PERIscope Spring 2024

Dear Reader...

Welcome to the Spring issue of PERIscope and the first of 2024.

In this issue you can read how permanent stop ends like BECOSTOP help drive efficiency on site. We also share how our scaffolding access system, PERI UP, is taking off in Northern Ireland.

It’s by collaborating with experts from these business segments that we can strengthen our offering and capabilities across the infrastructure projects we undertake, and this is evident in our involvement on Cross Tay Link Road – Scotland’s newest crossing over the River Tay – which also features in this issue.

Our growth in infrastructure continues steadily. Supporting projects that change people’s lives, from improved transportation to more sustainable energy sources, is something we are really proud of. For me, seeing Hinkley Point C’s journey from the ground up will always be a memorable moment in my career at PERI.

It’s been 3 years since I took the helm of the Infrastructure segment at PERI UK and I can honestly say our team of dedicated sales and engineering experts couldn’t be more prepared to tackle the challenges of modern rail, power, bridge and tunnelling projects across the UK today.

It’s clear to see that temporary works support and involvement throughout the construction process has gained more importance over the years, especially as we strive for early engagement on every project.

Equally, great customer service cannot be underestimated, particularly when considering the complexities of an infrastructure project that can span years, not months. Establishing a strong rapport between tier 1 contractors, sub-contractors and temporary works specialists maximises the value and benefits on any project.

Collaborating in the early stages can significantly improve project planning. I have worked on numerous projects where disciplines are often siloed with no consideration for the teams around them, who are all working towards the same goal.

Our aim is to remove these silos from a formwork and scaffolding perspective so we can advise, guide and support all the way through.

For complex projects, we create a dedicated project team that will work closely with our customers from start to finish to understand the project requirements, challenges, and our approach.

The combination of our products and services takes this a step further by making PERI a one-stopshop for our customers’ construction needs. As an example, when forming a tunnel, we can offer the access in the form of a PERI UP Tunnel Traveller to facilitate the installation of a waterproof membrane and subsequently to fix steel ahead of a secondary lining. We can then supply the travelling formwork, faced with PERI plywood to pour the secondary lining, with an integrated access system to finish the concrete face and install any mechanical and electrical components. All of this can be planned in advance and declashed with the support of our digital technology and engineering services.

As well as continuing our commitment on HS2 and Hinkley Point C (HPC), we are looking ahead to the future challenges in infrastructure. With projects such as Sizewell C on the horizon, which mirrors the scope of HPC, we are excited to apply the valuable lessons we’ve gleaned from our experience with the latter project.

Our substantial experience in tunnelling and proximity to our flagship depot in Brentwood also means we’re prepared for the opportunities the Lower Thames Crossing will introduce if the project is given the green light later this year.

Find out how we get on by following our journey and infrastructure updates across our PERI UK social channels.

Matthew McCarthy Sales Manager - Infrastructure

Editor

PERI Ltd.

Formwork

Scaffolding Engineering

Market Harborough Road

Clifton upon Dunsmore Rugby CV23 0AN United Kingdom

Responsible PERI UK

Editor-in-chief Jinal Kansara

Editing and graphics Dekany Design

Photos PERI UK

Print

Neil Terry Design & Print

Copyright

The photos used in this brochure feature certain situations at particular moments on various construction sites.

Additional images, e.g. regarding safety and anchor details, cannot always be considered as conclusive or final. These are subject to the risk assessment carried out by the contractor.

© PERI GmbH

Contents

6 Climbing full speed ahead with RCS MAX

Wembley Park Gardens, London

In Focus

9 Constructing the pier heads for Scotland’s newest crossing over the River Tay

Cross Tay Link Road, Perth.

10 The value of permanent stop ends when driving project efficiencies

UK Construction Accessories Manager, Neale Beardsley, shares his thoughts on why permanent stop ends are the way forward.

12 K2 Scaffolding: Rising with PERI UP

We share the progress scaffolding contractor, K2 Scaffolding, is making with PERI UP in Northern Ireland.

