PERIscope 2021 - 1

UK 1 2021

PERIscope The magazine for the construction industry

In Focus

Meeting complex temporary works demands on the UK‘s largest construction site Hinkley Point C, Somerset

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Dear Reader, First of all, a big thank you for your continued trust and confidence in PERI over the last year. 2020 was a year nobody anticipated, yet the construction industry adapted and rose to the challenge. I expected 2020 to be dominated with the implications of the Brexit Withdrawal Agreement that was announced at the end of 2019, however Britain’s departure from the EU at the end of 2020 passed more smoothly than many expected.

As we import our core products from Europe, a smooth transition and exit from the EU was always of great importance to us. At the time of writing in May 2021, I’m pleased to report that leaving the EU has only had minimal direct impact on PERI. In March 2020 when the COVID-19 pandemic and the first lockdown was announced in the UK, we quickly realised that we had to adapt and play our part to keep construction moving. We have strived to continue providing the best possible service at all times while adapting to each iteration of the Construction Leadership Council’s Site Operating Procedures as the situation changes.

Our 4-step support plan was put in place to meet the changes in our customers’ needs during this uncertain and challenging time. Resources such as our Quicksolve planning tool and product demonstration videos were created and made available to provide value-added services at a safe distance.

Feedback for change 2020 also gave us an opportunity to reflect. Our customer survey was completed during this time, and despite the pandemic being one of the biggest challenges, we received valuable feedback around some of our core products and services. I’d like to personally thank everyone that took part for your input and honesty. Our teams are working hard to make changes that will only improve the service you receive going forward – a few of which you will read about in this issue.

To the future Despite a year of uncertainty, we’ve been privileged enough to work with our customers on projects of all shapes and sizes – you’ll get to see some of these over the next few pages. Our employees have been our strength throughout this process and continue to be a pivotal part of our success.

With the UK making significant progress with its vaccination programme, we can only be more optimistic as we look ahead to the rest of the year.

And although we may feel we’re continuously adapting, one message remains constant – let’s continue keeping our staff and each other safe.

Here’s to rebuilding, together.

But there’s still a long way to go. While the construction industry has been fortunate to remain open since the initial phase of the pandemic, we are aware of the effects the pandemic has had at an individual business level. We would like to reassure you that our staff, services and products will continue to support you no matter how big or small your challenges are.

Alasdair Stables for PERI UK

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Contents 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 Simon Turner Darren Powell EDF Energy J Coffey Construction Ltd.

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T ravelling formwork for the UK‘s first curved box jack

Werrington Grade Separation, Peterborough

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Reaching new

heights with PERI UP Scaffolding &A with our Industrial Q Manager and Business Development Manager – PERI UP

Print Neil Terry 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

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W here architectural concrete meets steelwork V&A East, London

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V&A

East – The Customer‘s Perspective V&A East, London

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A better service for all

In Focus

An interview with our Customer Services Director, Stuart Robinson

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eeting complex M temporary works demands on the UK‘s largest construction site

Hinkley Point C, Somerset

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A safe approach to quicker results Our safety concept

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N ews

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Travelling formwork for the UK’s first curved box jack Werrington Grade Separation, Peterborough

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The Werrington Grade Separation scheme is being constructed to make way for a new diveunder railway line, which will increase rail capacity and improve journey times on the East Coast Main Line. So that multiple lines can run independently of each other, the diveunder is being constructed using a cut and cover, curved box jack method to allow the new tracks to pass under existing railway lines.

This has involved excavating the ground to form an offline jacking slab on which the UK’s first curved portal box was constructed and later jacked into position. The box jacking method

has minimised disruption to live tracks and resulted in greater cost savings compared to other methods that were initially considered. With the ground slab in place, the remaining structural

components of the tunnel, including the 1-metre thick roof slabs and walls have been constructed in situ using our travelling formwork system, known as a VTC carriage.

Early involvement

VTC design

Movement & hydraulic technology

Early engagement on a scheme like this, where the tunnel’s curvature introduced its own set of challenges, benefitted both our team and concrete contractor, Bell Formwork.

Over 160 metres of tunnel has been constructed using a single VTC carriage engineered by specialists in PERI UK and Germany. The tunnel’s curvature has been formed using standard, yet flexible off-the-shelf components from the VARIOKIT range along with GT 24 girders and wooden battens of various lengths on the inside shutters, helping to gradually form the curve. Standard components with this degree of flexibility reduced the need for bespoke material, contributing to greater cost savings.

