Kostal Bulgaria Automotive Ltd.


Dipl. eng. Emil Boichev, Dipl. eng. Radostina Bogdanova, ЕТ Bildboi, Plovdiv


Tomov-Trade Ltd.


Archpero Ltd., Arch. Avram Kadzhebov, Arch. Marin Malakov, Arch. Velemira Taneva



The automotive components factory in Pazardzhik is part of the development strategy of the German company Kostal, which is another investment in Bulgaria.
With the first stage of the construction of the enterprise, up to 1200 jobs are opened, thus stimulating the economic development in the region.
The building fund in the property is in fact the former metal Mill Machine Plant - ZMM 'metalik'. After nearly 60 years of operation, the obsolete buildings were removed or partially preserved, and in their place the industrial structure of the new plant was built. The partially preserved buildings have been completely reconstructed, updated and supplemented, and methods for strengthening and bringing the load-bearing structures to today's requirements for the technical characteristics of the constructions have been applied. The construction system of the existing building is a Russian model of prefabricated reinforced concrete elements - foundations, columns, beams, virendeel  beams, roof and wall panels.
The main goal in design and construction can be the creation of a modern high-tech factory, including a closed cycle of production - molding, assembling, qualification and logistics of elements for the automotive industry. A modern production base providing the opportunity to satisfy the needs of the investor and the relevant market as well as improving the environment and extending the life of the buildings.
The role of the design team for the specific task was to analyze, reorganize, develop and complement the existing building fund and infrastructure in the property, taking into account the required technological processes and functions as well as the necessary specific technical infrastructure. To define optimally: the situational, the master plan, the content, the architectural artistic image of the reconstructed buildings and the new buildings as well as the basic technical, economic, technological, functional and planned compositional requirements to the site. In view of the requirement for sustainable design and development, integration of modern design solutions, materials and know-how, consistency and synergy between the different project sections, the project aims at an optimal technical and economic solution for the reconstruction. The introduction of modern safety measures, energy efficiency, process automation, optimization of the costs of natural resources and electricity, creating a favorable and environmentally friendly environment and working conditions is sought after. Appropriate and effective absorption and sizing of built-up areas and volumes is ensured.
The newly built production capacity is located in the city of Pazardzhik, southern industrial zone, district 4. The access is from a main street for the industrial zone (Sinitevska street) from the northeast, as well as from a secondary street from the southeast. The total area of the site is about 52 decares at an altitude of about 205 meters.
Taking into account the existing infrastructure meeting the requirements of the former enterprise and the new design assignment, four main zones are envisaged within the plant.
1. Pre-production zone - the first zone, immediately after the approach to the enterprise from the street "Sinitevska". Includes: car / bicycle personal parking spaces, checkpoints, administrative and sanitary-housed housing, recreation and recreation areas, canteens with sparkling cuisine, training center.
2. Main production area - including the main production and warehouse building in production part and all adjacent service areas.
3. Ancillary production area - including areas for technical infrastructure, auxiliaries and farms.
4. Warehouse area - covering the second half of the main production and warehouse building in the warehouse part and adjacent service areas.
The master plan for the site meets the requirements of the investor for optimal utilization of the terrains, the unimpeded implementation of the transport-logistics function of the plant, compliance with the existing building fond, the terrain specificity and the possibilities for entry-exit portals. A minimum number of points of entry for the site, according to the road and human traffic to and from the plant, is provided, and the functional zoning and site development are accordingly improved. The rate of usability of the territory is increased. The vertical planning is consistent with the main transport flows, the necessary areas for external technological equipment and machines, facilities, buildings. Areas are provided for rest, landscaping, optimal transit and transport routes. All interior factory roads are designed and built according to specific features, parameters and loads, with a view to operating durability and reliability. Buildings are designed to work for disadvantaged people only in the company's administrative corps - due to the nature of work in the warehouse, main production and auxiliary production area. On the first floor of the administrative building are provided sanitary facilities for wheelchair users, as well as a staircase for access of workers or visitors to the second floor of the administrative building.
Regarding the materials, complete renovation, replacement and implementation of modern measures for energy efficiency and durability have been carried out. In the design process and in view of the technical and economic indicators of the developed activities, as well as the construction parameters and characteristics of the main production part, the laying of a completely new roof cover and partial reconstruction of the roof is provided and executed. The intervention includes the elimination of roof lighting windows, and the integration of modern natural light solutions, the necessary smoke and heat removal systems (smoke hatches), the closing of roof openings (partially) in view of excessive sunlight and overheating. A heat-insulation layer of stone wool and a waterproofing membrane is applied throughout the roof. Facade sandwich panels (thermal panels) are put on the facade after the removal of obsolete reinforced concrete composite panels. Floors, walls and ceilings materials are used to meet the specific requirements of production and functions, as well as building regulations and fire safety regulations. A complete static electricity control system has been implemented, including ESD control, hard and wear resistant electrostatic (ESD) flooring and electric grounding respectively.
The administrative corps, which is the "face" of the enterprise, is also completely reconstructed and renovated. The distribution of all premises has been transformed and reinforcing activities have been carried out to bring the respective supporting structure to the modern standards for earthquake protection. Thermo and hydroinsulating layers on the roof, ventilated breathable facade system with layered installation - rock wool, facade lamellas made of plasticized sheet metal, aluminum joinery with opening parts. Color solutions and textures are fully compliant with Kostal company's standards. Granite tiles, pvc and carpet anti-static tiles, terracotta tiles and faience on the walls of sanitary units and changing rooms, suspended ceiling systems are used for flooring.
Systems providing a favorable microclimate and safety in the enterprise include many modern technologies. These include the use of Hoval's decentralized HVAC systems, recuperation air-handling machines, air-conditioning units, heat pump boilers and others. Energy-saving LED lighting, building automation, complete CCTV and access control, fire detection and automatic fire extinguishing systems and others related to the specifics of production are installed. In the construction of the plant and the optimization of the performance main roles have the companies "Tomov-Trade", "Kiprida", "Andi", "Tempex", "Filkab", "Sament", "Zavodski stroeji", "Sectron" , '' Kontraks''.