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Contractors World 2010 Volume 1 Issue 10
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The size of the project required careful formwork planning for the 100 m long section of the lock chamber. The contractors work with Harsco experts in Germany (formerly Hünnebeck), who recommended highly practical, “slimmed-down” solution that perfectly met all the requirements of the project.GERMANY
Formwork solution for major lock refurbishment

The right-hand chamber of the Guttenbach lock on the Neckar River (near Heidelberg), in Germany has been under repair since May 2009.

The concrete structure as well as the steel lock gates and the electrical and control equipment were in much need of a complete overhaul after sixty years of service. The refurbishment project also includes the replacement of the outer concrete shell.

The contractors for the project comprises a consortium of Echterhoff Bau GmbH and Glass Ingenieurbau Leipzig GmbH who first had to remove the crumbling concrete of the lock chamber walls to a thickness of 40 cm, before a new concrete facing shell could be constructed.

The size of the project required careful formwork planning for the 100 m long section of the lock chamber. The contractors work with Harsco experts in Germany (formerly Hünnebeck), who recommended highly practical, “slimmed-down” solution that perfectly met all the requirements of the project.

Instead of a hydraulically powered formwork carriage, the contractors are using a crane-shifted project-specific custom form of timber beams supported by a three-dimensional scaffold.

The structure consists on both sides of an up to 9.5 m high and 17 m long single-face wall form of H20 beams with steel walers, covered with form-ply of 3-ply panels. Harsco’s custom formwork shop has built a total of 483 m² of timber beam wall formwork and supplied it to the site as ready-to-use elements.

     This basic stock of formwork for the standard section is also being used for concreting the up- and downstream ends of The formwork structure consists on both sides of an up to 9.5 m high and 17 m long single-face wall form of H20 timber beams with steel walers - covered with form-ply of 3-ply panels. The shoring between the two wall forms (roughly 12 m inner clearance) consists entirely of system materials to cut costs. ID15 frame supports on their sides (to take up the horizontal pressure) are combined with a kind of cage consisting of Modex modular scaffoldingthe lock chamber. To realize the specific geometry of these end sections, Harsco’s custom formwork engineers have simply added a small number of supplementary formwork elements.

The formwork structure consists on both sides of an up to 9.5 m high and 17 m long single-face wall form of H20 timber beams with steel walers – covered with form-ply of 3-ply panels.
    
The shoring between the two wall forms (roughly 12 m inner clearance) consists entirely of system materials to cut costs. ID15 frame supports on their sides (to take up the horizontal pressure) are combined with a kind of cage consisting of Modex modular scaffolding

The shoring between the two wall forms (approx. 12 m inner clearance) consists entirely of system materials in order to reduce costs. Horizontal ID15 frame supports that take up the horizontal pressure, are connected to a cage like structure of Modex modular scaffolding.

As a result of this combination, a load-bearing three-dimensional frame has been created with some 40 t of scaffold materials that is capable of withstanding the concrete pressure from the 40 cm thick walls.

The advantage is that the two systems can be quickly and easily assembled – an alternative structure of scaffold tubes and couplers would have been much more elaborate to erect.

With this system, after initial instruction and assistance from a Harsco formwork foreman, the men on site were able to assemble the custom structure without difficulty and, on completion of concreting (a total of six pours), to divide it into crane-shiftable units weighing approximately 6 t each.

At this time, virtually the entire lock chamber has been given a new concrete shell.

Harsco

 

 

 

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