rmd kwikform formula magazine issue 18 uk

UK ISSUE 18

ALSO IN THIS ISSUE... USA EXPANSION, LOS ANGELES BRIDGE, BASRA STADIUM, PARASLIM AND CHIVAS BROTHERS...

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BIRMINGHAMNEW STREET GATEWAY PROJECT

Welcome to the 18th edition of RMD Kwikform’s Formula UK magazine.

Formula UK has come a long way and despite the harsh economic climate in the construction sector RMD Kwikform has flourished as a major competitor in the global formwork and falsework industry. Since the last instalment RMD Kwikform has continued to win high profile projects, expanded into new markets and has reached new highs with product innovation.

In the UK RMD Kwikform has taken on some truly impressive projects including a major national infrastructure project; the redevelopment of Birmingham New Street’s Gateway Project for Network Rail. The challenging project will see one of the UK’s primary national train stations redesigned and repurposed for the 140,000 plus commuters passing through it each day, all while functioning as normal. However, not all of RMD Kwikform’s recent success has been isolated to the UK. In the USA its acquisition of CMC Construction Services’ heavy forming and shoring assets. As one of the leading resellers of formwork and falsework solutions in the United States, CMC has given RMD Kwikform access to an existing client base and established sales force in the world’s largest construction market and countless business opportunities.

RMD Kwikform has also maintained its winning ways in the Middle East, obtaining the shoring contract for the construction of the Basra Sports City Stadium in Iraq, which will be able to seat up to 65,000 people. Once complete the stadium will become Iraq’s premier national arena, playing host to the 21st Gulf Cup and other competitions and events, national and international, in the future.

Amongst all the success in the business, RMD Kwikform has also triumphed with technological innovation of its products with the launch of its new guided formwork system Ascent. The formwork system has the potential to transform the way formwork is designed and used in the future with its debut application taking place on London’s South Bank, one of the largest stages for construction in the world.

As always if you have a project you feel should or could be featured in Formula UK magazine, please do not hesitate to contact a member of the editorial team at the bottom of the page. Your stories, views and opinions are always welcome.

Until the next issue I hope you enjoy this edition of Formula UK.

Mike FollettUK Managing Director, RMD Kwikform

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WHO’S WHOEDITORIAL TEAMEditor - Chris Lawton: [email protected]

DESIGN AND PRODUCTIONEdson Evers - Peter Haddock: [email protected]

For free subscription information please call Chris Lawton on 01922 743 743 or email [email protected]

EDITOR VIEWPOINT IN THIS ISSUE

B’HAM NEW STREET 4

USA EXPANSION 6

LA BRIDGE 7

BASRA STADIUM 8

PARASLIM 10

CHIVAS BROTHERS 12

ASCENT 14

CONTACT DETAILS 15

RMD Kwikform is giving one lucky reader the opportunity to win an internet enabled TV so you can enjoy your favourite RMD Kwikform project videos on your TV screen. All you have to do to be in with a chance of winning is subscribe to Formula Online & RMDKwikform.tv at www.rmdkwikform.com/formula_online. The competition closes on the 30th September 2011 and the winner will be announced in October 2011.

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TERMS AND CONDITIONS: The closing date for entries is the 30th September 2011. Entries will be placed in a draw for the internet enabled TV with the winner notified by RMD Kwikform in October 2011. This competition is open to all readers of Formula Magazine. Only one entry per person will be accepted. In accepting the prize the winner will agree to participate in the promotion of future competitions, allowing their name to be used in promotional activity. For full terms and conditions please email [email protected].

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PROJECTS/BIRMINGHAM NEW STREETPROJECTS/BIRMINGHAM NEW STREET

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COLEMAN & CO. TRUSS UP FOR THE REDEVELOPMENT OF BIRMINGHAM NEW STREET TRAIN STATION WITH THE HELP OF RMD KWIKFORM

From an engineering perspective, the Megashor and Superslim soldier elements of the trusses were designed to lengthen and shorten, enabling the trusses to be used between the varied positions of the strong points in the floor, as and when they are needed.”

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Coleman and Company has been tasked with demolishing and removing two floors of mezzanine car parking above twelve working platforms. To assist them in this technical obstacle, Coleman and Company has brought in special trusses, designed by engineering and structural formwork and falsework expert, RMD Kwikform.

More than 140,000 people travelling to various destinations pass through Birmingham New Street train station on a daily basis, over double the amount of passengers the station was originally designed for when it was built in the 1960s. To improve the station and create more room for passengers Coleman and Company is removing 7,500 tonnes of concrete from what used to be a car park, using specially designed trusses from RMD Kwikform. The area that is being demolished will then become the new passenger concourse and ticket hall area, set to open in 2012.

