Sustainable Foundation Techniques for the Redevelopment of the Vlissingen Machine Factory

Optimal Use of Concrete Piles and Steel Components in Vibration-Free, Low-Emission Foundation Systems

The redevelopment of the historic Machinefabriek at the former Scheldewerf shipyard in Vlissingen serves as a prime example of how foundation engineering contributes to circular and sustainable construction. As part of this large-scale transformation project, existing industrial structures are being repurposed into multifunctional spaces for parking, sports, culture, and events. The foundation approach plays a key role in this, with an emphasis on vibration-free construction, electrification, and minimal impact on the existing structure.

Working within a historic structure

The Machinefabriek consists of large halls up to approximately 95 meters deep and 16 meters high. Carrying out the foundation work within this existing structure poses significant constraints, including in terms of available workspace, the bearing capacity of the subsoil, and logistics. Davy Maes, Managing Director/CEO of Fundex Group: “Conventional heavy-duty foundation machinery, such as large drilling rigs (for example, the F3500 and/or F4800 models), cannot be used in this context due to their size and weight. That is why we use a specialized, compact fleet of machines.” A central role in this is played by the electric CD20E drilling rig, which was specifically developed for applications in confined spaces and inner-city environments.

Vibration-free pole installation

As part of the project, approximately 160 foundation piles will be installed to a depth of about 25.5 meters. Vibration-free techniques will be used, including combination piles with grout injection. This method combines a mechanical screw technique with grout injection, resulting in a homogeneous pile with a controlled bearing capacity. “The major advantage of this technique is that it avoids peak loads during installation. This is essential in an existing structure where vibrations and settlement can cause damage. Furthermore, the continuous support of the borehole wall through grout injection ensures stability, even in heterogeneous soil conditions,” says Maes.

Electrification of Foundation Equipment

An important aspect of this project is the use of fully electric foundation equipment. The CD20E drilling rig operates emission-free on the job site and produces significantly less noise than diesel-powered rigs. This makes the technology particularly well-suited for inner-city projects and redevelopment projects.

In addition to light machinery, Fundex also offers heavier electric systems, such as the F4800E. These are equipped with electric winches, hydraulic systems, and battery storage, and can operate on either mains power or batteries. This hybrid concept increases operational flexibility and makes it possible to adapt to future energy supply options.

The benefits of electrification are clear: reduced CO2 and NOx emissions, lower noise levels, and improved working conditions. At the same time, this transition places new demands on construction site design, particularly in terms of energy supply and charging infrastructure.

Technical and Economic Considerations

Although zero-emission technologies offer clear advantages, there are also issues to consider. The initial investment costs for electric equipment are higher than for conventional systems. In addition, the availability of sufficient electrical capacity on the construction site is not always guaranteed. Maes adds: “Regulations and standards also pose a challenge. Innovative technologies often come up against existing frameworks that are not yet sufficiently adapted to new construction methods. This requires close collaboration between clients, contractors, and regulatory agencies.”

Integration into the design process

A key insight from the project is the importance of involving the foundation specialist early on. By contributing ideas about foundation concepts as early as the design phase, optimizations can be made in terms of pile type, construction technique, and material selection. This not only leads to a more efficient construction process but also to a lower environmental impact and better risk management. “The foundation thus evolves from a purely load-bearing element into an integral part of the sustainability strategy,” Maes emphasizes.