Kalzip roof Melexis
CUSTOMER
Client: RSB Rudolstädter Systembau
Photos: RSB Rudolstädter Systembau
Owner: Melexis Erfurt GmbH
PROJECT
CHALLENGES
On average, every new car worldwide contains 18 chips from Erfurt – making this site a key hub for semiconductor production. Back in 2002, RSB constructed a striking extension for Melexis, featuring a prominent Kalzip roof as an architectural highlight.
In 2024, the original translucent membrane façade was replaced with a durable, fixed construction – including a redesigned arched truss façade and a newly executed membrane bridge.
Challenges:
• Close coordination with membrane manufacturer: Implementation of specific technical requirements, including numerous small and attached components.
• Drawing precision: A large number of dimensional details had to be incorporated precisely into drawings of primary and secondary elements.
• Bending accuracy for rolled steel profiles: Tight tolerances required high manufacturing precision for curved girders.
• Varying radii in arched trusses: The trusses were composed of segments with multiple, non-uniform radii.
• Elliptical bridge geometry: This complex form could be processed by only a few manufacturers, requiring intensive collaboration with suppliers.
ADVANTAGES
Back in 2002, early versions of bocad were already used on this project. At that time, elliptic layout was not yet available – the solution was a segmented tube construction. Since then, bocad has evolved significantly and now offers extensive modeling capabilities.
Key benefits of bocad in this project included:
• Selective visibility of components: With numerous parts, the ability to show/hide elements helped maintain clarity and control in the model.
• Use of part colors and line styles: Differentiating between primary and secondary structures was essential for structured, error-free planning.
• Working with subsystems: Breaking down the project into logical units (e.g., coatings, assembly steps, construction phases) ensured clear documentation and execution from workshop to installation.