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2010 Volume 1 Issue 3
 
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[GERMANY - Complex formwork solutions . . . .cont]

In terms of the formwork required, the construction of the parking garage helices (inner cylinder 10 m) with their parallel entrance and exit lanes is extremely exacting.

In terms of the formwork required, the construction of the parking garage helices (inner cylinder 10 m) with their parallel entrance and exit lanes is extremely exacting.

 

 

 

The choice of formwork systems has been dictated not only by the need for an extra smooth surface, but also by a rigidly defined pattern of joints and ties.

The formwork systems employed consist of large-area elements (based on H 20 timber beams) which Harsco Infrastructure has prefabricated and supplied ready-for-use to the construction site.

For every single wall surface, the project developers have designed the required formwork elements, drawn elevations and submitted the tie and joint pattern to the architects for approval. The outcome of this elaborate formwork planning process is over 150 elevation, fabrication and assembly plans in A0 format to ensure that all the concrete surfaces are constructed precisely as desired.

As a result of the teamwork, the fabric constructors under the supervision of Züblin senior foreman Rainer Knödler have been achieving the demanded high quality and also complied with the narrowly defined deadlines.

Formwork elements for Class 3 fair-face concrete

The central demand for the straight wall surfaces (façade and staircases) is the creation of a continuous joint through all parts of the building (top edge at 2.77 m). However, this is only possible with elements of entirely different heights, varying from 2.5 to 6 m. The central demand for the straight wall surfaces (façade and staircases) is the creation of a continuous joint through all parts of the building (top edge at 2.77 m). However, this is only possible with elements of entirely different heights, varying from 2.5 to 6 m.

Because no infill strips are allowed, the formwork elements had to be additionally constructed with customized widths. The formwork elements are lined with a plastic ply, with a preferred panel size of 1.5 x 3 m. During the placement of the outer wall, another special factor to be considered was that the façade is perforated.

Harsco Infrastructure is also responsible for the precision fabrication of the window blockouts required during pouring. Once they are installed in the fair-face concrete formwork on site, concrete placement can start.

Another highly challenging formwork task is the construction of the helical parking garage ramps (inner cylinder diameter 10 m) with their parallel entrance and exit lanes. This is another case for custom-built large-area formwork elements, but this time curved ones made of H 20 beams and perimeter planking.

The 3.5 m high formwork stands on a folding scaffold and climbs in three lifts. The projecting 3.8 m wide ramp lane slabs are being shuttered with Topflex timber beam slab formwork and poured in parallel in a staggered process.

For the underside of the ramp lanes and for the entire helix, Class 3 fair-face concrete is demanded. The soffit, for instance, has a radial pattern. The Harsco Infrastructure custom formwork department has supplied precision-cut formply for this.

The all-round curved parapet adopts and continues the radial pattern of the underside of the slab and thus demands further custom formwork.

Overall, Harsco Infrastructure has supplied 110 custom formwork elements (600 m²) in 30 different variations for the curved fair-face concrete structures.

With over 75 percent of the cast-in-situ parts of the complex completed on time, Züblin project manager Stefan Sigler says “We're making good progress and the quality is excellent as well."

Harsco Infrastructure


 
 

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