scope Successful construction with PERI The Formwork Engineering Magazine Issue

Transcription

1 scope The Formwork Engineering Magazine Issue page 8 The St. James Condominium Tower PERI ACS used on architectural highrise page 10 Cooper River Bridge Longest cable stay span in North America page 12 Michigan s largest Water Retention Facility page 16 New Product Update TRIO TSE Shaft Panel Successful construction with PERI

2 The Versatile PERI TRIO Wall Formwork Adapts Easily to Various Sized Structures Shoal Creek Water Pollution Control Plant (WPCP), Atlanta, GA Atlanta is currently undergoing a major renovation of its water and wastewater systems. The Shoal Creek Water Pollution Control Plant is a $104 M (USD) facility, for which Western Summit Construction (headquartered in Denver, CO) and Pizzagalli Construction (headquartered in Burlington, VT) formed a joint venture to tackle this large project. They purchased 36,000 sq.ft (3,400 sq.m) of PERI s panelized TRIO wall formwork. The most important factor leading to this decision was TRIO s versatility and ease for reconfiguration using the BFD coupler that allowed them to reduce cycling times. The project included construction of nine seperate structures. The largest ones were the Water Filtration Plant, Ozone Building and a Pump Station. The TRIO wall formwork system s most important feature is the BDF coupler the only connection device needed, making panel connection and stacking fast and easy. This was one of the most crucial factors in achieving the aggressive completion deadline for this job. PERI was able to overcome the numerous wall penetrations of this waste water plant by offering a simple formwork design. Western Summit/Pizzagalli Construction Company (Joint Venture), Atlanta, GA Field Support: PERI Southeast Due to the tight construction schedule, various structures were built simultaneously utilizing the full versatility of the TRIO wall formwork system. Brent Koehn, Superintendent: This project has many different sized structures. The simplicity of changing gang forms with the BFD as the only coupling component made PERI the right choice for our jobsite. 9 (2.70) 21 (8.10) 2 Title: See page 10 for the report on the Cooper River Bridge: Longest cable span bridge in North America. For the high wall sections, the client used the RS 1000 brace. This brace has an extension length of over 32 ft (10 m). Only one coupling device, the BFD, is required to connect any sized TRIO wall formwork panels. A time saving device. Cost-effective: wall variation achieved with GT 24 girders and plywood attached directly to the TRIO.

3 Architectural Concrete Finish Achieved with PERI RAPID Column Formwork System 4 th Ave. Jail, Phoenix, AZ McCarthy Building Co. was awarded this $91 M (USD) jail project containing 1,360 cells. PERI Formwork Systems supplied McCarthy with its RAPID Column System in order to achieve the high level of finish required. The RAPID Column System is designed for a pour pressure of 2500 psf (120 kn/sq.m), thereby producing an architectural finish. It can be moved in two pieces from pour to pour. Mc Carthy Building Co. Phoenix, AZ Field Support: PERI Arizona Mike Wigness, Superintendent: This project was very fast pace, and PERI seemed to have solutions for all the different aspects of the job. As first time users of these systems we found the learning curve to be very minimal. The RAPID Column System does not have any loose parts and can be connected by hand. With only two halves, an architectural concrete column can be cast. RUNDFLEX and TRIO for curved Walls with integrated Pilasters ASU West Campus Extension, Phoenix, AZ The Arizona State University has recently initiated a project to provide its students with a 108 unit, 414 bed housing facility. The difficulty of this project faced by DPR Construction Inc. were the numerous pilasters integrated with the curved walls. The solution to cast these walls was to use RUNDFLEX with TRIO wall formwork panels for the pilasters. The RUNDFLEX circular wall formwork system has the same edge profile as TRIO, therefore using a standard BFD one can connect the two systems with each other. Ed Smith, General Foreman: We have completed numerous jobs with PERI and have been very happy with the support. The systems are the most advanced that I have used and produce solutions for every situation. Rundflex panels can form circular walls with a minimum radius of 3 ft (1 m). DPR Construction Inc. Phoenix, AZ Field Support: PERI Arizona Using only one coupling device, the BFD, one can connect both RUNDFLEX panels and TRIO panels, thereby producing pilaster forms. 3

