The Formwork Magazine

Jan. 2009 · www.doka.com

Safe and fast forming – at any height

Doka competence Forming record in Doha builds fast and efficient the Salem Al Fardan Residence Abdullah Salem Tower … page 3 Tower … page 7 Self-climbing premiere 50 years of success at the Capital Plaza Special anniversary in Abu Dhabi … page 6 for Doka … page 8 2 Doka Xpress

Editorial Doka News É Crystal Tower with Doka Kuwait – The 228-meter office tower will have 60,000 m2 of usable space on 52 floors and is sited in a densely built- up area. The core will be poured using a combination of SKE 100 automatic climbing formwork and Top 50 large-area wall form- work. Short repositioning times and positive experience with Doka formwork convinced A warm welcome to this first the contracting JV lead contractors. edition of Doka Xpress, the formwork magazine for the É Safe of Middle East. To help you make Marina 101 even more efficient use of Dubai – Marina 101 with 101 floors is one your valuable time, we have of the highest residential towers currently launched this customer ma- under construction in the UAE. For the gazine. Articles on interesting center core walls of the height of 425 m, the formwork solutions, written by Doka SCP 400 automatic climbing platform practising experts for expert is in use, climbing the entire formwork sys- practice, clearly point out tem in a single stage and keeping the crew all the main advantages and safe and protected from the weather. benefits, so that these can be seen at a glance. É Table Lifting System speeds construction In 2008, Doka celebrated Bahrain – The 32-storey Fontana Towers its 50th anniversary. Half a will be one of the largest residential com- century’s jobsite experience plexes in Bahrain. Saudi Build International in many countries of the world Contracting selected the Doka TLS system has left its mark on Doka. in order to save craneage (2 tower cranes On countless projects, on all in use instead of three) and speed up the continents, we have assisted construction workflow. Dokaalso delivered construction firms with our the necessary slab- and wall formwork. “Safe. Fast. Efficient.” form- work solutions.

A considerable part of this Page success can be put down to Index the partnership-oriented way Valuable construction time made up with Doka in which we work with our customers and share experi- Twin Palm Towers, Doha, Qatar ...... 4 ence with them. Their jobsite Self -climbing première in Abu Dhabi experience and ideas are Abu Dhabi, UAE ...... 6 constantly finding their way into our innovation process. New landmark on the Arabian Gulf Twin Palm Towers The result is new products and Al Fardan Residence Tower, Doha, Qatar ...... 7 services that offer even greater practical benefit in day-to-day 50th anniversary for Doka ...... 8 working on the site. I do hope Safe access for millions you will find this new edition Jamarat Bridge, ...... 10 of Doka Xpress an enjoyable read! In brief ...... 12 Doka’s central plant Mail us your feedback to [email protected].

Yours, Josef Kurzmann Executive Director, Doka Group Jamarat Bridge January 2009 3

t Doka’s Automatic Self Climb- ing Formwork SKE 50 speeds up construction at the Salem Abdullah Salem Tower.

The facts JOBSITE Salem Abdullah Salem Tower LOCATION Sharjah, UAE CUSTOMER Gustav Pegel & Sohn Contracting Engineering REQUIREMENTS High-rise building comprising car-park, office and residential storeys plus three technical floors and a helipad PRODUCT USED Automatic climbing formwork SKE 50, large-area formwork Top 50 and Dokaflex tables/ Dokaflex for the slabs

The solution Competent and With the Doka automatic climbing formwork SKE 50 the varying wall cross-sections are being cast swiftly and Dokaflex reliable forming tables allow perfect adaptabili- ty to any slab requirement.

