Formwork Scaffolding Engineering Issue 1 | 2012 GB Successful construction with PERI A470 Cwmbach to Newbridge bypass scheme, Builth Wells Page 2 Rosyth Dockyard, Fife Page 4 Bradfield Close, Woking Page 8 Frodingham Viaduct, Scunthorpe Page 10 scope Brighton & Hove Waste Water Treatment Works, Brighton Page 12 Howick Place, London, SW1 Page 15 Dear Clients and Readers, The outlook for the UK construction industry yet again this year, can only be described as ‘challenging’. But, by continuing to work hard and making the right adjustments for market conditions in 2012, many of us will undoubtedly continue to succeed and to move forward. At PERI, we have adapted to circumstances – and this issue of PERI Scope reflects the changes that we, as a business, have made. For instance, the newly developed VARIOKIT parapet system, designed specifically for infrastructure projects, is proving very successful. On page 3, we give details of the £50million bypass improvement project near Bulith Wells in Wales, which involved the building of two bridges. VARIOKIT modular cantilevered brackets and formwork used in the construction of concrete parapets on both, made a significant contribution in minimising overall timescales for the whole scheme. Infrastructure projects generally continue to be a growth area for us. The Rosyth Dockyard project on page 4, the renewable energy waste treatment plant built at Horsham and detailed on page 6, the Frodingham Viaduct project featured on page 10 and The Brighton & Hove Waste Water Treatment Works on page 12, are all typical of public and private projects that are still vital – and viable – even in these times of economic cutbacks. Educational construction is another area where projects are still going ahead and the articles on pages 5, 7 and 11 show the successful use of PERI equipment and systems in the building of several prestigious and iconic teaching establishments. Projects calling for high quality architectural concrete finishes, city centre projects – where fabrication and equipment storage space is at a premium – and projects on very tight timescales also continue to offer potential growth for us. Whether the call is for architectural fairfaced formwork, customised or standard formwork, these are all areas where contractors are increasingly calling for pre-assembled and transportable formwork elements. As a consequence, even more of the projects of recent months have relied heavily on the cost-effective use of our long-established fabrication services. The fabrication facilities represent a real opportunity for architects and contractors to demonstrate the many creative ways that high-quality concrete can be realised on today’s construction projects. Whether or not you have been before, we again extend a sincere open invitation to all our readers to visit us in Rugby. Take a tour of our facilities and spend some time in our exhibition hall which is home to working examples of all of our equipment – a facility which we believe is unequalled anywhere in the UK. Speaking of PERI innovation in formwork and scaffolding, it is the company’s avowed intention to continue the development of the PERI range in order to enable it not only to offer better, more complete solutions to existing customers, but also to reach beyond the concrete sector. Our goal is always to provide the best, most cost-effective solutions in concrete formwork, scaffolding and engin-eering systems, backed by the most comprehensive ranges of products and services. Once again, we thank you for your business and your confidence in us and we very much look forward to working with you on future projects. Carl Heathcote Managing Director 0.66 1.00 Richard Scoins, Project Manager: “PERI’s VARIOKIT is a quick and easy method of construction for bridge parapets and edge protection. The speed in the erection of this system has helped with the overall project timescale.” A new bypass improvement scheme between Cwmbach and Newbridge, near Builth Wells is under construction in a £ 50 million development. The scheme will create a new 5.5 km long single carriageway to straighten a twisting section of the south-north road link. The new route between the two villages, which is due for completion by the end of 2011, will cut out three-anda-half miles of road which currently has 2 Installation of the system by crane enables the large modular units to be installed fast and safely from above. Technical diagram showing typical section of the VARIOKIT Cantilever Bracket. a much higher mortality rate than that of similar roads, and is also in need of repair according to a Welsh Assembly investigation. work. For the support walls and piers TRIO formwork has been used, along with MULTIPROP and GT 24 girders for the sloping sections. Euro Construction has been appointed to carry out the concrete structure works and have two bridges that need to be constructed. For the construction of the pier walls, supports and parapets Euro Construction are using PERI form- For the construction of the parapet, VARIOKIT Cantilever Bracket was chosen. This