Precast concrete plinths, constructed in Bell Formwork’s yard, were used underneath the VTC system to assist movement and transfer the concrete load to the ground. Once up and running, only minimal adjustments needed to be made to the system during construction. Hydraulics were a key part of this, as it enabled all soffit and internal panels to be struck simultaneously, and was also used to push the system to the next casting section with no dismantling required.

After seeing a similar design during a visit to our HQ in Germany, both Morgan Sindall and Bell Formwork were impressed with the system and its speed. Understanding buildability and movement of the VTC carriage through sequence drawings very early on in the process helped Bell Formwork to visualise how this would work on the Werrington scheme.

For access to the soffit slabs, a suspended PERI UP stair tower was integrated at the front end of the formwork carriage. Its compatibility with the formwork solution enabled it to continue travelling with the VTC carriage to each casting section.

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The project was the first in the UK to experience the benefits of our latest hydraulic drive, which meant that no other hydraulic technology or equipment was needed to push the system back and forth. The speed of hydraulics helped save time during the construction of the tunnel, which was cast monolithically in nine segments, each measuring 17 metres in length and over 8 metres in height. Reducing concreting time as much as possible was crucial, hence monolithic construction also being the desired casting method. The combination of the pour sequence and the speed of the VTC system contributed to shorter cycle times, saving 10 days per segment.

Final move The completed 11,000 tonne structure was jacked into place in January this year during a 9-day closure of the East Coast Main Line. During this process, heavy-duty props were used to brace the structure as it was jacked forward on steel slide plates using large hydraulic rams.

“Early involvement has been the saving grace with everything, including the design of the structure and formwork from PERI. We got an understanding of the proposed solution, including a sequence drawing and how it would all come together. The PERI system was so quick and simple to use – it has worked brilliantly throughout the project.”

Duncan Keeling, Construction Manager, Bell Formwork Ltd.

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Reaching new heights with PERI UP Scaffolding Q&A with our Industrial Manager and Business Development Manager – PERI UP We have been making significant changes to our scaffolding business over the last year, expanding capabilities across all areas and developing our PERI UP Scaffolding range. The team has grown and will double in size with the addition of new site demonstrators, sales engineers and a new Industrial Manager, all dedicated to supporting the scaffolding market.

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We did a Q&A with our Industrial Manager for scaffolding, Mark Holmes and our Business Development Manager (PERI UP), Charles Stratford to find out what these changes mean for our customers. Read on to find out more.

Q: What do you think are some of the challenges facing the scaffolding industry?

Mark: 2020 has been a unique year and one which nobody could have predicted.

BREXIT followed by COVID-19 has made issues like the skills shortage more apparent, with sites experiencing slower progress than in previous years. Investing in our scaffolding division by bringing in new talent at a time like this shows our resilience and commitment to supporting our customers throughout the pandemic and beyond.

Charles: Following on from Mark’s point, scaffolding has changed over the years and the skillsets of scaffolders has been diminishing. I feel this has been a result of the industry designing fast-track courses which are great at encouraging people to join the industry and grow the pool of scaffolders, but it often means that a large portion of the sector has a lower skillset. This is where system scaffold is advantageous as it’s intuitive and easier to build which improves efficiency on site.

Q: What is the focus for PERI scaffolding going forward?

Mark: The UK industry is starting to adopt system scaffolding more than ever before and we want to ensure our customers receive the full benefits of PERI UP on their job. What’s great about PERI is that we’re not just a scaffolding supplier – there’s a whole range of supporting services that our scaffolding customers can benefit from. With these services all under one roof, it’s easy to collaborate with the likes of our digital and 3D specialists on complicated or bespoke projects, offering many benefits to the planning and decision-making stages.

Charles: We are keen to raise our scaffolding profile in line with our formwork products that are renowned across the globe. Getting the right people on board who speak ‘scaffolding’ has been crucial for us, as we further align our capabilities with our scaffolding customers’ requirements.

It’s an exciting time to build a team and diversify this area of the business.

We are confident that the experienced personnel that we have in place from across the industry will enable us to drive early engagement with our scaffolding partners. Scaffolding fits into all construction segments naturally, and we now have the capability to support

customers on the scaffolding jobs.

most

complex

Q: What products will you be adding to the scaffolding range?

Charles: Our products are evolving in line with what construction sites need today. A lot of the requirements around scaffolding involve speed and efficiency, often the faster the better.

We are excited to be introducing our latest system in the PERI UP range to our customers in the UK this year. PERI UP Easy is a system that is all about speed and safety, both of which are embedded into its design. The system’s built-in guardrail meets SG4.15 throughout, promoting a safer working environment for scaffolders before the build even starts. Reducing assembly and dismantling time is fundamental to the design of the system. The advance guardrail makes PERI UP Easy four times faster to erect than a traditional tube and fit scaffold and minimises material on site. One of the main benefits our customers and principal contractors can look forward to is the system’s potential to reduce prelims significantly and make larger savings.

