Project: Knorr-Bremse, Brake Test and Development Centre, Munich
Contractor: Baresel GmbH, NL München
Formwork Engineering: MEVA Formwork Systems, Munich branch, Germany
100 different test systems for utility vehicles and freight trains up to 1,585 m long, simulating and testing their braking behaviour according to European and Russsian standards in climatic conditions ranging from -60° C to +80° C. Plus a building area covering 16,900 m², of which alone the experimental workshops take up over 1,000 m².
These are only some of the highlights surrounding the test and development centre being built for Munich-based braking technology corporation Knorr Bremse at its company headquarters. Top international standards regarding safety, process organisation, efficiency, logistics and quality, energy saving and sustainable development are being put into practice.
The challenges facing the concrete team are unusual. Foundations and walls, 40 % of them with a fair-faced concrete finish, columns and slabs were poured using MEVA rental formwork supplied to the contractor Baresel GmbH.
Architecural finish with even tie hole and joint pattern required
The walls, up to 40 cm thick, are up to 15 m high in the basement, 9 m high on the ground floor and 3.80 m high on the upper floors. They were poured using the Mammut 350 wall system. The large wall sections are poured in cycles of 12 m in length. The 3 m panels are ganged to achieve the respective wall heights. Combining same size panels achieves a harmonious tie-hole and joint pattern.
The Mammut 350 system‘s high load capacity of 100 kN/m² saves much time, since there are no limitations on the pour rate up to a height of 4 m. The inside walls, partly interrupted by consoles, intermediary slabs und wall sockets were formed without any site- built shuttering thanks to the system‘s large choice of panel sizes. This, too, contributed to the top concrete finish.
Maximum worker safety thanks to continuous fall protection
Work protection is exemplary. Fall protection is installed without a gap. Even so, safety installations are placed so that work and material flow are not hampered. In addition to the KAB working platforms and MEP shoring towers, safety systems such as the CaroFalt column formwork are in use.
Brake test and development centre A fixed ladder access with safety cage and a working platform with all-round protection are part of the system. No further safety equipment is required.
Site managers Johann Rottenkolber, Andreas Stumpf and Nils Köster come to the following conclusion after their good experience with MEVA formwork and engineering on this challenging construction site:
“The large selection of panel sizes in the Mammut 350 system, the superior concrete finish achieved with every pour and the repair set with which we were able to fix damages to the alkus all-plastic facing on site appealed to the entire construction team.”
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„Dat was alleen mogelijk met de 3D-planning, door nauwe samenwerking en dankzij de flexibiliteit van de ingenieurs van MEVA“, aldus het commentaar van uitvoerder Matthias Unglert over de steunpilaren.