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Competent engineering and logistical services at Frankfurt Airport

PERI UP scaffolding on the longitudinal side of the building carry the loads until an intercepting floor has been constructed in a higher position. (Photo: Ed. Züblin AG)

PERI UP scaffolding on the longitudinal side of the building carry the loads until an intercepting floor has been constructed in a higher position. (Photo: Ed. Züblin AG)

Airrail Center, Frankfurt on the Main

June 2006 - The former roof of the long-distance railway station at Frankfurt airport – a 660-metre long and 65-metre wide platform – forms the base area for a nine-storey extension with over 150,000 square metres of floor space. During construction, contractor Ed. ZÜBLIN AG is faced with complicated boundary conditions and meeting a set of tough requirements. PERI is supporting the contractor with a tailor-made formwork and scaffolding solution as well as comprehensive planning and logistic services.

The size of the so-called Airrail Center in connection with the short construction period necessitates a high degree of equipment and personnel requirements: 17 tower cranes and up to 800 site personnel work in two-shift operations with extremely large quantities of materials in order that the tight schedule can be maintained. Due to the fact that the site is located between motorways and federal highways, the very limited open space that is available makes construction progress even more difficult. In addition, site personnel must fulfill very high safety requirements as safe station operations and flow of traffic must be guaranteed throughout the entire construction period - with designated escape and emergency routes available around the clock. One particular challenge is the transfer of the additional loads into the existing structure and ground.

Complex construction project with a wide range of requirements
With its extensive product line-up and the largest rental equipment pool worldwide, PERI can optimally fulfil the wide range of site conditions. Lead-managed by the Munich branch office, the formwork and scaffolding solution was drawn up, including reliable and flexible site deliveries - altogether around 800 truck loads of materials.

During the entire construction period, large quantities of different formwork and scaffolding systems will be use. On a total area close to 16,500 square meters – a surface as large as three football pitches – table modules are used. Around 21,500 square meters of the reliable TRIO panel formwork are proving their flexibility with construction of the stairway walls. Here, the 32 cores are not only differently designed in each case but also the layout changes from floor to floor. For constructing the columns, QUATTRO column formwork is being used which is moved in complete units thus saving on crane time. The lightweight and completely pre-assembled FB 180 platform system serves as working and formworking platforms in many areas. Special working platforms on basis of the MULTIFLEX system guarantee safety, where the systems parts can’t be used. Complete units with pre-fabricated guardrails can be quickly shifted by crane. Prop and shoring requirements for the Airrail Center are likewise enormous with 23,500 slab props alone in use on the construction site.

PERI UP on all levels
Transferring the loads from the height extension into the existing structure as well as the building ground itself must be ensured after the building has been completed via load transfer points which are integrated in the existing slab. The existing slab itself can only accommodate 10 kN/m² of the load - only half of this in the head area - therefore a detailed concept for load transfer during construction had to be prepared. Apart from this, erection of the falsework was hampered by the limited amount of open space.

Load distribution takes place via one intercepting floor which is positioned in the standard configurated area of the building above the fourth floor. Until this level has been completed, loads from up to three storeys must be transferred using temporary shoring towers and falsework into the ground. Using the flexible PERI UP modular scaffold for this purpose along the longitudinal sides of the building allows the system to demonstrate its advantages to the full: flexibility and lightweight together with high load transfer. Depending upon the height and load, standard applications with pre-defined tower units as well as individually configured scaffold towers are used. Due to the modular structure and the metric grid arrangement of the PERI UP system, the load-carrying construction is optimally adapted to deal with the forces: with 150, 75 and the short 25-centimetre ledgers, the single load-bearing capacities of 40 kN per standard in both lateral and longitudinal directions can be significantly increased for higher loads. In addition, superstructures are required for many areas, for example for access roads. Verification for the free access of escape routes is provided through drawings.

Apart from the actual scaffold planning and detailed drawings provided in the planning services for the Airrail Center, verifiable, static proof is also included. Furthermore, PERI provides the support formwork planners as well as the site management with load layout plans. On the basis of the leg loads specified here, parties involved can check the load transfer into the existing structure.

Due to the crowded site conditions, all shoring towers are vertically assembled. With the low weight of the individual components, the self-locking ledger connections and integrated user safety features, the scaffolding is efficiently and easily assembled. During erection, PERI UP towers are provided with load-bearing decks so that safe working areas are available on all levels and at all times. With the UDI industrial decks, the surfaces are completely closed without any gaps and the integrated locking devices also prevent the decking from sliding to the side. For accessing the working areas, shoring and industrial stair units from the PERI UP scaffold modular construction kit are combined.

Large slab areas quickly formed
Depending on the slab thickness, position and ground plan, various slab formwork systems are used. For the lower storeys, site personnel have used slab tables on PEP supports in order to be able to quickly form large surfaces. Many areas are formed using the flexible MULTIFLEX girder slab formwork with GT 24 lattice girders or VT 20K solid web girders, depending on the span and load. SKYDECK is also used; due to the drophead, the lightweight aluminium panel slab formwork can be stripped after only one day. As a result, on-site material requirements can be reduced.

For the edge areas, customized slab tables with integrated guardrails contribute substantially to fast construction progress. In the main, more than 1,000 tables are simultaneously in use in order to maintain the tight schedule. With the transportation fork, the tables are quickly lifted and transported. As the fork and slab table are always suspended in a horizontal position on the crane lifting gear, the formwork units are easily stripped, safely moved and quickly shuttered again.

In many areas, slab as well as beam formwork are supported using PERI UP towers. Compared to the use of individual supports, this has meant that horizontal loads can also be transferred without any additional measures.

With teamwork to success
The development of the entire project requires particularly close co-operation of all those involved especially logistics. Due to the limited amount of space available, materials are delivered directly to the place of use; for this reason, the time slots designated for deliveries and returns are very tight. 17 tower cranes are available so that each stage of construction can be sufficiently and directly supplied with the required materials.

With shipments of large quantities of equipment as well as fast and efficient deliveries to the construction site, the PERI logistics team from Frankfurt is making an important contribution to the successful completion of the project. During peak periods, ten truck loads are being shipped by PERI to the Airrail Centre site. The logistics department can also react very quickly to project requirements if changes are made to the schedule at short notice.

One particular highlight of the project has also been the good co-operation between the structural engineers and the test engineers, contractor and PERI engineers. In regular on-site team discussions, construction plans are discussed, solutions found and the required quantities of materials continuously adjusted to suit the current situation.

Contractor: Ed. Züblin AG, Direktion Nord, Hamburg
Field Service: PERI GmbH, Germany

PERI Systems In Use
- MULTIFLEX Girder Slab Formwork
- MULTIPROP Slab prop
- PEP 20 Props
- PERI UP Rosett
- PERI UP Site Stair
- SKYDECK Aluminium Panel Slab Formwork
- Table Modules
- TRIO

PERI was founded in 1969 and is today one of the leading providers of formwork and scaffolding systems. Along with the headquarters in Weißenhorn, Germany, the company has 47 international subsidiaries and 100 stock yards around the world. The company has over 5400 employees of which 850 are engineers. 2008 revenues was 1,220 million Euros.

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

Phone: +49 (0) 7309.950-1180
Fax: +49 (0) 7309.951-1180
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.

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