A project to create a new, 1,500-seat theatre building on a site with a restricted footprint and limited access has highlighted the industry knowledge, expertise and value which Harsco Infrastructure brings to construction projects. Harsco was able to design and construct an innovative, bespoke support girder system which overcame the restrictions of the site and allowed the construction of a number of key structural elements of the new building.
The new theatre in Bordeaux, France, is being built on a site surrounded by existing buildings. Harsco was asked to provide a support system to carry formwork for the construction of a number of 6 ft wide, 7 ft high, 105 ft long in-situ concrete beams. These beams needed to span the stage area and also support a further 5 floors of apartments and office accommodation being built above. The girder systems supplied by Harsco were to vary in length – with the longest being 30.90m – which needed to be lowered, relocated, and in some cases altered in length before work on the next beam could begin.
Working on behalf of Portuguese contractor BUILDIN, Harsco was able to draw on its wealth of technical expertise and devise a bespoke H33 braced truss-girder system which was sufficiently flexible and reliable to satisfy this demand. The Harsco H33 beam system offers a flexible, robust and reliable solution with the high load-bearing capacity needed for this type of project. Its excellent weight-to-capacity ratio made it ideal for the long spans involved, while the easy to assemble nature of the system components ensured rapid construction of the girders required.
This proved to be a faster, more cost-effective and practical solution than other alternatives which might have been used. However a severe lack of working space on the site meant that Harsco also had to adapt the traditional methods used to construct such a system.
“We actually did much of the construction work on the girders about 10km away from the site itself,” explains Harsco’s Ingo Schnelting. “This meant that we could prefabricate the girder sections under more controlled conditions, which made it far easier to ensure that they complied fully with the drawings. That way we were able to avoid any unexpected problems on site and be confident that the girders would fit neatly into place.”
Harsco was then able to partially dismantle the girders for transportation and deliver them to site. This also minimised the disruption to other trades that would have been caused by fabricating the units on the site itself. Lack of on-site storage space meant that Harsco had to adopt a just-in-time schedule for these deliveries and also co-ordinate this with special permission from the city authorities to operate extended length transport vehicles.
“We had to remain flexible in our approach to every aspect of this project,” adds Ingo Schnelting. “The different lengths of concrete beam that the building required meant that we sometimes had to remove the girders from the building and transport them the 10 km back to the construction area. There we were then able to re-configure their length before delivering them back to site and using hydraulic jacks to raise them into place, ready to support the formwork required to make the next beam.
“This was an excellent example of Harsco’s ‘Insight onsite’ philosophy in action and illustrates the way we are able to develop bespoke solutions that are tailored to the specific requirements of individual projects,” adds Ingo. “The end result of this approach is that we can deliver the highest standards of reliability, cost-effectiveness and safety and that was certainly the case on this project.”
For more information please call. 01372 381 300 or visit www.harsco-i.co.uk
Our In Focus feature this month is on the Berlin based Beta Tank design studio who are currently working on a project called ‘Scaffolding Brut’.
They will be showing off there works at the London Design Festival at the Victoria and Albert Museum between 17th and 25th of September 2011.
Beta Tank has been fascinated by scaffolding for a few years. Although these structures are found on almost every street, their aesthetic form comes from a system of safety requirements and repetitive engineering configurations, rather than any artistic endeavor.
The fact that such a visual construction universally exists untouched by design is an extremely interesting phenomenon that is inspirational.Beta Tank is primarily interested in the following questions, “If scaffolding systems are so impressive without design specifications, how utterly magnificent could they become if the need for beauty was attributed to construction?” And, “Given the fact that they cover large sections of any given city, rather than getting in the way, could scaffolding assist accessibility and mobility?
“Beta Tank is working on his second book Scaffolding Brut, which looks at scaffolding from all over the world and discusses its effect on cities, also providing possible futures for scaffolding, aesthetically and even on an engineering level.Scaffolding Brut will be a visual and animated investigation of the phenomenon of scaffolding, discussing the beauty of the fact that it is yet undesigned and exploring the possibilities of using the scaffolding system as an artistic medium, which one could use to design, with the hope of improving the aesthetics of urban life taken for granted.
Porcelain Scaffolding Couplers
These studio prototypes are two different types of porcelain scaffolding couplers; one rotates completely to create any angle, the other creates a 90 degree angle. Hand-made from glazed porcelain, each set includes a shortened pole and comes with either a gold or a platinum leaf nut and bolt. The Scaffolding Couplers Set are part of an edition of 50, each one numbered and signed by Beta Tank.
To find out more visit www.londondesignfestival.com/events/scaffolding-brut-eyal-burstein or www.betatank.net
Paul Hogan (Film Star)
The former pool lifeguard, union organizer and Sydney Harbour Bridge scaffolder who stumbled onto the telly in 1972 when his workmates dared him to enter a talent show.