4 PERI UNIPORTAL and MULTIFLEX Tables Provide Flying Formwork Solution Philadelphia Airport Double Helix Parking Ramp The PERI Baltimore engineering staff worked in close cooporation with Madison Construction, devising a tabilized forming solution for the complicated double helix geometry of the Philadelphia Airport parking ramp. Each ramp was poured in two 180 degree sections for a total of 14 pours. The double helix ramp also included four entry and egress ramps at each parking level. The folding leg capability of the PERI UNIPORTAL tables provided enough clearance between the underside of the down turned beam and the top of the parapet wall for the system to be efficiently cycled. 24 (61 cm) by 32 (81 cm) deep isolated beam formwork MULTIFLEX towers erected from ground level to top in sequence were used as support for the MULTIFLEX beam tables and TRIO beam formwork above. The down turned beam and parapet formwork consisted of UNIPORTAL tables and RUNDFLEX circular wall formwork. Jim Nicholson Site Superintendent, Madison Construction, Malvern, PA: PERI offered an economical tabilized solution for the complicated ramp geometry. The alternative of hand setting the ramps was out of the question from a labor and logistics standpoint. Interior slab formwork consisted of MULTIFLEX tables pre-assembled to match the complicated ramp geometry (0.65) (0.81) (0.73) (0.65) (0.81) 22 4 (6.81) A total of seven levels were constructed using this system of MULTIFLEX combined with RUNDFLEX. Madison Construction, Malvern, PA Field Support: PERI Baltimore 4

5 Critical Schedule Demands Quick Slab Forming System: PERI SKYDECK The Residences At The Ritz-Carlton, Grand Cayman The Fluor Corporation received the award to construct the luxurious $350 M (USD) 5 star Ritz Carlton resort in the Grand Cayman Islands. This stunning facility will incorporate 365 rooms, seven restaurants, tennis courts, spa and 71 luxury condominiums. Scheduling of this project required simple, yet quick forming solutions in order to achieve an opening date for To meet these deadlines, Fluor chose PERI s TRIO Wall Formwork System, KG Climbing Brackets and the MULTIFLEX and SKYDECK Slab Formwork Systems. Over 45,000 sq.ft (4,200 sq.m) of TRIO wall formwork panels and 100,000 sq.ft (9,300 sq.m) of SKYDECK slab formwork panels were supplied to this job. Fluor selected these systems since they required a versatile product for the construction of the irregular balcony layouts (2.95) (2.95) Using the SKYDECK Slab Formwork System with drophead feature allows the posts to stay in place during stripping, therefore decreasing cycling time. The irregular balcony layouts made the SKYDECK slab formwork system the right application for this project. Seven buildings were constructed at once. Logistics was a critical factor in completing this project on time. A consistent flow of equipment required PERI to ship over five trucks of equipment per day. Mike Mazzarisi, Decking Superintendent: SKYDECK goes up very quickly and the operation is clean. You don t need a tape to adjust MULTIPROPS to the desired length. Pictured: (Mike Mazzarisi and Brad Streb) Fluor Corporation (Caribbean) Inc. Field Support: PERI Southeast 5