Chris Holland, technical manager for Coleman and Company had this to say: “The first stage of the work we are undertaking is to clear a mezzanine slab level of car parking away to create a more attractive high ceilinged environment for the concourse and ticket hall area. The challenges that we face on this project are quite immense. The floor below is the only thing between the demolition and twelve active platforms of Birmingham New Street, so there is no room for error or disruption.

“In order to overcome these problems, we had to come up with innovative ways of taking down sections of concrete above the floor and removing them from the building without causing too much noise, dust and vibration. Most importantly all of this had to be done without loading the floor, which is only designed to take the weight of vehicles.

“At the early stages of analysing the task at hand, we realised we had to use the strength of the main beams to take the weight of the concrete being removed. In order to do this we needed to design a

modular system that could be adjusted to use these strong points. Because the beams were not in a uniform lattice structure, we had to have a flexible option.”

Having worked with support specialist, RMD Kwikform in the past Coleman and Company engineers were able to brief RMD Kwikform’s technical team to come up with a solution that met the projects objectives. Working together the teams were able to design a modular truss system created from RMD Kwikform’s Megashor heavy duty shoring and Superslim steel soldier components.

Chris: “The key to the projects success was how we used the truss system to support the landing of the beam sections, some of which weighed 90 tonnes, and from there safely transport the sections off site. This was achieved by designing a gantry crane that was supported from the beams above the floor we were removing. Sections could then be removed using wire cutting and diamond saw techniques.”

Neil Pagett, midlands sales representative for RMD Kwikform’s RMI Division commented: “Coleman and Company had a major task at hand with this job, not only from a speed of programme delivery but from a health and safety perspective. This is why it was important that we worked hand in hand with the team on a day to day basis to help them meet what were exceptional challenges.

“From an engineering perspective, the Megashor and Superslim soldier elements of the trusses were designed to lengthen and shorten, enabling the trusses to be used between the varied positions of the strong points in the floor, as and when they are needed.”

Chris concluded: “This project has shown that Coleman and Company are capable of carrying out technically challenging jobs. One of the key contributors to that success has been the work carried out by RMD Kwikform, and has helped Coleman and Company deliver Network Rail’s vision of a station fit for the Twenty-First Century.”

Neil added: “RMD Kwikform are well known in the construction industry for formwork and falsework solutions, but because of our engineering expertise we are now getting involved in more customised solutions such as the Birmingham New Street development.

“From a personal point of view it is really rewarding to see that RMD Kwikform can use its engineering expertise to work on a landmark project such as this with Coleman and Company to provide solutions safely, on time and on budget.”

For more information on RMD Kwikform products and services visit www.rmdkwikform.com

Demolition specialists Coleman and Company have employed a specialist truss system to complete works on the redevelopment of Birmingham New Street train station, also known as the New Street Gateway Project for Network Rail.

RMD KWIKFORM REHABILITATES BRIDGE TO ACCOMMODATE EXTRA TRAIN LINE RMD Kwikform supplied falsework to a Los Angeles bridge, allowing regular traffic to continue as a rail line was added.

PROJECTS/LA BRIDGEUPDATE/USA EXPANSION


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Contractors Griffith Company, called upon RMD Kwikform North America to design a shoring solution that enables both road and rail traffic to continue over and underneath the Slauson Avenue Bridge in Los Angeles, while an additional rail line is added to the existing main line track.

In order for an additional rail track to be added to the two already running underneath the Slauson Avenue Bridge, two of the seven bents supporting it needed to be removed and replaced, all while the bridge was functioning normally.

Vicken Dakessian, RMD Kwikform regional manager explained: “The existing train tracks ran underneath Bents 6 and Bent 7 supporting the bridge. However, as the main line tracks travel between them at an odd angle to the axis of the bridge it was not possible to accommodate an additional track without replacing the existing bents.”

“Bent 6 was made up of a Steel Pier Cap Beam set on top of two concrete columns that were replaced. The Megashor Towers that supported the two 52 foot long W27x217 header beams and had to first be put into place before the columns could be removed. Eight Megashor legs fitted with Hydraulic units were put in place to support the weight of the bridge and traffic overhead.

“After the new columns were repositioned and constructed, the eight girders comprising the bridge were then raised to remove the original Pier Cap Beam. A replacement Pier Cap Beam was then put into place once bearing pads to mount it on were installed

on the newly constructed columns. The bridge was then lowered into place onto the new Pier Cap Beam, and the Megashor and other equipment used to support the bridge was removed.