That character (who never wore a suit save in jest; who talked, Hogan said, “like the guys down at the pub”; and who could spot a poser a mile off) was assertively working-class, unashamedly Australian, and enormously popular. As Hoges the footy-loving pub philosopher of The Paul Hogan Show, and as Michael J. “Crocodile” Dundee, the bushman who conquers New York with a grin, a “G~day” and a big knife, Paul Hogan made himself into an emblem of Australianness–and sold it to the world.
Adrian Chiles (TV Personality)
Chiles was born in Quinton, Birmingham, to an English father and Croatian mother, and moved a few miles away to Hagley, Worcestershireat age four.
A feature of his presentations is his Birmingham accent. He also speaks Croatian, despite having a self-confessed imperfect understanding of the language’s verbs, declensions, and cases. Chiles started his education at Haybridge High School, and then worked in his father’s scaffolding business, before graduating with a degree in English Literature from the University of London (studying at Westfield College, now part of Queen Mary, University of London).
Richard Dunn (Boxer)
Richard achieved his 15 minutes of fame in May 1976, when a brave but futile assault on Muhammad Ali’s world heavyweight title that ended after five one-sided rounds. Despite the beating, Dunn fondly looks back on the night in Munich as ‘the greatest thrill of my sporting life’.
Dunn earned his opportunity following a run of success that yielded British, Commonwealth and European titles. His achievements were sufficient to have a sports centre in his native Bradford named after him.
However, five months after the Ali defeat, Dunn lost all three titles to Joe Bugner.
The intervening years have been difficult. After losing most of his ring earnings when a hotel venture collapsed, Dunn returned to scaffolding, a decision which almost cost him his life.
In December 1989, while working on an oil rig, he fell 40 feet, shattering both legs below the knee. The injuries have responded poorly to treatment and he will undergo further surgery in July.
Now a grandfather, he lives in Scarborough with his wife.
Tom Davis (Comedian)
Tom spent most of his adult life as a market trader and scaffolder; his first break into comedy came in April 2005 by answering a newspaper advert for people with interesting stories about the 1980’s.
Tom thought it would be a perfect platform to try out one of his comedy creations on the unsuspecting public – Steve Matthews, a luckless loser from Salford. He managed to blag the whole day as his alter ego and was hooked. Since then, Tom hasn’t looked back and has been able to create a world of characters, which he can slip in and out of at the drop of a hat.
Gary Wilmot (Actor)
Wilmot’s father Harry was a member of The Southlanders and died in 1961, when Gary was six years old – his father was the bass voice that sang the famous line “I Am A Mole And I Live In A Hole”.
Despite these show business roots, his upbringing was outside of the limelight, and his first jobs were relatively low-key occupations; he was employed as a scaffolder, forklift truck driver and messenger before entering show business.
Richard Cole (Music Promoter for Led Zepplin)
Cole was from Kensal Rise, in the north London borough of Brent. His father was an architect who worked for Rolls Royce vehicle design, and later in aircraft assembly during World War II.
At age twelve, Cole became interested in music after hearing Elvis Presley and The Everly Brothers. At age fifteen he quit school and with his first job working at a dairy factory in Acton, earned enough money to purchase a drumkit, to which he practiced along to Buddy Rich and Gene Krupa records.
The low wages forced Cole to take up an apprenticeship in sheet-metal working whilst also working as a scaffolder on construction sites. He was also very interested in the fashion industry, at one point harbouring plans to be a fashion designer, and he claims to have designed the shirts worn by John Lennon and Ringo Starr on the Revolver album cover.
This Vacancy is being advertised on behalf of Dutton International who is operating as an employment business. Advanced scaffolder required for 4 week contract in Whitby. Must have experience in signing off work and hold CISR card. Contact Dave or John at Dutton International on 01642 788080. WHI112
How to apply You can apply for this job by sending a CV/written application to Lisa Smith at Dutton International,[email protected].
A scaffold platform fell 100ft at Wembley Stadium instantly killing one man and seriously injuring another.
Police have said that the raised platform collapsed without warning and fell about 100ft at Wembley Stadium construction site in north west London.
The first man was pronounced dead at the site and the secound was taken to Central Middlesex Hospital via air ambulance.
Two Health and Safety Executive inspectors was sent to investegate the cause of the accident at the Multiplex project.
A spokesman for Wembley Stadium said: “I can confirm that unfortunately one person has been killed in an incident today.
“We’re trying to establish the full facts at the moment with the construction contractor Multiplex, who are in charge of the project overall.”
Five construction workers have been taken to hospital after scaffolding and cladding collapsed at a new academy building under construction in Shropshire.
