Sustainable construction using unique formwork elements

The constant change in curvature and inclination of the components meant that 3D formwork planning was required which was the only way to ensure that the structures could be created using the unique formwork units. In addition to the planning and delivery of the system components, PERI provided reliable logistics and competent on-site support for the contractor Ed. Züblin AG Abu Dhabi.

After completion, the Sheikh Zayed Desert Learning Centre (SZDLC) will offer a unique mixture of museums, galleries and natural history exhibitions. Located in the Al Ain region, this prestigious project symbolizes a change of course by the Emirates in the direction of more emphasis on sustainability, and demonstrates that the country attaches great importance to the preservation of both its landscape and culture.

Most notable is the observance of strict rules and regulations for the integral and environmentally-friendly construction and operation of the SZDLC. The aim of the builders is to obtain the estidama certificate - the official seal of approval for sustainable construction. Externally, the building is characterized however by its unique design, the particularly high demands placed on the construction work, especially regarding the formwork and temporary support structures.

Uniquie formwork units-mainly implemented with system components

When planning the formwork solution, the maxim was to accommodate the complex geometry by means of different component dimensions. No inclination, curvature, and arching featured in the components is repeated, thus an individual plan of execution was compiled for each wall formwork element. Furthermore, the large component dimensions resulted in high formwork loads during concreting. Among other things, the beams are up to 300 cm high and the walls - which carry the loads of large slab areas into a centred area - are up to 200 cm thick.

These boundary conditions made having a very flexible formwork essential - adaptable to all geometries as well as a fresh concrete pressure of more than 100 kN/m2. VARIO GT 24 girder wall formwork was eventually selected whereby the individual system components could be arranged according to the project-specific loads, cross-sections and heights. In order to connect the individual wall formwork elements with each other, in spite of the numerous inclinations and curvatures, the PERI team of engineers also developed some special steel connection components.

SB brace frames serve as a quick and safe solution for the single-sided transfer of loads. These divert the concrete pressure which occurs during single-face concreting into the sub-structure. For the Desert Learning Centre, the brace frames are used in combination with VARIO GT 24 girder wall formwork for wall heights up to 3.60 m and concrete pressures of up to 30 kN/m2.

The slabs with differing thicknesses and ground plans are formed with the MULTIFLEX slab formwork system. Due to the large slab thicknesses, GT 24 lattice girders are used as crossbeams as well as primary beams which facilitates the creation of large spans with a minimum number of moving parts. The proven GT 24 girder is characterized by a high flexural rigidity that in turn ensures low deflections.

In those areas of lower heights, PEP slab props carry the MULTIFLEX formwork. For higher slabs - especially in the roofing and at the top of the elevator shafts - PD 8 shoring towers are used. These have been type-tested for heights of up to 21.30 m and loads up to 62 kN. The supporting units can be pre-assembled on the ground, if necessary, and then lifted into the position of use by means of a crane.

Successful construction through teamwork

PERI took on the entire planning of the formwork elements using 3D CAD software. This was absolOriginals Campus