“The next part of the project is the removal of the single large concrete column and pier cap from which Bent 7 was constructed. This will also entail supporting the remaining bridge structure above whilst this process takes place. All the materials used to comprise Bent 7 have to be removed before the new footing column and cantilever pier cap are constructed. This is why we have designed two separate temporary supports, one 28ft to the left of the pier centre line and another 30ft to the right.

“As an added complication to this already technically demanding aspect of the rehabilitation of the Slauson Avenue Bridge, the left hand temporary support is required to extend over the existing active main line rail tracks. This means that four 100ft long W36x282 header beams will be used to support the girders making up the bridge.

“In turn, the beams will be supported by fourteen Megashor legs, fitted with hydraulic units; eight legs positioned at the centreline of bridge, while four legs set on a common footing were positioned under the south most bridge girder. Meanwhile on the north side of the train track two Megashor legs will be positioned in order to provide additional support.”

To overcome the seismic lateral forces, RMD Kwikform’s engineers have devised a solution that involves attaching four Megashor Legs,

set at 45 degrees from vertical to the header beams and anchoring them to the footings.

The right hand temporary support will be set up in much the same method as the left hand support with seven 64ft long W27x250 header beams supported by sixteen Megashor towers arranged in a similar fashion.

A project team spokesperson for contractors, the Griffiths Company commented: “RMD Kwikform’s engineers worked closely with the team heading up the project and a solution was formulated that suited the Griffiths Company’s budget and time frame while delivering an outstanding solution to the engineering problems that faced the project.

Devising a solution that involves keeping a bridge open and performing its regular duties while major rehabilitative work is being performed on it is no easy task, and RMD Kwikform was able to provide an efficient and effective means of achieving this goal.”

Devising a solution that involves keeping a bridge open and performing its regular duties while major rehabilitative work is being performed on it is no easy task, and RMD Kwikform was able to provide an efficient and effective means of achieving this goal.”

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RMD KWIKFORM EXPANDS OPERATIONS INTO USA WITH $35m ACQUISITION

RMD Kwikform, the global formwork, falsework, safety and access provider, is pleased to announce that it has reached an agreement to acquire the heavy forming and shoring assets, including related distribution centres, of CMC Construction Services (“CMC”), a division of CMC Steel Fabrications, Inc., which is a subsidiary of Commercial Metals Company. The $35m acquisition enables RMD Kwikform to expand its geographical footprint into the world’s largest construction market.

CMC has been one of the leading resellers of formwork and shoring solutions in the USA, primarily serving the civil engineering markets in Texas, Colorado and California, and has been a customer of RMD Kwikform since 2004. The acquisition represents an attractive opportunity to gain access to the largest construction market in the world via an existing client base and an established sales force, branch and distribution network.

In addition to acquiring the heavy forming and shoring solutions of the business from CMC, RMD Kwikform has re-employed the majority of the management and staff associated with this business activity. The business will be based in Denver and will operate from distribution centres in Houston, Dallas, Denver and Los Angeles.

Steven Dance, Managing Director of RMD Kwikform, commented, "This acquisition expands our international footprint and provides an attractive growth opportunity at a price that we believe represents excellent value. We are excited by the opportunity to leverage our expertise and experience to generate significant growth in the US over the coming years.”

We are excited by the opportunity to leverage our expertise and experience to generate significant growth in the US over the coming years.”

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FORMULAMAGAZINE/ISSUE18 WWW.RMDKWIKFORM.COM

PROJECTS/BASRA SPORTS CITY8 PROJECTS/BASRA SPORTS CITY 9

Constructed for the Iraq Ministry for Sports and Youth, ground works for the impressive new complex which is set to host the 21st Gulf Cup, commenced onsite in September 2009. Abdullah A. Al Jiburi Contracting Company then started bringing in RMD Kwikform Kwikstage and Rapidshor shoring, to support the main concrete construction of the stadium, in January 2010. With 1,000’s of beams, 100’s of columns and numerous slabs for the 8 level, 65,000 seater football stadium required, over 3,000 tonnes of equipment were shipped onto site.

In addition to RMD Kwikform’s Kwikstage and Rapidshor shoring, column, wall and beam formwork, including steel Superslim soldiers and GTX timber beams, were also supplied to the project. Due to the tight programme time of just 32 months from the commencement of the project, to completion, getting the formwork and falsework solution design, support and project sequencing right, were all key to Abdullah A. Al Jiburi Contracting Company, as project manager Abdul Hussain explains:

“Being such a high profile and socially important project for Basra and the country as a whole, we needed to make sure that before we reached the formwork and falsework stage, we had the right equipment, designs and support to ensure its smooth construction. Because we have

worked with RMD Kwikform on a number of projects, we know they have the resources that are setup to support our team on the ground and can therefore react quickly to any changes in sequencing or design.

