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Brochure tunnel formwork

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Understanding how to break through Formwork solutions for your tunnel project The Formwork Experts _Understanding your tunnel project as a partner _Understanding the construction process truly and being knowledgeable about it is the prerequisite for being a partner to the building sector We have this understanding from the initial planning stage through to completion of construction _Understanding such as this is based on our experience from infrastructure projects around the globe We rely on our flexibility and innovation as the key to success Successful and economic implementation of tunnel structures requires flexibility The people at Doka are your expert partners right from the start We know how to listen and ask the right questions in order to identify challenges and the factors that influence a project The custom-tailored solution from Doka includes not only formwork systems but also the services needed to ensure that together we will achieve project success So we are well-qualified to be your high-performing and reliable partner in tunnel construction Doka is able to look back on a long history of _ understanding Listening intently, understanding the world as seen through the eyes of our customers, learning to understand all aspects and thinking ahead We are passionate about not being satisfied with the first solution that might get the job done Rather, we continue fine-tuning it until we come up with a true benefit for our customers This is the only way a small woodworking shop could grow into a globally operating formwork company, known by the brand name Doka since 1956 It is all part of progress: innovative infrastructure solutions combined with ever shorter construction times Not to mention increasingly stringent safety requirements for the structure as a whole For planners, contractors and suppliers, this means one thing: the criteria are getting tougher All over the world Important notice: Always observe all relevant safety regulations (e.g as issued by construction-industry employee safety organisations) applying to the use of our products in the country in which you are operating In addition, the User Information booklets (Instructions for Assembly and Use), which contain information on standard system set-up and on compliant utilisation of Doka formwork systems, must also be observed The illustrations in this brochure show the situation during formwork assembly and are therefore incomplete from the safety aspect It could be dangerous to combine our formwork equipment with equipment from other manufacturers If you intend to combine different systems, please contact Doka for advice first We reserve the right to make alterations in the interests of technical progress © Copyright by Doka GmbH _ Understanding requirements Sound advice begins during the project development stage for the structure Because from this point on, it's all about cost efficiency and having a leg up on your competitor Which is why the our internationally experienced experts make a point of advising you very early, and very thoroughly Doka technicians work to put together the most suitable formwork solutions in combination with highperforming service packages, exactly tailored to each individual construction project and method Regardless of how different and unique, one thing holds true for all tunnel projects: our commitment to the entire project solution has one common denominator – to design a construction process that is fast, safe and as good as it can be Structural elements In addition to the main tunnel and depending on utilisation (road, rail, water), the stringent requirements for a tunnel project demand various safety, pedestrian and vehicular access structures including: cross-cuts, emergency shafts and galleries, exploratory galleries, operational and monitoring structures, portal head, breakdown lay-bys, recesses and monitoring structures Const ject o r p n ructio WHAT is being built? Geometry of structure The ideal geometry is determined on the basis of construction method, use type, terrain, length and loads to be transferred Construction method The construction method is selected based on circumstances related to geology, time and traffic-related conditions such as traffic concept during construction, the terrain, the length and intended location of the structure (water, land, mountain), groundwater, and so on Formwork systems Safety in every situation Your site team and our Doka specialists work closely together to select the right formwork system Site requirements such as overall construction time, workflow (cycle time) and personnel resources are factors in deciding on the right formwork system For our customers we develop project-specific safety