Gustav Pegel & Sohn Contracting Engineering are currently undertaking the construction of the Safe. Fast. Efficient. Salem Abdullah Salem Tower at Al Khan in Sharjah. Consulting and site assistance The Salem Abdullah Salem Tower is a optimized casting for the high number of residential and commercial building project casting steps. The platforms of the SKE Besides the products, ser- comprising ground floor, mezzanine, three 50 automatic climbers and the Top 50 vices play a crucial role for floors for offices & parking plus three park- were pre-assembled under the supervi- Doka and this is why Doka ing levels and in addition a health club, sion of Doka field technicians who have consultants are being invol- swimming pool and 34 residential floors also been providing assistance during the ved in the whole construc- with three technical floors & helipad. first casting steps. tion process. “Doka engi- neers and support teams Forming walls in the Flying tables are helping us to meet our most efficient way. The typical slab with a total formwork schedule with timely supply For the forming operations on the core area of 2,544 m2 is formed using 2 sets of of materials. Moreover, the walls having a total formwork area of Dokaflex tableforms with transport devic- use of Doka SKE automatic 747.35 m2, Doka’s Top 50 large-area es, which enables to move them around climbing equipments has formwork elements and Automatic Self horizontally with no need of crane. The significantly speeded up our Climbing Formwork SKE 50 are being vertical shifting is fast with a transport work. The quality of service used. The automatic climbing system fork. Using complete shiftable units is the is more than satisfactory” as with incorporated large-area formwork most efficient and manpower saving way quoted by Project Manager Top 50 allows high operational speed and to form this large floor area. Engr. Ziad Sabouni. 4 Doka Xpress

Topping out at 246 m and with a facade planned in the shape of a palm tree, the Twin Palm Towers are among the most spectacu- lar high-rise projects currently underway in Doha, Qatar.

The facts JOBSITE Twin Palm Towers Valuable construction LOCATION Doha, Qatar CUSTOMER Al Seal Contracting and Trading time made up with Doka NUMBER OF TOWERS 2 HEIGHT 246 m STOREYS 57 LAYOUT FOOTPRINT Polygonal To build the technically challenging Twin Palm PRODUCT USED Automatic Towers in Doha, contractors Al Seal opted for climbing formwork SKE 50 NUMBER OF AUTOMATIC automatic climbing technology from Doka and are CLIMBERS 180 profiting from smooth, safe forming operations. January 2009 5

p Architectural rendering of the two identical 246 m Twin Palm Towers in the West Bay District of Doha.

t The automatic climbing form- work is designed for maximum flexibility, providing optimum ac- commodation to the geometri- cally challenging cross-sections of the in-situ concrete cores.

The solution The two identical 246 m Twin Palm Tow- one casting section to the next – swiftly, The in-situ concrete cores of ers in the West Bay District of Doha are safely and independently of the crane. the identical twin towers are modelled on the silhouette of a desert The fact that the climbing brackets are being raised in a five-day cycle palm and characterised by a polygonal always anchored in previously cured using the versatile SKE 50 au- layout. Following technical complications concrete, and that the – generously sized tomatic climbing formwork from with the formwork concept from a local – working platforms are railed-in on all Doka. Railed-in working plat- supplier, and severe delays in construction sides, means that safe working condi- forms and climbing brackets progress, the Al Seal Contracting Com- tions are guaranteed in every phase of that are always anchored in the pany opted for a high-performing self- the forming assignment – even in windy concrete, ensure safe forming climbing formwork solution from Doka. conditions. The Site Management also operations. Doka’s high technical problem-solving opted for a complete enclosure of the capability, gained from over 250 automatic main working platform. As well as making climbing projects all over the world, and the crew feel much safer, this also reduc- Al Seal’s positive experience with Doka es to an absolute minimum the hazard in the building of the Al Seal Residential potential from dropped tools or rebar. Tower and the Zig-Zag Twin Tower, were Eli Nader, among the key factors behind the award Field service technician ensuring Al Seal of the contract. swift construction progress project To enable construction work to resume manager Automatic climbing formwork as soon as possible after the contract for complex cross-sections had been awarded to Doka, the work- The Professional For the building operations on the two ing platforms and the Top 50 large-area With the SKE 50 auto- in-situ concrete cores, each comprising formwork were delivered to the site ready matic climbing form- 57 typical storeys, 180 Doka SKE 50 to use and were mounted to the automat- work, we can carry on automatic climbers are in action. The ic climbers under the expert guidance of non-stop forming. The Doka automatic climbing formwork is designed an experienced Doka field service techni- field service technician showed for maximum flexibility, providing opti- cian. The intensive training given to the us how to work efficiently right mum accommodation to the geometri- overseers on how to handle the formwork from the beginning. We can cally challenging cross-sections of the equipment, and the support from the exploit the advantages of the two in-situ concrete cores. The automatic Doka field service technician at the be- automatic climbing formwork to climbers are fitted with Doka large-area ginning of the forming assignment, have the full, which is helping us to formwork Top 50, large gangs of which also greatly helped to ensure a smooth, make up for the delays we had are “jumped” by hydraulic cylinders from safe construction workflow. at the start of the project” 6 Doka Xpress

