Construction: 2014 - 2016 in three construction phases

Concrete renovation & strengthening of a waste bunker


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.

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

Result

Through close cooperation with our client and a project-specific formwork and blasting concept, we were able to lay the foundations for an optimum renovation process, as early as in the planning phase.

Thanks to careful preparation and experienced construction management on-site, we were able to maintain strict schedules and reduce downtimes. This was supported by operations mainly in 3 shifts.

Working under the highest quality criteria

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With more than 26 million passengers every year, Zurich is the number 1 airport in Switzerland. The airport is also an international player in terms of quality. Therefore, the chloride-damaged surfaces of the P6 multi-storey car park were overhauled to the highest standards, including the consistent use of certified particulate filters.

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Work on a European transport hub

Renovation of Felperbrücke - A13 Brenner motorway

The renovation works on the high-traffic Felperbrücke on the Brenner motorway were completed in three construction phases – with two-way traffic throughout – and posed great challenges to man and machine due to the tight interim and final deadlines.

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Renovation of the water-side dam wall

Maintenance of Pöhl Reservoir / Saxony

The structure required restoration due to the severely damaged concrete surface of the water-side dam wall. The remedial works for the dam wall were scheduled in two stages. Firstly, large areas of damage, weathered old concrete were removed by high-pressure water blasting. Secondly, a 20 cm-thick shotcrete facing formwork was constructed.

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Work on the North Sea bed

Renovation of the Limfjord Tunnel, Denmark

The Limfjord tunnel is a key link to the Aalborg region. Water penetrated the twin-tube undersea motorway tunnel due to leaky construction joints. The purpose of the renovation was to stop the water penetration and to reconstruct the damaged concrete.
 

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