concepts to permit unimpeded operation, safe repositioning of the formwork and safe and fast access at any height Safe, smooth work routines speed up the workflow Site infrastructure Smooth and efficient construction progress depends on functioning site infrastructure Well thought-out formwork solutions standardise and speed up repetitive jobs, reduce risk, allow for an ideal work environment and simplify the workflow HOW is it being built? ctio u r t Cons d tho e nm Budget Budget Formwork system Customer requirement It pays to invest in quality system formwork A solution customised to meet your project's unique requirements saves resources, as well as time and money We accomplish this with quality-tested formwork systems and a custom-tailored project solution 279-000531-Q10 TIME SCHEDULE 279-000531 - ELEVATED STATION - LINE 1/2 set set stem set crown V1 set crown V2 set shoring set stem set crown V3 set shoring Foundation - PART Foundation - PART Foundation - PART Foundation - PART V-Piers - MAIN - PART V-Piers - MAIN - PART V-Piers - PART V-Piers - PART V-Piers - PART V-Piers - PART remarks PC1 PC2; PC2; PC3, PC1, PC2; PC2; PC3, V1 (1 pcs) V1 (1 pcs) V2 (1 pcs) V2 (1 pcs) V3 (1 pcs) ORIGINAL SCHEDULED start date end date 11.10.2015 02.12.2015 15.11.2015 10.12.2015 11.10.2015 02.12.2015 15.11.2015 10.12.2015 30.11.2015 15.01.2016 02.12.2015 03.02.2016 26.12.2015 27.02.2016 15.02.2016 18.04.2016 12.12.2015 14.02.2016 V3 (1 pcs) 07.01.2016 12.03.2016 C-Piers - PART 1 set of column C-Piers - PART set of formwork Main Span - Viaduct Side Span concourse - PART 1a set of formwork Side Span concourse - PART 1b Side Span concourse - PART 2a set of formwork Side Span concourse - PART 2b Main Span - Viaduct - PART 1 set of formwork Main Span - Viaduct - PART C1, C2, C3 C1, C2, C3 40m span 20m span; L=27.0 m 20m span; L=27.0 m 20m span; L=27.0 m 20m span; L=27.0 m 20m span 20m span 08.12.2015 20.01.2016 27.01.2016 07.02.2016 07.02.2016 29.02.2016 09.04.2016 19.05.2016 19.05.2016 11.10.2015 Foundation - PART Foundation - PART Foundation - PART Foundation - PART V-Piers - MAIN - PART V-Piers - MAIN - PART V-Piers - PART V-Piers - PART V-Piers - PART resuse V-Piers - PART station C-Piers - PART reuse C-Piers - PART station 1 set of formwork Main Span - Viaduct Side Span concourse - PART 1a reuse Side Span concourse - PART 1b station Side Span concourse - PART 2a Side Span concourse - PART 2b Main Span - Viaduct - PART reuse Main Span - Viaduct - PART station Foundation - PART Foundation - PART Foundation - PART Foundation - PART V-Piers - MAIN - PART V-Piers - MAIN - PART V-Piers - PART V-Piers - PART V-Piers - PART V-Piers - PART C-Piers - PART C-Piers - PART Main Span - Viaduct Side Span concourse - PART 1a Side Span concourse - PART 1b Side Span concourse - PART 2a Side Span concourse - PART 2b Main Span - Viaduct - PART Main Span - Viaduct - PART reuse station reuse station reuse station reuse station resuse station reuse station reuse station reuse station reuse station Overall duration stations Prepared by Zitzenbacher Andreas 06.03.2016 duration 52 days 25 days 52 days 25 days 46 days 63 days 63 days 63 days 64 days start date 11.10.2015 25.10.2015 18.10.2015 01.11.2015 30.10.2015 09.11.2015 19.11.2015 29.11.2015 06.11.2015 DOKA end date 29.10.2015 12.11.2015 05.11.2015 19.11.2015 25.11.2015 05.12.2015 15.12.2015 25.12.2015 08.12.2015 23.11.2015 25.12.2015 32 days 16.12.2015 28.12.2015 05.12.2015 26.12.2015 29.03.2016 07.01.2016 17.02.2016 05.02.2016 17.03.2016 11.10.2015 31.12.2015 12.01.2016 22.02.2016 04.02.2016 08.05.2016 16.02.2016 28.03.2016 16.03.2016 26.04.2016 08.05.2016 15 days 15 days 79 days 40 days 40 days 40 days 40 days 40 days 40 days 210 days PC1 PC2; PC2; PC3, PC1, PC2; PC2; PC3, V1 (1 pcs) V1 (1 pcs) V2 (1 pcs) V2 (1 pcs) V3 (1 pcs) V3 (1 pcs) C1, C2, C3 C1, C2, C3 40m span 20m span; L=27.0 m 20m span; L=27.0 m 20m span; L=27.0 m 20m span; L=27.0 m 20m span 20m span 20.11.2015 04.12.2015 27.11.2015 11.12.2015 09.12.2015 19.12.2015 29.12.2015 08.01.2016 16.12.2015 02.01.2016 25.01.2016 06.02.2016 14.01.2016 05.02.2016 19.05.2016 17.03.2016 29.06.2016 07.06.2016 27.04.2016 20.11.2015 08.12.2015 22.12.2015 15.12.2015 29.12.2015 04.01.2016 14.01.2016 24.01.2016 03.02.2016 17.01.2016 03.02.2016 09.02.2016 21.02.2016 02.04.2016 16.03.2016 28.06.2016 26.04.2016 08.08.2016 17.07.2016 06.06.2016 08.08.2016 18 days 18 days 18 days 18 days 26 days 26 days 26 days 26 days 32 days 32 days 15 days 15 days 79 days 40 days 40 days 40 days 40 days 40 days 40 days 262 days PC1 PC2; PC2; PC3, PC1, PC2; PC2; PC3, V1 (1 pcs) V1 (1 pcs) V2 (1 pcs) V2 (1 pcs) V3 (1 pcs) V3 (1 pcs) C1, C2, C3 C1, C2, C3 40m span 20m span; L=27.0 m 20m span; L=27.0 m 20m span; L=27.0 m 20m span; L=27.0 m 20m span 20m span 01.01.2016 15.01.2016 08.01.2016 22.01.2016 20.01.2016 30.01.2016 09.02.2016 19.02.2016 