Setting the Pace in Off-Site Construction: Pipelife and Heembeton Create Fully Prefabricated Floor Solution

Off-site construction has opened new opportunities for the building industry, enabling large-scale projects to be commissioned faster than ever before. This year, a 20-story new build in Amsterdam was completed in just 18 weeks, relying on advanced construction solutions like precast concrete wall and floor elements and prefabricated piping systems.

_{Engineering Precast Floor System With Embedded Piping}

Approximately two years ago, Heembeton, a manufacturer specializing in prefabricated concrete wall and floor systems for high-rise buildings, approached Pipelife Netherlands with the proposal to develop hollow core flooring units with integrated plumbing and electrical systems. Both companies had successfully worked together before; thus, joining their expertise for a new solution felt like a logical step forward. 

"In a development process like this, connecting with the right partners is essential," says Erik de Vries, Innovation and Product Manager at Heembeton. "You need specialists from various disciplines — electricity, sewage, ventilation. We deliberately sought out manufacturers who shared our vision for the future of prefabricated construction."

A team of experts assembled to brainstorm, prototype, test and refine ideas, each contributing their unique expertise. Pipelife's know-how in prefabricated electrical setups played a key role, particularly with the Spider system, which has been employed in large-scale projects across the Netherlands and Germany. 

Each Spider solution is individually designed, pre-engineered and assembled under factory conditions, reducing the installation time by up to 75% compared to conventional conduit systems. Once delivered, Spider can be simply rolled out and secured in place, eliminating time-consuming tasks like pulling, cutting, stripping, wiring, and connecting cables and conduits.

"Integrating Spider within precast concrete floors allowed us to create hollow core slabs with added functionality," explains Rob van Hoorn, Electro Category Manager at Pipelife. "Once the floors arrive on-site, installers no longer have to do any wiring, as even complex electrical systems can be fully preassembled within the floor unit."

_{High-Rise Apartment Block Completed at Unprecedented Speed}

The expertise of Heembeton and Pipelife's teams led to the development of precast floor slabs pre-fitted with HVAC, electrical, and soil and waste piping systems.

The first large-scale use of the innovative flooring solution was in the Opportuna residential tower in Amsterdam. The 20-story building, featuring 174 subsidized rental units and a total floor area of 11,000 m2, was an ideal showcase for the speed and efficiency of prefabricated flooring.

Construction of the tower began in June 2024. For the contractor Bot Bouw, this was the first major experience with prefab concrete solutions; however, the team was impressed with the speed gains. 

"While more time was needed for preparation and modeling stages, this investment was more than regained once the construction started. An entire floor of the building could be completed within five working days!" emphasizes Mark Wulf, Superintendent at Bot Bow.

Employing the Spider system was integral to speed up the building process. The electrical installer, Blom Elektrotechniek, and Pipelife's in-house BIM team worked together from the early project stages to identify the most practical layout of conduits and connections. In total, 21,337 meters of conduits were used to create the tower's electrical system.

Daniel Tesselaar, Project Manager at Blom Elektrotechniek, recalls his team's experience with the preassembled electrical setup: 

"Our installers were genuinely thrilled about the outcome. The project moved forward seamlessly, and there was so much peace and quiet on the construction site." 

Choosing precast concrete also eliminated the need for scaffolding. Due to using prefabricated façade elements, flooring and piping systems, the Opportuna tower was completed at an unprecedented speed — in just 18 weeks. 

_{Unlocking New Possibilities in Urban Construction}

The Opportuna residential tower is set to welcome residents by early 2025. Leveraging off-site construction solutions, the project achieved remarkable efficiency, demonstrating how large-scale urban developments can become more time- and cost-effective. 

As demand for sustainable and streamlined construction grows across Europe, prefabricated systems keep setting standards and unlocking opportunities for the building industry. 

"This project represents co-creation at its best, resulting in a comprehensive and integrated solution," says Kees Tinke, Account Manager at Pipelife Netherlands. "Together with our partners, we push boundaries and seek better ways to meet the demands of modern construction, covering everything from design and production to full technical support."