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High-Rise Towers: an Integrated Approach Between Climbing Formworks and Stationary Booms

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High-Rise Towers: an Integrated Approach Between Climbing Formworks and Stationary Booms High-Rise Towers: an Integrated Approach between Climbing Formworks and Stationary Booms Ciribini, A.L.C. DICATA, Università degli Studi di Brescia (email: [email protected]) Tramajoni, M. Peri Italia (email: [email protected]) Abstract The Research aims to investigate how a Construction Management System dealing with the erection of the High-rise Towers could be enhanced. Furthermore, such an effective and proactive Management System purports that the integration between the climbing concrete forming machines and the concrete pumping, pouring and placing devices must be achieved. First of all, the methodology adopted by the Research Unit required to perform a comparative analysis, in close co- operation with the Leading World Manufacturers, through the investigation of the most effective managerial and technical available options. Furthermore, the investigation performed by the Research Unit took into account some meaningful case-studies (located in Germany, Italy, Spain, Sweden, and Switzerland). The main conclusion lies with the need for distinguishing amongst different kinds of High-rise Tower (depending on its heights and shapes) and the preferred models of Site Management to be followed. Keywords: high-rise towers, site management, formworks, concrete pumping system. 1 1. The formwork and steel fixing systems In Italy, the poor performances and the lack of managerial skills affecting the construction sites are due to an absence of the co-operation amongst the various Players (Client Organizations, Main Contractors, Sub-Contractors, and Suppliers). Indeed, quite often it happens that a Public or Private Client Awarding Organization seems to neglect the Site Management-oriented topics. Likewise, the Main Contractor does not want to be really involved into the Site Management-related solutions, preferring to leave the choice of the preferred formwork, steel fixing and pumping systems to its first- tier Sub-Contractors. Nevertheless, the Trade Contractors are sometimes forced to cope with a reduced margin profit and are not so available to take into account a wide spectrum of managerial and technical options in order to find out the most viable one. Therefore, it can happen that the original Site Plan must be suddenly amended because, for instance, the Trade Contractor decides to use a formwork climbing system instead of a self-climbing one, as it was previously planned and agreed during the tendering phase. Such a change to the original Site Plan, increases, of course, the total amount of the contract and modify the features of the tower crane to be installed: the results of the amendments to the original Plan might cause unforeseen risks and could cause a lot of delays and claims. However, according to a worldwide leading Manufacturer, large formwork elements on a retractable climbing scaffold have been adopted for the first time in 1972 for the construction of the Dresdner Bank Building in Mannheim, Germany. On that occasion, the formworks and climbing scaffolds were lifted with a single pick of the tower crane. Moreover, the first self-climbing system has been used in 1977 to build the Reichenberger Grund Valley Bridge, in Germany, too. The Research aims to investigate how the construction of some recent High-rise Towers has been planned and scheduled in several European Countries (Germany, Italy, Spain, Sweden, and Switzerland). The Researchers tried to identify the most effective usage of the formwork climbing or self-climbing devices, concrete pumping systems, pouring and placing equipments, to assure the most suitable co-ordination with the tower cranes in order to improve the handling of the materials and tools. The main goal to be attained was focused upon the preferable options to be used when a Construction Managers, acting on the behalf of a General Contractor, has to plan a Site Layout concerning such a Large Project. Indeed, a Construction Manager has to decide which constraints should be considered when choosing (to hire or to buy) a concrete forming machine in order to build the reinforced concrete-framed Core of a High-rise Tower or of a Multi-Storey Building. On the other hand, the standardized solutions for the climbing systems have to be tailored to a specific site and to the building requirements for forming the Core. Furthermore, the ways to assembly the formworks vary depending on the concrete pumping, pouring and placing systems and on the crane-lifting devices. A meaningful finding that the Researchers highlighted shows that the most effective solution needs to introduce the crane-independency of the formwork system, in order to speed up the works and to make easier the operations during all weather conditions (through a wind