“Due to the large scale of the project, we required a sizable fleet of equipment. Logistically identifying the correct amount of equipment, getting it to site quickly and setting up a storage facility was therefore quite a complex challenge. Here again we have benefitted from input on the project and in the past from RMD Kwikform, who share best practice techniques on equipment management that help to save both time and money.”

With concrete works already well under way and expected to last until late 2011, the landmark Basra Sports City stadium, which looks similar in design to the Beijing Olympics Stadium, is set to release the passion of a nation when it hosts the 21st Gulf Cup (Khaleeji 21) in December of 2012.

Commenting on its work in Iraq and being awarded the contract for the Basra Sports City Stadium, Regional Export Sales Manager for RMD Kwikform, Alexis Potter said: “As a business we have been working in Iraq for a number of years pre and post war, but it is our partnership with Abdullah A. Al Jiburi Contracting Company that has

now been in operation for over 2.5 years, that has led to increasing success within Iraq.

“Having worked with Abdullah A. Al Jiburi Contracting Company on infrastructure and water projects, including supplying formwork and shoring for Basrah Water Towers, Al Nassyryah Bridge and Jumhuria Intersection, we have built up a true partnership approach to supporting successful project delivering in Iraq.

“It is this partnership and our proven engineering experience in delivering large stadia work, like the Sydney Olympics, that ultimately led to us being awarded the prestigious Basra Sports City Stadium job. With any job of this scale however you will face numerous challenges. For this particular project the most important

RMD KWIKFORM SCORES IN IRAQ WITH BASRA SPORTS CITY STADIUM PROJECT Equipment and engineers from formwork and falsework specialist, RMD Kwikform is supporting the dreams of up to 65,000 Iraqi football fans, after being selected by construction specialist Abdullah A. Al Jiburi Contracting Company, to support it in the construction of the new Basra Sports City Stadium in Iraq.

element of our service delivery was how we were able to support the customer on the ground. When we first tendered for the project we recognised that this was critical to its delivery.

“We therefore took time to find the right person to support the customer at site level. The individual we recruited had over 15 years of experience in formwork and shoring, with a proven track record of working on large-scale projects in the Middle East region. In showing this commitment to the customer, we have been able to develop a good working relationship with the site team from the very start of the project.

“Where our site operative comes into his own is the management of equipment flow and availability. On a project of this type, when you are transitioning from dock, to site, to erection, to dismantling, storage and handling, the logistics can be incredibly complex. That is not to mention dealing with lost and damaged items that typically occur on any construction site.

“Part and parcel of this process is to gain the trust and respect of the individuals working onsite handling equipment. This is why with any project of this type, it is advisable to assist with training erection staff on the best use of equipment and erection techniques. Not only do you save them valuable time, so they can achieve set goals, you also help to improve site safety and therefore individuals can see you are thinking of them, not just the job. By having a formwork specialist educating teams on the ground on how to follow drawings and sequencing, the programme benefits can be substantial.

“Because the Basra Sports City Stadium is a large government project, with a very high profile, these factors are being watched an analysed constantly. So for Abdullah A. Al Jiburi Contracting Company, where working with RMD Kwikform really comes into its own is our focus on health and safety. No matter where the location, we adhere to our own global health and safety system, which is based on industry leading standards and practices.”

Engineering design challengesFor RMD Kwikform’s engineers, dealing with a large-scale project of this kind, overcoming the challenges of the structures construction were key to its timely delivery. One of the more challenging elements of the project involved supporting large beams at level 7 and 8 off the much lighter main concourse level, comprising of cast in-situ beams and hollow core precast concrete planks.

Alexis: “For this particular part of the structure, the engineering team had to create solutions that could support numerous operations. These included the casting of a 1.4m deep beam at level 7, including a beam cantilever just over 9.0m in length. A sloping raker beam from the edge of the cantilever was also required up to level 8 to act as a tie to secure the overall frame.”

“The falsework system therefore had to be designed for cumulative loading from levels 7 and 8 off the lighter structure below. In order to achieve this, Rapidshor falsework with a maximum leg capacity of 80 kN per leg used in conjunction with Superslim soldier spreader beams, was used as the primary support system up to the underside of level 7.

“On completion of level 7, with the primary support system remaining undisturbed, the raker beams up to level 8 were supported off a framework of Kwikstage Propping and Superslim Soldiers, an integral feature in resisting sliding forces induced by the sloping soffit. Beam side forms, soffits and columns at these levels were formed using steel Superslim Soldiers, GTX timber beams and recoverable Rapid Bar Ties. At

all times throughout this crucial stage, the input of our site operative was critical as he ensured all phases were erected safely and in accordance with our designs.”

