Factory for assembly of electronic controls of automobile air conditioning systems, industrial business zone

Technical indicators for stage 1: 

• Plot area 70 000 sq.m.
• Total Build-up area 14 693,26 sq.m. 
• Build-up area 9785,19 sq.m.
• Vertical planning: 36 400 sq.m. 
• Landscaping: 13 500 sq.m.

Stage 1:

The project consists of a production building with two technical buildings, a three-storey office building, a security booth and a waste shed.
The following summarised activities were covered in the implementation of the site by part:

Architecture
The façade of the office building is made with a curtain glass façade in combination with composite cladding. The production building has a wall enclosure of thermal insulation panels in combination with high quality joinery and sectional doors. A modern state-of-the-art system of movable louvres has been installed for sun protection.
The floor of the production area of 5255 sq.m. is made of electrostatic ESD flooring complying with the requirements of the production process. In the warehouse and technical areas, a polished concrete floor is laid.

Structure
A monolithic reinforced concrete structure has been deigned for the construction of an administration building, a new technical room attached to the production building for the HVAC equipment, an underground sprinkler tank with plan dimensions 17.1 x 34.9 m and a volume of 1600 m³, as well as two underground rainwater tanks. The security cabin, the waste shed, the canopies as well as the advertising facility with the investor's logo are made of steel construction.

Installations - HVAC; Gasification; Electrical installations and equipment; Building and site plumbing networks and external plumbing connections; Fire alarm and fire extinguishing systems  

Vertical planning and roads - 12600 sq.m. of paved surfaces, 1250 sq.m. of pavements and 2825 sq.m. of concrete pavements were implemented around the site.
 

Technical indicators for stage 2: 

• Total Build-up area 6479,96 sq.m. 
• Build-up area 5888,92 sq.m.
• Vertical planning: 27 000 sq.m. 
• Landscaping: 17 477 sq.m.

Stage 2: 

The project includes the extension of the production hall with a storage area and technical premises. Facilities such as a packaging storage shed, extension of the existing fire fighting tank with another wet chamber, a transformer station and extension of the existing car park with an additional 150 parking spaces were also constructed. 
During construction, a temporary partition wall of thermal panels on a steel support structure was constructed between the new and the existing parts of the plant to the design of the General Contractor. Thanks to this facility, Ber-Hella Thermal Control Ltd. was enabled to continue to maintain its production processes at their full capacity and to the required quality.
The implementation of the project covered the following summarized activities by parts:
Architecture

The production building has a wall enclosure of thermal insulation panels. 
The roof is executed with a layered installation of roofing sheet, thermal insulation wool and waterproofing membrane, and smoke domes and SOLATUBE light wells are installed, providing day lighting in the production and office part of the building. 
The floor of the production area of 4400 sq.m. is made of electrostatic ESD flooring compliant with the requirements of the production process. In the warehouse area and technical rooms, a polished concrete floor was laid. In the technical rooms, polyurethane flooring was installed.

Structure

The structure is prefabricated, composed of precast reinforced concrete columns, main and secondary beams. The floor slab is monolithic. The façade substructure, as well as the roof connections and reinforcements are made of steel.

Installations - HVAC; Gasification; Electrical installations and equipment; Building and site plumbing networks and external plumbing connections; Fire alarm and fire extinguishing systems  

Landscaping and irrigation system 
The works commissioned were professionally performed and completed to a high quality and in accordance with the statutory requirements, with very good organisation and adherence to the agreed timescales, without disrupting the normal functioning of the existing buildings and facilities and without impeding the workflow of the Investor’s staff. 

Technical indicators for stage 3: 

• Total Build-up area 14 046 sq.m. 
• Build-up area 10 618 sq.m.
• Vertical planning: 5190 sq.m. 
• Landscaping: 6000 sq.m.

Stage 3: 

The Project construction category is 1 (first) according to Article 137 of the Spatial Development Act. The project includes the complete implementation and integration into the 24/7 operating plant of an extension of the production hall with a storage area and additional facilities: an extension for loading and unloading activities, relocation of a shed for storage of packaging, expansion of the existing fire protection tank, and a new transformer station.

The following summary activities were covered during the implementation of the project:

Structure

The structure is prefabricated, consisting of prefabricated reinforced concrete columns, main beams and secondary beams. The floor slab is made of hollow core slabs. The facade substructure, as well as the roof connections and reinforcements, are made of steel. The design solution provides for the beams of the extension to rest on the columns of the existing building. For this reason, during construction, special insulating cells were built according to the General Contractor's design to provide a structural connection between the beams and columns within the existing production hall. This enabled BHTC Bulgaria to continue its production processes uninterrupted, at full capacity, with the required quality and without disturbing the microclimate. A total of 202 tons of steel load-bearing structures were installed.

Architecture

The wall cladding consists of 5000 m2 of TRIMO thermal insulation panels with a thickness of 15 cm and mineral wool filling - vertical installation. The exterior doors and the levelers in the loading and unloading area are HORMANN. 270 m² of ALUMIL window frames and curtain wall system solutions have been installed.

The roof insulation package has been installed in layers as follows:
11,762 m² of high-profile LT sheet metal LT153-290-870, manufacturer: ArcelorMittal Romania S.A. For the canopy, 264 m² of trapezoidal sheet metal T40-245-980, manufacturer: Tegasteel, Serbia; 10,930 m² of LDS 35 FIX+ KNAUF vapor barrier; 10,610 m² of 16 cm thick Knauf SmartRoof Tor Hx1200x2000 rigid rock mineral wool thermal insulation; 11,250 m² of SIKAPLAN 18G PVC waterproofing membrane.
The roof has 44 smoke vents and 2 LAMILUX Fl00 skylights for natural lighting. A GEВERIT PLUVIA vacuum roof drainage system has been installed. For convenient and long-term use of the roof space, 500 m² of SARNAFIL PVC WALKWAY PAD inspection walkways have been installed.
The floor of the production areas, with a total area of 7,000 m², is covered with 2 mm thick FORBO COLOREX EC electrostatic conductive ESD flooring, which meets the requirements of the production processes.
The total area of the polished reinforced concrete flooring is 13,742 m². Additional surface polishing has been carried out in the storage areas (4,674 m²). The interior finishing works, including the installation of KNAUF plasterboard walls, KNAUF AMF suspended ceilings, FORBO AKZENT anti-static carpet flooring, granite tiles and KAI ceramic tiles, and HORMANN fire-resistant doors, give the site a commercial look and create a pleasant working atmosphere for employees.

Installations

Installations serving the building and the production processes themselves have been completed on site:
•    HVAC installations and equipment
•    Compressed air installation (including Comp air compressor station) and nitrogen for the plant's technological needs
•    Electrical installations and equipment
•    BMS building automation system SIEMENS
•    Building and site water supply and sewerage networks.
•    Fire alarm system SIEMENS
•    Fire extinguishing system certified by VDS

Surrounding area

•    Vertical planning - 3030 m² of SEMMELROCK paving and 2160 m² of polished reinforced concrete paving were installed around the site.
•    During construction, a temporary access road was built and maintained to ensure regular deliveries of materials needed for production.
•     Landscaping and an irrigation system were completed on an area of 6000 m².

The site has been successfully commissioned and operates without defects.