Xanadú Shopping and Leisure Centre

The Xanadú Snow Park, located in Arroyomolinos (Madrid), was conceived as one of Europe’s largest retail and leisure developments, incorporating what was, at the time of construction, the largest indoor ski slope on the continent. The project covered a total area of 168,000 m², integrating retail, leisure and entertainment facilities together with extensive parking infrastructure. From a structural perspective, the development was characterized by large reinforced concrete areas and the need to optimize construction processes in order to meet particularly demanding project schedules

The structural scheme comprised isolated pad foundations, perimeter retaining walls, diaphragm walls and a two-level structural arrangement. The first floor was designed as a solid reinforced concrete slab, while the upper level incorporated a steel structural system. The project included approximately 40,700 m² of solid reinforced concrete slabs and required the fabrication and installation of more than 3,000 tonnes of reinforcing steel

ERSIGROUP participated in the supply, fabrication and installation of reinforcement steel, implementing an advanced industrialized reinforcement strategy. Following a detailed engineering review of the structural drawings, it was proposed that approximately 70% of the reinforcement works should be prefabricated off-site. This included foundation mats, column starter cages, prefabricated column reinforcement cages, perimeter ground beam reinforcement and retaining wall foundation reinforcement. The remaining wall and diaphragm wall reinforcement was assembled directly on site

One of the most innovative aspects of the project was the use of 6.0 m × 2.3 m welded reinforcement panels for both the top and bottom reinforcement layers of the slabs, replacing a significant portion of conventional reinforcement installation methods. Combined with prefabricated reinforcement assemblies and industrialized formwork systems based on movable tables and travelling formwork units, this solution enabled the project team to double production rates, completing all reinforcement works within only eight months

The rationalization of reinforcement design and the implementation of industrialized fabrication and preassembly processes developed by ERSIGROUP played a decisive role in reducing construction time, optimizing costs and ensuring the highest standards of quality, productivity and traceability throughout the execution of the structure

KEY MILESTONES:

• 168,000 m² retail and leisure complex developed as one of Europe’s largest commercial destinations
• Construction of the largest indoor ski slope in Europe at the time of completion
• More than 40,700 m² of solid reinforced concrete slabs
• Over 3,000 tonnes of fabricated and installed reinforcing steel
• 70% of the reinforcement works prefabricated off-site
• Fabrication of foundation reinforcement mats, column starter cages, prefabricated column cages, perimeter ground beams and retaining wall foundation reinforcement
• Use of 6.0 m × 2.3 m welded reinforcement panels for the top and bottom reinforcement layers of concrete slabs
• Implementation of industrialized reinforcement fabrication and preassembly processes developed by ERSIGROUP
• Production rates doubled through reinforcement rationalization and industrialized construction methods
• Completion of all reinforcement works within 8 months