The main working platforms and the follow-up platforms are safeguarded by a two-metre high enclosure made of sturdy trapezoidal sheet. u

The Facts JOBSITE The Capital Plaza Development LOCATION Abu Dhabi, UAE CUSTOMER Arabian Construction Company REQUIREMENTS five high-rise towers up to 157 m in height, 250,000 m2 of useable floor- space, 25,000 m2 of high- quality office space, 425 luxury apartments PRODUCT USED Automatic climbing formwork SKE 50, large-area formwork Top 50 and Dokaflex tables/Dokaflex for the slabs. Self-climbing première in Abu Dhabi The Solution 185 Doka automatic climbing formwork SKE 50 brackets and The Capital Plaza Development – a multi- more than 2000 m2 of Top 50 large-area formwork have been functional complex of five high-rise towers – is fielded for the works on the five Abu Dhabi’s first-ever construction project to be in-situ concrete cores. With the efficient SKE 50, the site crew built using Doka automatic climbing technology. are achieving a weekly cycle for the 3.9 m high typical storey. To carry out the works on the structure automatic climbers, in tandem with the cores, main contractors Arabian Con- wall formwork. struction Company are relying on Doka automatic climbing formwork SKE 50. It Maximum workplace safety can be raised in large gangs by only one ACC is raising these five structure cores Mohammed hydraulic unit, enabling work to progress in parallel with one another. Because the Ahmed Nasser, swiftly and efficiently. To permit optimum climbing scaffolds are firmly anchored project manager working cycles, a concrete placing boom in the concrete at all times, and are on each structure core is raised from “climbed” independently of the crane by The Professional one casting section to the next by two powerful hydraulic cylinders, the Doka automatic climbing formwork SKE 50 What convinced us, was ensures the very maximum in workplace the safe and quick lifting safety, in every phase of the formwork operation with hydraulic operations. The main working platforms cylinders and climbing profiles. and the follow-up platforms are also We don’t have to worry about craneage and we can work safeguarded by a two-metre high enclo- safely even in windy weather” sure made of sturdy trapezoidal sheet. This ensures that forming operations can continue smoothly even in very windy conditions. The dedicated support given This impressing multi-functional by the experienced Doka field service complex of buildings will com- prise five high-rise towers and technicians to the site crew is another offer more than 250.000 m2 of crucial factor helping work on the project useable floor-space. u to run so smoothly. January 2009 7

The Facts JOBSITE Al Fardan Residence Tower LOCATION Doha, Qatar CUSTOMER Construction Development Company (CDC) REQUIREMENTS 240 m in-situ concrete core to be built safely and in a tight construction schedule. The cramped site conditions in the densely built-up city centre location presented some tough demands regarding operations scheduling and efficient site logistics PRODUCT USED For the in-situ concrete core, 94 Doka automatic climbers SKE 50 have been deployed. Automatic climbing formwork The CDC site crew is forming, reinforcing and pouring the 64 casting sections in a 3 to SKE 50 and large-area form- 4-day cycle. work for the concrete core and Dokaflex tables for the slabs

The Solution New landmark on The site crew achieves a 3 to 4-day cycle for the 4.1 m high casting steps with the SKE 50 automatic climbers. the Arabian Gulf With its detailed formwork planning, just-in-time deliv- eries to minimise the on-site formwork quantities, and At a height of 243 m, the Al Fardan Residence streamlined materials- Tower marks a new record for Doha. scheduling for maximum eco- nomy throughout the formwork operations, Doka is helping the CDC site crew carry out The over 240 m in-situ concrete core is underlining the benefits of the self- this major project in a typically being climbed in 64 casting steps, each climbing formwork from Doka. “Safe. Fast. Efficient.” manner. 4.1 m high, using 94 SKE 50 automatic climbers, in a 3 to 4-day cycle by the Cost-effective floor-slab formwork contractors Construction Development The 1900 m2 area of slab in each of Company (CDC). Fitted with Top 50 the typical storeys is being formed by large-area formwork, these self-climbing the CDC site crew using cost-effective, scaffolds are easy to operate and very economical Dokaflex tables, which were Maher Al ruggedly built. The all-round fall-protec- delivered to the site ready for immediate Saudi, tion on the working platforms, and the use. This took a lot of pressure off the CDC project fact that the automatic climbing formwork site logistics, ensuring that work could manager is anchored in the concrete at all times, move ahead rapidly. together ensure safe working conditions The floor slab above the basement level The Professional in every phase of the formwork opera- was constructed using an economical The Al Fardan Residence tions, and smooth construction progress. combination of the versatile hand-set Tower is already the se- “The Al Fardan Residence Tower is al- formwork system Dokaflex and the easy- cond project that we’ve ready the second project that we’ve built to-erect d2 load-bearing towers. The built using Doka SKE 50 auto- using Doka SKE 50 automatic climbing columns in the typical storeys are being matic climbing formwork. The formwork. The quick and easy repositio- formed using the high-strength column quick and easy repositioning ning operation, powered by hydraulic formwork Top 50. Thanks to the effici- operation, powered by hyd- cylinders, the high safety standard and ent formwork planning and the smooth raulic cylinders, the high safety the outstanding product quality con- progress of the forming operations, standard and the outstanding vinced us right from the outset”, notes this project is right on time and right on product quality convinced us CDC project manager Maher Al Saudi, budget. right from the outset”. 8 Doka Xpress

Aerial view of Doka’s central plant in Amstetten.Ñ A history of success – Doka turns 50

Doka is celebrating a very special anniversary: 50 years ago, on 6th May 1958, Doka was first registered in the Austrian Register of Companies.

50 years later, Doka is a brand that fast as it could make them. In a short- enjoys worldwide recognition and is a by- ened version of the name of the client word for quality, innovation and capability for whom they were first produced, they in all areas of formwork technology. With were referred to simply as “Doka” sheets, its outstanding products, high-calibre a term which ultimately also gave the advisory service, competitive production company its name. Building on this suc- operations and comprehensive package cess, Doka successively moved in the of service offerings, Doka makes a major direction of system formwork. contribution towards sharpening its cus- 1955 tomers’ competitive edge. Innovation ensures growth Première for Doka formwork By constantly innovating, Doka always sheets at Ybbs-Persenbeug. From a shop keeps a step ahead. When developing to an industrial concern new forming systems, workload reduc- The roots of the parent Umdasch tion, ease of handling, safety, durability company go all the way back to 1868. and system compatibility are always its Construction of the Ybbs-Persenbeug top priorities. By as early as 1965 Doka hydroelectric power station on the River had already developed large-area form- Danube in 1955 ushered in a new era for work. This was followed in 1971 by the the company. For it was on this project first climbing formwork, which was used that the novel, glue-bonded formwork for the building of a ship lift at Lüneb- sheets from the Umdasch carpentry firm urg, . In 1977 Doka enlarged its in Amstetten made their debut, being range of climbing formwork with the SKE 1961 used by the client “DOKW”. The advan- 175 hydraulic automatic climbers. These Impressive growth: tages of these sheets were so convincing enabled the 180 m tall piers of what was the plant in . that soon the firm was selling them as then ’s tallest bridge, the Kochertal January 2009 9

t The Seidewitztal Bridge in Germany was built with the Doka forming traveller.

1971 Première for Doka climbing formwork.

1985 First building site with Framax framed formwork. Viaduct, to be formed without a crane. In production line, and 4 moulding stations 1981, Doka developed a special cooling for the end-reinforcements on the “H20 tower formwork. The hand-set formwork top” beam, will take annual output to 12 system Dokaflex 20 and repositionable linear metres of formwork beams. tableforms were also premiered in the same year. The Framax framed formwork International expansion system, now in service in its millions, Doka is currently represented in more started speeding up work on the site than 65 countries, with over 140 branch- in 1986. Over the past few years, Doka es and logistics facilities. Cost-saving has initiated a new chapter in the history approach, the high quality standards, of formwork-technology with its use of and the exceptional service are the basis 1996 high-tech wood/plastic composites, as of Doka’s long-lasting business relation- Doka climbing formwork for exemplified by the “H20 top” beam and ships. Listening closely to the contractors the colossal “sail” of the Burj the Framax Xlife sheet, to name but two. needs, the sales locations in the Middle al Arab. Other products such as the Load-bearing East had been established following a tower Staxo 100, the Self Climbing form- strong market demand in the context work SKE, the Table Lifting System TLS of an unprecedented expansion of the and the Platform system Xsafe show that construction industry. The first branch to continual innovation is at the heart of the be opened in the Middle East, and more Doka corporate philosophy. specifically in Kuwait, was in 1977, fol- lowed suit by Doka Gulf in the UAE, Doka State-of-the-art production facilities Establishment in Saudi Arabia, Bahrain, and efficient logistics Lebanon, and Qatar. For more than a To ensure its continued ability to meet decade Doka Middle East have been tak- ever-rising demand, Doka has been invest- ing up all the challenges, participating in 2007 ing heavily in expanding and upgrading its the most ambitious landmark projects in Forming the future with Doka production facilities. A new beam-flange the region. in Dubai. 10 Doka Xpress

The Facts JOBSITE Reconstruction of Safe access for millions Jamarat Bridge LOCATION City of Mina, Kingdom of Saudi Arabia CUSTOMER A structure to handle 1 million people at once. Saudi Bin Laden Group REQUIREMENTS Multi-level pe- destrian bridge with four main Reconstruction of the Jamrat Bridge, a the bridge structure and 20 tower cranes tiers 600-meter long each, pedestrian access bridge that enables are engaged. Doka formwork is being supported on a high number of pilgrims to get close to the three pillars used to form all elements of the concrete in situ concrete columns. - each known as a jamrah - in order to from the column walls to the main floors. PRODUCT USED Top 50 large- stone them, started in January 2006 and The Top 50 large-area formwork with easy area formwork, Frameco and should be completed towards October to assembly elements is implemented for Frami wall formwork, Doka 150F climbing formwork, clim- 2009. Stoning the jamrah pillars is a ritual in situ concrete walls, columns and edge bing formwork K that symbolises stoning of the devil and it beams. There are in use two types of forms part of the annual Islamic pilgrim- framed formwork; Frameco enabling short age to Mecca. The bridge, which is being framing times of the walls up to 3m and constructed by the Saudi Bin Laden higher, and Frami handy panel formwork, Group, contains a wider column-free which is used for smaller areas as it interior space and expanded jamrah pil- enables fast and economical forming. D2 The Solution lars, additional ramps and tunnels as well supporting scaffolds are used for edge Wide range of offered Doka as emergency exits and subway tunnels beams and ramps. Doka 150F climbing systems, engineering support directing the flood of supplicants safely formwork provides an economical and and timely deliveries enable to the focal areas. speedy solution for the many columns. contractors to cast swiftly al- The modular system can be quickly repo- most half million cubic metres Doka systems forming different sitioned, keeping crane usage the mini- of concrete and carry out this structural shapes. mum. It is used with Doka folding bracket complicated project in the Contractor Saudi Binladen Group is cast- K, enabling the platform and formwork to most efficient way. ing some 450,000m3 of concrete to create be lifted together. January 2009 11

p Four-tiered Jamarat Bridge with inflow and outflow ramps, emergency exits and subway tunnels, is designed to handle safely 1 million people.

t A crucial element of the struc- ture is the 600m-long four-tiers main bridge, supported on a high number of closely -spaced in situ concrete columns.

Mohammed Haneefa, Doka Saudi Technical Manager

Your contact We produced all of the shop and assembly drawings in just one and a half months and took less than three months to deliver all the formwork needed to cast al- most half a million cubic metres of concrete.” 12 Doka Xpress In brief

News, dates, media, awards

DOKA TURKEY OPENS NEW BRANCH DOKA AT THE PROJECT IRAQ 2008 Doka Kalip-Iskele in Turkey has opened its Doka Lebanon has participated in the new facility in the Gebze Organized Indus- Project Iraq 2008, the International Trade trial Zone. The new facility is located about Exhibition for Construction, Building Mate- 45 km east of Istanbul and occupies a total rials and Equipment. The exhibition that of some 17,000 m2. Along with the three- is one of the largest Iraq reconstruction storey office building there are 900 m2 trade events was held in Erbil from 4th till of enclosed storage and a 900 m2 area for the 7th of November. Doka has been pre- the Equipment Service. The new facility sent with its own exhibition stand, which lays the foundation for the dynamic expan- became with more than 500 visitors one Å Doka Turkey’s team in the sion of Doka in Turkey. Doka Kalip-Iskele of the most often visited places during the new building. is determined to increase its market share event. and strengthen its position as a leading local formwork partner. HIGH ACCOLADE FOR DOKA Doka has been awarded the Solid- Bautech Prize 2008 for the formwork operations on the building of the Burj Dubai, which was rated the best project in the “concrete construction” category. In particular, the university professors and internationally renowned construction experts singled out the ingenious materi- als-scheduling, the self-climbing formwork Å Doka Lebanon at the solution and the record-breaking three- exhibition Project Iraq 2008 day cycle for the over 180 casting steps as an extraordinary and indeed exemplary Solid-Bautech Prize for Doka Ñ accomplishment.

Doka GmbH Josef Umdasch Platz 1 3300 Amstetten, Austria Tel. +43 (0)7472 605-0 Fax +43 (0)7472 64430 E-Mail: [email protected] Internet: www.doka.com

Doka branches www.doka.com worldwide E-Mail: [email protected]

Impressum: „Doka Xpress“ is a publication of the International Doka Group. Publisher: Doka GmbH, Josef Umdasch Platz 1, A 3300 Amstetten, Austria. Editor-in-chief: Agata Orlowska. Layout design: Como GmbH, Linz, Austria In some cases the site photos show the situation during formwork assembly and are therefore not always complete from the point of view of safety.

Doka Gulf FZE Doka Saudi Arabia Doka Bahrain Doka Lebanon Dubai, U.A.E. Jeddah, K.S.A. Manama, Kingdom of Bahrain Beirut, Lebanon Tel. +971 4 8818096 Tel. +966 2 669 1008 Tel. +973 17 402 810 Tel. +961 1 612569 Fax +971 4 8818097 Fax +966 2 664 8625 Fax +973 17 401 436 Fax +961 1 612570 E-Mail: [email protected] E-Mail: [email protected] E-Mail: [email protected] E-Mail: [email protected]

Doka Emirates LLC Doka Saudi Arabia Doka Qatar W.L.L. Doka Jordan Ltd. Abu Dhabi, U.A.E. Riyadh, K.S.A. Doha, Qatar Amman, Jordan Tel. +971 2 676 5855 Tel. +966 1 479 10 03 Tel. +974 450 0628 Tel. +962 6 5545586 Fax +971 2 676 5840 Fax +966 1 477 54 16 Fax +974 450 0608 Fax +962 6 5545587 E-Mail: [email protected] E-Mail: [email protected] E-Mail: [email protected] E-Mail: [email protected]

Doka Emirates LCC Doka Saudi Arabia Doka Kuwait Doka Turkey Sharjah, U.A.E. Dammam, K.S.A. Salmiyah, Kuwait Gebze-Kocaeli, Turkey Tel. +971 6 556 2801 Tel. +966 3 832 06 06 Tel. +965 2 4822462 Tel. +90 (0) 262 751 50 66 Fax +971 6 556 2802 Fax +966 3 832 31 93 Fax +965 2 4822472 Fax +90 (0) 262 751 50 05 E-Mail: [email protected] E-Mail: [email protected] E-Mail: [email protected] E-Mail: [email protected]