With the formwork and shoring phase of the project on schedule for completion in late 2011, the overall complex is due to be opened to the public in late 2012, ready for the 21st Gulf Cup in December 2012.

Alexis concluded: “From a business perspective, in the delivery of this project, we will be privileged to achieve an important goal for RMD Kwikform, in that we will have played a part in a landmark project that will put a very proud nation back on the sporting excellence map.”

Once completed the stadium will be surrounded by water and accessible to patrons by bridge. The 360-acre complex, designed to be one of Iraq’s major sports centres, will also contain a smaller stadium, practice facilities, a training complex, a swimming centre, and other facilities.

For more information on this and other projects from RMD Kwikform visit www.rmdkwikform.com/ae

From a business perspective, in the delivery of this project, we will be privileged to achieve an important goal for RMD Kwikform, in that we will have played a part in a landmark project that will put a very proud nation back on the sporting excellence map.”

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PRODUCTS/PARASLIM 11PRODUCTS/PARASLIM

For the contractor onsite, Paraslim could be pre-assembled into modules at ground level as a non programme critical path activity. Once the bridge girders were erected, modules could quickly be craned into place and levelled ready for steel fixing. This meant that just two joiners, assisted by one site engineer could erect and level up to 60 linear metres of Paraslim equipment in a single shift, a huge improvement over under slung systems.

Further programme benefits were soon realised with contractors electing to assemble the Paraslim equipment in its entirety onto the bridge girders at site level, prior to lifting the girders into place. Although larger cranes were required, critical path activity was reduced and the Paraslim equipment could immediately form a ready made access and material platform at high level.

These elements allowed for an access up and down the bridge at no extra cost, increasing safety and reducing overall programme time delivery. Erection and dismantling in modules by crane almost eliminated work at height, thus pre-empting introduction of the work at height regulations by a number of years.

Now in its 15th year, Paraslim has become the preferred method of construction for composite bridges in the UK and Ireland and has gained popularity in other markets across the globe. Where it was revolutionary in its introduction Paraslim continues to be the market leader and continues in its own innovative path with the recent move towards offsite preassembly.

Again supported by the industry and endorsed by major players like Costain who has adopted preassembled Paraslim as its composite bridge product of choice Paraslim continues to support the drive for efficient and safe construction.

Ian: “I think a key element behind the successful introduction of Paraslim was the approach of the industry as a whole to the safe implementation of the system with training and support key to its development. As the industry continues to embrace change it will be the development of future systems like Paraslim that will make a clear difference to the market.”

It was at this point that engineers at RMD Kwikform in Aldridge accelerated their development of an entirely new system that would be launched into the market in 1995 as Paraslim. At the time, the six strong design team were given a completely free range to look at the development of the new system. This was important as the industry itself, being already well established, had very clear ideas about how systems should work and be brought into the market.

What the team was able to do by adopting this method was to design a modular system where each triangular frame was supported directly from the top flange of the bridge girders by a single diagonal tie. Similar systems pre-existed in the US market but suffered from safety and access issues, as equipment had to be removed piecemeal from the beneath the bridge once the deck cantilever had been cast.

The drive for efficiency, shorter construction times, and a move towards offsite fabrication played an important role in the need to advance composite bridge construction.”

A key element behind the successful introduction of Paraslim was the approach of the industry as a whole to the safe implementation of the system with training and support key to its development. As the industry continues to embrace change it will be the development of future systems like Paraslim that will make a clear difference to the market.”

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“It was in the 1980’s when the popularity of composite bridges first took off. There had always been composite structures for varying reasons, but as the industry developed there was a greater need for more radical change.

The drive for efficiency, shorter construction times, and a move towards offsite fabrication played an important role in the need to advance composite bridge construction. This was further enhanced by the industry’s desire to reduce onsite labour cost and the level of operative skill required. All of these factors added up to the increase in popularity of composite bridge construction and led it to gradually become the preferred option over in-situ concrete bridge casting.

Composite bridges by their very nature however still required a level of in-situ concrete forming to produce the concrete deck slab. Initially this engineering and equipment challenge focused on improving the methods of constructing the cantilever deck sections at the edge of the bridge. The development and use of various methods, all of which had their own technical, practical and safety challenges created a major opportunity for a new more modern method of construction.

With the vertical load carried by the diagonal tie at a single point, rotational stability of the triangular frame was affected by horizontal support from the webs of the bridge girders.

Engineering Director for RMD Kwikform, Ian Fryer who drove the development comments: “The Paraslim system works in the same way as when you are carrying a heavy box in your arms. The stiff box represents the triangular frame, with your arms held diagonally being the diagonal Paraslim ties. The near end of the box reacts against your body in the same way as the Paraslim system reacts against the bridge girder and provides rotational stability for the box.”

