KTN Hornhaven, Amsterdam | Sophisticated pilot complex in Amsterdam harbor

Amsterdam's Hornhaven is experiencing even more activity than usual these days. In no time at all, nine storage warehouses of Katoen Natie are rising, intended for the storage of cocoa in bulk. Especially the 8.5 meter high and 45 centimeter thick walls in on-site poured concrete are quite a challenge, while the construction of the warehouses should only take six months.

Ivan Vinck: "When placing the foundation, we immediately integrate the waiting reinforcement."

The port of Amsterdam is the world's largest storage and transshipment port for cocoa. Katoen Natie did not want to be left behind and invested in the realization of a brand new storage site in the so-called Hornhaven. The complex covers approximately 45,000 square meters and has nine warehouses. ASK Romein was the designated party to erect them. "We have been continuously carrying out projects for Katoen Natie for almost twenty years, both at home and abroad. In total, we have thus already realized more than 1.2 million square meters of warehouses. Over the years a great mutual trust has grown. It should therefore come as no surprise that Katoen Natie has also asked us to build the new warehouses in Amsterdam's Hornhaven", says managing director Ivan Vinck.

During the realization of the concrete walls, ASK Romein is working in phases of 51 running meters.

Concrete walls with a manual
In general, the sheds have a fairly classic structure (foundation piles-foundations-concrete walls-concrete floor-steel structure-steeldeck-roof sealing-roof cladding). What is much less classic is the size of the poured concrete walls. "They are no less than 8.5 meters high, and their thickness also captures the imagination: at the foundation massif they are 45 centimeters wide, and at the top 30 centimeters," explains Ivan Vinck. "The realization of these conical walls is, of course, a separate story. When we place the foundation, we immediately integrate the waiting reinforcement. Then we build the walls step by step, each time working in phases of 51 running meters. After pouring, the concrete remains in the formwork for two days, and then remains braced for two days as well. In other words, a concrete pouring phase takes four days. Given the high stacking and pressure loads of the cocoa, our engineers carried out a thorough study during the tender phase to arrive at the most economical and efficient concept, in which the foundations, concrete retaining walls and roof structure are fully integrated."

The conical concrete walls are as much as 45 centimeters wide at the base.

Challenges galore
Even for an experienced company like ASK Romein, which specializes in the realization of distribution centers, Katoen Natie Hornhaven is a unique project. "The first concrete wall was concreted during the week of January 7 to 13, and by the end of April all concrete walls should be ready, so that the project will be fully completed by July 5," said Ivan Vinck. "This is an ambitious schedule. Moreover, the concrete work is not evenly distributed. For example, the smallest of nine sheds, which is highly compartmentalized, contains 50% of all concrete walls. Another peculiarity is the presence of underground tie rods at the level of the existing quay wall, between which we have to place three thousand floor piles. In short: challenges galore, and so far we are perfectly on schedule!"  

Text | Tim Janssens  Image | ASK Romein/LucidLucid
Featured image: One of Katoen Natie's new warehouses in Amsterdam's Hornhaven under construction. By July 5, the entire complex should be ready.

Construction Info

Builder
Katoen Natie (Antwerp)

Architect
ASK Romein (Malle)

Arch. Joris van der Vorst (Roosendaal)

Main contractor
ASK Romein (Malle)