27.01.2016 13.02.2016 07.03.2016 19.03.2016 25.02.2016 27.04.2016 09.08.2016 07.06.2016 18.07.2016 18.07.2016 28.08.2016 01.01.2016 19.01.2016 02.02.2016 26.01.2016 09.02.2016 15.02.2016 25.02.2016 06.03.2016 16.03.2016 28.02.2016 16.03.2016 22.03.2016 03.04.2016 14.05.2016 06.06.2016 18.09.2016 17.07.2016 27.08.2016 27.08.2016 07.10.2016 07.10.2016 18 days 18 days 18 days 18 days 26 days 26 days 26 days 26 days 32 days 32 days 15 days 15 days 79 days 40 days 40 days 40 days 40 days 40 days 40 days 280 days 11.10.2015 November December January February March April May June July August September Workflow planning 32 days 65 days 60 days 68 days 120 days 72 days 72 days 72 days 72 days 86 days 79 days 307 days 06.02.2016 28.03.2016 26.05.2016 19.04.2016 19.04.2016 11.05.2016 20.06.2016 13.08.2016 06.08.2016 13.08.2016 October duration 18 days 18 days 18 days 18 days 26 days 26 days 26 days 26 days Optimised workflow planning is the basis of a cost-efficient formwork concept Planning takes into account the different structural elements, the construction method, the geometry of the structure, site logistics and all project-specific boundary conditions and it also saves time and money set A set B set B set B set A set A 40 days set A set B set A set B set A set A 42 days set A set B set A set A set A set A 07.10.2016 362 days Page _ Understanding effective consultation right from the start Your project success depends not only on selecting the right formwork solutions The close support of our experts from the start produces a comprehensive solution concept for your tunnel project Because we provide single-source supply for products, services and planning, project management and logistics es rvic sembly nician e s te as ch Pre- r / Te n-si O s L tic ogis cto ork rmw Instru tion • Fo rmwork k Inspec • Fo rmwor bled e • Fo assem r Servic as tome bly s • Cu is-assem D • ry elive ty h wit me nt > ject s o r P ces suc a Dok tion or enta nstruct m u I ms oc k • D rmwor n-site rk syste • Fo aining o ormwo f • Tr rtified e C • e Saf a ge rn d etu nd R ya liver e • De t in tim tics g jus Logis eturn ditionin n R e o t i k c • S rmwor nd Re a • Fo eaning l C a • yDok •m Project man ods eth ns for m tion utio ruc ct sol thod t s Con proje ver me and -and-co thod e ns od ut • C ining m r meth statio d ng • M p-cove nes an itori n o i o L T em • etro: erts cret • M x Culv te o o • B ncrem o C • nd id a n b to tio tion nsulta is a t i Inv ial co Analys ents init ctural quirem y e tru • S roject r ity stud • P easibil •F ing eer ssion g n i Eng submi Plannin Planning n al Bid • v io ons i ntat ppro • A pleme alculat ing C m I • tatics ly Plann • S ssemb •A Every tunnel is unique – as is the associated formwork solution The basis for developing a custom-tailored formwork solution is laid by consultation and support for your project from the very start Doka experts discuss the requirements in detail with you Structural Analysis SÜDRÖHRE NORDRÖHRE Einschüttung Bestand 30 66 32 2.90 11 11 29 11 3.12 33 99 5.97 5.91 5.40 50 R5.49 50 1.27 48 42 48 42 1.33 50 1.45 80 88 77 50 25 1.40 7.00 1.70 6.58 35 1.70 05 12 3.63 55 4.70 3.49 08 4.70 88 1.60 32 1.79 1.20 3.50 4.25 4.25 1.27 1.50 1.80 65 3.51 75 1.33 4.25 4.25 1.06 50 10 1.00 3.00 AUTOBAHNACHSE R = 800m 51.1 1.68 179 2.00 3.30 3.00 Only a solution based on a fundamental analysis of the entire project supports the best possible construction process It is important to identify the critical requirements jointly, as early as during the bid stage 4.05 Project requirements Focused bid planning is based on your sitespecific general conditions such as overall construction time, required cycle time, workflow planning and local conditions Feasibility study The formwork concept is elaborated on the basis of the boundary conditions identified beforehand In this step the custom-tailored formwork solution is determined by our experts and yours working together closely Minor adjustments in the workflow are identified to help optimise feasibility and d i n o b ltatio t on u ati cons alysis nts t i Inv itial ral An ireme in tructu requ udy t t • S rojec ility s P b i • eas •F _Understanding engineering: Efficient planning for a safe project sequence Efficient formwork solutions can be developed economically only if there is an understanding of project requirements and construction processes This understanding is the basis of Doka engineering services Bid submission Following thorough analysis of the structure, detailing of the project requirements and check of feasibility, the jointly elaborated solution is presented in a detailed bid Approval Planning Based on the most recent version of the planning documents, final formwork solutions are discussed in detail with you and released in writing ring on e e in ing issi ng Eng subm lanni Plann lP n id • B pprova entatio ations A