system is a modular cantilevered formwork specifically designed to enable the construction of concrete parapets to composite steel girder and pre-cast con- New bypass bridged with VARIOKIT Parapet Front Cover PERI UP providing safe access at Bradfield Close, Woking. See more on page 8 A470 Cwmbach to Newbridge bypass scheme View from below the bridge deck showing the system components. Contractor Euro Construction Field Service PERI UK, Bristol Office The VARIOKIT modules provide safe access for the workforce to reach the parapet edge. 5.26 5.33 crete bridge decks. The VARIOKIT brackets are suspended by a single diagonal anchor tie, and all adjustments, striking and removal of these anchors are carried out from above the bridge deck. MULTIPROP and GT 24 girders provided the formwork and falsework for the central pier. 2.07 Technical diagram showing typical section of the MULTIPROPs and GT 24s module. 3 Dock entrance widened with PERI formwork Rosyth Dockyard, Fife At the Babcock-owned Rosyth site, contractor BAM Nuttall is part way through a project to widen the direct entrance from the Firth of Forth into the non-tidal basin. This is to allow large prefabricated sections of the Royal Navy’s next generation of aircraft carrier to be floated through for final completion. The gated entrance to the inner nontidal basin has to be widened by 4 m from 38.20 m to 42.10 m to accommodate the new carriers. This new sliding dock gate must be able to retract fully into its own chamber. To accommodate this extra length an 8 m section is being trimmed from the entrance on the northern side while a 4 m extension is added to the southern side. Top: SKS & TRIO formwork. Bottom: Assembly of the SKS system. As part of the construction process the BAM Nuttall team is breaking out a large part of the existing north quay down to the dolerite outcrop 25 m below the top of the harbour side and 20 m below the surface of the Firth of Forth. For the construction of the new gated entrance BAM Nuttall came to PERI to 4 source their formwork requirements. SKS, the single sided climbing system which is the choice of system for dam, weir and lock structures was coupled with TRIO wall formwork. SKS was used as the concrete pressure imposed on the forms during construction can only be taken on one side the load to be transferred. Contractor BAM Nuttall Field Service PERI UK, Glasgow Office John Slaven, Sub Agent: “Construction of the new entrance structures was on the critical path of our programme. Once the system was erected it was easy and quick to turnaround, helping us beat our programme. PERI also provided good technical support throughout. I would not hesitate in using this system again.” Iconic Sixth Form Centre built with PERI Phoenix High School, Shepherd Bush, London A new £8.7m, 260 capacity six form centre is under construction at Phoenix High School. This Post-16 Centre is being constructed using in-situ concrete and incorporates an iconic design to integrate the building with the rest of the school. new in-situ concrete building and approached PERI to source their formwork and falsework requirements. SKYDECK aluminium slab formwork is being used for the floor slabs together with the high load aluminium MULTIPROP. The upper levels cantilever 24 m from the ground floor building, and it is thought to be Europe’s largest cantilevered building. With an overall building length of 51 m, the cantilever is almost 50 % far greater than the general rule not to exceed 33 %. The huge cantilever was to prove a test for the technical team at PERI due to the enormous load that would be placed onto the falsework. With the original construction sequence the resulting prop loads would have been too great, even for a heavy duty shoring system. The only way to achieve this John Doyle Construction has the task of constructing this Construction of the 2nd floor slab with SKYDECK. would be to use a temporary support structure of either concrete or steel columns. PERI’s technical team developed an alternative sequence to use PERI standard equipment. The solution is to strike the structure from the roof down in order that the loads travel from one element to another. Stripping the central zones first means the two large spinal beams can take the majority of the weight of the building and transfer it down to the V columns. Contractor John Doyle Construction Ltd. Field Service PERI UK, Brentwood Office John Hughes, Project Manager: “Due to the nature of this project the technical back up required was of importance and PERI were able to provide us with a high level of expertise throughout. The SKYDECK system allowed to strike the slabs quickly and re-use material on upper floors.” Finished concrete slab from struck SKYDECK. 