08.11.2018 Special formwork solutions for extraordinary façade

Ingenious custom formwork solutions from Hünnebeck have saved time and money in the construction of a new office building complex in the west of Munich. Specially adapted column batteries of H20 custom formwork, for example, have enabled the cost-effective pouring of countless façade columns.

An architectural one-of-a-kind that outwardly communicates the attractiveness and quality of the rooms in its interior – this is how the Munich client, CA Immo Deutschland GmbH, describes its new project MY.O (meaning “My Office”). The curving multi-level arches and arcades in particular are intended to give the plastered reinforced concrete building its striking appearance. The building ensemble (approx. 25,000 m² of gross floor space) consists of an elongated building with five and seven levels and a free-standing six-level building with two sub-levels for an underground parking garage and technical installations.

After not even twelve months for construction, the building fabric is now almost complete. To ensure rapid and at the same time safe building progress, Hünnebeck has been actively assisting the contractor Baresel GmbH (Munich branch) with a formwork strategy worked out in detail. In the early stages, Baresel project manager Andreas Stumpf and the formwork experts of Hünnebeck’s Munich branch got together to sound out the special features of the project in hand.

Beneficial in two ways

The outcome was a formwork strategy that envisaged not only conventional formwork solutions for the walls, slabs and columns, but also a variety of custom solutions particularly for the unusual façade. For example, for the economic pouring of the precisely 1,454 façade columns, the Hünnebeck formwork specialists designed column batteries consisting of H20 custom formwork. This made it possible to shutter five 44 cm x 25 cm columns simultaneously with just two crane lifts. The ingenious feature of this solution was that both the standing and closing forms were equipped with aligning props, which made it possible to transfer the standing forms first and abolished the need to temporarily “park” the closing forms. In addition, the use of these column batteries made it unnecessary to erect a façade scaffold or use bracket scaffolds, as the column formwork is manipulated exclusively from the safety of the slab. Overall, this column strategy saved roughly 250 running meters of bracket platforms and the associated fittings.

For the arch blockouts extending over two stories (5th and 6th levels), Hünnebeck also developed and supplied a custom form. "Last year, we pooled our custom formwork construction activities in a central competence center. This is where all custom constructions of steel or wood for unusual geometries are designed and fabricated at short notice so that we can supply the construction sites punctually with the desired custom forms," the Hünnebeck expert serving the sites explains. "Custom formwork construction is an important activity for our company. In both the design and production of custom solutions, our customers benefit from a wealth of experience from already completed solutions. We’re never short of ideas."

And this also applied to the arch blockouts. Hünnebeck produced them in the conventional way using wood with a perfectly fitting shape-imparting substructure with several changes of radius. To permit stripping without a crane, the formwork was supplied to the site in several, manually portable parts. The 21 mm form lining was slitted on the reverse to allow for the tight curvature of the arches. A plastic coating on the concrete side ensured the demanded number of re-uses. The blockouts were attached on site to Manto frame formwork and fixed or braced. With this combination of Manto system formwork and custom-made formwork, an accuracy of fit was achieved that would have been impossible with the equipment and gear conventionally used on construction sites.

Rapid shuttering with Manto and Topec

All the wall expanses were shuttered with heavy-duty Manto large-frame formwork – 40 m² of shuttering can be transferred in a single crane lift without further bracing. On the MY.O site, some 1,400 m² of the quality formwork was in use, mainly including the 3.3 m high panels. Like all panels of the Manto range, these are extra-rugged thanks to the 14 cm thick, rigid frame and interior stiffening ribs.

For the slab surfaces, Topec aluminum modular formwork was mainly used, a system well-known for being extra-easy to handle. The up to 1.8 x 1.8 m Topec panels – i.e. 3.24 m² of shuttered surface area – are erected and dismantled by a maximum of two people from the safety of the ground in just three steps: hook it on, push it up and prop it.

900 m² of Topmax steel-frame slab form tables were also in action on the Munich construction site. These were employed by the fabric constructors in the upper part of the building as a slab formwork system, but were used primarily as safe, projecting (2 m) and load-bearing platforms to facilitate the pouring of the two-level arch blockouts. The alternative use of a conventional platform system would not have been economic in view of the large, irregularly arranged façade openings coupled with varying wall thicknesses.

Summing up

With work on the fabric now coming to an end, the project managers are highly satisfied with the formwork solutions proposed and supplied by Hünnebeck: "Above all, we received terrific support all the way through," says the site team. "They always had a sympathetic ear for us, for an idea or a special solution. Throughout the project we’ve maintained cooperative and above all excellent personal relations – even during phases with high deadline pressure and physical resources in short supply. We were very pleased with that."

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  • 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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