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Q: What part will training play?

Mark: As mentioned, we are working in a time where skilled scaffolders in the industry are scarce. This makes any training more fundamental to the construction process, whether that’s through on-site demonstrations or teaching best practice through our accredited training programmes that we deliver in-house.

With dedicated demonstrators we now have greater capacity to support our customers in a live environment. Onsite issues can be rectified immediately, helping to reduce downtime. This also eases the transition from traditional tube and fitting to system scaffolding.

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Charles: Reiterating what Mark said, site support is for me one of the key pillars that adds value to our product – having product specialists will aid our growth strategy and give our customers the confidence to overcome new challenges using PERI UP. Formal training will continue to play a big part in our scaffolding journey. Our CISRS-accredited centre in Brentwood provides the ideal space for training and demonstrating PERI UP Scaffolding’s compatibility with other products from the PERI range.

Q: What is the outlook for the Industrial segment?

Mark: PERI UP has a lot to offer the complex industrial environment. Our customers are currently experiencing this on the largest construction project in the UK, where our scaffolding and formwork systems are working together to support construction of Hinkley Point C. The site has benefited from our support services too, where we’ve trained apprentices and also provided site supervision – all of which have been carried out by our team in the UK. The successes we’ve experienced on this project certainly puts us in a stronger position to tackle other challenges in this sector with confidence.

We are a digitally-enabled business, which allows us to implement smarter ways of working in these complex environments using the power of data. We have already started trialling 3D scanning in conjunction with our digital engineering team, which means we will be able to help our customers remove or accommodate obstacles ahead of assembly.

Another development that we want to introduce to our UK scaffolding customers in the future is our Integrated Scaffolding Programme (ISP), created by the global PERI Industrial Business Unit.

This will certainly help to streamline the operations involved on industrial projects, and give customers more

control of scaffolding costs by enabling full visibility of material requirements in the pre-planning phase and beyond.

Q: Any final comments?

Charles: We are a one-stop-shop for our customers’ scaffolding requirements, which ultimately means almost any requirement can be fulfilled in-house.

If you want to find out how we can support you on your next project, please get in touch sales@peri.ltd.uk

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Where architectural concrete meets steelwork V&A East Museum, London

The V&A East museum is part of the Stratford Waterfront East Bank project, led by London Legacy Development Corporation and delivered by Mace, the international consultancy and construction company.

Like V&A Dundee, the V&A East museum came with its own set of challenges for all involved, with much of the architectural work involving faceted forms on its façade, and freestanding cores featuring unique wall layouts and patterns inside the building.

The architectural requirements across parts of the new museum’s three central cores involved using bespoke temporary works systems, similar to what we had previously designed for the iconic Scottish museum.

Forming the finish In the early stages of the project, we were presented with the challenge of

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proposing a suitable pattern for the fairfaced finish. Our specialists suggested using a VARIO formwork solution in parts of the core that would create the desired symmetrical ply and tie layouts.

Combined with the finish, the large amount of steelwork on the project meant that de-clashing was an even bigger challenge. The steelwork forms the structural frame of the building, which consists of large embedment plates cast into the cores, tying all elements of the building together.

When positioning climbing anchors and formwork ties, careful planning between concrete contractor J Coffey and our design team was required to avoid

clashes with the steel plates below – the size of these plates making it even more complicated to accommodate.

Fabricating the formwork shutters off-site at our Rugby depot made it easier to achieve the unique patterns and accommodate the plates as the core evolved. The prefabrication work included the creation of single and double skin layers depending on the level of detail required. For the latter, this involved adapting ply sheets by incorporating striking details into the panels. This allowed the shutter to be removed without affecting the pattern.

RCS climbing

Safe access with PERI UP

System compatibility between our RCS climbing platforms and our formwork enabled the core to progress ahead of the steelwork. Again, detailed offsite planning helped the team work around steel connections and openings throughout the core.

Our formwork designers were also heavily involved when planning the lifting sequence and access to working levels. This involved understanding how operatives would access each level from the PERI UP tower erected inside the core. A second stair tower was erected between cores 1 and 3 to provide dual access. The stair tower was designed for access to core 1 first and was later adapted so operatives could also access core 3 as it progressed.

Safety features like PROKIT edge protection barriers and special laser cut mats were supplied by our team to provide a safer working environment and enclose the RCS solution. The PROKIT barriers provided protection up to 4 meters high at various levels, whilst the mats were used to seal off any gaps in the climbing platforms.

