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TOYOTA CAR ASSEMBLY PLANT

CLIENT

Toyota Motor Manufacturing Russia

SCOPE OF WORK

Procurement, Construction

SECTOR

Building Works

LOCATION

St. Petersburg, the Russian Federation

PROJECT DURATION

May 2006 – September 2007

Project Description

In 2006, ENKA was awarded the contract for the construction of Toyota Car and Assembly Plant in St. Petersburg, Russia. The plant, with an annual production capacity of 50,000 cars, is one of the biggest Toyota factories in Europe. The factory was constructed on a land covering 214,000 mwith a building area of 57,000 m.

The plant consists of four major process shops of 12,000 meach, as well as a 5,000 m2  utility shop and a 4,000 m2  administration building. The poor soil conditions and the high underground water table made it necessary to use deep bored piles and sheet piling techniques for structures, such as sludge pools and booth pits. The plant was completed and handed over in September 2007.

The major process shops included a paint shop, a general assembly shop, a body shop and a production control shop. All the shops were constructed as single storey buildings. The plant also included a 50,000 mshipping yard for new cars and a 27,000 mcontainer yard.

ENKA Scope of Services

The work included the construction of an automobile factory, including four process buildings and 11 service buildings. The project also included the procurement and construction of electrical and mechanical works, roads, parking areas and landscaping.

All slab-on-grade, as well as the foundations and pits were supported with driven piles averaging 29 m in length. The roof structure was made of primary and secondary trusses with a purlin grid of 2.5 m. The steel structure for the roof system rests on precast concrete columns with dimensions of 80mm x 800mm dimensions. The roof covering system was made of two layers of steel load bearing sheets with 140 mm of insulation layer between them. All the shops are single storey buildings and the plant’s facade is a sandwich panel system with insulation.

The mechanical and electrical systems include: HVAC, hot and cold water supply and a fire water main, power supply and lighting, intruder alarm, fire alarm, fully automatic sprinkler, public announcement and emergency evacuation systems, smoke extraction, as well as pressurization and building automation and control.

Key Quantities

Total Floor Area 57,000 m²
Utility Shop 5,000 m²
Administration Building 4,000 m²
Container Yard 27,000 m²
Excavation 100,000 m³
Filling 50,000 m³
Driven Piles 105,000 m
Bored Piles 11,000 m
Concrete 30,000 m³
Reinforcing Steel 4,000 tons
Structural Steel 3,500 tons
Roofing 55,000 m²
Wall Cladding 20,000 m²
Ground of slab hardening 44,000 m²
Infrastructure Piping 17,000 m
Utility Piping 31,000 m
Cabling 147,000 m
Landscaping 110,000 m²
Construction of roads and parking areas 70,000 m²

Gallery

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