Stationary formwork unit for double-T slab production delivered to Mindelheim

Glass GmbH Bauunternehmung commissioned Avermann Betonfertigteiltechnik with modernizing and upgrading its Mindelheim precast production line. This contract included delivery of a stationary formwork unit for double-T roof and floor slabs. This unit was to be installed on the existing 60 m long prestressing bed.

Helene and Albert Glass founded their building construction business in 1948. Today, Glass GmbH Bauunternehmung is being managed by the third generation of family owners. The Glass Group employs about 750 people at its operations in Mindelheim, Munich, Bad Wörishofen, Leipzig, and Berlin. The company headquarters and the precast plant are located on a 170,000 m² site in Mindelheim in the German Lower Allgäu region.

The group of companies includes Glass GmbH Bauunternehmung Mindelheim with a Munich subsidiary, Glass Ingenieurbau Leipzig GmbH with a Berlin subsidiary, Kreuzer GmbH & Co. KG Bauunternehmung in Bad Wörishofen, Glass GmbH & Co. Umwelttechnik KG, and Swiss Concrete GmbH.

Glass GmbH Bauunternehmung has a nationwide as well as European presence. Its activities cover all fields of construction, focusing on industrial, general building, turnkey projects, civil engineering, power stations, sewage treatment plants, and the complete range of activities in real estate. Another key part of the business is the construction of turnkey buildings for paper mills, particularly in other European countries. Furthermore, the company operates another precast plant in Türkheim, also in the Lower Allgäu region, specializing in the production of tunnel segments.

Glass continues to be dedicated to providing its customers with the proverbial “Swabian reliability” also in the coming years. To achieve this goal, the company hires 50 trainees per year and has implemented a comprehensive continuing training and development program for its employees.

According to the company, the Mindelheim precast plant is one of the most modern, highest-output operations in Southern Germany. It excels with its high level of integration, high quality standard, and on-time delivery and assembly – factors that shorten the construction phase and enable tailor-made solutions. The sophisticated range of precast elements has been certified to European and national standards.

Glass commissioned Avermann

Avermann Betonfertigteiltechnik GmbH & Co. KG was commissioned with modernizing and upgrading the production line. This contract included delivery of a stationary formwork unit for precast double-T roof and floor slabs to be installed on the existing 60 m long prestressing bed. This unit comprises a heavy-duty base frame with a central core whose width is adjustable by mechanical means, as well as two hydraulically operated side parts. The width of the core element can be set in a range from 1,000 to 1,350 mm.

Its robust base is supported on rubber-metal vibration dampers and anchored to the floor. Crossbeams and transfer carriages are installed on this base frame to ensure dimensional stability of the adjustable central core and the mobile side parts of the form. The central core is divided in the middle in the longitudinal direction; it is manually adjustable to various web widths. The intermediate space is filled with formwork panels; abutments and drill holes for fixing them are located in this area. Core and side parts are covered with an 8 mm thick steel sheet layer. Both sides are used as working platforms; they can be reached via two stairs on the front side and in the middle, as well as three ladders for side access. Permanently installed steel rails include a mid-rail and a toe board to provide effective fall protection.

Double-acting hydraulic cylinders ensure displacement of the side parts over the entire length of the prestressing bed. This arrangement results in a crosswise travel distance of about 875 mm at a web bottom width of approx. 200 mm. Synchronization is provided via mechanical shafts. Pressure is continuously applied to the hydraulic cylinders in order to ensure adherence of the form’s side elements to the floor. The scope of supply also includes a pressure controller unit. The form’s design eliminates the need for top bracing.

When deciding in favor of this new formwork system, Glass GmbH placed particular emphasis on effectively utilizing the form and shortening setup times. The parties involved in the project engaged in many discussions over a period of 1.5 years to agree on smart solutions and details that consistently meet these requirements.

Adjustment of the core width, for example, requires only a fraction of the original changeover time because all necessary work steps can be completed from outside, supported by hydraulic systems. There is no need for manual work inside the confined space when setting and clamping the central core. In the event of any gap between double-T slab production runs, the formwork system can also be used for other products thanks to a dedicated feature that allows quick adjustment of the conical core and side walls to a rectangular cross-section in order to manufacture beams. This arrangement provides added flexibility so that Glass GmbH Bauunternehmung can quickly respond to the prevailing market conditions.

Comprehensive contract scope

Specially profiled forms with integrated magnets supplied by B.T. innovation were used for the edge areas of the side surfaces. Thermal oil heating elements have been integrated in the webs in order to accelerate curing. Heat accumulation foils are suspended on the side parts to mitigate heat loss. The contract scope also included delivery of the complete hydraulic equipment, including controller units, and its assembly and commissioning.

64 Wacker AR54/6/250 vibrators were installed to ensure effective compaction. At the same time, Howal delivered a universal formwork system. Glass ordered the associated junction boxes, indicator lights, timer, system accessories, and inverter control unit directly from Wacker after close coordination with the suppliers, thus ensuring smooth and effortless commissioning.

Satisfied project stakeholders

All project stakeholders were exceedingly satisfied with the outcome: Thomas Strach, Sales Engineer at Avermann Betonfertigteiltechnik, highlighted the outstanding cooperation during the entire project, including initial contract-related discussions, delivery and assembly, and the smooth handling of the commissioning process.

Franz-Reiner Göhrle, Plant Manager at Glass GmbH Bauunternehmung, reiterated: “We are particularly pleased with the high performance of the Avermann equipment, which is set to render production of double-T slabs much more effective at the Mindelheim factory.”

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