14 News

Climbing full speed ahead with RCS MAX

Wembley Park Gardens, London

We are working with Flatley Construction to deliver the concrete frame for this project. Phase one consists of three tower blocks, all of which will comprise energyefficient apartments on completion. With the concrete shell on blocks A and B almost complete, the focus is now on delivering block E in time for its projected completion date this summer. Work on the tower started in December 2023 and the project has been ahead of schedule ever since, partly due to adopting a cranefree climbing approach.

Jumping the core

After using the CB 240 climbing system to form the cores on the first two blocks, Flatley Construction wanted to speed up the pace of construction by automating the process on the final instalment of phase one.

Given the 22-storey height of block E coupled with limited crane availability in this area and the site’s small footprint, reducing crane operation without causing delays to the project was crucial.

We introduced our newest rail-guided climbing system, RCS MAX, which was the ideal system for the height of this tower.

Currently, RCS MAX is enabling all six formwork platforms to jump simultaneously, with additional capacity to lift up to eight. Using a rail-guided system has saved time as the site team can continue jumping the core even when the crane is winded off or busy with other lifting procedures.

The system has enabled Flatley Construction to achieve one pour per week, resulting in faster construction cycles and improved safety due to the absence of leading edges between platforms.

The rail-guided climbing method is also helping to overcome challenges with space as formwork units do not need to be removed from the core and repositioned with the crane at each level. Instead, the units are lifted seamlessly on rails with the push of two buttons, taking less than 30 minutes to cycle from one level to the next.

Equally, space inside the core was limited. Using flexible PERI UP scaffolding components to create an access system has ensured the available space is fully utilised from the bottom of the core all the way up to the working levels, with the option to adapt throughout.

Archie Peck Technical Sales Representative

“As a former Formwork Designer, I understand how our systems are designed to work on site. However, being new to sales it was important for me to see the process from the customer’s perspective and gain a full appreciation of how they work with our systems once they are designed and then delivered to their site by prefabricating the platforms alongside the operatives in our customer’s yard. ”

Hands-on service

To optimise efficiency and space on site, all RCS platforms were prefabricated in the customer’s yard under the guidance of our site demonstrators. Demonstrators also assisted the team with the assembly of hydraulic components and ensured the smooth operation of the system upon installation.

Also participating in the prefabrication of RCS platforms for the first time to support the site team was our Technical Sales Representative, who has additionally managed and ensured timely deliveries throughout the project.

The importance of training

Training has been crucial on this project, especially considering the working at height requirements involved. We engaged early with Flatley Construction to maximise the benefits of accredited training for site operatives. This enabled them to get familiar with the RCS MAX system from the start, helping to maintain the pace of the project through safe and efficient handling of our systems.

As formwork qualifications and certification become compulsory prerequisites on more sites before system operation, training will play a crucial role in future-proofing Flatley Construction’s investment in RCS MAX and success on subsequent climbing jobs. By enabling their workforce to demonstrate competence through endorsed CSCS cards, it ensures project continuity and efficiency moving forward.

Constructing the pier heads for Scotland’s newest crossing over the River Tay

Cross Tay Link Road, Perth

Construction of the Cross Tay Link Road is well over halfway. Valued at a construction cost of £150m, the project, which is being delivered by BAM for Perth Transport Futures, aims to reduce congestion and air quality in Perth city centre.

With the new route spanning over the mainline railway and River Tay, the project also promises to reduce journey times and improve mobility between the A9, A39 and A94 north of Scone.

Phase 2 involves the construction of a 3-span bridge stretching 307m across the River Tay. It’s the largest new bridge to be built since the Queensferry Crossing. We were appointed by BAM to design and supply the temporary works systems for the concrete pier heads.

Sustainability at the forefront of its design

From recycling excavated earth to shortening bridge spans, reducing carbon emissions throughout construction has been one of the key deliverables from the outset. So far, BAM has cut carbon emissions by 35,000 tonnes. Much of this stems from the design of the project and the construction methods applied.

