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Constructeursdag Amsterdam 14.06.2018 Markus Walder

Zugspitze: steel structures, faรงades and more on Top of Germany


Video Stahlbau Pichler


SĂźdtirol-Alto Adige


About us


International


Key facts Employees

Value of production


Production


Expertise


Know how


De Rotterdam - only reference in NL


Top references


Reference on top of Germany


Upper station We signed the contract for the steel structures of the upper station on 17th December 2015!

Visualisierung: Š Bayerische Zugspitzbahn Bergbahn AG/Hasenauer Architekten


Zugspitze May 2015


Construction site in April 2016


Lower station In January 2016 we got assigned the façades for the upper station. In June 2016 we received the order for the steel structures and the façades for the lower station.

Visualisierung: © Bayerische Zugspitzbahn Bergbahn AG/Hasenauer Architekten


History of the old Eibsee-Areal tramway • • • • •

Construction time: 1961- 1963 , Opening: 15th May 1963 Type: areal tramway with 2 cabins Cabin size: 44 guests +1 cabin attendant Performance: max. 270 guests/hour and direction Last ride: 2nd April 2017


Technical details: New areal tramway • • • • • • • • • • • • • • • • •

Client: Bayerische Zugspitzbahn Bergbahn AG Architect: Hasenauer Architekten Statics: Baucon Areal tramway: Garaventa AG Construction time: 2015 - 2018 Type: areal tramway with 2 cabins Length: 4.466,9m Upper station: 2.943m Lower station: 998m Difference: 1.950m (World Record) Longest span field: 3.213m (World Record) Pillar: 1 steel pillar Height of pillar: 127m (World Record) Cabin size: 120+1 Cabins: 2 Travel time: 10 min Capacity: 580guests/hour Visualisierung Kabinendesign: © Bayerische Zugspitzbahn Bergbahn AG


Animation Upper station


Structural engineering – Upper station

• Supporting cable tower (Shaft construction with reinforced concrete) • Steel structures SOUTH: Back-tension construction with A-pillars and head section Staircase south • Rear clamping element • Steel structures NORTH: 3 levels - Arrival platform - Restaurant level: 540 seats - Viewing terrace:: 1500 m²


Static forces on the upper station Restaurant

Terrace south

Supporting cable tower for contract rope

Terrace north


Specifications of the site • Zugspitze is the highest mountain in Germany - 2.962m • The site is next to the summit and was the highest construction site in Germany. • No access to the construction site


Our contract = our mission Steel structures and façades for upper station Total steel structures: 1.100t

• • • •

Steel structures South: 200t Rear clamping element: 50t Steel structures North: 800t Other steel structures: 50t

Total façades: 6.000m²

• • • • • • •

Transom-Mullion-Façade-ALU: 700m² Stick system: 1.400m² Metal paneling ALU-Prefa: 600m² Metal paneling ALU-composite panels : 300m² Fire doors and windows R30, R90: 300m² Sandwich panels - Wall coverings-R90: 1.700m² Sandwich panels - Ceilings panels-R90: 1.100m²


Our contract = our mission Steel structures and façades for lower station Total steel structures: 130t

• Y-Pillar: 30t • Steel structures roof construction: 100t Total façades: 2.400m²

• • • • • •

Transom-Mullion-Façade: 1.100m² Interior glazing: 150m² Fire doors and façades: 140m² Wave profile cladding ALU-Prefa: 250m² Wall coverings Alu-Composite-panels: 500m² Alu-Composite-panels: 250m²


3D technical drawings Snapshot from our BIM-Software „Tekla Structures“ for steel structures and façades


Production of steel structures in Bolzano Start: March 2016

Elements for A-Pillar

Footboard for A-Pillar

Weld preparation


Production of steel structures in Bolzano

Footboard for A-Pillar


Storage and pre-assembly space

Storage and pre-assembly space next to the lower station of the material ropeway


Material ropeway Transportation of all materials (steel and façades) started from the pre-assembly space with material ropeway to the construction site: • Difference: 1.700m • Max. load capacity: 5t • Travel time: 12minutes


Takeover place - Upper station of material ropeway


Crane – Upper station Construction site North: Liebherr Crane 150 EC–B - for area north with ABB: • 50m max. throat: 2,5t • Up to 24,4m throat: 6t


Construction site south Liebherr Crane 71 EC – B5 - for area south with ABB: • 50m throat: 2,9t • 16,6m throat: 5t

Installation of crane on construction site south: April 2016


Construction site in April 2016


Construction site in May 2016


Installation steel structures rear clamping element (old) Technical details: Carrier grid made of rolled beams Corrosion protection: coated Steel weight: 50t Start installation: 18.04.16


Installation steel structures rear clamping element (old)


Installation steel structures South (Back-tension construction)

A-Pillars Technical details:

