24.01.2019 Scaffolding extreme

Sometimes scaffolders have to do real pioneering work. For example, when scaffolding an inaccessible aerial tramway pylon in the Berchtesgadener Land. The Bosta scaffolding material was brought to the site by helicopter and assembled by experienced fitters to create a safe working and protective scaffold for the upcoming concrete refurbishment.

The historic Predigtstuhl aerial tramway has been reliably and safely carrying up to 25 passengers plus a conductor up the Predigtstuhl mountain in Bad Reichenhall all year round since 1928. This makes it the world’s oldest aerial tramway still in its original state. The classic reversible aerial tramway with its two cabins synchronously traveling in opposite directions floats at 18 km/h from the valley station (476 m) to the 1,583 m high top station in 8.5 minutes. Loving care and careful maintenance have kept the aerial tramway, a “technical monument” since 2006, in perfect condition.

The necessary work also includes the regular inspection and overhaul of the concrete pylons carrying the support and propulsion ropes. Currently undergoing refurbishment is the 32 m tall Pylon II, which stands in the middle of rocky terrain. A tailor-made scaffold construction made from Hünnebeck’s Bosta frame scaffold system in combination with lattice girders and tubular couplers encloses the pylon’s challenging geometry and provides safe access for the refurbishers.

Detailed Planning

“The scaffolding was above all a planning and logistical challenge,” explains Managing Director Gert Fischer of CSG – Chemnitzer Stahlrohrgerüstbau GmbH, Munich office. The company had impressed the client with optimally coordinated scaffolding project planning and a detailed risk analysis based on the specific geographical location of the construction site. A total of 46 helicopter flights were required to bring the required roughly 28 t of scaffolding material to Pylon II – lashed without slipping and limited to a maximum of 600 kg per flight.

On site, the CSG scaffold erectors first assembled an approximately 40m2 cantilevered material platform comprising lattice girders and steel tubes on the west side of the pylon and anchored it in the rock with threaded spindles (using adhesives). This platform is the starting point for all work activities and is where all materials are deposited before being lifted to the desired scaffolding level by construction hoist.

The four scaffold erectors also worked their way up from this base. Within 4.5 weeks, they scaffolded the aerial tramway pylon on all sides with a Bosta working and protective scaffold of load class 4 (300 kN/m²) and enclosed it with safety nets. Both up- and downslope, the scaffolding reaches to the top of the pylon at a height of 32 m – downhill, a Bosta 70 scaffold staircase also provides safe access to the scaffolding. The west and east sides were only scaffolded up to a height of around 26 m so that aerial tramway operation could be continued during refurbishment. The systems material employed was combined with brackets of various sizes as well as structural tubular steel elements and lattice girders in such a way as to achieve optimum adaptation to the upwardly tapering pylon geometry.

“We have been using the Hünnebeck scaffolding range for many years and have always come up with practicable and safe solutions for all our projects. Whether Bosta 70, Bosta 100 or the modular scaffolding system Modex, all Hünnebeck systems are noted for their high quality, high safety, simple assembly and design flexibility. “They can all be combined with each other if required, for example,” says Fischer to explain why his company relies on Bosta and Modex.

Eventful company history

CSG’s currently 41 industrial employees mainly erect scaffolds in the central part of Germany, Berlin-Brandenburg and, through their Munich office, in the Bavarian region as well. Through the initiative and unrelenting efforts of company founder Siegfried Ranft, the business was founded in 1990 shortly after the collapse of the East German regime. The former head of the scaffolding department at “Bau- und Montagekombinat Süd” took the plunge into the market economy and hired the former GDR-combine scaffolding specialists for his new company. Hünnebeck was therefore operating in post-communist eastern Germany right from the start. People already knew each other well from many – actually forbidden – meetings at the Leipziger Messe. This partnership continues to this day and is being continued by Michael Ranft in the second generation.

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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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