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Construction of a New Acetylene Plant for BASF
Modular Steel Construction – Project Management – Industrial Plant Solutions
Modular Steel Construction – Project Management – Industrial Plant Solutions
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At BASFs joint location in Ludwigshafen, one of the world’s most advanced acetylene production plants was built. With an annual production capacity of 90,000 tons and a footprint of 40,000 m², this project ranks among BASF’s largest investments. The sheer scale is impressive: the columns rise up to 95 meters, dominating the site’s skyline.
Sikla played a key role in this ambitious project. In total, we supplied 8,750 modular support structures and over 9,100 pipe supports. Thanks to close and trusted collaboration, we achieved significant time and cost savings while meeting stringent safety requirements.
Challenge:
The major problem was the replacement of already prepared secondary steel structure.
The solution:
A decisive factor for BASF was a secondary steel construction planning tool that was fully integrated into the PDMS CAD system. Sikla successfully implemented this planning tool in collaboration with BASF. The issue of safety was also extremely important, in particular compliance with the regulations through the static verifications according to EC 3 and the in-house production control according to EN 1090.
Additionally, Sikla handled material pre-assembly and ensured on-time delivery directly to the construction site, significantly accelerating the installation phase.
In an interview, Klaus Schmitz, Senior Construction Manager at BASF SE, shared his perspective on the challenges and benefits:
“The sheer size of the project was impressive: 35,000 m³ of concrete, 8,500 tons of steelwork, 440 machines and units, and more than 5,000 pipelines had to be coordinated. Modular secondary steelwork gave us the flexibility we needed.”
Key benefits highlighted by BASF:
Shorter delivery times compared to welded structures
High load-bearing capacity combined with rapid availability
Reduced interface complexity between steelwork and mechanical contractors
Sikla’s integrated project management also proved invaluable. A single point of contact, streamlined processes, and efficient material flow management contributed significantly to the project’s success.
The technical details underline the advantages of the system:
Average pipe diameter: 160 mm
Average secondary steelwork weight: only 27 kg
Installation possible with minimal lifting equipment
Over the entire life cycle of the plant, modular system steelwork offers further benefits. During plant modifications or turnarounds, adjustments can be implemented quickly and cost-effectively—a clear advantage over welded constructions.
For additional information on the construction of the acetylene plant watch the video and look out for the yellow Sikla protective caps in the background!