THE EUREKA MOMENT The eureka moment came with development of the all-new Paraslim tie system. Sheathed with a tapered stripping device, the tie was extended upwards through the deck concrete and this, combined with the ability to gang the frames together into crane handlable modules, enabled the equipment to be struck and removed from above with the need to go below the concrete slab.

Attachment of the single tie to the top flange of the bridge girders posed further technical challenges. Initially fabricated steel brackets were welded by a manual metal arc process to the top flange of the girders. Heat generated by this method however risked damage to the girder paint finish and less costly and more reliable methods were sought.

Following rigorous testing of various different solutions, the RMD Kwikform engineering team sourced an M24 drawn-arc weld stud to effect the anchorage. In order to achieve efficiency gains by using the system, weld studs were designed to be connected to the bridge girder during the manufacturing process.

By using methods identical to those employed for the top flange shear studs, an already established method readily accepted by all parties, the overall solution fitted well with the girder manufacture process. M24 weld studs are load tested to above full working load in the factory, thus providing an additional quality measure.

Once this hurdle had been overcome, development of the complete system could be finalised. RMD Kwikform engineers drew on the established Superslim Soldier to make up the top member of the diagonal frame, with new adjustable components developed to form the other two smaller sides of the triangular frame. The modular nature of the Superslim system meant that the top member of the system could be varied in length up to 4.5m to suit the bridge profile and the centres of frames could be altered to suit the applied loading.

It was using this base of the trusted Superslim steel beam product, that ultimately enabled the team to make a system that was both affordable and readily accepted by the market. The real endorsement of this came with the system’s very first real life use onsite. This involved the construction of a composite bridge for Jackson Civil Engineering over the West Coast Main Line in Peterborough. Following this early success on a high risk and high profile project, the Paraslim system rapidly took off and quickly established itself as the preferred method for composite bridge construction.

As the system was continually developed and used onsite, further benefits were soon realised. The short stiff load path almost eliminated deflection and hence grout loss was massively reduced, leading to a much improved quality in finished construction and reduced making good costs.

HOW PARASLIM HELPED CHANGE COMPOSITE BRIDGE CONSTRUCTION By Ian Fryer, RMD Kwikform Engineering Director and inventor of Paraslim

FORMULAMAGAZINE/ISSUE18 WWW.RMDKWIKFORM.COM

PROJECTS/MAFRAQ INTERCHANGE 1312 PROJECTS/CHIVAS BROTHERS PROJECTS/CHIVAS BROTHERS

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RMD KWIKFORM FALSEWORK PROVIDES SPIRITED SUPPORT TO RENOWNED WHISKY PRODUCER CHIVAS BROTHERSFormwork and falsework specialist, RMD Kwikform supplies 13,435 Superslim Soldiers from around the world to help specialist contractor Bluevale Structures safeguard valuable stocks belonging to Scotch whisky company, Chivas Brothers in Scotland.

Housed in bonded warehouses at Mulben and Keith, the heart of whisky’s famous Speyside region, countless oak casks of maturing Scotch whisky are currently being protected by 13,435 Superslim Soldier beams from RMD Kwikform, the largest ever UK movement of the product, completed in record time.

The 608 tonnes of falsework have been assembled into long push pull props to support the walls of 31 individual warehouses. These props are the first and crucial stage in an important warehouse refurbishment process. In order for structural work to be undertaken safely, added protection for the warehouse walls was also required. This was also put in place to negate the potential impact of severe winds predicted for later in the year, which

could have put at risk the valuable maturing stock destined for markets around the world.

Commenting on the need for speed and the importance of the refurbishment project, Chivas Brothers Bill Lamb said: “As a World renowned Scotch whisky and premium spirit producer, Chivas Brothers under the ownership of Pernod Ricard is responsible for the production of a whole range of brands. These include the worlds most prestigious Scotch whisky, Chivas Regal, which has the ultra premium Chivas Regal 25 year old at its pinnacle, and the world’s No 2 Scotch whisky brand, Ballantine’s.

“What this essentially means is that we are the custodians of a tradition of producing the finest products that was started by

the Chivas Brothers in the 19th century. Because we produce 250 million bottles of spirit a year, in order to keep production at the level the market demands, at any one time we have to store and have access to in the region of 6 million casks of product in special bonded warehouses.

“To minimise disruption, we chose to build a new structure around the original. Our main concern throughout this process is obviously keeping the casks and product safe at all times.

“In order to meet our very tight refurbishment programme needs, we had to ensure extra support was given to the walls of the warehouse structures. We had a very tight window for this part of the process to be completed, so that we could

get to work on the refurbishment in the summer months. It was therefore essential that the propping stage was finished very quickly indeed.