ul • plem s Calc anning m I l • tatic ly P • S ssemb •A Implementation Planning Implementation planning is the basis for fast, safe forming operations compliant with country-specific standards and regulations It includes the deployment plans and any assembly and fabrication plans necessary to ensure best possible assembly and utilisation Statics Calculations Project-specific statics calculations compliant with local standards ensure that the formwork is stable and suitable when used as intended on site Depending on need, these calculations range from a simple project statics through to exact dimensioning including documentation (structural analysis) and certification that they were checked by a civil or testing engineer (verified structural analysis) Assembly Planning The plans created and approved by Doka provide you with the individual steps for assembly down to the last detail They are the guidelines for fast and safe on-site assembly by your site crew _ Understanding: Custom-tailored formwork solutions Individual formwork solutions custom-tailored to your requirements for your tunnel project 10 Metro Qatar The first phase of the infrastructure project consists of more than 82 km of underground lines and 25 underground stations The Red Line, or "Coast Line" as it is also known, traverses the Emirate from north to south and is the main line in Qatar's public transport system, phase of which is now in the implementation stage Location: Doha, Qatar Project owner: Qatar Rails Project solution: • certainty of costs, schedule and quality with coordinated overall formwork concept and onsite support • just-in-time deliveries for fast response even to workflow changes at short notice • on-time planning and delivery by provision of a logistics team • compliance with tight construction schedule and supporting advice in all stages of construction Red Line Challenge: • extensive large-scale project requiring a great deal of technical planning • formwork solution must comply with and support tight construction schedule Products used: Large-area formwork Top 50, Framed formwork Framax Xlife and Frami Xlife, Load-bearing towers Staxo 100 and Staxo 40, Heavy-duty supporting system SL-1 Project start: 2013 58 Green Line Box Culverts Quick and easy production of collector ducts, culverts and supply shafts These "small tunnels" are ducts, shafts, openings, galleries and culverts are encountered in widely differing structures and not just in tunnel projects A simple, speedy solution making outstandingly efficient use of synergies on your site can be constructed with Framed formwork Framax Xlife and Large-area formwork Top 50, products to be found in use on most builds Can quickly be readied for use ƒƒ minimum planning with prefabricated standard solutions in a 10-cm grid ƒƒ framed formwork Framax Xlife and Large-area formwork Top 50 can be used ƒƒ slab thicknesses up to 60 cm dealt with in the system Speeds up the construction workflow ƒƒ lightweight so easy to handle by crane, or repositioning with the integral steel rollers Easy access to operating points ƒƒ strong frame made of standard multi-purpose walings for walkthough openings even in structures with very small cross-sections  Pre-defined 10-cm grid to meet any set of requirements  Early stripping by uncoupling the joint plate 60 Forming is fast because there are not many points to be operated Walk-through openings even in structures with very small cross-sections Concrete monitoring with Concremote Measuring concrete temperature and strength in real time Concremote makes it possible to measure concrete strength and temperature in real time It uses the weighted maturity method (as developed by de Vree) to provide reliable, standards-compliant information online This facilitates targeted management of the forming and CIP concreting operations and helps ensure the necessary quality Reliable measures values straight from the concrete so that reaction can be fast Optimisation of the construction process resulting from real-time monitoring of concrete strength Targeted management of the forming and CIP concreting operations Proof of thermal stresses in structure to prevent cracking: Proof of concrete strength for safe stripping: Concremote can depict relationships (e.g.: core temperature to surface temperature) of all measuring points to one another and send out real-time notifications if thresholds are exceeded Graphs are generated automatically and can be called up at any time via the Web portal Concremote logs concrete strength and issues notification when the level necessary for stripping the formwork is reached Temperature development Data analysis Display of delivery, maximum and minimum temperatures from various positions Evaluation of ratios (e.g.: core temperature to edge temperature

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