### FOUNDATION WORKS
We are currently constructing a production and warehouse hall for Aerometal in Sóskút, where the foundation works are now underway. What we can currently see are the monolithic concrete foundation blocks that will later support the steel columns and transfer the structural loads into the subsoil. In this case, pits measuring 2x2 meters in width and 1.3 meters in depth need to be filled.
The process begins with concrete mixers filling the excavated pits with concrete. During pouring, immersion vibrators are used to compact the concrete and eliminate air bubbles that could otherwise reduce the strength of the foundation blocks. Before the excavation is fully filled, formwork is installed to ensure perfectly straight sides for the pad foundations, while laser measuring equipment is used to precisely set the required level. Once everything is accurately aligned, the surface is finished smooth. A total of 117 foundation blocks are required to ensure the building stands on a stable structural base. The concrete foundations reach the required strength after approximately 21 days, allowing the steel structure assembly to begin.
ANCHOR BOLT INSTALLATION
At our Sóskút construction site, the installation of anchor bolts has now begun in preparation for the steel structure erection. The process starts by accurately measuring and marking the bolt locations on the foundation blocks according to the construction drawings. This is followed by drilling holes to the required depth, ensuring sufficient long-term structural stability.
Dust and debris generated during drilling would reduce both the effective depth and bonding strength, so the holes are thoroughly cleaned using brushes and compressed air. Adhesive is then injected into the holes to securely bond the threaded rods into the concrete. Immediately afterward, the threaded anchor rods are installed and precisely aligned to ensure they protrude uniformly from the concrete surface, as these will later support the base plates, washers, and nuts of the steel columns.
At the same time, cranes are already unloading the steel components into their designated assembly areas. Once the adhesive has fully cured, the erection of the structural steel sections can begin.
STEEL STRUCTURE ERECTION
Our Sóskút project has now reached the steel structure assembly phase — one of the most visually impressive stages of construction. Here are five reasons why steel structures are an excellent choice for industrial construction projects:
1. Steel structures consist of prefabricated modules that are easy to transport and quickly assembled on-site.
2. Steel structures are generally lighter than reinforced concrete structures of similar size.
3. Steel systems can be more easily modified or expanded during different phases of the project.
4. Steel structures are ideal for time-sensitive projects where fast completion is essential.
5. Steel is highly recyclable, and steel structures can be dismantled and reused, reducing construction waste and environmental impact.
In practice, the steel elements are first placed into their designated assembly areas. Based on the assembly drawings, the structural elements are then connected step by step. The columns form the primary load-bearing framework of the building and must be installed with exceptional precision. Small leveling plates are used to ensure perfectly vertical alignment.
The spatial stability of the structure is further reinforced through elements such as cross bracing and compression members. Thanks to the expertise of both the structural engineering team and the construction crew, every hall we build receives the necessary reinforcement systems to withstand demanding structural conditions. This particular steel structure was completed in only three weeks.
FIRE PROTECTION COATING
Fire protection coating plays a crucial role in increasing the fire resistance and overall safety of steel-structured buildings. The steel surfaces are first thoroughly cleaned of contaminants, grease, and corrosion while the condition of the steel is carefully assessed. A corrosion-resistant primer layer is then applied to protect the steel and ensure proper adhesion of the fire protection coating.
The intumescent fire protection paint is applied in multiple layers, with the number and thickness of the layers determined by the required fire resistance rating and the critical temperatures specified by the structural engineering design for each steel section.
When exposed to heat, the fire protection coating expands and forms an insulating layer that protects the steel from direct heat exposure. This significantly slows down the heating process and extends the amount of time before the steel loses its structural integrity during a fire.
The coating forms a thin and aesthetically discreet surface, preserving the architectural appearance of the building. Additionally, fire protection layers are easy to maintain and repair in case of damage or wear.
Overall, fire protection coating is one of the most important and cost-effective methods for increasing the durability, fire resistance, and safety of steel structures.