Formworkpress

Formwork News News for for Professionals Professionals Formwork II/2013

International Panorama
A Look at Sites across the World . . . . . . . . . . . 2 Practical Tip

Strong Support
Shoring Tower Space for High Walls . . . . . . . 11

Superlative Geometries
University of Economics & Business, Vienna . . . 4

Working Tools Online

Concrete Pressure Calculation . . . . . . . . . . . . 12

Top Finish, High Pressure

Recycling Center Zingg in Tbach, St. Gallen . 8

Welcome!
Invitation to bauma 2013 . . . . . . . . . . . . . . . 12

Complex and from A to Z

Hotel Complex Complete in 9 Months . . . . . 10

Zaha Hadid

Formworkpress
II/2013

MEVAs International Panorama

p New Haven, Connecticut, USA As part of the Truman School project in Connecticut, O&G Industries constructed an overflow tank to aid New Haven with storm water overflow. The project used a MEVA STB single-sided system and the heavy-duty formwork system. The support frame STB and wall formwork panels handled the recommended pour rate and exceeded the contractors expectations for onesided concrete placement. The 8 m high walls were dry-tied at the top, with short rails to clamp the STB. t Bradford College, Bradford, Great Britain MEVAs heavy-duty wall formwork Mammut 350 on the climbing platform KLK is being used to build the new Bradford College campus. Contractor is GRKC LLP. The engineering solution was provided by the MEVA Formwork team in Tamworth, Staffordshire, Great Britain. One of the reasons for choosing MEVA formwork is the 100% wood-free, all-plastic facing alkus that is easy to clean and makes re-facing completely redundant. u Wellness Centre Hagymakum in Mako, Hungary MEVAs StarTec wall formwork system and the shoring system MEP helped to build this new wellness centre in the Hungarian town of Mako. Contractor was Keviep Kft. of Debrecen.

FormworkPress II/2013

u Condominium, Surferss Paradise, Queensland, Australia This commercial and residential tower with 77 levels, 288 appartments and 40 shops is being built in Surfers Paradise on Queenslands Gold Coast. Once again, it was the MevaDec slab formworks capacity to achieve a 3-dayper-slab cycle that made the selection of the right system clear from the start for the contractor Grocon Pty Ltd of Melbourne. The all-plastic, 100 % wood-free facing in the MevaDecs light-weight panels means that no down-times have to be taken into account because the facing never has to be replaced. That saves time and money, speeds up work flow and ensures a high-quality concrete finish from the first pour to the last.

FormworkPress II/2013

Formworkpress
II/2013

Zaha Hadid

A model showing the inside of the Library & Learning Center (LLC) with so-called canyon walls. The name originates from the walls asymmetric geometries with different slanting angles and varying heights over several storeys. The impression reminds one of a natural canyon. Shown left: a canyon wall after the formwork has been stripped.

University of Economics and Business, Vienna

Superlative Concrete Geometries

The Making of Exceptional Concrete Architecture
Viennas new faculty of economics and business campus was designed by the internationally acclaimed and prizewinning Zaha Hadid Architects. The universitys architectural highlight is the Library & Learning Center. Its architecture is breathtaking, its construction a masterpiece of engineering. And the formwork solutions required to pour the unusual designs a true challenge for MEVAs engineers at headqarters in Haiterbach and in MEVAs Vienna offices. The task was to design formwork for irregular, asymmetric and constantly changing concrete geometries; to achiev a high-quality, even, smooth concrete finish throughout and get the job done within a reasonable budget. Experience, know-how, creativity and inventiveness, precision and clever planning were the most important tools. To describe the process, we let the photographs express what words could hardly do.

The all-plastic, 100 % wood-free facing alkus can be bent and shaped to create special forms. In this way, reliable architectural results can be achieved from the first pour to the last.

FormworkPress II/2013

Above and right: Each of the five cores has a different shape and requires a unique formwork design. All of these forms are equipped with rough boards to achieve the board imprint. Also refer to photos at right bottom and on the following page.

