The production of composite facade elements for a building in Horten, Denmark

SGS had an available facility in Lysekil, Sweden.

TBB was contracted for plugs and moulds manufacturing and to help set up and manage a factory that would produce 4000 m² (43.000 ft2) of these modules. Each module is approximately 4x4,5 metres.
The set up included everything from lighting, ventilation, vacuum pumps, ovens, tools and material flows to training of employees in infusion techniques.

Factors:
- Weight limitations on the facade, max 100kg/m2
- Complex 3D geometry with 6 basic shapes to produce moulds for
- 30 mm Travertine stone to be mounted as surface (75kg/m2 stone only)
- A tight schedule enabled by the off site production :

• Start test & design October 2007
• Fire test of one element in December 2007
• Start set up of factory April 1st, 2008
• Finished design and mockup in May 2008
• Production start May 15th, 2008
• Start installation on building week 45, 2008
• Complete installation week 7, 2009