Formwork, Scaffolding and Engineering for huge power plant construction

07.09.2011 | Refuse Derived Heating and Power Station, Spreerecycling GmbH & Co. KG, Spremberg, Germany

Massive components with a high degree of reinforcement and weight as well as large heights – these are the challenges facing the construction team for the realisation of a new power station in the Schwarze Pumpe Industrial Park in Spremberg (Germany). For this, PERI planned and supplied a comprehensive formwork and scaffolding solution. The combined use of climbing formwork, access technology, reinforcement scaffolding and shoring through to heavy duty shoring towers has been perfectly matched to suit jobsite requirements.

The Glass Ingenieurbau Leipzig GmbH construction team have to deal with a tight schedule with just 18 months available to complete the skeleton work for the over 50 m high power station complex with fuel and slag bunkers, boiler house and flue gas purification unit as well as a tipping hall. Start of operations is planned for the beginning of 2013 with the facility having been designed to generate 110 megawatts of thermal power. The short construction time not only results in the need of large quantities of formwork and scaffolding materials but it also requires perfectly coordinated planning of the system equipment being used.

System-realised heavy shoring
Four VARIOKIT heavy-duty shoring towers temporarily support the cantilevered components. With an individual leg supporting height of 23.60 m, each legs of the falsework carries loads of 560 kN – this means that a single tower supports more than 200 tonnes. Assembly of the heavy duty towers is carried out easily and safely horizontally on the ground using two 10 m sections which are supplemented with the corresponding base and head units.

The possibility of combining the units with the PERI UP Rosett Flex modular scaffold system allowed the formation of safe working platforms in the head area. These had already been fixed to the shoring when it was positioned horizontally on the ground and then erected together with the tower unit. Thus, no risky assembly operations were necessary at great heights.

Flexible and versatile scaffolding
In addition, the PERI UP scaffolding system provides the basis for all access means as well as the shoring and reinforcement scaffold on the jobsite. The Glass site personnel mount the scaffold units and continually adapt these to match the construction progress. In the process, the flexible fields of applications of the system maximize material utilisation. Another advantage is the craneability of larger scaffold units which clearly accelerates the moving process.

For fast and safe access to all working areas, large numbers of staircase towers have been installed. 75 cm wide, easy to handle stair elements are used in order to realise the up to 60 m high access points. The permissible load of the high strength aluminium flights of stairs is 2.0 kN/m². With lightweight but high load bearing system components of the flexible PERI UP Rosett Flex scaffold, the walkways and landing junctions are also realised.

Furthermore, PERI UP is being used by the Glass team as type tested shoring for supporting heights of up to 20 m. The metric grid dimensions ensure here a maximum degree of adaptation of the load-bearing system to the actual loads – and, hence, the optimization of material requirements. In addition, PERI UP also serves as reinforcement scaffold. The units are up to 10 m high and can be transported as 60 m² moveable units with the crane to the next construction phase without requiring any time-consuming modification work.

Climbing on a large scale
The CB 240 climbing scaffold system and VARIO GT 24 girder wall formwork form crane moveable climbing formwork units for constructing the massive walls of the building with concreting cycle heights of 4 m. The formwork concept that has been developed requires in particular adapting different climbing cycles to suit the complicated geometry: the walls have haunched corners and taper upwards from 1.40 m to 0.30 m. The PERI solution takes into consideration all climbing cycles whereby adjusting to a 10 cm wall thickness difference each time is required.

Contractor: Glass Ingenieurbau Leipzig GmbH
Field Service: PERI Cottbus/Leipzig and Weissenhorn (Germany)

PERI Systems In Use
- PERI UP Rosett Shoring Tower
- PERI UP Stair Tower 75
- VARIOKIT Heavy-Duty Shoring Tower
- VARIO GT 24 Girder Wall Formwork
- PERI UP Scaffold Units
- CB Climbing System

PERI was founded in 1969 and is today the leading provider of formwork and scaffolding systems. Along with the headquarters in Weissenhorn, Germany, the company has 49 international subsidiaries and 100 stock yards around the world. The company has over 5500 employees. 2010 revenues was 825 million Euros.

PERI GmbH
Editorial Office
P.O. Box 1264
89259 Weissenhorn
Germany

Phone: +49 (0) 7309.950-1191
Fax: +49 (0) 7309.951-1191
E-Mail: redaktion@peri.de
Web: www.peri.de

Re-prints are free of charge quoting "Source: PERI GmbH". Please send a copy to the PERI Editorial Office.

This release was published on openPR.