Prefabricated shell for sustainable French fry factory

As a valued partner of Aviko, main contractor Alheembouw and the architect, Valcke Prefab Beton is responsible for the engineering, production, delivery and installation of the precast concrete structure and precast façade panels. "A great assignment, also in a very short time frame," according to project manager Thomas Naessens.

Valcke Prefab Concrete specializes in the construction of production halls, logistics buildings, business centers, retail spaces, offices and showrooms. "In that capacity, we have worked with Alheembouw as a subcontractor for many years," said Naessens. "The Popering architectural firm Vandewynckel has also regularly called on Valcke Prefab Beton in the past for the execution of various projects. Finally, we also delivered and assembled all prefabricated concrete elements at the existing Aviko site in Proven. So we are definitely a known party."

3D models

Given the complexity and size of the new plant, Aviko deliberately chose to put the civil construction out to tender at an early stage. Valcke Prefab Beton also soon came into the picture. Many parts of the construction were prefabricated. Naessens: "The advantage of working with precast concrete elements is that you can build quickly and efficiently on site. On the other hand, it requires a bit more time in the preparation to achieve good coordination. Everything must be known and recorded in advance. Making changes afterwards is detrimental to the planning. Although Valcke Prefab Beton does have the advantage that we have our own study and drawing office and can therefore respond quickly. We therefore have everything under our own control, from design to delivery. We can quickly process and apply any changes to the elements that have not yet been produced. All elements are fully drawn and calculated in 3D by our study and drawing office. The 3D models also form the input for production control."

Dynamic interaction

Valcke Prefab Concrete is supplying precast columns, beams, vaults and façade panels, among other things, for Aviko's new production facility. "In short, the complete supporting structure," Naessens summarizes. "And that for the various buildings. The project is so large that it covers several plots. All elements are produced at our plant in Vlamertinge, a stone's throw from Aviko's site." According to Naessens, the planning poses quite a challenge. "There was only a limited time between engineering and execution. That required a dynamic interaction, especially in the preparation phase, between the Aviko team, Vandewynckel, Alheembouw, the engineering firm, the installation parties and us as the precast supplier. But that has worked out well, we can now cautiously conclude. Moreover, the quality is guaranteed by production under strict quality control and conditioned conditions. For Valcke Prefab Beton, Aviko's new production facility in Poperinge is in any case a wonderful reference."