By taking advantage of PERI UP’s versatility, designers were also able to create an ‘up and over’ access solution, as the final floor levels followed up behind the core and were not yet in place. By using the PERI UP scaffolding solution, operatives could gain access

from one side of the formwork shutter to the other. Units were crane-lifted in and out of position when required, providing easy and safe access over walls, formwork, and even protruding rebar. One of the main benefits is that the ‘up and over’ solution could be used for access while shutters were in the pouring position and even after they were struck.

Crane-free formwork Whilst the larger formwork requirements were fulfilled with VARIO and TRIO, the smaller concrete elements, such as the wing walls, benefitted from our lightweight formwork system, DUO. Offering crane-free handling in confined areas, the DUO system followed up behind the RCS platform to complete the smaller structures inside the core.

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V&A – The Customer’s Perspective Sean McDonagh, Project Manager - J. Coffey Construction Ltd

What was the biggest challenge for your team?

All three cores had to be completed to a very high standard on this project. The specified finish meant all of the anchors and ties for the formwork system had to be coordinated with the design. This included coordination with the steel embedment plates which we had to cast in during the progress of the works to facilitate the structural steel frame.

What was the chosen construction method and why?

The formwork solution was driven by the jumpform system. We decided against slipform because of the aesthetic finish and the time needed to achieve the required standard. The finish demanded a precise construction sequence and structured environment, especially when taking the complexity of the rebar into account. The jumpform system was also ideal in accommodating the large steel embedment plates.

project, that we were choosing the right solution and temporary works partner.

Myself and my team pushed it up the line that we wanted to work with PERI on this project.

PERI also designed and supplied some of the coordinating systems to support the jumpform, providing the full temporary works package and ensuring a safe working environment.

They worked closely with us to map out crucial requirements such as internal and external access.

The whole process was not a traditional falsework ‘erect and strike’ approach due to the structural steel frame. We have built the concrete cores first, enabling the steel frame to follow swiftly behind, and the slabs – a mix of traditional in-situ and some precast – will follow once the steel is well advanced.

The up and over access solution was ideal on this project, as it avoided operatives climbing over rebar in potentially unsafe conditions. It was a simple yet effective solution where the site team were able to move between two sides of formwork via a safe up and over scaffold.

Why PERI?

The scaffolding systems dovetailed into the main requirements and design of the project, enabling smooth integration with what we planned in terms of storey heights and tie positions.

We chose to work with PERI, partly because of our long-standing relationship with the company but also what they brought to the table. They realised the significance of the project and the level of coordination and input that would be required from an early stage.

There was a real understanding from the team at PERI, in particular the sales and design teams who engaged with us fully. This gave us the confidence, despite the challenges involved on this

We also trusted in PERI’s off-site fabrication capabilities and quality. This meant that we could minimise work on-site in line with Site Operations Procedures and COVID-19 guidelines, and also maintain productivity levels.

PERI always gave us the confidence in their resources and delivery of these materials.

By plugging in so diligently in the early stage with regards to design, coordination, off-site fabrication and structural challenges, we were able to work relatively smoothly once we got the green light to proceed. This enabled us to work more productively as a unit, as any issues could be ironed out at the start instead of at the work’s face, which would have had an impact on time and efficiency.

Alongside off-site design and fabrication, we also had support from a PERI Project Manager, Stuart, who acted as the ‘glue’ that brought everything together. Stuart was able to adapt the level of support we received from the team at PERI to meet the changes in our requirements due to COVID-19, which has been a real factor over the last year. There were a lot of challenges, but Stuart always plugged in and was a vital link between us and PERI’s off-site teams, like fabrication and transport which were well organised and managed. He was also able to identify and quickly resolve any issues along the way so that they didn’t have an impact on the progress on site.

Any final words?

It’s been a good journey for the team at J Coffey and I’d certainly be an advocate for PERI on our next job.

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A better service for all An interview with our Customer Services Director, Stuart Robinson

After 23 years’ experience working in the technical and sales teams at PERI, Stuart Robinson was appointed as Customer Services Director last year. The newly created role is important for the PERI brand in the UK as we continue to build long-term relationships with our formwork and scaffolding customers.

Stuart shares his thoughts on the importance of the new function and how it will benefit PERI customers going forward.

PERI is evolving on a global scale; our teams are expanding or being restructured to deliver what our customers need. One of my priorities is to strengthen our offer to the UK construction industry through fast and accurate responses to temporary works requirements with the support of a dedicated customer services team.

