Prefab construction streamlines Nexus Leiden build

The new Nexus Leiden science building, located in the Leiden Bio Science Park West, has been completed using innovative modular construction methods to minimize disruption and accelerate delivery.

Covering 9,100m² across four floors, the state-of-the-art facility will house laboratories and offices for life science, health, and pharmaceutical research. Due to the site’s limited space in the busy science park, precast concrete and steel modules were chosen, with Mammoet supporting main contractor Dura Vermeer Bouw Zuid West and concrete supplier Holcon BV in the assembly of the structure.

Key challenges included the installation of a steel atrium staircase, 2,400 precast elements, and the absence of external laydown areas. Mammoet devised a just-in-time delivery strategy, coordinating directly with the German factory producing the modules. At peak times, trucks arrived every two hours to keep the construction sequence on track.

A single 250t Kobelco CKE2500 crawler crane, placed at the building’s center, enabled the phased assembly in a U-shaped progression. Detailed lifting plans ensured every element was installed in sequence, akin to assembling large-scale prefabricated furniture.

Early engineering input during FEED proved critical, helping optimize constructability and scheduling. “It was important that we were involved from the outset,” said Frank Melse, Mammoet’s Director Projects Benelux. “Time and space were limited, so everything had to run precisely.”