When it comes to design and sustainability, temporary works has played a part in increasing efficiency and improving build time through the

reduction of timber waste, material reuse and system adaptability.

Forming the pier heads

In line with the other elements of the bridge, a smooth finish was required for the pier heads. We provided a design comprising VARIO formwork. For the underside of the pier heads, VARIO was mounted on top of VARIOKIT components, allowing the formwork to be adjusted once in situ by moving our SLS spindles as required.

VARIOKIT provided the flexibility that couldn’t be achieved with timber. This also helped reduce the timber requirement on site to form some of the trickier pier head geometry – a vital saving considering the sustainability credentials of the project.

We also supplied the plywood lining to complete the VARIO formwork solution. Reusability and quality were the prime reasons our plywood was applied not only on the pier heads, but the main deck structure too.

Non-slip wiremesh plywood was used for the deck, providing a high degree of safety when working in the wet weather conditions frequently experienced on the project.

Understanding how the formwork would be lifted in and out of position was important for BAM. Our Senior Digital Engineer was able to work with BAM’s Digital Team to integrate BAM’s 3D model with our model comprising the formwork and shoring elements involved. Having visibility of the lifting plan in advance will prevent clashes with the larger structural props on site when removing the formwork in real time.

Access from the cofferdam to the pier heads and the top of the shoring towers was possible with our PERI UP scaffolding, which is being provided by Peoples Safety Ltd.

An adaptable shoring solution

Our ALPHAKIT shoring towers are being used to temporarily support the pier heads. Ideal for bridge heights up to 30m and spans of up to 27m, we have fully utilised ALPHAKIT’s load bearing capacity for the scope of this project with each leg capable of supporting 300kN.

ALPHAKIT can be used variably with just a few core steel components. These components are also very lightweight, with the heaviest components weighing 44kg. This enabled BAM to work around potential clashes with structural steel and temporary props which prevented the shoring towers from being craned into position from above in certain areas. As an alternative to using the crane, the only viable option for installing the shoring in this specific area was to assemble ALPHAKIT towers in-situ around the existing steel by hand.

Typically, ALPHAKIT would be bolted into the base slab to stabilise the tower. However, the thickness of the rebar in the slab made this difficult. As an alternative, spindles were used to prop the ALPHAKIT legs from the cofferdam on the East and from pad founds on the West. Spindles were also used between the towers for greater stability.

Scaffolding components have been integrated with ALPHAKIT to create working platforms at the top of the shoring towers. These platforms will facilitate the build of the main working platform on top of which the formwork shutters for the pier heads will be positioned.

Once the pier heads are constructed, the team will be able to remove the formwork safely with the support of integrated hydraulic units on each shoring tower.

The main structure is expected to be completed later this year, ready for its estimated opening date in February 2025.

The value of permanent stop ends when driving project efficiencies

PERI UK Construction Accessories Manager, Neale Beardsley, shares his thoughts on why permanent stop ends are the way forward on construction sites.

In the age of virtual reality and artificial intelligence, should the ability to successfully pour large concrete slab foundations still rely on timber shuttering or frames and a team of skilled carpenters?

The cost of the materials and dwindling pool of carpenters needed to install the construction joint prior to each pour, then remove it all afterwards, should have been reason enough for construction firms to seek a more efficient method of creating foundations and deep slabs.

Further costs are introduced when concrete joints need remediating after the traditional shuttering is removed, ensuring a secure bond with the adjacent slab. Not only does this increase costs, it also adds time to the entire construction process.

Improving on-site efficiency

Permanent stop end systems like BECOSTOP provide full continuity of reinforcement for the installation of construction joints and overcome the issues most associated with temporary timber shoring, starting with the inherent delays.

Consecutive bays can be poured on consecutive days with BECOSTOP, which could deliver a four or five-day advantage when casting deep reinforced slabs for large infrastructure projects. With traditional systems, the stop end would need to be built elsewhere on site, potentially even off site depending on the space available.

BECOSTOP comes to site ready to install, with a full temporary works design provided, including structural design and CAT checks. This is in stark contrast to the absence of calculations behind timber shoring for a similar application.