Different Cores
The five cores of the LLC have different and varying shapes. Differently slanted walls and corners rounded to different and varying radii made the forming task even more complex. Each pour needed its own form design, requiring a large number of different formwork solutions. MEVA delivered a practical answer that enabled engineers to take account of different geometries and do so within budget constraints. To do so, special designs were combined with standard panel sizes to minimize the time and effort for custom-made forms.

Continued on page 6

The board imprint: The ends of the core walls slant at different angles and the architects wanted the board imprint lines to run parallel to the slant. The adaptation to different angles was achieved by fanning-out filler boards that remain invisible to the eye.

FormworkPress II/2013

Formworkpress
II/2013

A typical inlay with the sharp edges required by the architects. These were achievable because the all-plastic facing alkus can be precision-cut and doesnt loose its shape with an increasing number of pours. Using wooden facing would not have worked.

Architectural Concrete alternating between Board Imprint and Smooth Inlays

The core walls stay exposed and require a high-quality, even concrete finish throughout. The board imprint is contrasted frequently with smooth inlays, for instance around door and window openings. To achieve them, normal all-plastic alkus facing boards were precision-cut to size and welded together a unique feature of the alkus facing to achieve the desired geometry. This allowed different shapes and sizes to be achieved with a perfectly smooth, even concrete finish.

As board imprint and inlays alternate shown in the photograph below left it was essential to plan each formwork design and pour workflow carefully. MEVA engineers came up with the idea of mounting all-plastic facing for the smooth inlays directly onto the wooden boards. This made handling easier.

FormworkPress II/2013

A view of the formwork shows the dynamic, varying geometries of the canyon walls. In order to save costs, standard wall formwork panels were used wherever possible, complemented by special designs developed and manufactured in MEVA facilities in Haiterbach.

The Canyon Walls

The canyon walls are located between the cores of the LLC. They consist of balustrades and beams. Their significant characteristic is that they are slanted and rounded at different angles and radii. A careful 3D-planning preceded custom-manufacturing of the specially designed formwork units.

One of the distinguishing features of the all-plastic facing alkus is that it can be bent and shaped without any structural disadvantages to achieve the different shapes and bends as with this exceptional building project. Here, a thin version of the facing board is laid on a lattice construction like a carpet.

FormworkPress II/2013

Formworkpress
II/2013

Top Concrete
Zingg is a waste disposal specialist for industrial, commercial and household clients. To increase its performance, the recycling center built in 2001 required a new sorting hall. Contractor STUTZ and Gautschi chose MEVA formwork for all concrete pours and reported a successfull project. The new 1,800 m sorting hall has a height of 16 m. The concrete walls, 8m high, carry a steel construction with a large transparent facade that allows daylight into the halls to save lighting costs. The design of the new building is functional and straight-forward to match the existing centre. Large forming areas for quick crane-ganging High walls and large concrete areas typical in industrial construction are home ground for the Mammut 350 wall system with its large panels and high concrete load capacity. 267 m of formwork were pre-assembled to form three large-sized forming units, each 10 m long and 8.25 m high. While one pour using two units was in progress,

Recycling Center Zingg in

Finish, High Pressure

Tbach, St. Gallen, Switzerland: Architectural Finish
the third unit was employed for rebar works for the next pour. Crane-ganging complete large-size forming units from one pour to the next saved much time. Quick concrete pours on high walls with optimum worker safety High walls include the risk of high concrete pressure, requiring robust formwork panels to enable fast pours. The Mammut 350 has a load capacity of 100kN/m, unsurpassed among panelised formwork systems. This means that concrete can be poured without any limitations to speed up to a height of 4m. For the Zingg site, this meant that the walls could be poured in a mere 90 minutes. To be on the safe side, the supervisor decided to attach pressure gauges on the panels with which the concrete pressure can be monitored continuously throughout each pour. The monitoring results proved what was expected: Mammut 350 stood firm throughout. Architectural finish: symmetrical joint and tie-hole layout The architects defined a high-quality concrete finish. The all-plastic facing in all MEVA systems delivered this quality first time, every time. In addition, the Mammut 350 panels leave a perfectly symmetrical tie hole and joint pattern, emphasizing the architectural concrete finish. The Mammut 350 exceeded our expectations, concluded site supervisor Claudio Zulian and his formwork teams.
Pressure gauges on the panels allowed the supervisor to monitor the concrete pressure during every pour.