5 TRIO & DOMINO formwork constructs new renewable energy waste treatment plant Biffa Waste Services, Horsham Contractor JB Developments & Construction Ltd Field Service PERI UK, Brentwood Office Biffa Group has agreed a £1bn plus deal with M+W Group’s UK team to build a new MBT facility in West Sussex. The facility will be built as part of a 25-year contract between Biffa and West Sussex County Council to treat the county’s residual municipal waste. Over the lifetime of the contract it will save the council around £300 million with up to 80% of the waste being diverted from landfill. The plant is due to become operational in 2013, and at full capacity will produce up to 3.5 MW of renewable energy, enough to power around 7,000 homes. 6 treatment works tanks and associate structures and have come to PERI to source a suitable formwork system to achieve this. TRIO formwork was chosen as the wall formwork system to construct the 6 m concrete AD tank walls and DOMINO for the 7.40 m fire and separation walls within the steel frame of the Main Process Building on the project. JB Developments & Construction Ltd have the task on constructing the With just one component for all connections, the BFD alignment coupler allows more cost-effective construction as one multipurpose component avoids time consuming searching and sorting. TRIO formwork forming the 6 m high tank walls. Struck walls in one of the AD tanks. Justin Barrett, Project Manager: “Within the project there have been many different structures and aspects to overcome, with the use of PERI’s formwork systems we have been able to deal with the clients requests and specification to achieve what was required.” The steel work and cladding surrounding the concrete tank walls. State of the art college built with PERI expertise Bournville College, Birmingham RCS Rail Climbing System SKYDECK slab formwork VARIO wall formwork A new £66 million college is under construction in Longbridge, which when completed, the 4.2 acre campus which is prominently located on the junction of the A38 Bristol Road South and Longbridge Lane, will consolidate Bournville’s existing three campuses with capacity for over 15,000 students. For the multiple cores on the project O’Donnell Developments used PERI’s RCS (Rail Climbing System). The rail guided climbing formwork coupled with VARIO wall formwork ensures that the access platform and formwork remain in contact with the structure for the entire construction period of the core increasing safety levels on site. Contractor O‘Donnell Developments Ltd. Field Service PERI UK, Glasgow Office O’Donnell Developments have the task of constructing the six storey concrete frame, which will house a 250,000 ft² state-of-the-art education facility including a learning resource centre, business school, construction workshop and leisure and sport facilities. Scheduled to be open in September 2011, ready for a new intake of students, O’Donnell have sourced their formwork and falsework requirements from PERI. Over the six story frame SKYDECK, the aluminum slab formwork system was used. With the SKYDECK system featuring a drophead, this component allows striking to occur after a short time allowing the panels and beams to be moved up to the next pour. This results in less material needing to be on site thus increasing the cost effectiveness for the customer whilst delivering more flexibility over the course of the project. Kieran Madden, Site Manager: “PERI’s RCS system enabled us to progress efficiently and safely with the construction of the cores. Using SKYDECK has resulted in quick and efficient pour cycles of the slabs due to the reuse of panels.” 7 PERI UP providing safe access to new mixed use development 3.20 Bradfield Close, Woking A variety of PERI products were used on this development. Facade scaffold typical lower section. New Central, a development by Midgard Ltd, part of the JRL Group is well under way in its construction of 449 apartments. Based in the centre of Woking the mixeduse development is spread across ten blocks ranging from 1 to 21 storeys’ in height comprising studio; 1bed and 2 bed apartments. footprint which will provide parking spaces for up to 354 people. The ground floor podium is a mixture of private residential, office space, retail units, fitness suites, and management / concierge office. The site sits on a basement occupying the majority of the The concrete framed blocks have an envelope which consists of render, facing brick, coloured facing brick and terracotta cladding. The first phase of the build is on for completion by autumn 2011, with the full development completed by winter 2013. Having worked with the JRL Group for a number of years, PERI had a large influence in the construction process providing a multitude of form- MULTIPROP and GT 24 girders being used to construct the slabs. 