The main challenge in constructing the new hangar lay in complying with building regulations. As permission was granted solely for a replacement structure, the footprint and the curved shape of the original building had to be retained. Unlike the old steel hangar, however, the new one was to be built from timber. To emphasize the industrial architecture aesthetic while conveying a sense of lightness, the architectural firm Smyk Fischer opted for a truss structure. In response, Ripkens Wiesenkämper, together with Marx Krontal Partner, developed a purely timber truss system that, thanks to the use of nearly 600 innovative timber nodes and beams, required no steel at all.

The structural framework consists of fifteen impressive two-hinged arches, each 26 meters high. The top chords and diagonal truss members are integrated into a roof shell made of cross-laminated timber panels. An aluminum standing seam cladding forms the protective outer skin. An extraordinary feature is the huge double-leaf door. To precisely move the massive door wings, each weighing 72 tons, special expertise in handling large movable components was essential. Dr. Schippke + Partner brought this expertise to the project. In collaboration with the hydraulic engineering specialists, they developed a combination of massive hinges and a track system along which the door wings are guided by 80-horsepower electric motors.

The Airship Hangar Mülheim is not only impressive for its unique structure – it is also setting new benchmarks for sustainable construction. By using a total of around 557 tons of spruce timber, approximately 156 tons of CO₂ were saved compared to a lightweight steel structure. At the same time, the building follows the principles of circular construction: both the timber framework and the aluminum exterior skin are 100 percent dismantlable and can therefore be reused or recycled. To support this, all components of the building have been documented in a building resource passport on the Madaster material database. Parts of the hangar are already “second-hand”: the substructure consists of the foundations from the old airship hall, and the floor uses old concrete slabs salvaged from a former logistics center.

Ripkens Wiesenkämper used ALLPLAN for the structural design. To begin with, they created a complete 3D model of the structure, including detailed points such as complex connections and other critical areas. The model was regularly used for clash detection to identify potential conflicts between building components as early as possible. It also served as a basis for precise material and cost estimation. In addition to the structural model for the hangar, the engineers developed a reinforcement model for the hangar’s foundation, which enabled a precise representation of the reinforcement layout and allowed for the direct derivation of formwork and reinforcement drawings. Thanks to cloud-based planning in real time, multiple designers were able to work simultaneously on the same model in ALLPLAN.