6 Unexpected Jobsite Adjustments Made Easy Using PERI SKYDECK Potomac Center, Washington, D.C. The concrete slab overhang area was formed using SKYDECK and shored to part of the existing office building (7.06) (0.30) (2.79) (0.30) The Potomac Center in Washington DC, is an 11 story office building, designed by architect Hickok Warner Fox. General Contractor was James G. Davis Construction Co. and Concrete Sub Contractor was Brothers Concrete Construction Company. Brothers Concrete used PERI SKYDECK to form both slabs and beam bottoms in a strict four month schedule. The standard Main Beam 375 was cantilevered in order to create the slab edge and a safe working platform. This 11 story office building project was completed in four months using the patented SKYDECK shoring system. Mike A. Karinshak, Vice President of Operations: The ease of installation and removal of the PERI SKYDECK System coupled with the quality of the concrete left behind, makes this a very competitive forming system. Brothers Concrete Construction Co. Field Support: PERI Baltimore Accelerated Schedule Achieved Using PERI SKYDECK Slab Formwork System Optima View Towers, Evanston, IL The Optima View Towers built by McHugh Construction Company, is a 28 story concrete and glass building with a unique angled facade that maximizes views with some residences having three sided, 180 degree observation areas of Lake Michigan. Using the patented SKYDECK Slab Formwork System, McHugh was able to achieve a high cycling rate of material. This minimized the amount of material on site and increased achievable scheduled deadlines. Ray Uniejewski, Carpenter Superintendent: We were first time users with the PERI SKYDECK system, however after this project we are definitely going to be using it again. It is a very efficient and cost-effective slab forming solution. PERI Formwork Systems supplied SKYDECK Slab Formwork System KG Climbing Brackets VARIO Wall Formwork System (for the architectural walls) TRIO Wall Formwork System 6 Erected Drophead lowered Using the drophead allows the MULTI- PROP to stay in place during stripping. There is no need to remove or re-adjust the post during the stripping procedure. James McHugh Construction Company Chicago, IL Field Support: PERI Chicago

7 Large Wall Formwork Gangs increase Efficiency PERI TRIO Humphrey Light Rail Terminal Platform and Core, Minneapolis/St. Paul International Airport, Minneapolis, MN Knutson Construction Services used PERI Formwork Systems on the light rail transit station at the Humphrey Terminal of the Minneapolis / St. Paul International Airport. Steve Krampert, Superintendent: The PERI Shaft Panels operated very smoothly and were quite rugged. Knutson had good results using PERI on several previous projects and had confidence that PERI would perform well for them again. Using the TRIO wall formwork system allowed them to quickly connect modular forming gangs, which could be flown in single lifts. The TRIO Shaft Panel allows the internal core formwork to collapse and give a 2 inch (5 cm) clearance to the concrete while lifting with a crane. TRIO with external KG platforms allow the formwork to be raised from level to level safely and efficiently. Knutson Construction Services, Minneapolis, MN Field Service: PERI Minneapolis TRIO Wall Formwork System: Few Components Results in Fast Assembly and Cycle Times Children s Mercy Hospital Expansion, Kansas City, MO The JE Dunn Construction Company located in Kansas City, Missouri was awarded the Children s Mercy Hospital Expansion project which consisted of a 4 level (below grade) parking garage with 9 levels of mixed hospital space on top. JE Dunn used PERI s single sided SB Brace Frame with TRIO wall formwork, KG 240 climbing brackets and the new Shaft Panel 330. One sided foundation walls of 28 feet (8.5 m) in height were completed using SB-Brace Frames with TRIO panels. JE Dunn Construction, Kansas City, MO Field Service: PERI Midwest Keith Diercksen, Superintendent: The PERI Forms performed extremely well. See page 16 for more information about the new TRIO shaft panel The new TRIO Shaft Element allows for the internal cores to be stripped and reset as a complete unit. 7

