Sustainably Impressed

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Sustainable construction should benefit the environment, company, and local residents alike. The award-winning solution at Porsche’s headquarters in Zuffenhausen is a case in point. A visit to the site.

Taking a deep breath is especially gratifying in a forest of birch trees. Strolling across a meadow, glancing up to the treetops, shaking off the stress from the early shift – this must have been more or less what the construction managers at #porsche had in mind when they opted not to cover the ground with concrete for the site extension.

Dr. Christine Lemaitre is also delighted to find a patch of #green at the heart of Porsche’s new Plant 4. The CEO of the German Sustainable Building Council (Deutsche Gesellschaft für Nachhaltiges Bauen – DGNB) has come to Zuffenhausen on a visit. She wants to see for herself how #porsche brings sustainability to life.

Jürgen King, head of construction and facility management at #porsche, shows Lemaitre – who has a PhD in construction engineering – around the premises. Chatting as they stroll, the two have just passed through the birch trees. King explains that – from a purely legal perspective – #porsche could have builton most of the site’s #green area. Instead, management chose to keep the havens of greenery for the employees to recharge their batteries during breaks. Christine Lemaitre nods affirmatively: “Sustainable construction means more than just building with particular materials.” She notes that, here among the birch trees, it does not really feel like she is walking through an industrial area.

Porsche could have used the space. The company is growing, especially in Zuffenhausen, and these days more than 8,500 people work at the main site. More than 200 sports cars come off the assembly line every day. And Mission E is now heralding a new era in sports car engineering: The company is investing some 700 million euros – in a dedicated assembly facility, for example, and extensive modifications to the engine shop for production of electric drives – to build the #porsche that will run purely on electric power. It is a clear sign of commitment to the Zuffenhausen site, and an important signal for the region and for Germany as a center of engineering excellence. In the long run, Mission E will create more than 1,000 new jobs in the area north of Stuttgart.

Which means the company is going to need more space. The ultramodern paint shop, the new body shop being built, the training center, the new engine shop scheduled for completion in 2016 – they all need space. By purchasing additional land, the footprint of the plant has more than doubled since 2011 – from 284,000 to 614,000 square meters.

Growth of this magnitude does not just represent opportunity, however; it also entails enormous responsibility for the site, as both Jürgen King and Christine Lemaitre agree. Any construction does not just affect the company’s management and staff; it also impacts the environment, as well as local residents and road users. #porsche is fully aware of its obligation – and embraces socially and environmentally compatible expansion as a challenge: How can construction be done in a way that ensures everyone benefits?

The two continue on their way toward the new engine shop. As King explains, #porsche is determined to use sustainable construction. But not just as window dressing on a project that is almost done, or in reluctant compliance with the minimum legal requirements. Instead, he says, it will be an essential element in every plan, right from the very start, in keeping with the company’s philosophy. For example, the company taps into new space by efficiently modernizing or replacing old buildings. Using the principles of robust architecture it can even gain additional space with ease later – for example by including additional intermediate floors.

In 2014, the German Sustainable Building Council already acknowledged how successful – and advanced – #porsche has been: The sports car manufacturer was awarded DGNB pre-certification in gold for its planning of Plant 4, making it the first industrial site in Germany to receive this highest accolade. As Jürgen King explains: “For us at #porsche, the meaning of sustainability extends far beyond the ecological aspect. It applies just as much to our employees and our surroundings as a whole.”

For DGNB, sustainability also means accepting responsibility for current problems – such as climate change and the growing shortage of resources – instead of leaving future generations to cope with them. “I see these ideas being put into practice here,” says Christine Lemaitre.

Jürgen King explains that #porsche embraced the philosophy of sustainability from a purely ecological perspective a long time ago. The production plant in Zuffenhausen voluntarily submitted to assessment by the European Union’s eco-management and audit scheme – EMAS – as far back as 1996. In doing so, #porsche was far ahead of its peers in the automobile industry, and is still far from the finishing line.

Porsche has always been eager to push the boundaries of what is technically feasible – and that applies just as much to sustainability in production. The company makes sure resources are used as prudently as possible along the entire value chain. Its environmental and energy management standards rank among the highest. The new Training Center out on the eastern edge of the tour of Zuffenhausen is a good case in point. It houses four energy regeneration systems to make sure the new building has a positive environmental impact and uses 30 percent less energy than specified in the energy efficiency directive issued by the German federal government.

In fall 2015, certification and accreditation body TÜV-Süd also recognized the company’s efforts to ensure the greatest care in using resources wisely and compliance with the highest environmental and energy management standards. Their experts once again certified Porsche’s compliance with ISO 14001 and ISO 50001 at the sites in Zuffenhausen, Sachsenheim, and Weissach.

Another of the top priorities at #porsche – alongside the balance with nature – is the inner equilibrium of its employees. Having reached the new engine shop, Christine Lemaitre glances around the entrance hall with fascination: “This architecture alone creates a very good atmosphere. It will benefit all of the employees.”

The impressive curving staircase, quality of materials and spacious interior –Lemaitre described them as inspiring, and noted that space had been made for people to meet and exchange creative ideas. The construction engineer also approved of the production hall in the new engine shop, which is flooded with daylight: “That is still by no means standard in production – not even today and not even in new buildings. People working in this hall still have a feel for the outside world, the weather, the seasons, and the time of day, all of which are important to their wellbeing.” The fresh air concept – which is as appealing as it is energy efficient – is another high scorer in the eyes of the DGNB CEO, as are the quiet rooms and lounge areas that are spread throughout the plant, and the health center at the center of the site.

Not to mention the good coffee in the new cafeteria where the two stop to rest after their walk. Smiling, Lemaitre says, “It is a social factor one should never underestimate. People spend a large part of their lives at work. They eat there, meet others, learn, and train. Our assessment hinges on ensuring that all endeavors focus primarily on the people.”

Christine Lemaitre and Jürgen King agree that energy efficiency, a pleasant work environment, and room to recuperate are all elements of sustainable construction that benefit employees and the environment alike. King is also aware, however, of what the strongly industrial character of the site and its expansion sometimes means for the local residents: heavy traffic, commuters fighting for parking spaces, noise, or poor air quality. This is why looking after the neighbors on an ongoing basis is one of the responsibilities of construction management at #porsche.

The substantial increase in the number of staff parking spaces is one example of trying to maintain a good relationship: The company’s parking capacity has climbed from 3,100 to 5,700 since 2011. Equally, plans to build a tunnel under the rail tracks to connect with the new engine shop are easing the situation in Zuffenhausen as it means vehicle parts can be transported without using the public roads, thus reducing the traffic load.

As Christine Lemaitre concludes at the end of her visit: “Porsche is a true pioneer when it comes to sustainable construction. This is why #porsche fully deserves to be one of the first companies in Germany to be awarded the pre-certificate in gold for its site in Zuffenhausen.” She also praised the site’s accessibility to public transportation and the frequency of connections, before boarding a regional train to the main rail station – sustainably impressed.