The incident happened at around 4.25pm this afternoon at the Abraham Darby School on Ironbridge Road in the Madeley area of Telford where Kier Moss is main contractor on the £35m new academy job.
Two rapid response vehicles, four ambulances, the Midlands Air Ambulance from Cosford, the Hazardous Area Response Team and two paramedic managers were sent to the scene.
A West Midlands Ambulance Service spokesman said: “When ambulance staff arrived, they found a large metal structure that had been put up around the school had collapsed.
“At the time of the collapse a number of workman had been on the structure and had become injured as a result of the incident.
“In total, there were four serious injuries:
“A man in his 40s had suffered spinal injuries. He was immobilised using a neck collar and spinal board and was airlifted to the Queen Elizabeth Hospital Birmingham.
“A man in his 50s had leg and chest injuries, a man in his 20s had abdominal injuries and another man in his 20s had back and pelvic injuries. All three were taken to Princess Royal Hospital in Telford which had been alerted to the possibility of a large number of patients.
“The final patient was a man who had minor injuries and was taken for a check up.
“The ambulance service worked with colleagues from the fire service to get all of the patients out of the wreckage of the collapsed structure. The structure was then searched to ensure there were no further patients.
“Despite the complexity of the incident and the difficult working conditions, all of the patients were on route to hospital within only an hour of the first 999 call.”
Four workers were injured today when a large scaffold canopy collapsed at a Shropshire secondary school.
The incident happened today at Abrahm Darby Academy in Telford at 16:28 GMT.
Out of the four people injured one of the men has been taken to Birmingham’s Queen Elizabeth Hospital by the Midlands Air Ambulance.
West Mercia Police said: “emergency services were on the scene and the Health and Safety Executive (HSE) had been informed.”
Cape’s offshore operations in the Far East/Pacific Rim have recently been buoyed by the award of two new contracts:
North Rankin B (Heerema) Woodside
Heerema, an existing Cape client in the UKCS, has awarded Cape its first contract in Australia with an estimated value of £6m. Mike Harding , Director of Offshore Operations Asia Pacific Rim explains, “Cape has been working closely with the Heerema Engineering team for some time providing detailed scaffolding designs and work packs for the known scaffolding scope. We have also been engaged at Batam providing innovative rope access solutions and scaffolding supervision for the local labour force erecting all the preliminary scaffolding.”
The main ramp up for all trades will be in September that will see Cape provide the full range of professional non-mechanical industrial services for the project inclusive of rope access, abrasive blasting, specialist protective coatings and scaffolding for the hook up scope.
Due to the locality of this project and the fact that it will be joined by two bridge sections to the existing North Rankin Platform it is an excellent opportunity for Cape to demonstrate its services not only to Heerema but also to Woodside.
PNG LNG Jetty (BAM Clough JV) Exxon Mobil.
Cape has also been awarded a service contract by the BAM Clough Joint Venture to provide Scaffolding Services for the PNG LNG jetty construction works.
The PNG LNG and condensate jetty will be constructed adjacent to the planned LNG facility twenty kilometres northwest of Port Moresby on the coast of the Gulf of Papua New Guinea.
Cape will deploy the first batch of operatives to the project at the end of August; for the initial phase of the construction works. Topside construction works are due to commence in January 2012 and take approximately twelve months.
BAM Clough is a joint venture group specialising in marine projects and construction in the Far East/Pacific Rim region. Headquartered in Perth WA, BAM Clough also has offices in PNG and Singapore. Although Cape has relationships with various Clough entities across the world, this will be the first contract with the BAM Clough JV.
Securing this contract is seen as a major achievement for the newly established operations in PNG.
Martin May, CEO of Cape Plc, commented:
“These contract awards again highlight the momentum building in the offshore market in the Far East/Pacific Rim region. The North Rankin contract is our third offshore contract award in Australia and we are delighted to be working with Heerema in the region. The BAM Clough award is also our third contract award in PNG this year and provides an excellent opportunity for us to demonstrate our offshore capabilities.”
Major international sporting events contracts have been won by an events scaffolding business which will also be expanding in China.
RIM Scaffolding Events Services which is based in Leeds has won the contracts to provide specialist access scaffolding for the ongoing test events for the London Olympics, and for golf’s Omega World Cup in Mission Hills, China.
RIM Scaffolding has created 18 new jobs this year and a total of 65 staff with a £3.5 million annual turnover.
The company provides scaffolding structures including TV camera towers, seating grandstands, marquee sub structures, commentary boxes, bridges, scoreboards and LED screen supports for customers which include the BBC.