protection panel which is often also used as an advertising area or 2 surface). The Crane-independency deals with the forming, striking and climbing, and allows the work procedures to be accelerated on the Construction Site, without any increase of the Health & Safety- related risk levels. In such a manner, different kinds of gangs and crews (carpenters, steel-fixers, concrete pumpers, etc.) could work over the platform without any risk to fall from the height, too. The self-climbing movement is allowed by a rail in order to make sure that the units are always connected to the building by the means of a climbing shoe which has been conceived to do so. The climbing shoe guides the rail during the moving process to the next connecting unit. With the climbing systems any asymmetrical load distribution can be adjusted by a hydraulic system. Indeed, just the hydraulic jacks which lift the whole units through a mobile equipment (a noiseless 2, 4, 6 or 8-fold operational hydraulic pump), make free carpenters, steel-fixers and concrete pumpers from the assistance of the tower crane. The climbing mechanism has a lifting power of approximately 100 kN and raises the unit to the next concrete pouring step without the need of any intermediate anchor at a speed of 0.3 m/min. Figure 1: The anchors (Peri) A climbing cylinder for the self-climbing formwork system has been conceived in a manner that it can be handled, used and also shifted more easily. Anyway, a highly performing bracket spacing reduces the amount of the anchors to be fixed: the system can be climbed just the day after the pouring of the concrete. Finally, the whole movable system is mounted on a carriage which can be retracted by 90 cm without any usage of the tower crane. Moreover, a special version of the formwork system functions with one bracket which makes possible to hang both formwork sides on one gallow: even the opposite working platform is attached to the same gallow. Figure 2: A complete assembly of a temporary self-climbing formwork (Peri) 3 Therefore, the tower cranes might be made available for other tasks (e.g. to handle materials, tools, etc.), without interfering with the concrete pumping, pouring and placing-oriented tasks. On the other hand, by the means of a platform, the steel bars might be stored on the enclosed working platform before the further climbing lift: the climbing tasks can be achieved during wind speeds of up to 72 Km/h. The main versions of a movable forming machine depend on: • the need for a large working and storage area; • the monolithical concrete pouring of the slabs and walls. The complete cycle of moving the formwork, the platform and the placing boom to the next section can be performed in approximately 15 minutes. When folding out and mounting on a self-climbing formwork, the pouring and placing of the concrete could be managed through a stationary boom, instead of the traditional buckets. However, the choice of the most effective solution depends on how many levels (usually 1 till 3) in advance the shuttered Core has to be climbed and on the amount of days needed to achieve a complete storey (usually 3 till 10-day cycles). Very often the scheduling of the tasks to be performed shows as a compelling requirement to concrete the Core walls two or three levels in advance of the slabs. Likewise, the stationary boom for the concrete pumping could be self-climbed or can climbed on a climbing formwork system, if required. Otherwise, if a climbing formwork has to be moved by the means of a tower crane, the Site Planner must not neglect the location of the tower crane itself and the assessment of its usage cycles in order to carefully choose the most suitable climbing system. When scheduling a lot of tasks to be performed, the usage of the tower crane must be assessed in centesimal hours according to a weekly survey of the amount of handling movements that should be performed by a tower crane operator. Once defined the total amount of the hours for the usage of the tower crane, the idle times have to be evaluated, too. The Research Unit reckoned, according to a survey it accomplished, that the usage of a tower crane could reach up to 85% of its potential, considering different reasons for the delays. However, the productivity rate in a working cycle should be assessed in hrs/m2. The duration of the formwork-related activities must broken down in: • base time; • additional time; • idle time. 4 Parts to be handled on a weekly basis Amounts of Duration Hrs/Crane Movements Handling of the formworks (15 min per cycle) 70 0,25 hrs 17,5 Handling of the steel reinforcing bars and cages 55 0,10 hrs 5,5 Placing of the concrete (14 m3 / week using a ½ m3 bucket) 28 0,25 hrs 7,0 Handling of the other elements 87 0,10 hrs 8,7 Total amount 38,7 Figure 3 : The weekly resource demand of a tower crane (Peri) The main activities could be listed as it follows: • assembling the formworks; • positioning the compensations.
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