8 Custom Steel Formwork Produces Architectural Finish for Exceptional Facade Design St. James Condominium Tower, Philadelphia, PA The PERI SKYDECK Slab Formwork System was utilized in order to achieve a four day pour cycle. PERI provided two floors of SKYDECK shoring in order to maximize equipment efficiency and minimize material storage on site. Elevator and Core: ACS-G (Gallows); ACS-P (Platform), designed to support a working platform. The St. James Condominium Complex is considered the premier residential high rise facility in the city of Philadelphia. Signifying this distinction can be easily seen in the intricate design of the architectural facade. This structure will grow to a height of 501 ft (153 m) with 47 above ground floors, holding over 307 rooms. The Carson Concrete Corp., selected PERI Formwork Systems to supply a custom steel column form that could achieve the stringent requirements for exposed architectural concrete (shown below). Other systems used on this project included the ACS Automatic Climbing System, SKYDECK slab formwork system and VARIO Wall Formwork System to construct a typical floor footprint of 11,000 sq.ft (1,000 sq.m). The PERI Automatic Climbing System combined with VARIO wall formwork were used for the elevator and stair core. Using the PERI ACS climbing system eliminated the necessity for a crane when moving to the next pour sequence. PERI also provided a separate ACS system with custom steel wall formwork required for the architectural exterior columns and spandrel beams (2.95) (2.95) (2.95) Exterior Columns: ACS-R (Regular) Note: A placing boom was used in conjunction with ACS-P. Exceptional finish of concrete surface achieved using hinged steel column form. Utilizing this hinged column form allowed the contractor to strip and cycle the equipment quickly and easily. 8 Custom Steel Panels were used to form the architectural facade. Carson Concrete Corporation, Conshohocken, PA Field Support: PERI Baltimore and PERI Germany John Lewis, Site Superintendent: The architectural finish from the custom steel formwork was incredible. PERI s hinged column form solution reduced labor costs substantially and allowed us to keep our tower schedule.

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11 Safe, Accurate and Fast PERI ACS for 175 m high Bridge Piers Arthur Ravenel Jr. Bridge, Charleston, SC With PERI ACS, four working levels together with the formwork are lifted from cycle to cycle without the use of a crane. The four levels consist of: Concreting platforms, working platforms, hydraulics and finishing platforms. The finishing platforms are used to disassemble climbing shoes and anchors. Climbing cycle sequence for change in inclination on bridge pier. Peo Halvarsson, Contract Manager: Our previous experience and an excellent working relationship with the PERI engineers made our decision regarding the choice of the formwork supplier an easy one. The PERI solution provided us with a formwork system with which we could work quickly and produce quality results at the same time. Two 574 ft (175 m) high piers, at a distance of 1,548 ft (472 m) from each other, distribute loads of this cable stay construction which connects both sides of the Cooper River. The short construction time together with strict logistical requirements (all materials had to be transported to both piers using barges) and the necessity to save on crane capacity meant that the use of a self-climbing formwork system was essential. The PERI engineers designed an extremely efficient formwork concept containing detailed pre-determined working speeds. These were maintained by the construction crews with a high degree of productivity. The high requirements placed on the concrete surface together with the dimensional accuracy were fully met using PERI ACS combined with VARIO GT 24 girder wall formwork. The scaffolding units remained permanently connected to the structure even during climbing which ensured high levels of safety throughout. All wind loads were taken into consideration during the planning phase. Approximately 10,760 sq.ft (1,000 sq.m) of VARIO GT 24 girder wall formwork was used as well as eight ACS-V platforms for the inclined pier sections and eight ACS-R platforms for the sloped areas. On the lower half of the piers, up to the change in slope, one pour section of 13 7 (4.15 m) was finished per week. Due to the simplified reinforcement arrangement and smaller construction geometry, pouring took place every four to five days and the contractors were able to reduce the scheduled pour sequence from seven to five days. The new bridge has created optimal conditions for meeting today s demanding road and waterway traffic requirements. The road itself lies 200 (61 m) above the surface of the river which allows the passage of large ships. Contractors: Palmetto Bridge Constructors: Joint Venture Tidewater/Skanska USA Inc. and HBG Constructors Inc./Flatiron Structures Company Field Support: PERI Baltimore and PERI Germany 11

