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FormworkpressFormwork News for Professionals II/2013Formwork News or Proessionals

Formworkpress

International PanoramaA Look at Sites across the World 2

Superlative GeometriesUniversity of Economics & Business, Vienna 4

Top Finish, High PressureRecycling Center Zingg in Tbach, St Gallen 8

Complex and from A to ZHotel Complex Complete in 9 Months 10

Practical Tip

Strong SupportShoring Tower Space for High Walls 11

Working Tools OnlineConcrete Pressure Calculation 12

Welcome!Invitation to bauma 2013 12

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FormworkPress II/20132

MEVAs International Panoramap New Haven, Connecticut, USAAs part of the Truman School project

in Connecticut, O&G Industries con-

structed an overow tank to aid New

Haven with storm water overow. 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 one-

sided concrete placement. The 8 m

high walls were dry-tied at the top,

with short rails to clamp the STB.

t Bradord College, Bradord,

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.

uWellness 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.

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u Condominium, Surerss

Paradise, Queensland, Australia

This commercial and residential towerwith 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-day-

per-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 panelsmeans 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 ow

and ensures a high-quality concrete

nish from the rst pour to the last.

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University of Economics and Business, Vienna

Superlative ConcreteGeometries

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

The Making of Exceptional Concrete Architecture

Viennas new faculty of economics and

business campus was designed by the

internationally acclaimed and prize-

winning Zaha Hadid Architects. The

universitys architectural highlight is

the Library & Learning Center. Its archi-

tecture 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

ofces.

The task was to design formwork for

irregular, asymmetric and constantly

changing concrete geometries; to

achiev a high-quality, even, smooth

concrete nish 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 canbe bent and shaped to create special forms. In thisway, reliable architectural results can be achievedfrom the rst pour to the last.

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Different Cores

The ve 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.

Above and right: Each of the ve cores has adifferent shape and requires a unique formworkdesign. All of these forms are equipped withrough boards to achieve the board imprint. Alsorefer to photos at right bottom and on the follow-ing page.

The board imprint: The ends of the core wallsslant at different angles and the architects wantedthe board imprint lines to run parallel to the slant.The adaptation to different angles was achievedby fanning-out ller boards that remain invisibleto the eye.

Continued on page 6

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Architectural Concrete alternating between Board Imprint and Smooth Inlays

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

The core walls stay exposed and

require a high-quality, even concretenish 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 boardswere 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 aperfectly smooth, even concrete nish.

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 doesntloose its shape with an increasing number of pours. Using wooden facing would not have worked.

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The Canyon Walls

One of the distinguishing features of the all-plastic facing alkus is that it can be bent and shaped with-out any structural disadvantages to achieve the different shapes and bends as with this exceptionalbuilding project. Here, a thin version of the facing board is laid on a lattice construction like a carpet.

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

The canyon walls are located between

the cores of the LLC. They consist ofbalustrades and beams. Their sig-

nicant characteristic is that they

are slanted and rounded at different

angles and radii. A careful 3D-planningpreceded custom-manufacturing of the

specially designed formwork units.

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8

Top ConcreteRecycling Center Zingg in

Zingg is a waste disposal special-

ist or industrial, commercial and

household clients. To increase

its perormance, the recycling

center built in 2001 required a

new sorting hall. Contractor STUTZ

and Gautschi chose MEVA orm-

work or all concrete pours and

reported a successull project.

The new 1,800 m sorting hall has a

height of 16 m. The concrete walls, 8 m

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 orming areas or

quick crane-ganging

High walls and large concrete areastypical 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,

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Finish, High PressureTbach, St. Gallen, Switzerland: Architectural Finish

Project

Waste sorting hall

Client

Zingg Industrieabflle AG,

Tbach, St. Gallen, Switzerland

Contractors

nSTUTZ AG, St. Gallen

n Gautschi AG, St. Margrethen

MEVA System

Wall formwork Mammut 350

Formwork Engineering

MEVA Formwork Systems,

Seon, Switzerland

PROJECT DATA

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 saety

High walls include the risk of high

concrete pressure, requiring robustformwork panels to enable fast pours.

The Mammut 350 has a load capac-

ity of 100 kN/m, unsurpassed among

panelised formwork systems. This

means that concrete can be poured

without any limitations to speed up to

a height of 4 m. 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 through-out each pour. The monitoring results

proved what was expected: Mammut

350 stood rm throughout.

Architectural fnish: symmetrical

joint and tie-hole layout

The architects dened a high-quality

concrete nish. The all-plastic facing in

all MEVA systems delivered this quality

rst time, every time. In addition, the

Mammut 350 panels leave a perfectly

symmetrical tie hole and joint pattern,

emphasizing the architectural concrete

nish.