8 work, falsework and access solutions for the external façade and support for the concrete frame. PERI TRIO wall formwork was used to build the concrete frame with the GT 24 girder and MULTIPROP system. PERI UP Rosett Flex system scaffolding is being used to access the facade on approximately 60% of the blocks. PERI UP has a uniform length and width grid dimension of 25 or 50 cm, which allows al-most any adjustment to be made to suit site conditions. All ledgers have a rectangular profile which is 30% lighter compared to a round tube with the same load bearing capacity, this results in easier man handling of kit around the site. For the tallest block in the development at 21 storeys, PERI provided their Rail Climbing System which was used on every elevation to install the SFS and CP board. RCS rail climbing system used to install the SFS and CP board. PERI UP facade scaffold to one of the blocks. Contractor Midgard Ltd. Field Service PERI UK, Leeds & Birmingham Office James Markham, Assistant Project Manager: “The speed, durability and safety of PERI formwork allowed good progress to be made on the project. The speed and ease of erection of PERI UP coupled with the adaptability of the system allowed changes to be made throughout the project without causing delays to the tight schedule.” 9 Busy railway stretch strengthened with PERI GRV Frodingham Viaduct, Scunthorpe The completed re-strengthened concrete lined arch. Contractor May Gurney Field Service PERI UK, Glasgow Office GRV articulated waler formwork in position ready for concreting, for strengthening works to underside of arch. Frodingham Viaduct was built in 1866, in 1912 the viaduct was in-filled to form an embankment with only two arches left open for access. The 84 span brick viaduct stretches for 21 miles and is the most used freight railway setion in England. Each span is 10.70 m between the centres of the piers, with piers estimated to be 9.50 m from top of foundation level to springer level. The arches above the piers for each span are semi-circular, with an average radius of 4.60 m. Many of the arches are in poor condition, with cracks and defective brickwork, therefore strengthening work is required on three arches on this particular 22 week phase in order to maintain and prolong life of the railway line. May Gurney are the main contractor for Network Rail and their scope of work includes repairs of arch barrels, grouting up spandrel voids and works to spandrel faces. The arches will be lined with a 375 mm thick reinforced concrete under ringing. The reinforced concrete will be supported on transverse reinforced concrete beams, which are tied into and supported on the existing piers by the use of rolled steel beams at regular centres in grouted core holes to transfer 10 the full loads to the piers. May Gurney have come to PERI to source their formwork requirements for the project. GRV articulated circular formwork was supplied by PERI for the project and is the most economical solution for circular, segmental, compound and other arch shapes. Combined with GT 24 girders, PERI push-pull props and compression braces almost any arched bridge can be shuttered almost entirely with standard components. Using standard components on a customised project results in cost-effective formwork solutions throughout the construction period. GT 24 girders and articulated walers form the skeleton of the GRV system. Mark Simpson, Site Agent: “Due to the limited space around the structure to work with, we found that PERI GRV formwork was initially quite labour intensive in getting into position. However, following the first arch the subsequent two arches went very well and were very pleased with the end product. I would not hesitate to use this system again should a similar project arise in the near future. I was also impressed with the site support service from PERI’s design team when minor issues arose during the first pour.” Once the shell has been lined with plywood, the system is raised into position. PERI construct new flagship library for University of Aberdeen University of Aberdeen, Aberdeen Construction of one of the most prestigious new buildings in Scotland, a flagship £ 57 million library for the University of Aberdeen nears completion. The 15,500 m² of floor-space will host over a quarter of a million books, maps and manuscripts, as well as 1,200 reader spaces in a variety of environments, where cutting edge technologies are available. The new library will be run by approximately 60 staff and serve a community of over 16,000 students. Standing at 10 storeys in height, the new library is square in shape and set on a double height base that is inset slightly from the main bulk of the building. PJ Carey have the task of constructing the concrete frame and have come to PERI after previous successful projects for their formwork and falsework requirements. Peter Murray, Construction Manager: “This was the second time that we had used PERI’s RCS and the ease of the climbing system meant that the project was kept on track, whilst the wide platforms enabled safe working conditions. The PERI UP aluminium stairs were light and adaptable allowing changes in height on various stories from level to level.” RCS CL (RCS Lite) and CB 240 climbing formwork constructs the cores. Contractor P J Carey Ltd. Field Service PERI UK, Glasgow Office For construction of the cores, PERI’s RCS CL, the Light Rail Climbing System was used, with VARIO GT 24 wall formwork. The RCS CL (RCS Lite) is fixed to the structure by means of the climbing shoe through which the rail travels, which maintains alignment and structural stability of the system at all times. With the innovation of the Advanced Rail Extension and with a short fixed length rail of 3.50 m the system is installed and fully operational from first wall pour. For access inside the cores and on site, PJ Carey asked PERI to supply their PERI UP Aluminium site stairs. Being manufactured from aluminium, the stairs are lightweight and easy to transport around the site. Standard components can be adapted and built to suit all floor heights in increments of 25 cm. VARIO formwork was used on the majority of the core walls and columns. PERI UP aluminium stair tower providing access up the core to the slab levels. 