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US Site Review
1/2004
Conesco Doka takes formwork technology
and customer service to new levels in the US.
The Heritage at Millennium
Park, Chicago
37th Street Theatre, New York World of Concrete Metro tunnel extension in Largo, MD
Conesco Doka helps concrete Conesco Doka to prove its superb Doka systems keep Maryland
contractor in a tight situation Page 2 formwork technology capability Page 4 metro project on track Page 7
37th Street Theatre, New York
Conesco Doka helps concrete All of the Top 50 gangs and
MF 240 platforms were pre assem-
bled in Conesco Doka’s Ready-to-
contractor in a tight situation Use pre-assembly service in Little
Ferry, New Jersey and shipped to
the site. At various stages of the
An intricate architectural concrete theatre is being constructed project, entire sections of form-
on a tight New York City site only 75 feet wide by 100 feet deep, work were replaced with new
using pre assembled Top 50 gangs with MF 240 climbing brack- ones to accommodate the varying
ets, telescopic shaft beam platforms, custom steel forming changes in the building plan from
plates and both Dokaflex and 10 Kip shoring. floor to floor.
Accuracy in both the engineer-
ing drawings and in the pre-assem-
bled gangs together with perfect
timing of deliveries was critical to
ensure a continuous work cycle.
The Theatre is 8 stories high with
various openings in all of the
walls. Each of the floors has a dif-
ferent height. The structure is be-
ing built in 18 lifts to accommodate
the varying floor levels within the
structure.
Two of the exterior walls are
being built adjacent to the existing
structures with only 3” of clearance
between the theatre walls and
these structures. Conesco Doka fur-
nished custom steel forming plates
with captured tie nuts as an outside
form to fit into the 3” space. Since
the beginning of the project there
have been numerous changes in
the shape and quantity of walls.
According to Peter Ruttura, Vice
President of Ruttura and Sons
“Being able to rely on a formwork
partner with the strength, expertise
and commitment to service that is a
The Top 50 gangs and MF 240 platforms were pre-assembled in Conesco trademark of Conesco Doka has
Doka's ready-to-use service in Little Ferry, New Jersey. enabled us to undertake this most
difficult project. We couldn’t have
R uttura and Sons Construction
Corp of Farmingdale, New York
is the concrete contractor chosen
tectural patterns were achieved in
both placement of the plywood
forming sheets and tie locations.
done it without them.”
to build this complicated structure
known as the 37th Street Theatre, Accuracy in the engineering draw-
with no room for storage. ings and the pre-assembled gangs,
Ruttura decided to use Conesco and perfect timing of deliveries
Doka for this project because of our were critical to ensure a continuous
engineering expertise, our knowl- work cycle. And that work cycle
edge of limited clearance forming, was carried out to perfection by a
our ability to provide just in time de- highly committed formwork gang.
Formwork News 1| 2004
liveries of pre assembled equip-
ment and our expert field service. From left to right: Tom Bruno,
Conesco Doka worked closely Conesco Doka Account Manager -
with both the contractor and the Paul Pereira, Carpenter Foreman -
architect to ensure that the final Peter Ruttura, Vice President -
concrete structure met with every- Bobby Leonard, Superintendant -
2 one’s expectations. Special archi- Dave Marques, Superintendant.
The Heritage at Millennium Park,
Chicago: Conesco Doka’s Midwest
Branch developed a tailor-made
formwork concept for Walsh Con-
struction based on SKE automatic
climbers.
re-erection cycle down to just 1.5
hours - a record for any highrise
project Doka has been involved
with in the U.S.
Dokaflex 20 is used for all typical
floor slabs applications. Walsh also
chose 10 Kip/Leg shoring for sup-
port of beams, ramps, high floors
and the helix at the parking struc-
ture, and Framax framed panel
formwork for all retaining walls and
shear walls, the columns in the
basement level and the entire park-
ing structure below level 9.
Concrete work started on 2 Janu-
Heritage climbs ary 2003. By year-end, the high-rise
tower was up to level 37 and the
ahead of schedule
low-rise was almost complete.
Mike Hoge is the Superintendent
for Walsh Construction. He says,
"Maintaining our 3-day-cycle per
Contractors working on a 92,889m2 (1m ft2) residential develop- floor and considering some addi-
ment in downtown Chicago are set to complete concrete pouring tional time for changes in the top
operations almost three months ahead of schedule, thanks large- floor layouts and various heights
ly to a tailor-made formwork system supplied by Conesco Doka. within the upper levels of the tower
The Heritage at Millennium Park is a 190m (625 ft) tall landmark we should top out at this building
along the Michigan Avenue skyline. Comprising the 28-storey by May 2004."
Park Plaza and the 57-storey Skyline Tower, it combines a curved
glass façade and detailed exterior concrete architecture with four
existing six-storey façades built during the 1920s.
