The A6 is Germany’s busy motorway from the Greater Frankfurt area to Northern France and Paris. The motorway section near the town of Kaiserslautern was enlarged to 3 lanes per driving direction to better handle the traffic. Near Kaiserslautern, the motorway crosses the steep Waschmühl valley on a historical stone arch bridge that is 264 metres long and dates back to the 1930’s. A new steel composite bridge resting on three pairs of piers was constructed on the northern side of the historical bridge. The six piers, all of them between 12 and 29 metres high and conical at the bottom, were made of reinforced concrete. The piers‘ cross sections at the bottom range from 1.70 metres (all piers) to 1.35 until 2.19 metres. The top part of all piers is sized 1.70 m by 1.30 m.
The abutments and pier foundations were poured using MEVA’s Mammut wall formwork. MEVA recommended using their shoring towers Space instead of conventional climbing systems to pour the piers – and that is what the contractor did, saving much time and efforts when pouring the piers. The shoring tower is designed to effortlessly transfer the loads of the props that brace the formwork placed on it. What’s more, the shoring tower is fast and easy to relocate – it can be crane-transported as a complete tower or in several units, depending on the height of the shoring tower and formwork. The shoring tower is assembled from light-weight frame units that are 3 metres high. The tower units with a square footprint of 4.80 metres are pre-assembled and bolted together at ground level. Extension pieces allow for height adjustments of 50 and 100 centimetres. The working platforms are integrated in the tower units.
Fast assembly, relocation and disassembly
The bridge piers were formed and poured section by section. As the piers grew upwards, the shoring towers were height-extended unit by unit to place the formwork and pour the concrete. No built-in components for formwork support were required in the concrete as the formwork was supported by props placed on the tower. Assembling, relocating and disassembling the shoring tower is approximately double as fast as for conventional climbing systems and makes the shoring tower an interesting and economic alternative to conventional climbing systems when constructing medium-sized bridges and pouring bridge piers up to some 40 metres high. Piers and building parts with the following maximum dimensions can be poured using the shoring tower: 2.63 by 0.87 metres (if rectangular) or 1.75 by 1.75 metres (if square) or round building parts with a maximum diameter of 2.74 metres. The rectangular dimensions are linear, i.e. if one dimension is below 2.63 metres, the other dimension can exceed 0.87 metres as long as the two dimensions add to a total of 3.50 metres. Depending on the formwork and accessories used, especially at corners, the piers and building parts can be somewhat larger than indicated above.
„We saved much time and efforts“
„The MEVA suggestion and solution was well thought out. Using MEVA’s shoring tower Space instead of conventional climbing sytems saved us much time and efforts. MEVA technicians gave us a thorough support on the construction site and we are pleased with the pouring results“, says foreman Gatzke of contractor Alpine Deutschland.
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