“That said, we also wanted a solution that was well engineered, safe, could do the job of protecting our product and that was ultimately well priced. That is why, following a competitive tender, we awarded the job to RMD Kwikform and Bluevale Structures, whilst also employing our own engineering consultant, Blyth and Blyth to assist with the process.”

In order to support the warehouse structures, push pull prop sets were designed by the engineering team at RMD Kwikform under the guidance of project co-ordinator, Neil Hawkins with the Superslim soldiers driven up from Aldridge in convoys to RMD Kwikform’s Glasgow branch.

Once at the branch, the falsework was unloaded into a special compound created on site for Bluevale Structures, where a team of eight erectors worked seven days a week to pre-assemble individually designed three-prop sets. These props were then transported directly to each warehouse and fixed into position using prepositioned tilt plates, with 38 prop sets used to support each warehouse. The pre-assembly process carried out by RMD Kwikform, improved quality control and Health and Safety factors, whilst also reducing site installation time by more than 50%.

Commenting on the speed, design input and logistical challenge faced by RMD Kwikform to supply the Superslim Soldiers, RMD Kwikform project co-ordinator, Neil Hawkins said: “When the initial enquiry and competitive tender came in, we soon realised that the scale of the job meant we did not have enough equipment in the UK to cope with the rapid deployment and scale of demand.

“However we were not going to let that stop us from winning the job, as we were able to call upon our colleagues across our global business for support. Initially we took stocks from the UK then from Ireland and Spain finally shipping in containers from the Middle East.

“Putting supply to one side, the additional challenge with the project was brought about by the variations in the ground geometry around the perimeter of each warehouse, together with the position of extensive adjacent buried services. These variables conspired to affect the position and levels for the pad foundations onto which each triple prop set was to be founded.

“This meant that the length of every single set of props had to be individually designed, detailed and the relevant soldier lengths required to make up the required length sourced and delivered to site. In order to reduce the time it would take to produce the 1200 drawings required for the project, the RMD Kwikform engineering team customised its AutoCAD software to semi-automate this process completing the task in a fraction of the normal time.”

Harry Wylie, owner of main contractor Bluevale Structures comments, “Commercially, with a job of this kind you need to make sure that the method you use is appropriate and cost effective. The key to RMD Kwikform winning the business was its ability to offer a ‘one system’ approach, but most importantly its ability to supply all of the equipment. Without this we would have had to work with a number of companies using different products with different capabilities, which under the tight programme time would have been extremely difficult to manage.

“Following a site survey from WES consulting and thanks to the swift response from RMD Kwikform, we were able to start work onsite sooner than expected, preparing each building for the prop set installation by casting concrete fixing points and fitting tilt plates to the structure, supplied in advance of the props arrival.”

Working directly from the raw site survey issued by WES Consulting, RMD Kwikform engineers at its head office in Aldridge methodically issued the 1200 drawings required to complete the project to the Glasgow branch. Here the components and stock were managed and reports issued for additional requirements, streamlining the logistics and delivery schedules to branch, and once assembled, out to site.

Concluding, Neil said: “Being able to deliver this project is proof that RMD Kwikform can rapidly respond to the needs of our customers, no matter what the challenge. The effort and support from the UK team and our colleagues across the globe enabled us to play an important role in supporting both Chivas and Bluevale Structures. From a personal point of view it has a also been a very exciting project to manage.”

Being able to deliver this project is proof that RMD Kwikform can rapidly respond to the needs of our customers, no matter what the challenge.”


14 CONTACT DETAILS 15

WWW.RMDKWIKFORM.COM

UK HEAD OFFICERMD Kwikform,Brickyard Road, Aldridge, Walsall, WS9 8BW, UKTel: +44 1922 743743Fax: +44 1922 743400Email: [email protected]

SCOTLAND1650A London Road, Glasgow,G31 4QGTel: +44 141 554 7425Fax: +44 141 554 8392

WALES AND SOUTH WESTPenarth Road, Cardiff, Glamorgan, CF11 8UPTel: +44 29 2037 4521Fax: +44 29 2023 8703

NORTHMillfield Lane,Haydock Ind Est, St Helens, Merseyside, WA11 9UTTel: +44 1942 273815Fax: +44 1942 273819

LONDON AND SOUTH EAST22 Ferry Lane, Rainham, Essex, RM13 9DHTel: +44 1708 552975Fax: +44 1708 557048

MIDLANDSMidland Sales Centre Stubbers Green Road, Aldridge Walsall, WS9 8BLTel: +44 1922 450 800Fax: +44 1922 450 896

