The Nexus Leiden project in the Netherlands stands as a shining example of how prefabricated and modular construction can transform the delivery of large, complex buildings in high-density urban environments. Situated in the heart of the Leiden Bio Science Park West, the 9,100m² Nexus Leiden building brings together laboratories and offices to support cutting-edge research in life sciences, healthcare and pharmaceuticals, all constructed with remarkable efficiency, precision and minimal disruption.
Modular construction enables smart, efficient delivery
For Dura Vermeer Bouw Zuid West, the main contractor on the project, modular construction methods offered a way to overcome one of the site’s biggest challenges: space.
With the Nexus Leiden plot located in one of Europe’s leading science parks, surrounded by active research facilities, traditional construction techniques would have caused significant logistical and operational disruption.
Instead, prefabricated concrete and steel components were manufactured off-site and assembled on-site with the support of heavy lifting specialist Mammoet and concrete supplier Holcon BV. This prefab construction approach not only accelerated the build schedule but also improved quality control and reduced waste, as elements were produced in a controlled factory environment before being transported to the site.
A standout feature of the new building is its steel staircase structure at the centre of the atrium, an architectural and engineering focal point requiring precision lifting and placement within tight spatial parameters.
Overcoming spatial constraints with innovative lifting solutions
With no available area outside the construction zone for cranes or material laydown, the project team had to devise an ingenious engineering and logistics plan. Mammoet’s solution was to position a single 250-tonne crawler crane (Kobelco CKE2500) inside the building footprint, allowing all lifting operations to take place within the site boundary.
This internal crane setup enabled the prefabricated structure, comprising over 2,400 individual components, to be installed in carefully sequenced stages. The building was assembled in a U-shaped configuration, progressing around the crane as it completed each section.
To ensure seamless operations, Mammoet implemented a just-in-time (JIT) delivery system, with trucks arriving at two-hour intervals to deliver pre-cast elements from the German fabrication plant. This precision scheduling minimised on-site storage requirements and maintained the construction timeline.
Early involvement drives project success
A key factor in the project’s success was Mammoet’s early involvement during the Front-End Engineering Design (FEED) stage. This proactive collaboration enabled the engineering team to assess constructability challenges, optimise the critical path and develop a detailed lifting and assembly strategy before construction began.
“It was important that we were involved from the outset,” said Frank Melse, Director Projects Benelux at Mammoet. “We assessed that we would need to assemble the structure from the inside, and in stages. It was equally important for us to understand how we would organise incoming elements and ensure structural integrity during the build.”
By integrating digital construction planning tools, such as 3D modelling and lifting simulations, Mammoet’s engineers were able to visualise and validate each phase of assembly in advance. Every prefabricated component, from steel columns to concrete wall panels, was assigned a unique reference number and lifting plan, allowing for a precise, step-by-step assembly process.
Prefabrication delivers precision and predictability
The Nexus Leiden modular construction project illustrates the broader benefits of prefabrication and digital planning in modern construction. Off-site manufacturing ensures higher precision and better quality assurance, while on-site assembly can be carried out quickly and safely under tightly controlled conditions.
This approach aligns with the construction sector’s growing focus on industrialised construction, sustainability, and resource efficiency. By reducing on-site activity, projects can cut emissions, noise and waste, key objectives for both digital construction and sustainable building design.
At Nexus Leiden, prefabrication enabled the shell structure to be assembled in just six months, approximately 25% of the total two-year build timeline, allowing interior fit-out and commissioning to proceed without delay.
A model for the future of digital and modular construction
While Mammoet is best known for its expertise in heavy lifting and transport, projects such as Nexus Leiden highlight the company’s growing role in modular and prefabricated building assembly. With tight deadlines, confined spaces and the need for precise coordination across multiple stakeholders, the project demanded exceptional engineering and execution discipline.
“There were many parts that needed to be constructed in the right order and with very little space,” Melse added. “We also knew that time was critical. Therefore, it was vital that everything ran smoothly and on time.”
The successful completion of Nexus Leiden demonstrates how digital construction planning, off-site manufacturing and just-in-time logistics can combine to deliver large-scale, technically complex buildings faster, safer and more sustainably.
As cities continue to densify and the demand for high-performance science and technology facilities grows, the prefabricated modular construction approach used at Nexus Leiden offers a compelling blueprint for the next generation of smart, efficient, and resilient buildings.
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