12 Michigan s Largest Water Retention Facility: Built Using PERI s Formwork Know-How Kuhn Drain GWK Drainage Project, Detroit, MI The George W. Kuhn Drain Improvements Project conducted in Oakland County, Michigan, is an expansion of the existing retention basin, designed to increase drainage to 124 million gallons of storm water runoff. When completed in 2005, this facility will be the largest retention treatment facility in Michigan and among the largest in the country. The total contract value has been pegged well over $100 M (USD). PERI Formwork Systems were the leading providers of formwork solutions to Walbridge Aldinger Construction Company located in Detroit, MI. Systems used on this project included: MULTIPROP Towers with MULTIFLEX, TRIO wall formwork panels, SRS Columns and TRIO Columns. PERI provided a unique solution using the MULTIPROP Towers. This tabilized system allowed the contractor to move the tables from pour to pour with a column mounted roller system designed and fabricated by PERI. Crane access was limited and a column mounted rolling system was the only way to move these tables over a base slab inclined over 40 degrees. SRS column forms with a 2 (60 cm) diameter were used on this project. Also shown are the TRIO column forms. Stakking of the TRIO column form is achieved by using only one connecting device: the BFD coupler. 12 Walbridge Aldinger Constr., Detroit, MI Field Support: PERI Michigan Using Push-Pull Props, the 18 (5.5 m) battered wall could be easily adjusted. The resulting finish proved to be of excellent quality. The TRIO wall formwork system was able to accommodate the battered walls because of the angle of variation achieved using taper ties.

13 Ed Shultz, Carpenter Foreman, Walbridge Aldinger: PERI s jobsite service helped us solve the unique challenges we ran into with this project. We were amazed with the strength of the components and connections. We were able to get a lot of reuse out of each system. 1 6 (0.46) 29 5 (8.98) The few pieces required to assemble MULTIPROP Towers minimizes material handling on site (4.88) (6.10) (6.10) (6.10) (6.10) (6.10) Once the tables were released, the beam bottoms were removed using a hinged design. This allowed for the tables to clear the columns with the connected beam side form and move to the next pour location. This hinged design allowed the beam bottom forms to stay in place during transportation from pour to pour. Using the MULTIPROP Swivel Base allowed the client to have these tables easily aligned with a base offset up to 3 degrees. This patented swivel base design eliminates the need for wedges when faced with sloped slabs. 13

14 Pre-Assembled Custom Tunnel Formwork Allows Hydro Quebec Project to Continue on Schedule Toulnustouc Dam and Power Plant, Northern Quebec, Canada RUNDFLEX Curved Wall Formwork, MULTIPROP Shoring Tower, VARIO Wall Formwork. Using the tie-less GRV system with a radius of 18 ft (5.5 m), PERI was able to provide Aecon with a pre-assembled solution to form the entrance area for a diversion tunnel (6.00) Hydro Quebec has begun another mega project in the northern part of Quebec called the Toulnustouc River Dam. The utility company will be spending over $50 Billion dollars (CND) in the next 15 years to build a series of hydro-electric facilities. Using the tie-less GRV Circular Formwork System on the diversion outlet tunnel, allowed Aecon to achieve pour pressures of 2500 psf (120 KN/sq.m). PERI s expertise in carpentry was critical in delivering a product that would exceed Hydro Quebec s expectations for a quality concrete finish. The preassembled Bull Nose formwork was fabricated and shipped as a complete unit from the Toronto assembly shop. Along with Engineering knowhow, PERI offered the simplest solution for a complex project. Aecon Civil, Montreal, QC Field Support: PERI Toronto, PERI Montreal and PERI Germany PERI UP: Meeting All Safety Requirements With Faster Erection Phase 1 of New Terminal 1 Toronto Pearson Airport, Toronto, ON The Toronto Pearson Airport is undergoing a $4.4 Billion (CND) redevelopment in order to meet the growing demands of air travelers. A new terminal is being constructed and Select Drywall & Acoustics were chosen to perform the majority of the drywall installation. Their decision to use PERI UP Scaffolding was based on safety concerns and erection speed. With features including an end gate that has a ledger and toeboards built into one piece, PERI provided the necessary equipment to perform all of the clients scaffolding needs (10.84) 14 Select Drywall & Acoustics, Concord, ON Field Support: PERI Toronto The rigid PERI UP system can be assembled quickly with working platforms providing safe working areas. Access ladder boards allow for decks to be installed in one operation (2.50) (3.00) (2.00) (2.00)