PROJECT DATA
Project Waste sorting hall Client Zingg Industrieabflle AG, Tbach, St. Gallen, Switzerland Contractors n STUTZ AG, St. Gallen n Gautschi AG, St. Margrethen MEVA System Wall formwork Mammut 350 Formwork Engineering MEVA Formwork Systems, Seon, Switzerland

Formworkpress
II/2013

Ground floor walls being poured with Mammut 350 wall formwork.

Complex, complete from A bis Z

Concrete works on hotel complex completed in 9 months with 8 MEVA Systems
A new luxury and a standard hotel with 330 and 205 rooms are being built next to the main entrance of Munichs expo facilities. Both hotels are located in one complex to be opened for business in the autumn of 2013. Scheduling was tight, leaving only 9 months for building works on the 8-storey complex with a layout of 132x59m. This required careful planning with foresight. In the early quotation phase, MEVA developed a detailed plan for quick work flow, inventory and formwork supplies. The MEVA engineers were challenged to provide a static concept, starting with a cost-effective method of pouring the floating ceiling for the conference room. Other work flow tasks included exact detailing for shoring and back-propping as well as precise timelines for formwork assembly and stripping. In addition, loads exerted by the prefabricated bathroom units weighing around 5 tons had to be accounted for. Floating ceiling for conference room The conference room on the ground floor measures 29.50 x 14.80 m and has a floating ceiling at 5.70 m height.
10

MEP shoring towers with single props connected with bracing frames were perfect for the job. MEP 450 and 300 props were connected to square tower units, 110 cm wide. Walls extended through two levels are designed to carry the slab and the MEP shoring tower was employed to take up these loads also. Formwork could be stripped as soon as the slab above the second level reached the 28 day setting time. For static reasons, bracing through to the foundation slab was required. Different wall heights The basement floors are 2.80 m and 3.70 m high, the ground floor 5.70m and the upper levels 2.85 m. Mammut wall formwork with its 97kN/ m load capacity was used to pour the walls, allowing rapid pours and saving time in the tight work schedule. Round walls and columns The popular circular formwork system Arcus achieved a superior finish on the rounded walls of the parking garage access ramp. Only two sets of the foldable mobile column formwork CaroFalt with basic heights of 360 and 270 cm plus a 120 cm extension were needed to complete all columns at a rate of one per day. The circular columns were

formed with the steel column formwork Circo that provides a continuous first class concrete finish on columns with diameters between 30 and 70 cm. Slabs and beams Beams measuring up to 2.60 m in width and 1.10m in thickness were poured before the slabs. This was done with 125 cm Mammut panels set horizontally. In inaccessible areas where all tasks had to be done by hand, the light-weight hand formwork EcoAs took over. Because of the beams, all slabs above the basement and ground floors, 30 to 45 cm thick, were poured using the conventional MevaFlex wooden girder method. Safety and time-saving solution achieved with special designs From the first floor upwards, the slabs float on concrete edge beams. A custom-made solution provided the answer: slab edge tables measuring 3.90 x 3.70 m and made of MEP shoring towers. The tables acted as a support grid and were assembled without facing. They were equipped with a working platform on the front and a safety railing that provided optimum worker protection. The tables were lifted as a complete unit using a transFormworkPress II/2013

Ground level: MEP shoring towers ready to take the load of the slab formwork needed to pour the floating slab above the conference room.

port spreader from one level to the next, saving assembly time. On building sections with outer walls, the folded working plattform KAB 190 provided a safe working situation. Where necessary, the Mammut wall panels were placed on the 190 cm wide platform. Cantilevering parts interrupt the facade on the southern and northern side. In order to ensure worker safety, a shoring tower with prop frames was used.

