Fast, economical and weather-independent construction

Van Berlo is widely praised for its super-flat commercial and industrial floors. But did you know that the "flooring specialist" is also extremely adept at prefabricating foundations, dock constructions, loading pits, gutters and manholes? In fact, the firm has even set up a separate division for it. Van Berlo System Foundations focuses on fast, economical and weather-independent construction. Glenn Verhoef of Van Berlo talks about the added value of this in-house division.

Van Berlo System Foundations has developed various solutions, especially for distribution centers and warehouses, for example.

For more than forty years, Van Berlo has been engaged in realizing (super)flat commercial and industrial floors. "In order to offer clients a total package, we set up our own engineering department in 2003," says Verhoef. "That tasted like more, because barely a year later the Van Berlo System Foundations division saw the light of day, followed by the Van Berlo Funderingstechnieken division, which produces floor piles. These were logical steps, mainly due to market demand for a total solution. Meanwhile, the System Foundations division has grown into a serious organization of over thirty employees."

Own prefabricated factory

Since moving to its current location in 2008, Van Berlo has had its own precast plant, which the System Foundations division eagerly uses. "It's completely in line with our philosophy," Verhoef suggests. "Anything you can make under a fluorescent lamp is more pleasant for our employees than when they have to stand in a puddle of mud ánd it increases the quality of the final product. Production is not only faster, but also more economical and weather-independent. As for the precast foundation beams, on site it is a matter of lifting the elements into place with a crane and filling them with concrete."

Commissioned by Heembouw, Van Berlo realized the complete foundation construction for the new building of Hordijk Verpakkingen in Zaandam, including a prefabricated crushing pit and of course the floors.

'Solid hollow-wall system'

Van Berlo Systeemfunderingen has developed various solutions, especially for distribution centers and warehouses, for example, where high-quality loading and unloading pits are crucial to seamlessly link internal and external transport. Verhoef: "We can supply the complete foundation construction in prefab for the entire building, right down to the loading docks and loading pit structures such as retaining walls, gutters and manholes. Unique in this respect is our 'solid hollow wall system', which consists of a prefabricated solid retaining wall with an integrated foundation beam. In one operation, both the foundation and the ground retaining wall plinth are realized."

Van Berlo's precast plant was working overtime last year. "In our precast plant last year we processed no less than 3,800 m³ of concrete, made and set 450 loading docks on site and processed 19 kilometers of foundation beams," says Verhoef. "Prefabrication is the method to make building even more attractive in the future. By sitting down at the table with all the parties involved at an early stage, we can contribute ideas for an optimal design. In doing so, we can relieve clients throughout the entire process, from pasture to anchor bolt."  

Hordijk Verpakkingen opts for total concept Van Berlo

Commissioned by Heembouw, Van Berlo is realizing the complete foundation construction as well as the floors for the new building of Hordijk Verpakkingen in Zaandam. "It involves 900 meters of prefabricated foundation beams, 33 pieces of 1-pile whorls and 21 pieces of 2-pile whorls. In addition, we set 250 anchor groups, realized the dock construction with eight loading docks and the loading pit construction with 42 meters of collision reinforcement at the end of the pit to absorb the pressure of the trucks. The gutter construction also comes from our precast plant. We realize the 22,500 m² floor, equipped with traditional reinforcement, on 5,000 Van Berlo Mini Vibro piles. Finally, we also made a prefabricated crushing pit measuring 6 by 15 by 2.5 meters. In short, this is where we prove our added value as a total provider."