13.09.2018 Rapid slab construction with Topec and Topmax

Erecting an almost circular building in a stepped pattern in confined space in only eight months– this feat has been accomplished on the building carcass of the outpatient department of RHÖN-KLINIKUM AG in Bad Neustadt an der Saale, Germany. It has all been made possible by skilled work preparation, efficiently coordinated execution planning, and flexibly utilized Hünnebeck formwork systems. Construction was accelerated particularly by the slabs shuttered with a small share of infill.

RHÖN-KLINIKUM AG is investing in a big way in the construction of a highly advanced clinic complex in Bad Neustadt an der Saale. “RHÖN-Campus-Konzept” is the name of the large-scale project that is geared to the tight organizational and spatial meshing of treatment specialisms. The emphasis is on the close dovetailing of the in- and outpatient areas and, thanks to close cooperation and digital networking with physicians with their own practices and service providers, this approach is all set to become a landmark strategy for a comprehensive medical service in the rural area.

Construction work at the RHÖN-KLINIKUM Campus Bad Neustadt is making rapid progress. Most of the planned new buildings have already been erected. On a roughly 100 m long and 75 m wide plot the building carcass of the clinic’s centerpiece has recently been completed: the new “Zentrum für ambulante Medizin” (ZaM or “center for outpatient medicine”), which will occupy a central position not only spatially. For the circular ZaM (diameter 70 m at its base) will also be the focal point of the entire campus – for patients and employees alike. The clinic’s outpatient department will be serviced by medical specialists, treatment practices, a pharmacy, a dentist, and other providers.

Architecturally, the ZaM is an eye-catcher. A self-supporting glass and steel structure spans a central hall extending from levels 0 to 3. The various floors of the ZaM are arranged around the new dome in a stepped pattern to account for the upwardly diminishing dome radius. But this is not all, for there are two building centers, with different radii on each floor. On levels 1 to 3, a continuous gallery encircles the dome’s central space.

Testing conditions

So that this complexcarcass could be erected as efficiently and safely as possible, the contractor Anton Schick GmbH + Co. KG from Bad Kissingen teamed up with Hünnebeck in developing an integrated formwork strategy – as on the construction of the new “Zentrum für klinischeMedizin” (ZkM or “center for clinical medicine”). The detailed execution plan was produced by Hünnebeck’s project developers in close cooperation with Schick’s work preparation team. The challenges included confined on-site space, immediate adjacency to an existing glass dome, different foundation heights, a stepped construction pattern in the building’s interior, and projecting slabs at a height of 15 m.

After meticulous analysis of all site conditions, it was soon obvious which formwork systems should be put to use. All the wall surfaces were shuttered with the aid of Manto large-frame formwork. Its main field of application was on the sublevel where Manto was set up in combination with trestles as single-face wall formwork against a 4.5 m high bored pile wall (the zone contiguous to an existing building). Combined with integrated wooden blockouts,Manto formwork was also used for the pouring of the striking N-shaped columns.

On the slabs, Topec beam-free modular slab formwork and Topmax steel-frame slab form tables came into their own. Their use has a major hand in the speed of construction progress – not least thanks to the extremely small amount of infill despite the curved building shape. Some 1,500 m² of manually handled Topec and 650 m² of slab form tables were kept available on site. Schick’s work preparation team carefully planned their use, so only a few areas had to be additionally shuttered on site in the conventional way.

Topec modular formwork for the interior slab areas

The Topec system consisting of lightweightaluminum frame panels with a dimensionally stable plastic form lining again demonstrated its straightforward, safe, and consequently rapid handling on the clinic construction site in Bad Neustadt. The large Topec panels measuring 1.80 x 1.80 m were mainly used. Owing to the slab height of over 4.50 m, shuttering and stripping were performed with the aid of the Topec Lift that hydraulically raises and precisely positions the panels. The comprehensive range of panels of the Topec system enabled the work preparation experts to devise a highly efficient formwork plan for the demanded building geometry. The share of infill was thus kept to a minimum. A large part of the Topec slab formwork has since been added to the now 4,000 m² of Topec equipment belonging to the Schick Group.

Topmax slab form tables for the peripheral areas

The peripheral slab areas were the domain of the Topmax steel-frame form table. The change of system ensured that the projecting balcony surfaces could be poured in rapid time. The two systems were erected simultaneously on each floor. However, the projecting balconies with a direct finish were only produced when the same finish was executed on the reinforced concrete slab.

Here again, despite the curved slab geometry, the Hünnebeck system employed impressed highly with the small proportion of infill, which was easily accomplished as well. This was made possible by squared timbers that are simply inserted into the 12 cm high steel frame of the Topmax slab form table to produce adjustment and infill areas. Depending on the size and shape of the area being produced, the system also makes it possible to combine the panels of manually handled Rasto/Takko frame formwork with the slab form table. Time was additionally saved by the direct attachment of the Hünnebeck Protecto edge protection system to the steel frame of the Topmax table – functional fall protection was therefore rapidly established on the 13 m² slab edge tables.

Conclusion

The shuttering of infill and adjustment areas costs money. The smaller their share, the faster and more cost-effective construction can proceed. Efficient formwork planning and ingenious formwork systems structurally adapted to such “obstacles” lighten the construction worker’s burden and reduce the formwork-related effort.

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Contact
  • Hünnebeck Deutschland GmbH

    Rehhecke 80 | 40885 Ratingen | Postbox 10 44 61 |Tel. +49 (0)2102 937-1 | Fax.: +49 (0)2102 37651 | info_de@huennebeck.com

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