Strength and consistency of the construction joints created are key benefits of using BECOSTOP when laying a slab in multiple smaller pours. The continuity of reinforcement offered by BECOSTOP also ensures the diameter of the reinforcement steel will not have to be increased.

Traditional shuttering with smooth timber risks leaving a day joint with a low-bearing capacity, unless the surface of the joint is scabbled to roughen it or is chemically treated prior to the next pour - all of which requires additional time, labour and cost.

The quality of the joint now depends on the experience of the team undertaking the scabbling process, which also faces the risk of vibration white finger. There are also the noise and silica containing dust considerations of this slow process, which not only affects workers involved or in close proximity, but neighbours to the site.

The problems extend beyond their lowbearing capacity, with poor joints also compromising the structural integrity of the concrete. Joints formed without remedial work to create a strong bond, reduce the slab’s durability and increase the risk of water ingress, which can lead to the corrosion of the reinforcement steel.

A key profiled solution

The BECOSTOP panels are manufactured using steel from a sustainable source and utilise a unique trapezoidal profile which allows for full 100% bearing capacity according to EC2. The perforations are designed to reduce the flow of concrete through them, which allows enough time for it to cure and create the key profile needed for strong construction joints. The profile of the perforations in the panels also allows for a release in

concrete pressure, which means we can design at 50% of full hydrostatic pressure for the pour.

The BECOSTOP panels are designed to create a joint surface with a roughness coefficient [c] of 0.5, which exceeds that of a traditional joint created with timber and scabbling, when the coefficient is typically 0.2.

The elements allow for a limited flow of concrete, which significantly reduces the pressure on these stop end units and requires a lower concrete pour pressure, which in some cases can be reduced by 50%. There is also the added advantage of these key-profiled joints eliminating the need to install couplers into the structure by providing full continuity of reinforcement.

Rather than needing skilled carpenters to create the timber shuttering, the BECOSTOP panels are fixed to the rebar cage using inexpensive tying wire and the skills of site labourers, with no extra supports needed for the panels, which self-support up to 1.5m.

At PERI, we can provide full technical and design support, with drawings and temporary works calculations provided for any project to ensure each concrete slab can be constructed more quickly.

BECOSTOP is the modern solution for projects that require day joints or have wall stop ends. The panels are manufactured to order and tailored to the unique design requirements of each project, ensuring they are ready to install direct from the pallet.

Final words

BECOSTOP is an extremely useful addition to our Construction Accessories range, offering Project Managers a modern, more cost-effective alternative to outdated timber shuttering and shoring for pouring concrete slabs.

The BECOSTOP system allows contractors to make up time on site, save the cost of the timber and carpenters needed to fit it, whilst delivering a result with the attributes of a monolithic slab, rather than one with inherently weaker construction joints.

BECOSTOP on site

K2 Scaffolding: Rising with PERI UP

Northern Ireland based scaffolding contractor, K2 Scaffolding, prides itself on delivering the highest level of service to its customers.

Determined to increase the scale of projects they undertake across the residential and commercial sectors, K2 Scaffolding invested in £400,000 worth of our system scaffolding in 2022, becoming the first company to make a substantial investment in PERI UP in Northern Ireland.

Since then, we have partnered with the contractor to provide engineering and commercial expertise, enabling the team to deliver fast façade and stair access solutions across projects in and around Belfast.

Queen’s University Seamus Heaney Centre

For this project, we supported K2 Scaffolding with perimeter access to all floors during the ongoing restoration work on the building to protect its historic listed status.

Perimeter access was installed to facilitate roof and window replacement. One of the main challenges during the design and installation of the scaffolding was protecting as much of the façade as possible, including its bay windows, which would determine how and where

the scaffolding would be tied into the structure.

Our design team proposed a layout that would reduce the number of ties required. We incorporated cantilever brackets to accommodate the bay windows and support the scaffolding deck spanning above. Brackets were also used externally to increase the width of the working platform and provide safer and seamless access to the on-site cabin.

