The power of system integration in the renovation of the Krammer lock complex

The renovation of the Krammer lock complex is one of the most extensive hydraulic engineering projects at the moment. The complex, located between the sweet Volkerak and the salty Oosterschelde, plays a crucial role in shipping, road traffic and water management in the Netherlands. With four lock chambers for commercial and recreational shipping, a movable bridge and a unique function in the fresh-saltwater separation, this is the largest concrete complex in the Netherlands. 
"Since the commissioning of the Krammer lock complex in 1987, much of the technical infrastructure has become very outdated," begins Wout van Tol, Manager System Integration. "In the coming years, almost all installations will be renewed: from electrical systems to hydraulics and mechanical engineering. The complexity is not only in the size, but especially in the need to carry out the work while the complex remains in use. More than 66,000 ships pass through here every year, it is part of an important international shipping route."

Integral coherence

The implementation is in the hands of the ZEEKR consortium, a joint venture between main contractor BESIX Unitec, Croonwolter&dros, Demako, Iemants and Bosch Rexroth. "ZEEKR is a reference to certainty in time, integration and connection with the environment and shipping," explains Van Tol. The multitude of disciplines requires tight control and an integrated design process in which all components fit together seamlessly. This integral coherence is monitored by the system integration team, in which INNOCY also plays a central role. "Together with the design teams, we ensure that all disciplines – from machine safety and cyber security to RAMS and design – are brought together in one coherent design," says Thijs van den Eerenbeemt, RAMS engineer at INNOCY. "We are a connecting factor between all design teams. We look across the board, pierce right through the disciplines and, together with the design teams, ensure that the pieces of the puzzle fall together in the right way."

"With their pragmatic and life-cycle-oriented approach, INNOCY already delivers added value in the preliminary design. It results in designs that are optimized for risks, costs and performance, such as hinterland protection and continuity of the waterway."
- Wout van Tol, Manager System Integration ZEEKR

Lifecycle-oriented approach

INNOCY thinks along with you about the entire life cycle of the complex. Not only about the design phase, but also about operation and maintenance. "By making smart choices at an early stage, a lot of time, money and energy can be saved later on. That is also the reason why we involve maintenance at an early stage," explains Thijs. "This way we avoid having to make expensive adjustments or parts proving difficult to maintain." INNOCY helps to make conscious trade-offs in choices between robustness, maintainability and price. "That combination of broad technical knowledge, experience with this kind of complex and large-scale work and independent management is scarce," Van Tol knows from experience. "With their pragmatic and life-cycle-oriented approach, INNOCY already delivers added value in the preliminary design. It results in designs that are optimized for risks, costs and performance, such as hinterland protection and continuity of the waterway."

"By realizing a balanced robust and maintenance-friendly design, the safety, availability and maintainability of the complex are optimally designed." - Wout van Tol, Manager System Integration ZEEKR

Steel giant

The renovation of the Krammer lock complex will run until the end of 2028, after which another three years of maintenance will follow. The first lock gate, a steel giant of 26 meters long, 4 meters wide, 12 meters high, was taken to the Smulders shipyard in Vlissingen in October for overhaul. "Each door is then tackled in phases in a rhythm of 26 weeks per door," explains Van Tol. During the renovation, the system must continue to function, which makes the need for integral coordination even greater. According to both gentlemen, the project is unique in its kind. "A work of this size, with so many installations and disciplines at the same time, does not often occur in the Netherlands," says Van Tol. The added value of system integration lies in preventing failure costs and increasing reliability. "By realizing a well-considered robust and maintenance-friendly design, the safety, availability and maintainability of the complex will be optimally designed."

The renovation of the Krammer locks is part of Rijkswaterstaat's broader renewal task. Many roads, bridges, locks and viaducts in the Netherlands were built decades ago and are being used more and more intensively. By maintaining and strengthening them now, we ensure that everyone can continue to travel safely, smoothly and reliably – also in the future.