The Mammut 350 exceeded our

expectations, concluded sitesupervisor Claudio Zulian and his

ormwork teams.

Pressure gaugeson the panelsallowed thesupervisor to

monitor theconcrete pressureduring everypour.

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A new luxury and a standard hotel

with 330 and 205 rooms are beingbuilt next to the main entrance

o Munichs expo acilities. Both

hotels are located in one com-

plex to be opened or business in

the autumn o 2013. Scheduling

was tight, leaving only 9 months

or building works on the 8-sto-

rey complex with a layout o

132 x 59 m. This required careul

planning with oresight.

In the early quotation phase, MEVA

developed a detailed plan for quick

work ow, inventory and formwork

supplies. The MEVA engineers were

challenged to provide a static concept,

starting with a cost-effective method

of pouring the oating ceiling for the

conference room. Other work ow

tasks included exact detailing for

shoring and back-propping as well as

precise timelines for formwork assem-

bly and stripping. In addition, loads

exerted by the prefabricated bathroom

units weighing around 5 tons had to

be accounted for.

Floating ceiling or conerence room

The conference room on the ground

oor measures 29.50 x 14.80 m and

has a oating ceiling at 5.70 m height.

Complex, complete from A bis ZConcrete works on hotel complex completed in 9 months with 8 MEVA Systems

MEP shoring towers with single props

connected with bracing frames wereperfect 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.

Dierent wall heights

The basement oors are 2.80 m and

3.70 m high, the ground oor 5.70 m

and the upper levels 2.85 m. Mammut

wall formwork with its 97 kN/ 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 nish on the

rounded walls of the parking garage

access ramp. Only two sets of the fold-

able 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 form-

work Circo that provides a continuousrst class concrete nish on columns

with diameters between 30 and 70 cm.

Slabs and beams

Beams measuring up to 2.60 m in

width and 1.10 m in thickness were

poured before the slabs. This was done

with 125 cm Mammut panels set hori-

zontally. 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 groundoors, 30 to 45 cm thick, were poured

using the conventional MevaFlex

wooden girder method.

Saety and time-saving solution

achieved with special designs

From the rst oor upwards, the

slabs oat 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 shor-

ing towers. The tables acted as a sup-

port 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 trans-

Ground oor walls being poured with Mammut 350 wall formwork.

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port spreader from one level to the

next, saving assembly time. On build-

ing sections with outer walls, the

folded working plattform KAB 190

provided a safe working situation.

Where necessary, the Mammut wallpanels 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

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



Munich Branch

PROJECT DATA

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

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 push-

pull props and support ounda-

tions 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 xed 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

Warehouse for car manufacturer

Contractor

Klebl GmbH, Neumarkt, Germany

MEVA Systems

n Shoring tower Space

n Heavy-duty braces Triplex



Munich branch

PROJECT DATA

Strong SupportShoring Tower Space plus Triplex Heavy-Duty Braces

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MEVA SchalungsSysteme GmbH, Industriestrae 5, D72221 Haiterbach

PSdg, Deutsche Post AG, Postage paid, E 42057

Hall A2

15.-21.04.


The site photos show situations which do not always depict the nal assembly of the form-work 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 andre-use of any editorial content only by copyright permission. We accept no liability for the con-tent of external internet sites, nor for a violation of privacy or any other law arising from these.

Welcome!We look orward to your visit

MEVA stand in Hall A2, Munich expo,

from 15 to 21 April 2013. Reach usvia Entrance West, take the Atrium

directly to Hall. Well keep you posted!

Working ToolsOnlinemeva-international.com offers a wide range of

documentation and working tools that are con-

stantly updated. Go to the download section to

nd product information, parts lists, all technical

instruction manuals as well as tools for calculat-

ing concrete pressure on wall formwork and for

working out reshoring / backpropping for slabpours. You are not required to register and the

download is free of charge.

www.meva-international.com

www.meva.de [at, ch, r, hu, nl, ro, ru]

2434GB30002/13M,P

rinted

inGermany

RUSMoskva, Tel. 495 7813737

RUSSankt-Peterburg, Tel. 812 6802890

SGP-Singapore, Tel. 67354459

SLO-Petrovce, Tel. 03 7131500

UAEDubai, Tel. 04 3411180

USASpringfeld, Tel. 937 3280022

A-Pasttten, 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

MEVA Schalungs-Systeme GmbH

Industriestrasse 5

D-72221 Haiterbach

Tel. +49 7456 692-01

Fax +49 7456 692-66

[email protected]

www.meva-international.com

IND-Mumbai, Tel. 022 27563430

LT-Kaunas, Tel. 0684 82795

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2013-01-FP_II