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.
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