11 Bringing Cleaner Seas to Sussex with PERI formwork Brighton & Hove WWTW, Brighton Neil Jackson, Site Manager: “The PERI UP scaffolding enabled safe access around the digester tanks and was a quick and easy system to erect and modify to suit the needs of the work force.” Contractor MJ Gallagher Construction Ltd. Field Service PERI UK, Brentwood Office A full range of PERI equipment was on display during the construction of the project. 12 PERI Ltd has provided their expertise and equipment to help develop Southern Water’s £ 300 million environmental improvement scheme in Sussex. The project includes a new wastewater treatment works at Peacehaven and two pumping stations located at Marine Drive in Brighton and Portobello, Telscombe Cliffs, and will involve ­tunnelling between 8 m and 41 m below the ground’s surface. Based upon their experience and longterm relationship with Southern Water, 4Delivery, the joint venture between Costain and MWH, was commissioned to deliver the project. Trueform Ltd and M J Gallagher were commissioned as the concrete contractors who in turn specified PERI Ltd to help construct the scheme. The shafts which will house the three pumping stations over the three sites are a massive 18 m in diameter. To develop these, RUNDFLEX, the Circular Wall Formwork was used to form the circumference of the shafts. PERI’s SKS Climbing system was employed with the RUNDFLEX on the external lining walls to carry the high concrete loads. The SKS system is a crane handled climbing formwork specifically designed for single sided formwork applications. TRIO formwork was used to pour the concrete lining the central dividing wall and other internal and external walls smoothly and evenly. The TRIO system was coupled with CB 240 climbing formwork to provide a combination which would allow the workforce safe access during the construction of the central walls. At the main site, the construction of the BAFF tanks, Lamella tanks and Flocculation tanks was required to carry out the main treatments. For this TRIO formwork was once again specified, along with SKYDECK aluminium slab formwork. SKYDECK system features a drophead, which means that striking can be carried out after a very short time, freeing materials up for the next concreting cycle and reducing equipment needed onsite for the contractor. PERI UP Modular System Scaffolding was used for the external scaffold around the three Digester Tanks which receive sludge – a bi-product of the treatment process. PERI UP provides the maximum level of safety, where the guard rail for the next level can be installed safely from the level below. MULTIPROP and TRIO to LIMPET Chambers. 2.05 0.40 0.25 10.04 Peter Gowman, of Trueform Ltd commented, “Working in a physically limited and confined underground space produces unique challenges and problems. At an early stage Trueform identified that finding the correct temporary works solution was essential to the success of this project, and by working closely with PERI from pre-tender and throughout the construction process, succeeded in providing practical and safe solutions for this demanding and complex project.” TRIO formwork and MULTIPROP in the early stages of constructing the BAFF tanks. TRIO formwork used in the construction of the BAFF tanks. 13 PERI’s Climbing System aids in regeneration scheme Dundee City Council HQ Building, Dundee On North Lindsay Street, Dundee, a new £ 34 million development has been under construction. The new headquarters for the city’s council will include a new flagship customer centre that will underline the city council’s commitment to modernising contact with the public. Dunne Group were awarded the concrete frame contract for the project which included two complex cores to be constructed, with one tight to the exterior façade of the old building which was to remain in place. Dunne Group came to PERI to source their exper- RCS CL (QCS Lite) climbs one of the cores. 