IRELAND HEAD OFFICEBallyboggan Road, Finglas, Dublin 11Tel: 00353 1 882 6012 Fax:00353 1 830 2522Email:[email protected]

CORKWatergrasshill Business Park,Watergrasshill, Co Cork, IrelandTel: 0021 488 9950 Fax: 0021 488 9980

BALLINASLOEKilcooney,Ballinasloe, Co Galway, IrelandTel: 0090 964 2196Fax: 0090 964 2950

BELFASTUnit 3B, Nutts Corner Business Park,Nutts Corner,Crumlin, IrelandTel: 0048 9038 1771 Fax: 0048 9038 132

PROJECTS/ASCENT


LONDON DEBUT MARKS LAUNCH OF NEW GUIDED CLIMBING FORMWORK SYSTEM - ASCENT

RMD Kwikform’s latest new guided climbing formwork system, Ascent is set to be launched into the UK market in style as it makes its debut on London’s South Bank.

Designed in-house, RMD Kwikform’s latest innovation Ascent is a dual application climbing system, offering both formwork and screen applications. Ascent will be put into action for the first time in the construction of the Hilton Tower Hotel on London’s South Bank. Ascent is the latest addition to RMD Kwikform’s guided climbing range, joining the Autoclimb, Rapidclimb and Tru-Lift systems.

Talking about Ascent General Manager Neil Thomas said: “Ascent has been specifically developed with RMD Kwikform’s customers to given them an extremely safe, versatile, efficient and easy to use guided climbing formwork and screen system.

“Ascent can be used in conjunction with any formwork system our customers choose and can be applied to construct piers, straight or curved walls sloping by up to 20 degrees, as well as inclined and stepped surfaces, making Ascent’s involvement in almost any project requiring a climbing system possible.

“As Ascent has been developed directly with the help of those in the industry who

are going to be using it, its components have been designed with cost savings and safety in mind. The screen system can be pre-assembled off-site, complete with extendable sections, and can be transported in and out of sites up to four units at a time on standard delivery trucks, eliminating the need for unnecessary cranage. With no site fabrication needed this reduces labour, shrinks construction costs and increases site space, simultaneously reducing the need to store additional equipment and making for a cleaner and therefore safer site.

“As well as being developed for ease of use, Ascent has also been designed with changes in the construction industry in mind. In recent years site construction programs have been shortened with site managers looking to save on costs and time. Ascent has been adapted to this fact and is capable of considerably speeding up construction cycle times due to its involvement right from the first wall pour.

When it comes to the first wall lift wall brackets can be pre-mounted on the cast-in wall anchor, before adding connection bolts and guide masts, which can be easily and safely extended once Ascent has been initially installed.

“There are many interesting features in the Ascent design. For example when it comes to safety and operation, site staff will benefit from the use of highly visible latches that connect securely to the Ascent

Ascent has transformed the standards of normal site safety with its capacity to operate in conditions that would not normally be considered safe”

wall brackets using Electronic Latch Engagement Verification (ELEV), giving added reassurance when working at height.

“In addition, Ascent has transformed the standards of normal site safety with its capacity to operate in conditions that would not normally be considered safe. For example, in the case of high winds when no cranage can be safely operated, Ascent is able to lift itself to its next level of construction using a simple hydraulic lifting system, allowing you to stick to tight construction schedules.

“As well as performing its duties as a climbing formwork system Ascent also boasts a secondary function as a screening system which can be utilised, for example, as a protection for site workers working at height against risk of falling.

“At the end of a job Ascent can be dismantled without complication by raising, lowering or moving directly outwards depending on the requirements of the site, reducing dismantle time, money and required crane height.

“In conclusion, Ascent is definitely a game changer for the future of guided climbing formwork and will certainly give end users the confidence to benefit from a new approach to building in the future.”

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Introducing Ascent

• Starts from the first lift - Speeds early cycle times• Can be lifted in the high winds - Reduced downtime• Modules can be assembled off site - Saves time and space• Handles building corners and curved faces - No need for bespoke timber details

Call us now on

0800 389 8231 or visit us at

www.rmdkwikform.comwww.rmdkwikform.tv

(Available for sale and hire)

Ascent is the new guided climbing system from RMD Kwikform. Developed in partnership with our customers, Ascent is cutting edge equipment designed to speed cycle times and reduce labour costs.

Ascent Safety Screen is fully adaptable to accommodate your project and choice of cladding material.

Ascent Climbing Formwork is fully adaptable and fits with all Formwork systems. Suitable for inclined, stepped, circular or straight surfaces.

To learn more about Ascent call us now on 0800 389 8231

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rmd kwikform formula magazine issue 18 uk

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