The 25mm increments between the length of our scaffolding decks enabled scaffolders to install working platforms close to the chimney walls on the roof. We used our UHA spigots to create flexible ledger to ledger connections which accommodated the chimney’s geometry with no additional fittings required.

The entire build of the scaffolding solution was completed in just five days with 42 tonnes of PERI UP Flex erected over the course of the project.

“We had an awkward chimney scaffold to erect, and the adjustable spigots made this challenge easier to overcome. The locking and ladder decks are a great advantage for both time and safety. It saved a significant amount of time as the self-locking feature meant the team didn’t need to tie the decks down during windy weather. These components played a big part in the speed of the project, reducing the predicted project time by 50%. I’m looking forward to working with PERI on our next project and I’m sure the PERI UP scaffolding system will continue to impress.”

Cathal Abram K2 Scaffolding, Contracts Manager

The National Bank

To support the roof upgrade on this Grade I listed building, K2 Scaffolding required a façade access solution that would avoid tying the structure into the bay windows. Given the height of the scaffolding structure, it was not feasible to avoid tying entirely.

Our design team were tasked with creating a solution that would minimise and position ties to prevent damage to the bay windows and other delicate areas of the framework.

By using PERI UP console brackets on the internal standards, we were able to reduce ties and direct contact with the façade. With these components, we could step the scaffolding back from the building while maintaining proximity to the façade. The console brackets extended the surface area of the platform, bridging the gap between the scaffold and the building.

Additionally, variable deck sizes provided the flexibility needed on a project like this, as we could work with K2 Scaffolding to deck out any gaps between the bay windows, providing a closed off structure and safe working platform.

What made this project challenging is that no structural drawings of the building were available. Our design experts worked closely with K2 Scaffolding’s experienced team to develop an ‘as-built’ solution on the roof.

This involved utilising a site survey to get a better understanding of the structure as well as adapting PERI UP components during the build to create the best solution to accommodate the shape of the roof.

At ground level, we were tasked with designing a pavement gantry to create a safe public walkway which incorporated a bespoke PERI UP fan to shield pedestrians from falling objects.

Belfast International Airport

As part of the 5-year revamp and extension project at Belfast International Airport, we supported K2 Scaffolding with the design of a PERI UP Flex staircase and walkway. System scaffolding was specified for this project to replicate a clear and unobstructed emergency fire escape route which would be used throughout the duration of the demolition and remedial works.

With demolition work taking place very close to the emergency route, we had to ensure the PERI UP scaffold design was set within the same parameters of the permanent stairs that existed before. The design also had to accommodate the double level scaffold beams which were fixed to existing steel structures to support the suspended walkway above. The walkway would be the only available emergency exit route for passengers on the left-hand side of the building and so we alternated the layout of the decks on every bay to support a maximum live load of 3.00 kN/m².

We also provided K2 Scaffolding with loading bays leading off from the walkway. The loading bays cover a footprint of 5m x 4m which will be used to store material to support the remedial work.

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The PERI UP Cladding system

A flexible enclosure that is easy to install

The PERI UP Cladding system works with our system scaffolding products to create a flexible enclosure that is easy to install in any setting, thanks to its use of lightweight man-handleable components, which makes it lighter than currently available systems.

The large translucent panels include an integrated handrail for ease of handling and fitting, without the need for specialist tools. The ability to enclose all or part of the construction site using fewer components than similar systems, ensures a fast, flexible installation.

CEMflex

Sealing vertical and horizontal joints in concrete structures

Versatile Application – adapts to the unique requirements of your project

Simplified Installation - simplifies installation by securely fastening components with a user-friendly clip mechanism

Effective Waterproofing - acting as both an active and passive barrier at construction joints, CEMflex effectively blocks the transmission of water

“We are confident this is a significant addition to the PERI UP Scaffolding Kit. It addresses so many of the environmental challenges faced by contractors and also delivers improved protection against break-in and theft thanks to the inability for panels to be removed from the outside.”

Matthew Binder UK Product Manager