We’re one of the only businesses in this sector with a services function like this, and that in itself is exciting. It’s an opportunity to do better and continuously improve the customer experience.

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Great service has always been a fundamental part of our key business functions, from sales and on-site support to design work. The customer services team takes our commitment to quality service a step further as we’ll provide additional support directly to our customers.

We have already introduced new roles such as our Aftercare Officers who will provide postproject support, and more Project Managers to guide our customers through complex construction projects across all sectors.

We are confident that our customers will see the value these roles add to the construction process and how they will improve efficiency in the future.

These changes also mean that our other customer-facing functions will serve a more specific purpose going forward -– whether that means customers receive more face-time with our sales engineers, or designers can focus on preparing the most efficient and innovative solutions.

With clear support channels, our customers will be able to get the answers they need much faster.

About Me I joined PERI in 1998 as an Assistant Designer, the first junior designer that the UK subsidiary had employed.

Spending 10 years of my career in the technical team I learned a lot about our products and the design process.

With a new challenge in mind, I later moved into sales. This was a chance for me to understand and work directly with

on-site contractors. It was a completely different experience working from a desk to then being on the move and in front of our customers.

Going a step further, I even took the opportunity to work with one of our longstanding customers on a secondment in their technical team. It gave me a valuable insight into the customer’s day-to-day operations and the impact a

formwork and scaffolding supplier has on some of these processes.

Dividing my time between technical and sales throughout my career at PERI constantly reminded me of our customers’ requirements from different perspectives. It was, and still is important for me to ensure that we are aligned with these requirements wherever possible.

The customer survey and beyond The timing of the 2020 customer survey was ideal. Not only did it reinforce that these changes were in line with our customers’ needs, it also gave us a chance to identify new opportunities.

We were able to understand what we were doing right and, more importantly, what needed to be improved.

We found that a big pain point for customers across the industry typically occurs at the end of the process when closing a project and returning rental equipment.

Understanding the impact of this on our customers made it one of my priorities to improve our returns process, making sure it’s as smooth as possible for any contractor that works with us.

Some great work has already gone into this – we have developed our ‘CitNOW videos’ which will give customers a visual summary of their returned items, providing more clarity and transparency.

There is also alignment between our Aftercare Officer roles and the feedback

we received. These roles will ensure any problems are resolved quickly and fairly before closing a project, similar to the after-sales support you would expect when making personal purchases.

We have also introduced Product Gurus. These are technical experts who will be available to support customers with specific product-related queries, improving response times and accuracy.

The survey is just the start of our journey as a new business function. We are keen to continue asking for feedback across all touchpoints and use this data to make a difference to our customers and the wider industry.

As a family-owned business, customer loyalty is important to us. When customers choose PERI, I want them to feel reassured that their investment spans wider than just the project. It’s pleasing to know that almost half of our customers have worked with us for more than 10 years, and I am passionate about growing that number through the value-added services we can offer.

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Meeting complex temporary works demands on the UK‘s largest construction site Hinkley Point C, Somerset

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Meeting formwork demands on Hinkley Point C Hinkley Point C, one of the largest infrastructure projects in Europe, is making progress in Somerset. The foundations for the plant’s first reactor base, were completed in June 2019, with the same milestone for Unit 2 completed on 1 June 2020.

A combination of formwork and falsework was designed by our team to form many aspects of this complex, large-scale site.

Temporary works were crucial for the 175-m round concrete slabs that make up the foundations for the main reactor buildings. For these large structures, single-sided RUNDLEX formwork

was used with SB-Lite Frames, which transferred loads into the existing structure. RUNDFLEX’s ready-built panel arrangement demonstrated speedy assembly on site, making it ideal to deliver the shape of the concrete foundation. Pre-existing plates and pits in the ground were avoided by using post fixed anchors instead of cast in anchors.

Following the successful completion of Unit 1’s foundations, Unit 2 set a new record as it became the largest continuous concrete pour in the UK. This involved using 9,000 cubic metres of concrete, which was poured over four days.

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Declashing on the HK building Situated next to the reactor will be the plant’s fuel building. Our formwork is being used for the internal walls which change in layout on each of the eight floors. To improve construction time, a combination of TRIO and VARIO has been used to form the walls.

Challenges on this part of the site involved greater consideration around the positioning of ties and props, which helped to avoid clashes with steel plates in the surface. 3D and declashing tools in this case were paramount to ensuring the plates were avoided. The benefit of this technology is that our formwork could be designed around the model provided by the customer.

This ensured the formwork design and steel plates were coordinated, allowing

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the formwork model to be integrated into the client’s models. By doing this, the formwork worked in harmony with other aspects of construction.

