idea was to construct a completely independent building, but for various reasons, that turned out not to be the best solution. By connecting the new warehouse to the previously built warehouse, we were able to optimize the column sections, which created extra space for pallet storage. The connection between the two buildings was made using a steel structure, which helps distribute wind loads on the new building across more columns.

 

 

Ensuring Structural Integrity During Construction

Because part of the existing building – including the load-bearing columns – had to be removed, it was crucial to maintain the structural integrity of the remaining section during construction. The remaining structure was still subject to wind loads. To address this, we installed temporary buttresses just behind the high-bay warehouse, allowing us to demolish the roof safely. As the new warehouse was gradually erected, it was also connected to the rear of the existing building.

 

 

Preserving the Tiled Floor

As with the first warehouse, the contractor wanted to retain the existing tiled floor. Given the greater height of the new warehouse, foundation piles were first drilled at specific locations, followed by the pouring of foundation pads. Then, on top of the existing floor, a 20 cm-thick concrete slab was poured using Dramix® steel fiber reinforcement, making execution easier than with traditional reinforcement mesh.

 

 

Precise Column Placement

Between the existing and new high-bay warehouses, there is a narrow corridor with a conveyor system that transports pallets. This conveyor had to be preserved and kept operational throughout the construction process. At the same time, the columns of the new warehouse had to be placed as close as possible to the wall of this corridor, without clashes and with proper tolerances for accurate placement.

 

 

Construction Partners: