Smart formwork for bridge piers

Combination of boarded and panelised formwork for guaranteed stability

Data & Facts

  • Project
    • Footbridges at railway stations in Lundby and Vordingborg (DNK)
  • Contractor
    • CG Jensen A/S
  • MEVA systems
  • Engineering and support
    • MEVA Schalungs-Systeme GmbH, Køge, Denmark

Foundation formwork set by hand

Public transport will play a major role in future mobility. Linking up villages and small settlements will be an important factor in this respect. In the small Danish towns of Lundby and Vordingborg, work is proceeding on the development and expansion of the relevant infrastructure.
 
Here, MEVA's formwork systems were used to build new footbridges over railway lines. CG Jensen, the contractor responsible for the projects, was faced with different tasks at the two locations. 

Extension of existing piers
The job in the village of Lundby was to extend existing round piers, 2.7 m tall and made of reinforced concrete, in order to build a higher bridge. These piers had been cast with boarded formwork. To raise them to a height of 4 m, the experts at CG Jensen decided to use MEVA's modular MEP shoring tower. This was assembled around the circular piers and served as a scaffold.

Boarded and panelised formwork 
To recreate the shape of the existing piers, an exact copy was first made of the boarded formwork. Two semi-circular timber forms were then fixed to AluStar wall formwork panels. The assembled boarded formwork thus ensured the continuation of the required shape. At the same time, stability was guaranteed by MEVA's proven panelised formwork system, which is structurally certified under GSV (German Concrete Formwork Quality Protection Association) standards. Though a genuine lightweight – with the largest (270 x 90 cm) panel weighing only 65 kg – the performance-to-weight champion can accommodate a fresh concrete pressure of 60 kN/m². 

Wall formwork on MEP
With the formwork assembled on the MEP shoring towers, it was possible to extend the existing piers to the required height. For reliable positioning and fixing of the individual panels, the contractor used a mobile working platform that allowed easy movement between the piers. 

Foundation formwork set by hand
The job in Vordingborg, further south, was to construct completely new bridge piers. The foundations were built using the lightweight AluStar wall formwork system. Its low weight offered obvious benefits due to the possibility, in many cases, of setting the formwork by hand. Another useful feature was the ergonomic grip profile on the rear face, which simplified handling. 

Large-area piers with Mammut 350
The bridge piers in Vordingborg also had to be provided with a recognisable boarded formwork finish. However, the plan shape here was slightly different from that of the polygonal-round piers in Lundby. As a result, further boarded formwork units were produced and fixed to Mammut 350 formwork, which served as a carrying construction. As in Lundby, the MEVA system solution with its closed hollow frame profile allowed reliable prediction of the fresh concrete load capacity. The heavy-duty formwork is able to accommodate pressures of up to 100 kN/m². Mammut 350 thus allows unlimited pour speeds up to a height of 4 m. Thanks to the large contact areas of up to 8.75 m², extensive wall areas can be efficiently formed with only few panels. 

"The works performed with MEVA's formwork systems ran very smoothly," says site manager John Rasmussen. "At the same time, the MEP shoring tower and the wall formwork delivered impressive quality, handling and flexibility."