Flexible tie positioning offered by the VARIO formwork system was ideal for the combination of high loads and the minimal tie requirement.

Irregular-shaped columns

At nine metres high, getting the first pour right was tricky in itself as it was concreted in one hit. Along with the system’s flexibility, in-depth conversations between our project manager, designers and the site team enabled a suitable solution to be designed. Two standard formwork panels were used to make up the required height for this shutter. Larger formwork components like our RCS rails, were used to reinforce the formwork, helping the shutters support the concrete load for this pour and as well as the changes in geometry further up the structure.

The HK columns involve some of the trickiest designs on site due to changes in its geometry. These structures will tie the surrounding buildings together for structural support. As a lot of these structures will be tied into one another, protruding rebar has been a constant challenge for our designers.

In particular, the reduction in ties has involved a lot of consideration. With only four ties in plan, designers had to position these in the most suitable locations to sustain the concrete pressure and steer clear of the rebar.

Despite returning to standard pour heights after the first pour, the rebar and geometry continued to pose challenges.

Through the PERI global network, PERI Germany supported our UK team with the design and fabrication of special components to join walers together at irregular angles and meet the design intent. This helped to reinforce the connection between shutters.

Climbing and Access for the columns To enable the columns to rise from the ground, VARIO was integrated with RCS climbing platforms. A meticulous approach to the climbing sequence was crucial to avoid RCS rails clashing with the rebar, especially in areas containing denser rebar. This was a complex design that required special components and design calculations from our team in Germany.

One of the earlier challenges during the climbing stage was that there was nowhere to cast the anchors in certain locations. In this case, PERI UP access towers provided entry and egress to the working levels.

This was extended to enable full access, up to 24 metres from the ground, to all working platforms around the column.

Again, post fixing was not an option as this could have damaged the rebar within the column. Our global support network meant we were also able to work alongside experts in PERI USA to find an alternative to stabilise the tower. The final solution involved tying the scaffolding into the protruding rebar for support.

Formwork below the ground An aspect of the project located below ground is the HCT shaft. The shaft forms part of the complex engineering work to deliver the tunnels under the seabed. The shafts will enable water to be discharged out to sea via the tunnels.

Formwork selection for the shaft’s outer wall was determined by its shape and ability to minimise operations. 20 VARIO panels were integrated with 2.4m-long platforms for swift access to all working areas. Starting its ascent 44 metres below ground level, the formwork gradually climbed over 15 metres on our single-sided climbing system (SCS). The shutters were retracted on platforms during the striking and cleaning process, reducing dismantling operations and therefore enabling seamless working operations throughout the build.

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A safe approach to quicker The PERI safety concept undergoes practical testing

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results

An article by the PERI Group

Hitting great heights in a safe manner during the refurbishment of the world’s highest church steeple – Ulm Minster – was possible thanks to the PERI safety concept. The project provided irrefutable proof that efficiency and safety on site are not mutually exclusive. In actual fact, safety can even speed up the construction process and reduce costs.

Throughout the world, safety requirements in the construction industry are becoming increasingly important. The multitude of guidelines, regulations and requirements all have one thing in common: they all aim to make construction sites safer – irrespective of whether they are applicable worldwide, in Europe or only in certain countries.

The issue of safety should be of paramount importance to companies on account of their responsibility towards personnel, not simply because of the necessity to meet legal requirements.

A high degree of safety is also a quality characteristic. It is advantageous to companies on several fronts: after all, promoting health and safety in the workplace also benefits the company from an economic point of view.

For example, the campaign “Netzwerk Baustelle”, which was run jointly by accident insurers and the federal states of Germany, demonstrated that compliance with occupational safety regulations resulted in a reduction in the number of accidents and, consequently, operational downtime and the associated costs, and prevented delays in the construction process.1 Furthermore, the study “Return on Prevention” by the German Statutory Accident Insurance Organisation illustrated that it is worthwhile investing in occupational safety and

health protection.2 The internationally implemented research project compared the costs and benefits of preventative measures. The findings: occupational health and safety in the workplace can have a positive impact on productivity and the number of operational disruptions. After all, healthy employees are more motivated and more productive. By implication, this leads to more efficient processes and an increase in productivity, which, in turn, have a positive impact on the quality of

the project. In this way, construction delays and costly downtimes are reduced to a minimum. Safety is a topic that is relevant to all parties that are involved in the construction project and are present at the construction site. In Germany, for example, it is primarily the client who bears overall responsibility and can therefore be held jointly liable.

However, architects, site managers and coordinators from companies working on the construction site may also be held liable for accidents.

