Sarens is Proud to be Part of the Bernabeu Stadium Redevelopment Team – Heavy Lift News
17 Feb 2023

Sarens is Proud to be Part of the Bernabeu Stadium Redevelopment Team

It’s one of this century’s most remarkable feats of engineering, and Sarens is honoured to be a part of it: the redeveloped Bernabeu Stadium, home of the legendary Real Madrid football team, is taking shape as one of the most fascinating, complex, and beautiful structures in the world.

As part of a nearly billion-euro renovation project, the world-famous Bernabeu is increasing seating capacity by 4.000, adding 10m of height, and installing a stunning new retractable roof and pitch. And it’s doing it all without disrupting a single game, thanks to a Roman-inspired building approach that allows for construction to continue without interrupting on-field events.

Once completed, Bernabeu will host a variety of spectacles for most days of the year, from business conferences and concerts to tennis matches, basketball games, and of course Real Madrid victories.

PHB Weserhütte, a subsidiary of the Asturian group TSK, was awarded the contract for the industrial pitch automation system as part of the remodeling of the Santiago Bernabéu stadium.

A retractable pitch means that the stadium’s six massive trays of grass turf can be moved underground via a hydraulic elevator, revealing a new concrete surface for a variety of sporting events, concerts, and conferences.

Teaming up with client PHB to work on Real Madrid’s famous stadium, Sarens transported two retractable beams inside the stadium and proposed and developed a new method of statement for jacking and skidding the 650t Hypogeum (huge concrete shaft were the pitch grass trays can be stored) top slab and the 6 trays of grass. Considering the project’s parameters, Sarens recommended and deployed the following equipment, which arrived from several depots by road within 2-3 days:

  • 1 SPMT 8 lines with PPU
  • 16 climbing jacks up to 250t
  • 8 SarSkid skidding lines up to 30m (more than 200m in total)
  • 8 double long skid beams
  • 8 push-pull units up to 25t
  • 16 hydraulic jacks up to 100t and 150mm stroke

As part of this visionary redevelopment project, the Sarens crew operated within an extremely tight schedule, sharing a work area with many other subcontractors at the same time. The crew had to prepare and assemble/disassemble all equipment, plus perform jacking and skidding works, exclusively from the pitch area so as to avoid disrupting the work going on inside of the Hypogeum. They also faced the challenge of working in a busy city environment, which meant that transporting equipment to the site and out presented its own logistical challenges.

However, with the right equipment ready for the job, Sarens performed the jacking and skidding of the Hypogeum’s top steel slab and one of the six massive grass trays with minimum supporting points. This was notable considering the steel slab measured 115m x 13m x 1,5m and weghed 650t. The 6 grass trays meanwhile, weighed 350t and measured 115m x 11,5m x 1m. Each element was jacked up almost 1,5m from 16 points, then skidded nearly 15m with eight skidding lines and double skid beams per line. They were then jacked down nearly 0,5m.

SPMTs also transported two steel retractable beams from outside of the stadium. Each beam measured 15m x 2,25m and weighed 30t. Sarens client had tried bringing these inside via normal means, but the total transport height proved too high to pass through the inner stadium gates. When Sarens got an urgent call on a Saturday morning, they were able to arrange everything without delay so that the SPMTs were ready and on-site by Monday night. Their two SPMT operators managed the small curves as they handled the load, passing through the internal stadium gates and travelling up and down a 17,6% slope.

With seven crew members giving it their all, Sarens executed all operations on time and was congratulated by PHB’s construction director for their performance from start to finish–and especially for solving the site’s issues ASAP so work could be completed on time.

Sarens is grateful to have been part of this iconic project and is cheering on its successful completion as it enters the final phases of construction work. Sarens would like to thank all crew members involved for making it possible, and to our client for entrusting us with such a momentous operation.

Source Sarens and PHB Weserhütte