Project-specific formwork and blasting concept for challenging dimensions and geometries:
Concrete renovation & strengthening of waste bunker / Ruhleben waste-to-energy plant
2000 tons of rubbish is loaded into the waste bunker of the Berlin waste-to-energy plant to generate energy and district heat. The 130 metre-long and more than 30 metre-high structure ensures that the five incineration lines are supplied with sufficient waste at all times.
Job Report – Factsheet
- Project:Waste-to-energy plant – Waste bunker (special structure)
- Contractor Berliner Stadtreinigungsbetriebe
- Client: Matthäi Bauunternehmen GmbH & Co. KG
- Type of operation:: Concrete renovation and reinforcement of wall and ceiling, as well as curved and projecting parts
- Special feature:Difficult accessibility, wall heights above 30 m, 24/7 use
Special formwork concept
The geometry and intended purpose placed special demands on the equipment technology. For example, a 6.50 m cantilever platform allowed access for the heavy equipment technology.
The traversable formwork scaffolding measuring 11 m long and 13 m wide was first used as a platform for the heavy cutting equipment, and later as formwork scaffolding for renovating the bunker walls.
The scaffolding block was increased in stages of 4 to 6 metres and ultimately measured 34 m high and weighed 90 t.
![](fileadmin/user_upload/hdw/referenzen/MHKW_Ruhleben/wannenwetsch_hdw_referenzen_schalung_ruhleben.jpg)
Concrete cutting
Cutting on the concave curvature between floor and wall, as well as the indentations for the 20 drainage hatches was tackled by the telescopic robots with 12 m jibs. This avoided cumbersome and non-traversable scaffolding.
Then, the robots gradually climbed the wall using the scaffolding. Finally, the areas inaccessible for mechanical cutting were blasted using hand lances.
Overall, more than 500 m³ of concrete with an average depth of 15 cm was removed, and 1000 m² of substrate was prepared.
Technical fact: Use of telescopic robot, standard robot and hand lance | Performance of the unit: 1000 bar
![](fileadmin/user_upload/hdw/referenzen/MHKW_Ruhleben/wannenwetsch_hdw_referenzen_betonabtrag_ruhleben.jpg)