1W. Klette (2008): Sicherheit und Gesundheitsschutz auf Baustellen: Qualitätsmanagement am Bau. Berlin, Vienna, Zurich: S. Beuth, p.14f.

2 German Statutory Accident Insurance Organisation e.V. (ed.) (2013): DGUV Report 1/2013. Calculation of the international “Return on Prevention” for companies: costs and benefits of investing in occupational health and safety in the workplace.

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System safety by means of intelligent design So what are the specific measures that help to improve the level of safety on construction sites? It is important to have a comprehensive safety concept that takes all phases of the project into comsideration rather than focusing merely on a subsection of the construction process. This is where the PERI safety concept comes in. It consists of four elements that come together to provide an outstanding level of safety on the construction site: system, application, process and result.

We address the topic of safety as early as the development and design phases for our formwork and scaffolding systems. As a result, the safety technology used in our products is often built into the system itself.

Numerous smart features of the modular PERI UP Flex Scaffolding System can improve both the degree of safety and the economic efficiency.

One of these is the Locking Deck – the clamp on the deck engages with the rectangular ledger without the need for any additional measures. Therefore, all PERI UP decks are automatically secured against lifting as soon as they are installed. What’s more, the

perforated and hot-dip galvanised steel decks provide a high degree of slip resistance. They can be walked on securely at any time, even in the most adverse weather conditions.

Another feature of PERI UP Flex is the Gravity Lock, which facilitates a swift and safe ledger assembly procedure.

The connection on the PERI UP Ledger is in the form of a wedge which is hooked into the rosette opening. As a result, the securing wedge drops into the rosette opening on account of its own weight and locks automatically.

After that, one hammer blow is all it takes to fix the wedge in place. Next, the ledgers can be attached quickly and safely to the rosette nodes of the PERI UP Standards.

Safety is a particularly important area of focus when working at great heights.

The Ulm Minster restoration project exemplifies this perfectly. Extensive PERI Scaffolding Solutions were installed on the highest church steeple in the world in order to carry out the renovation work on the vaulted ceiling, the choir stalls, the main tower and the 86-m-high choir tower.

Three construction sites, one church – you can find more information about the Ulm Minster refurbishment project here:

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Hitting great heights in a safe manner during the refurbishment of the world’s highest church steeple – Ulm Minster – was possible thanks to the PERI safety concept. The project provided irrefutable proof that efficiency and safety on site are not mutually exclusive. In actual fact, safety can even speed up the construction process and reduce costs.

Application safety and reliability thanks to safeguarded assembly and working In addition to the high quality of the systems and their innovative technology, the ability to use the systems safely is of significant importance. The simpler the assembly process and the subsequent application, the higher the degree of safety.

For example, the fact that the PERI UP Modular Scaffolding System could be adapted flexibly and easily to the given weight and geometry in 25cm increments was of paramount importance when installing the scaffolding on the main tower of Ulm Minster. The grid allowed seamless access from the PERI UP Flex staircase to the scaffold bay, thereby creating trip-free working levels. This resulted in tiered working levels and access

options that allowed work to be carried out safely on both the choir vault and the choir stalls at the same time. The PERI UP Flex toe boards along the landings also prevented small objects from falling to the ground.

The scaffolding was installed safely on Ulm Minister using the easily manageable, modular lattice girder ULS Flex, which is compatible with all PERI UP Flex standards and decks.

This meant that bridgings with a length of up to 10 m could be formed. The five individual parts of the girder could be transported easily using only small goods vehicles at a height of up to 30 m.

The fact that the assembly process could be carried out quickly and easily without additional tubes and couplings

made the refurbishment work simpler.

On account of its low weight, quick assembly process and straightforward adaptability irrespective of the storey height, the PERI UP Flex 75 Stair Tower also contributed to the success of the project.

All PERI systems are designed for easy assembly and handling with few tools.

The assembly process can also be carried out quickly and easily due to a low number of system components. If necessary, certain systems can even be delivered to the construction site preassembled, increasing the degree of application safety and reliability further still.

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Process reliability due to optimal support at all phases of the project

Process reliability also plays a role in ensuring that the construction process is straightforward. Our formwork and scaffolding systems can be optimally combined, giving our customers a clear advantage. Considering the fact that our portfolio, with its various consultancy, engineering and project related services, offers solutions for all phases of the project, we are able to provide a comprehensive support package whenever required.

By using Building Information Modelling (BIM), we can offer you real added value.