15 Slim TRIO Profile Allows Contractor to Build on a Very Confined Site 1 King Street West, Toronto, ON The 51 story residential tower on 1 King Street West in Toronto, Ontario will be a display of engineering achievement along with classic historical design once completed. Resform Construction Ltd. was awarded the contract to construct a 578 ft (176 m) high rise building only 3 ft (1 m) next to the historical 1913 Toronto Dominion Bank. The only viable solution was to use the TRIO Wall Formwork System along with shear wall climbing brackets. Having an overall profile width of 4.7 (12 cm), the TRIO Wall Formwork System provided the optimal solution for working in confined areas. Utilizing a single rigid connecting element called the BFD, the contractor was able to gang TRIO panels together and precisely fly the units into place. Other systems used on this project included the TRIO Shaft Element, MULTIFLEX Slab Formwork, UNIPORTAL Tables, SB Single Sided Brackets, HD 200 Shoring and the SKYDECK Slab Formwork System. The aluminum SKYDECK system provided Resform with a solution minimizing material storage and handling. With less components than conventional frame systems, Resform was able to cycle more equipment without a crane in less time. Marco Centofante, Foreman: PERI offered the best solution for our complicated floor layouts. PERI s range of products made our project easier to keep on track. Restricted storage space was overcome using the versatile yet modular TRIO Wall Formwork System. UNIPORTAL Tables were supplied to the site pre-assembled. The only requirement for the contractor was to simply connect the MULTIPROP to the table form, thereby again minimizing the space requirement for equipment storage. Resform Construction Ltd., Toronto, ON Field Support: PERI Toronto UNIPORTAL Tables used on the upper tower were an ideal solution. It was easier and faster to cycle smaller modular tables due to the confined spaces. 15

16 Time Savings achieved in the Erection of Shaft Formwork The new TRIO TSE 330 Shaft Panel NEW During the reconstruction of a residence hall, an elevator shaft with a clear opening of 7 4 x 9 5 (2.20 x 2.88 m) had to be built. For the first time, the site crew successfully applied the new TRIO Shaft Panel for a total of five cycles with pour heights of 9 to 13 7 (2.75 to 4.15 m). This platform is based on folding bearing plates fixed to the respective wall section below. The final pouring height of 13 7 (4.15 m) was done with TRIO (TR 4 x 2 /120 x 72) extension panels. The inside TRIO panels remain in place for all subsequent cycles. As of the second climbing cycle, the inside formwork unit is placed on a shaft platform. The mechanical system of the shaft panel ensures that the formwork is horizontally released from the face of the newly casted concrete wall. A stripping space of about 1.2 (3 cm) on each side of the shaft formwork makes it possible to safely remove the complete inside formwork unit. Ulrich Ersing, Foreman: The PERI TRIO Shaft Panel works extremely well and does not require any separate compensation. Compared to other solutions we are able to erect the shaft formwork up to four times faster with the PERI System. Mayer/ PPG, Laupheim, Germany Field Support: PERI Germany The TRIO shaft panel, TSE, is available in heights of 4 (1.20 m), 8 11 (2.70 m) and (3.30 m). 16 The illustrations in this brochure are photographs of real site situations. Safety or formwork anchor details are therefore not to be taken as a definitive guide to the way the equipment is to be used. Copyright by PERI GmbH, 2004 PERI USA 7272 Park Circle Drive Suite 200 Hanover, MD Phone: Fax: or call toll free: USA: PERI CAN: PERI PERI Canada 45 Nixon Road Bolton, Ontario L7E 1K1 Phone: Fax: US 1/ ho Art.Nr