PROJECTS / AIRBUS HAMBURG

The merger of several European aerospace companies into EADS was a major economic success. The consortium, headquartered in Toulouse, was able to secure significant market shares in the global aircraft market, particularly against American competition. The company has expanded significantly and is the only aviation company in the world daring to build a new large aircraft. For its production, the largest halls in the world are needed at the Airbus site in Hamburg-Finkenwerder.

The designated site in the Mühlberger Loch is a freshwater tidal flat of the Elbe River. In this ecologically sensitive area, Airbus is constructing a new production hall so large that it must be "landscaped" to blend into its surroundings. To find a suitable solution, an architectural competition was held, to which Christoph Ingenhoven invited. The architects assumed that the 750-meter-long hall made structuring with traditional architectural elements impossible and designed a hall that is as low as possible facing the Elbe, so as not to disturb the landscape too much.

To be prepared for future developments, the architects, in collaboration with structural engineer Werner Sobek from Stuttgart, chose a flexible, support-free structure that allows for a variety of adjustments. The hall accommodates both section production and equipment assembly. Both areas can be changed or replaced without interference with the structure, the infrastructure, or the roof. Other product lines can also be integrated. The glass sliding gates are 10 by 21 meters in size, allowing for views into and out of the hall across the Elbe. The compact hall’s orientation to the north prevents excessive heating from the sun. The natural daylight also improves the quality of the working environment.

The designers chose an asymmetrical structure that has no supports on the Elbe side and therefore does not require structural height there. The cantilevered structure, which spans about 100 meters, ensures that the facade on one side is only as high as needed for the interior space.

The cantilever arms supporting the roof are anchored in pairs of supports. The geometry of the cantilever arms is optimized for minimal use of steel. The complexity of the connections is limited, allowing for modifications. The extensive prefabrication and simple construction contribute to the efficiency of the low-maintenance structure. The roof covering is corrosion-resistant, durable, and robust. Openings in the roof allow for zenithal light to enter the hall, enabling natural ventilation and, in case of fire, smoke extraction. Outside air flows in through the louvers in the glass sliding doors. No ventilation systems are planned for the section production and equipment assembly. In the paint shops, the air-handling systems are centralized, assuming a staggered painting process in two adjacent halls. Although the equipment assembly requires a lower height, while the section production needs a consistent clear height of 23 meters, the architects opted for the greater height throughout to simplify the system. The roof is clad with welded stainless steel panels that feature a bead-blasted, non-directionally matt finish, reflecting light and, like the waters of the Elbe, taking on the colors of the sky. This makes it perceived as part of the landscape, contributing to the acceptance of the ecologically controversial construction project.

The design for the Airbus halls in Hamburg is a prime example of interdisciplinary collaboration between architects and structural engineers, as the architectural form of a hangar is largely determined by its structural system. Yet the enormous project integrates elegantly into the landscape.

The Elbe landscape at Mühlberger Loch is predominantly flat, and the ebb and flow of the tide shape the landscape. The scale of the production halls requires a responsible approach to the natural environment. A precise analysis of the local geographical conditions has led to a building concept that heavily incorporates natural resources into the building’s management.

The cantilever beams span the entire hall, allowing for efficient use of space. The structure consists of standardized steel elements from standard profiles. The modular design allows for the realization of further construction phases. The prefabricated beams can be delivered by ship and welded on lifting platforms. The cantilever beams are then lifted into place using hydraulic towers, where they are mounted. The geometry of the structure is optimized for minimal steel consumption. The primary structure’s cantilever beams span the hall with a projection of around 100 meters without additional supports. The cantilevered design minimizes the structural cross-section of the framework in the area of the facade. The clearance profile of the structure is designed so that manufacturing and assembly processes can be carried out at any point in the hall.

The roof covering of the hall is made of seam-welded stainless steel panels. The bead-blasted surfaces are non-directionally matt and non-reflective. The roof is corrosion-resistant, durable, waterproof, and possesses robust mechanical properties. Extensive prefabrication, optimized geometry, and simple construction contribute to an efficient building.