BIM is a forward-thinking approach that can be used to plan and control all construction processes. All of the trades that are involved in the construction process work on the basis of a digital 3D model that has been developed with the aid of CAD software. In this way, even individual alterations made during the construction project are immediately visible to all parties. On the one hand, this increases the transparency of the project, but also improves the level of efficiency and ultimately leads to a greater degree of planning and cost reliability. Any planning errors and safety risks can be identified at an early stage and rectified in good time.

Source: Minster Site Office, Ulm

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The BIM method was also used during the Ulm Minster refurbishment project. The on-site support provided by engineers from our global PERI team during the Ulm Minster project ranged from 3D planning to tests for structural integrity. While the scaffolding for the main chamber could be planned in a conventional manner, the process of surveying the sanctuary proved to be the biggest challenge that the engineers faced during the project: “We only had access to historical 2D as built plans which made it impossible to plan the scaffolding for the complex geometry of the sanctuary,” explains the project manager in charge, Lothar Stärk.

Together with the Minster Site Office and the scaffolder, he came up with a concept that met all of the geometric and safety-related requirements pertaining to the high working level required for the restoration work.

A 3D scan of the interior provided the basis for this. This made it possible to determine the dimensions and then translate them into a three-dimensional building model. Finally, Lothar Stärk worked out the complicated, threedimensional geometry of the sanctuary’s interior with the numerous niches and curves in the vaulted ceiling and an overall size of 13,000 m³ using a freestanding, metric system grid in 25 cm

and 50 cm steps. What was particularly challenging was the fact that no ties could be anchored to the historical building for fear of causing damage.

The three-dimensional visualisation of the scaffolding also served as a common communication model and delivered added value during meetings involving all project participants. It was possible to identify and quickly resolve clashes in an optimal manner.

Thanks to the BIM method used, both the scaffold planning and assembly process proved to be efficient. The client benefited from a high degree of planning reliability and from time savings throughout the entire construction process. The delivery of materials was also planned in consultation with the scaffolder and was carried out using a just-in-time approach on account of the spatial restrictions.

The regional nature of PERI as a company proved to be extremely useful in this regard. The central location of the rental park for system units at PERI’s German head office in Weissenhorn offered a short transport route to Ulm – and on-schedule supply of materials without any down-time.

Sticking to the demanding schedule was straightforward.

Guaranteed results borne out of expertise By having a hollistic view of the construction process, we can use our expertise to assist architects and planners from an early stage. Drawing on their international expertise, our experienced engineers can, on request, provide support over the course of an entire construction project and carry out structural preliminary planning work and feasibility studies. All of this

contributes to the desired outcome, where work is carried out in a safe and efficient manner.

As was the case with Ulm Minster: “The time frame of only four weeks to carry out the scaffolding preparation work for the sanctuary of Ulm Minster was extremely demanding,” says master builder of the minster, Michael Hilbert.

That is why the combined approach of laser scanning and scaffold planning was the topic of focus. Thanks to the professional support provided by PERI, the scaffold assembly process for the sanctuary lasted only three weeks. In the end, Hilbert was delighted with the result: “An incredible achievement.”

Michael Hilbert took over as Head of the Minster Site Office in Ulm in 2013. The 58-year-old died in April 2020 following a serious illness. He was incredibly influential in his time as master builder of the minster. For example, a decision is to be made in autumn as to whether the Minster Site Office should be included in UNESCO’s list of the Intangible Cultural Heritage of Humanity. PERI enjoyed a long-standing partnership with Michael Hilbert and is deeply saddened by the loss.

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News SONO WZ Concrete Sensor The most efficient way to measure water to cement ratio on site

With the SONO WZ analyser, the water content of fresh concrete can be quickly and precisely determined on site.

The device is based on the innovative TRIME® radar technology and supports simple quality control procedures on the jobsite.

Designed to work in today’s fastpaced construction environment, you can receive accurate test results in just two minutes.

To find out more get in touch at ukdigital@peri.ltd.uk

RCS MAX

Taking our RCS climbing system to the next level

The new RCS MAX Rail Climbing System is a further development of our tried-andtested RCS Climbing System. You can simply add the new RCS MAX modules – the RCS MAX Hydraulic Unit and the RCS MAX Drive Rails – to your existing RCS system components.

With its completely new approach to climbing, the RCS MAX Rail Climbing System revolutionises climbing techniques and improves productivity and safety on your construction site. This is achieved by enabling several platforms to climb a structure simultaneously in fewer steps – open building edges are therefore a thing of the past. What’s more, the system now provides you with the option of transferring loads via the lower climbing section.

For more information about RCS MAX, speak to your local sales engineer or visit: link.peri.ltd.uk/RCS-MAX

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Formwork Scaffolding Engineering www.peri.ltd.uk

UK en 01 | 2021