14 ience in formwork and falsework solutions. PERI designed a solution with RCS CL, their light rail guide formwork system which was able to accommodate the limited space between the existing structure and new core as well as provide a solution for the floor slab which was running tight in behind the core. The RCS CL rail guided system provided a further solution to the 6 m exclusion zone that the main contractor had in place around the base of the cores. That traditional crane handled formwork could not be used as it would RCS CL platform in a confined section. breach this exclusion zone. With the RCS being guided through the climbing shoes, the system remains in contact with the structure for the duration of the construction, eliminating this risk and pro­viding a safer working environment for the construction teams. Dunne Group also used the lightweight aluminium PERI UP staircase which they required for tight spaces. This gave versatile access to all levels and could be man handled in confined spaces for erection and dismantling. PERI UP aluminium stairtower provides access to the decks. Gerry Hobson, Construction Manager: “PERI’s RCS was a safe system to use for the workforce and with less work required from the crane due it being rail guided, this increased the productivity of the core. The PERI UP stairs were quick and easy to erect and dismantle and gave flexible access to all levels.” Contractor Dunne Group Field Service PERI UK, Glasgow Office PERI RCS CL (RCS Lite) aids in 10 storey mixed used development Howick Place, London, SW1 RCS CL, the Light Rail Climbing System constucts the tree cores on the project, with a just-in-time system of delivery for the platforms due to the tight footprint of the building. Contractor Joseph Gallagher Ltd. Field Service PERI UK, Leeds & Glasgow Office At the site of the previously used House of Fraser department stores, Joseph Gallagher Ltd. are underway with constructing the new development that will fill the now demolished site. John O’Dwyer, Contract Director: “Although the workforce was new to the PERI climbing system, it was straight forward and simple to erect, and was easy to adapt to. Designs were turned around quickly and the good input that came from the sales and technical staff gave us the confidence in resolving any issues we had quickly and efficiently to ensure the smooth running of the programme.” The new 10 storey mixed used development will provide a total of 139,000 square feet of grade A office, accommodation and retail space in London’s SW1 area. The scope of works undertaken by Joseph Gallagher that started in February 2011 included ground works, pile caps, the sub structure, basement, car park, temporary works, the ground floor podi-um slab and the 3 cores, of which 2 were 8 storeys and the remaining one 10 storeys. Joseph Gallagher came to PERI to source their formwork requirements for the project and also took advantage of PERI’s ability to offer pre-fabricated formwork and systems. Due to the tight footprint of the site Joseph Gallagher asked PERI to prefabricate the platforms for the RCS CL light climbing system which would be used in the construction of the three cores. A Just in Time system of delivery was adopted for this project and resulted in the platforms being installed straight off the back of the transport that was delivering them. Using the RCS CL, Joseph Gallagher was able to achieve 5 and 6 day concreting cycles on the three cores. TRIO wall formwork was used on all the vertical walls on the project which together with the cores included the basement, car park, and car lift. PERI UP aluminium staircases measuring only 1.50 x 2.00 m were utilised throughout the project for access in the three cores. 15 Focus on Fabrication: Inside the PERI workshop at Rugby‘s Yard PERI News PERI Fabrication department at the Rugby yard. PERI Ltd. provide this service in our state-of-the-art assembly halls at our Rugby head office. Here, well-trained and highly qualified personnel work with optimally-designed machines and equipment which ensures cost-effective solutions even for the most unusual architectural requests. and therefore can an be delivered to client on a “just in time” basis so that stock does not have to be stored on site. With having the formwork prefabricated at PERI, costs can be controlled and quality assured under controlled conditions which can not be replicated on site. Radial shutter being fabricated. By bringing these skilled experienced employees and specialist tooling together, industry leading fair face finishes are achieved which are setting substantially new standards for concrete construction. Highly qualified personnel work with optimallydesigned machines. GB en 03 | 2012 6eb 793036 © PERI GmbH Increasingly, contractors are demanding pre-assembled and transportable formwork elements such as slab tables, special column formwork, architectural fair faced formwork or customised formwork. The advantages offered by PERI in providing this service are less time for customers making up on site, a solution to city centre sites where space is usually a premium and large storage areas to cater for equipment fabrication are rare The illustration featured in this brochure are photographs taken at a particular time on a construction site. This is why the safety details shown cannot be considered as final. © PERI GmbH PERI Ltd Formwork Scaffolding Engineering Market Harborough Road Clifton upon Dunsmore Rugby, Warwickshire, CV23 0AN Tel. +44 (0)1788.8616 - 00 Fax +44 (0)1788.8616 - 10 info@peri.ltd.uk www.peri.ltd.uk