• Welding girders

• Size 1,4 m x 1,4 m

• Corrosion protection: galvanized

• Height Pillars: 14,4 m – 18,6 m

• sheet thickness : 35mm

• Start installation: May 2016


Installation steel structures for A-Pillar

Measuring and setting up the foot parts

Preloading the M64 anchors by Montagezustand vor dem means of hydraulic preload Anziehen der Litzenanker cylinders - preload force 127t


Installation steel structures south with scaffolding


Welding steel structures south

Preheating device for welding joints

Temperature control: 124°


Weld inspection steel structures south

Weld inspection SLV – Munich Ultrasonic testing


Head assembly steel structures South (Back-tension construction)

Technical details: • Sheet metal welded construction • Corrosion protection: galvanized • Length: 10,7m • Width: 4,2m • Height: 3,9m • Start: June 2016


Head assembly steel structures South (Back-tension construction)

The galvanized components were set up and bolted • Anchor rod assembly • 64 pieces M64 – 180kg each


Installation of staircase south Technical details: • Roller support structure • Corrosion protection: galvanized • Length: 12m

• Width: 10,7m • Height: 15m • Start: September 2016


Installation of faรงades for staircase south Stairway was scaffolded for later faรงade installation


Façades for staircase south – interior view


Installation of faรงades for staircase south


Installation steel structures north

Technical details: • Rolling and welding carrier construction • Corrosion protection: galvanized • Building cantilever: ca. 30m

• Width: 30m • Height: 28,5m

• Start: November 2016


Steel structures north

Ground plan


Installation steel structures north Installation procedure NORTH-Middle Platform


Installation steel structures north Installation procedure NORTH-Middle Platform


Installation steel structures north Installation procedure NORTH-Middle Platform


Installation steel structures north Installation procedure NORTH-Middle Platform


Installation steel structures north Installation procedure NORTH-Middle Platform


Installation steel structures north Installation procedure NORTH-Middle Platform


Installation steel structures north Installation procedure NORTH-Middle Platform


some details ‌

180 days with snow, rain or hail 490cm snow on 20th April 2017

-27,2°C temperature on 6th January 2017 180km/h wind strengh on 6th Dezember 2017 48 days with gale-force gusts (>104 km/h)


Daily business ‌


Installation steel structures north Mounting the support brackets on the towers – middle platform East and West


Installation steel structures north Assembly of the safety devices on the components


Installation steel structures north


Installation steel structures north Mounting slanting overhang and top strap carrier – middle platform


Installation steel structures north


Bild.de

‌ huge media awareness ‌


Steel workers on #topofgermany ‌


Steel workers on #topofgermany ‌


Steel workers on #topofgermany ‌


‌ 85 years after Manhattan


January 2017


March 2017


20 April 2017


May 2017


July 2017


August 2017


Installation scaffolding for faรงades


Installation façades Upper station Perron Level: Stick system Raico +56 SI Restaurantlevel +2: Transom-Mullion-Façade ALU - Raico Therm +56 AI Stairway South + Stairway East: Stick system Raico +56 SI Windows: Schüco ALU AWS 75 SI Doors: Schüco ALU ADS 75 SI

Fire doors: Wicona Fire protection interior glazing: Vetrotech EI 30 Glazing:

• ESG-H 10/16/VSG-TVG 6+6; 1,52mm PVB (Stairway south) • ESG-H 10/16/VSG-ESG-H 6+6; 1,52mm PVB (Stairway south) • ESG-H 10/16/VSG-SPG 6+6; 1,52mm PVB (Stairway south + Restaurant) • Cold façades: VSG-TVG 10+10mm; 1,52mm PVB


Installation façades Lower station Perron level: Transom-Mullion-Façade ALU - Raico Therm +56 AI

Cable car technology Level+1: Stick system Raico+56 SI Windows: Schüco ALU AWS 75 SI Doors: Schüco ALU ADS 75 SI Fire doors/windows: Wicona Fire protection interior glazing : Vetrotech EI 30 Glazing: • Insulating glas: ESG-H 10/16/VSG8+8;1,52mm PVB • Insulating glas: ESG-H 10/16/ESG-H 6/14/VSG-SPG 8+8; 1,52mm PVB • Cold façade: ESG-H 10mm and VSG-TVG 10+10mm; 1,52mm PVB


September 2017


October 2017


October 2017


October 2017 - Nightshift


November 2017


20.12.2017 - One day before inauguration


21.12.2017 – Official inauguration day!


Brief summary Steel structures:

Start: March 2016 Finish: July 2017

Faรงades:

Start: August 2017 Finish: December 2017

Our total construction time: less than 2 years! Opening ceremony of new aeral tramway on 21st December 2017 Interiors of new Restaurant: Start January 2018

Inauguration of new Restaurant on the upper station on 29th June 2018


Timelapse Upper station


12th June 2018

Thank you!

Zugspitze: steel structure, façades and more on Top of Germany  

Details and background information on our project on Top of Germany with spectacular pictures!

Zugspitze: steel structure, façades and more on Top of Germany  

Details and background information on our project on Top of Germany with spectacular pictures!