Ratingen/Frankfurt am Main Whether Frankfurt or Paris: Hünnebeck demonstrates infrastructure expertise in the current expansion and conversion of important European airports. In Frankfurt, after the completion of Pier H, the new construction of Pier J is another successful major construction site: Nine building cranes and several mobile cranes are simultaneously in use to create a new pier from around 60,000 m3 of in-situ concrete and more than 4,500 prefabricated parts. Hünnebeck’s formwork and support solutions play a major role in the rapid construction progress of this challenging project.
The new Terminal 3 at Frankfurt Airport is taking shape: Parallel to the now completed shell construction at Pier H (also with Hünnebeck’s involvement) the construction company Anton Schick GmbH + Co. KG (Bad Kissingen) has also been building Pier J since 2019. The 600 m long above-ground structure with 27,800 m2 of floor space is being built in eight building sections. A mix of in-situ concrete (exposed concrete up to class SB 3) and prefabricated parts (around 4,500 units) characterises the shell construction of the four full storeys and two service storeys.
Hünnebeck has delivered a solution with ST 60 shoring towers, the manually operated Topec modular slab formwork, the crane-dependent Manto wall frame formwork and various special formwork to this project – formwork and support systems known by the site team for their high level of working safety, flexibility of use and cost-effectiveness. A sophisticated formwork and implementation concept, which makes optimal use of the available crane capacities, creates the preconditions for a safe and economical shell construction of the approximately 80,000 m2 wall area and 30,000 m2 slab area.
ST 60 support scaffold: high load-bearing capacity, little material
One third of the slab areas to be constructed are over 10 m high. Therefore, special attention is paid to the use of the ST 60 shoring towers in this project, as they act as formwork support in these high areas of cantilevered slabs with many girders. « We need a powerful support system that is not just safe and quick to assemble. It also needs to be geometrically flexible enough to allow the 11 m high, Y-shaped prefabricated supports to be integrated into the support scaffold, » says the Schick construction management team, describing what is important on the large-scale airport construction site.
Thanks to the high load-bearing capacity of the ST 60 system (up to 240 kN load-bearing capacity per shoring tower/60 kN per leg), the airport construction site can manage with comparatively few towers at relatively large distances for slab support. This saves time, material and provides space for the massive Y-supports. Although the ST 60 system with its advancing side protection and its patented decking relocation procedure offers permanently secured assembly and dismantling from inside the tower, it was decided on the airport construction site to assemble the towers horizontally on the ground and to erect and later move them by mobile crane.
Simple system, high level of versatility
The Schick team had already learned to appreciate the advantages of the ST 60 system during previous construction projects. For example, the simplicity of the design: The ST 60 construction kit consists of only six basic parts weighing max. 15 kg, from which highly loadable shoring towers (up to 240 kN/60 kN per leg) can be produced in three system dimensions. Two frames, three tower widths: 113 cm x 113 cm, 150 cm x 150 cm and 113 cm x 150 cm. In order to connect the shoring towers to each other, load-bearing nodes are arranged on the ST 60 frames in a 50 cm grid, which enable force-fit connections in eight directions. The best prerequisites for a high level of versatility and fast assembly, which is why Schick took over a larger quantity of ST 60s into its own inventory after the first project.
Everything on schedule
As with the new construction of Pier H, the Schick work preparation department planned all the formwork and support solutions required at Pier J in great detail and discussed them with the Hünnebeck formwork experts. This meant unpleasant surprises could be avoided. It will be some time before the first planes dock at the new pier and passengers can take advantage of the wide range of retail and catering options. But the shell construction phase will soon be completed successfully and on schedule.
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