The joint managing directors William Irish and Peter Madden are launching a new office in Guangzhou China with plans to open a office in United Arab Emirates to expand its services in the Middle East
Mr Irish said: “We achieve 85% repeat business on annual events and are currently heavily involved with the Olympic test events which is a good indication of our involvement with the London 2012 Olympic Games.
Harsco Infrastructure has provided Self-Climbing Formwork (SCF) which is now helping ensure quick and safe access during the construction of a 320m tall pylon for the world’s longest cable-stayed bridge.
The Harsco solution provides a fully enclosed temporary working environment which protects against extreme weather conditions during construction of the pylon and its 70m tall approach piers, which together form part of the record-breaking Russky Island Bridge at Vladivostok in Russia.
Optimised planning
During the technical planning phase Harsco’s SCF team used their expertise to accelerate the construction schedule and ensure maximum safety, particularly for the two climbing units used on the pylon. This eliminated the need for any time-consuming conversion work and resulted in a formwork and platform solution that is perfectly adapted to the tapering and inclined geometry of the pylon itself.
At the base, this calls for a ground plan of 7.8 x 13 m with a 2 m wall thickness, tapering to 7.1 x 7 m with a 0.7 m wall thickness at the top. The in-depth planning means that only a single work platform has to be removed from the SCF assembly, which is being done during a pre-scheduled break in construction work. All other adjustments and climbing can be carried out safely and without holding up the site work unnecessarily
Seven work levels
The SCF unit provides seven work levels with a total height of 19 m, with the top two used for upstream steelfixing. As both the external – and unusually also the internal – working platforms are all full-scale, steelfixing can proceed immediately after concrete pouring, thus saving time and increasing safety. On the next two levels, work is carried out on the formwork and the concrete surface can be heated from here if necessary. To accelerate work flow, the formwork level also has separate projecting materials platforms served by a crane.
The three trailing platforms round off the rigid, steel-frame climbing pier production unit. These platforms allow the concrete to be protected from the weather for two complete cycles after pouring, and again, heated if necessary. The result is that the concrete can be protected from the weather for almost three whole weeks after pouring, with any patching work carried out in a heated environment – a huge advantage during extreme winter conditions.
72 climbing cycles
To accommodate the tight construction schedule the system was specifically designed to allow adjustments to the self-climbing formwork, and the 72 climbing cycles of 4.5 m, to be performed quickly. Rigid separation between the steelfixing levels and the shuttering and climbing operations means that once the steelfixing is completed, the formwork can be retracted and cleaned before the climbing shoes are fitted and the climbing rails raised and tied for the next pouring cycle. This allows the SCF platforms to be raised immediately after completion of the steelfixing and the formwork to be moved into its new position ready for the next pour. Once pouring is complete, the steelfixing for the next cycle can begin.
Protection from the elements
To protect men and materials from the severe climate, the self-climbing formwork is fully enclosed, complete with a modular, movable roof. The enclosure ensures risk-free operations, even at extreme heights where the wind forces can be exceptional. It also allows the work chamber to be heated so that the concrete can set or be patched, even with external temperatures of 35O below (Celsius).
The SCF bracket: High load-bearing capacity, a single tying point
The exceptionally high load-bearing capacity of Harsco’s SCF brackets (150 kN vertically and 100 kN horizontally) is crucial to this project. The pylon’s special geometry and continuous tapering mean that only six of the 22 brackets employed actually climb vertically, with the others climbing at transverse and often changing angles of up to 5% from the vertical. Despite its high load-bearing capacity each SCF bracket requires just a single tie, with installation of the tie cones being a simple task. The cones only need to be positioned at the correct horizontal intervals, and unlike pairs of cones, they do not need to be set at a precisely measured angle. There is therefore no need for elaborate realignment of the bracket to accommodate changes of angle or inaccuracies when setting-up the formwork.
Perfect package
Harsco is providing a formwork foreman and a number of technicians to support the project and ensure that the meticulously planned work processes are followed on site. Along with Harsco’s SCF formwork and various other ancillary services it is providing, this is helping the construction process progress swiftly and safely.
Record-breaker
With its 1,100m central span the 3,100m Russky Island Bridge will ultimately be the world’s longest and tallest cable-stayed bridge. Traversing the Eastern Bosphorus, it will link the far east port of Vladivostok with Russky Island, which belongs to the city. The Russian building contractor, SK MOST, is aiming for a record-breaking construction period of just 43 months so that the bridge’s four-lane road is open in time for the Asia-Pacific Economic Cooperation summit at the end of 2012.
Russky Island Bridge – Data
Bridge deck width (steel structure): 21 m
Headroom under bridge: 70 m
Bridge length: 1,885.53 m
Total bridge length: 3,100 m
Largest span: 1,104 m
Height of bridge pylons: 320.9 m
Budget: €360 million
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