PROJECT DATA
Project Hotel complex next to the Munich expo fairground Contractor Baresel GmbH, Munich Branch MEVA Systems n Wall formwork Mammut n Hand-set formwork EcoAs n Circular formwork Arcus n Column formwork CaroFalt n Circular column formwork Circo n Slab formwork MevaFlex n Shoring system MEP n Working platform KAB 190 Formwork Engineering MEVA Formwork Systems, Munich Branch

Strong Support
Shoring Tower Space plus Triplex Heavy-Duty Braces
How do you support a 22 m high and 48 m long warehouse wall, where the slab that would provide cross bracing is to be poured later? Conventional solutions with pushpull props and support foundations are too time-consuming and insecure because the prop length would not withstand high wind velocity. The shoring tower Space is a safe and cost-effective alternative. It consists of 3 m steel lattice units arranged in a square base layout of 4.80 m. The tower units are pre-assembled on the ground. Extensions of 50 or 100 cm can be inserted to adjust the tower height. The towers are fixed to the ground using heavy duty anchors. Four Space shoring towers, 18 m high, were supported on this project by two 10 and 16.80 m long Triplex heavy-duty braces.

PROJECT DATA
Project Warehouse for car manufacturer Contractor Klebl GmbH, Neumarkt, Germany MEVA Systems n Shoring tower Space n Heavy-duty braces Triplex Formwork Engineering MEVA Formwork Systems, Munich branch

FormworkPress II/2013

11

MEVA SchalungsSysteme GmbH, Industriestrae 5, D72221 Haiterbach PSdg, Deutsche Post AG, Postage paid, E 42057

Formworkpress
II/2013

The site photos show situations which do not always depict the final assembly of the formwork with regard to safety regulations. Imprint: Edition II/2013. Circulation: 3000 copies. Publisher: MEVA SchalungsSysteme GmbH, Industriestr. 5, D72221 Haiterbach. Layout: Marketing Dept. Print: C. Maurer Druck + Verlag, D-73312 Geislingen/Steige. Reprint and re-use of any editorial content only by copyright permission. We accept no liability for the content of external internet sites, nor for a violation of privacy or any other law arising from these.

Working Tools Online Welcome!

We look forward to your visit MEVA stand in Hall A2, Munich expo, from 15 to 21 April 2013. Reach us via Entrance West, take the Atrium directly to Hall. Well keep you posted! meva-international.com offers a wide range of documentation and working tools that are constantly updated. Go to the download section to find product information, parts lists, all technical instruction manuals as well as tools for calculating concrete pressure on wall formwork and for working out reshoring / backpropping for slab pours. You are not required to register and the download is free of charge. www.meva-international.com www.meva.de [at, ch, fr, hu, nl, ro, ru]

Hall A2 15.-21.04.

MEVA Schalungs-Systeme GmbH Industriestrasse 5 D-72221 Haiterbach Tel. +49 7456 692-01 Fax +49 7456 692-66 info@meva-international.com www.meva-international.com

A-Pfaffsttten, Tel. 02252 20900-0 AUS-Adelaide 08 82634377 B-Kruibeke, Tel. 03 250 11 11 CHSeon, Tel. 062 7697100 CO-Columbia, Tel. 01 5204236 FSarreguemines, Tel. 0387 959938 GBTamworth, Tel. 01827 60217 HBudapest, Tel. 01 2722222

IND-Mumbai, Tel. 022 27563430 LT-Kaunas, Tel. 0684 82795 MAL-Perak, Tel. 12 5209337 N-Oslo, Tel. 067 154200 NLGouda, Tel. 0182 570770 PA-Panama City 507 2372222 PL-Bialystok, Tel. 085 6768159 ROBucuresti, Tel. 021 2066460

RUSMoskva, Tel. 495 7813737 RUSSankt-Peterburg, Tel. 812 6802890 SGP-Singapore, Tel. 67354459 SLO-Petrovce, Tel. 03 7131500 UAEDubai, Tel. 04 3411180 USASpringfield, Tel. 937 3280022

2434 GB 3000 2/13 M, Printed in Germany