PROJECT DATA

Sophisticated Bridge Construction

Project: Dultenaugrabenbrücke, Germany

Contractor (and Architects): Porr Germany GmbH

MEVA Systems: KLK, Mammut, Special Designs

 
 
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Project

Bridge Construction: MEVA expertise in special formwork for infrastructure projects

MEVA Engineers are known for their creativity in combining standard formwork with specially designed forms to achieve economically and technically viable solutions. An example is the Rheinfelden bridge in south-western Germany with its tapered octagonal piers with varying inclinations and cross sections; projecting octagonal pierheads and abutments with a conical front at either end of the Bridge.

The Project
The A 98 single-lane motorway is being extended by a second pair of lanes. Work began in 2007 and required building a second bridge at Rheinfelden, parallel to the existing one and identical in design and construction. The eight-span continuous girder composite steel construction has a total span of 444 m and stands on piers up to 45 m high. The bridge is scheduled to be opened to traffic in the spring of 2010. Munich-based contractor Porr Deutschland GmbH won the German federal contract and requested the support of MEVA´s engineers in Munich and Haiterbach.

Foundations with Cross Sections in Different Size
The 7 piers stand up to 75 m apart on foundations whose cross sections vary depending to the pier height, the load and the substrate. The largest is 11 m x 13 m x 2.4 m (length, width and height). All foundations were formed using MEVA’s large format Mammut formwork system with the highest possible concrete load capacity of 100 kN/m2.

A Multi-Use and Custom-Tailored Solution for the Conical Piers
The piers (including pierheads) are 16 to 42 m high. The 8 sides of all piers taper towards the top – with different inclinations, some with a ratio of 1:70, some with 1:50. To achieve this efficiently and within a tight schedule, MEVA engineers developed two units of formwork inside wooden girders that could be adapted from pier to pier.

The girders on the outside remained in a plumb-vertical position. The tapered side was achieved with conical-shaped square timbers on to which the forming face was fixed. With the inclined facing locked into the plumb-vertical construction, there was no need to change the construction for the pouring cycles further up. As the cross sections tapered, the forming unit´s corner bracing was adjusted. This multi-use solution for all piers and cross sections saved much time and money. Another major benefit was that the solution required only one visible anchor in the middle. This enhanced the superb concrete finish achieved.
Climbing was done with the MEVA KLK 230 climbing formwork which proved its worth as an easy-to-assemble and operate solution.

The Custom-Tailored Solution for the Pierheads
The octagonal pierheads are approximately 5 m high and cantilever with differing inclinations. They were formed using Mammut base frames onto which a plywood case was attached to achieve the required conical shape. As with the piers, the base frames on the outside were plumb-vertical. 14 differently shaped conical plywood cases were pre-assembled, making up four forming units on the MEVA KLK 230. Its ample load capacity was sufficient even for pouring the projecting pierheads.

Abutments with a Conical Front Side
The piers (including pierheads) are 16 to 42 m high. The 8 sides of all piers taper towards the top – with different inclinations, some with a ratio of 1:70, some with 1:50. To achieve this efficiently and within a tight schedule, MEVA engineers developed two units of formwork inside wooden girders that could be adapted from pier to pier.

“We made the right choice“
MEVA Engineers are known for their creativity in combining standard formwork with specially designed forms to achieve economically and technically viable solutions. An example is the Rheinfelden bridge in south-western Germany with its tapered octagonal piers with varying inclinations and cross sections; projecting octagonal pierheads and abutments with a conical front at either end of the bridge.

 
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