T he structural design calls for the
shaft walls, the floor slabs with
upturned and downturned span-
The cores at the center of the
structure are formed one level
ahead of the slab using Doka Top50
drel beams and exterior columns to large-area wall formwork gangs
be poured monolithically to mini- and Doka SKE100 self-climbing
mize construction joints. In addi- platforms. A concrete placing boom
tion, a combination of concave and climbs together with the core
convex shapes and straight transi- forms, delivering an uninterrupted
tion zones demands extremely ac- supply of concrete. The four-man
curate planning. crew has gotten the stripping and
To accommodate these require- "The key to the success is the use of
ments and avoid the need to set in- steel forms for the entire outside of
side panels by hand, Conesco Doka the building with all reveals and de-
and the main contractor, Walsh tails welded to the formwork pan-
Construction, together have devel- els," says Mike Hoge, Superinten-
oped a climbing formwork system dent (left), with Karen Latus, Project
with steel panels that open on one, Engineer (center) and Roy Eikeland,
two and, in some places, three General Superintendent. According
hinges. This allows the entire form- to Roy, "We felt confident working
work unit to be rolled back and with Conesco Doka as our forming
climb vertically without disturbing partner that, together, we would
the freshly poured concrete. solve all of our forming problems."
Conesco Doka to prove its superb formwork technology
capability yet again – at "World of Concrete".
Equipped with the new Xlife sheet
plus accessories for simple shaft
formwork and extra-large panels
for faster forming, Framax Xlife
system provides the perfect
framed-formwork solution.
cause no extra fillers are needed to
aid stripping. This reduces the
number of wall-ties that are need-
ed, and improves the quality of the
concrete surface. The shaft form-
work can then be repositioned as a
complete system, thereby also sav-
ing valuable hours of labor.
"Leadership in formwork technology" – this is the motto under Complete "all-in-one" reposition-
which Conesco Doka will be presenting several major innova- ing of large deck units is also revo-
tions, all aimed at making formwork assignments on the site lutionizing the field of floor-slab
even more efficient and at giving construction firms a sharper formwork. With its new Dokamatic
competitive edge. table, Conesco Doka offers a sys-
tem of preassembled and standard-
"Increasing the durability of the When it comes to stripping form- ized formwork units for all areas of
formwork, minimizing damage to work inside shafts, the new Framax slab. Tableform units of up to 300
the form-facing, reducing the bias cut corner I is a tremendous sq. ft can be repositioned "in one
amount of cleaning needed - and practical help. The stripping mech- piece". The "Dokamatic" makes a
improving the quality of the con- anism can be operated effortlessly quick and easy job of adapting to
crete surface at the same time". It and without any special tools. The widely varying slab thicknesses.
was to satisfy exactly these require- new shaft formwork is easy to strip Because it can be repositioned so
ments from actual practice that the from the concrete, simply by turn- quickly and effortlessly using the
Doka Formwork Experts developed ing spindles – and without having Doka shifting appliances, with only
a new system: The Xlife Framax to use the crane to break the forms a minimum of labor, it makes
gang form system. The new sys- free from the concrete. The system work go ahead very efficiently. For
tem comes with a package of out- also offers a further very significant slabs at heights of over 23 ft, the
standing product advantages: By advantage, however: The inside table superstructure can readily be
combining the twin materials of formwork can be assembled from combined with Conesco Doka’s
wood and plastic, a completely the widest possible panels – be- shoring. The integral table plat-
new form-facing came into being – forms make it unnecessary to
the Xlife sheet. As its name implies, mount work and safety scaffolds,
it makes for a significantly longer and provide a high level of safety
lifespan, while drastically reducing for users. Thanks to the easily
its tendency to damage. Whereas transferable swivel-heads, chang-
on plywood with a thin film coat- ing geometrical and structural-
ing, chips tend to break away when design requirements can be ac-
nails are hammered into the sur- commodated very quickly. The new
face, the tough, elastic plastic sur- Dokamatic table fits seamlessly
face of the Framax Xlife sheet with- into the existing Dokaflex 1-2-4
stands very much greater stresses. floor-slab product line.
Formwork News 1| 2004
The result: No damage to the form-
facing, and no imprints on the con- With the Framax Bias Cut Corner
crete surface. Another advantage is shaft formwork can be stripped
the minimal amount of cleaning and repositioned as a single unit in
needed after pouring, as the con- as little as a quarter of the time it
crete is so easy to remove from the takes using conventional formwork
4 special smooth coating. stripping systems.
The new Dokamatic table makes
it possible to reposition large-area
slab formwork units in one piece.
Its integral platforms and connec-
tors, and compatibility with the
flexible Dokaflex 1-2-4 system,
make Dokamatic a highly-economi-
cal formwork solution.
At many jobsites, the quality and
durability of system components -
like formwork beams, for example -
have a critical influence on costs.
The new Doka beam H20 top has
a novel end-reinforcement that
multiplies the lifespan of the
beam several times over. Investi-
gations into different types of
damage, and the frequency with
which they occur, pointed clearly
to this area as one where damage
could be minimized. The new
beam will be used with the
Dokaflex 1-2-4 floor-slab systems,
the new Dokamatic table and Doka
timber-beam formwork.
Another highlight at this year's
show is the use of the Doka Top 50
system for bridge construction.
A full size mock up of a box
girder bridge form will be dis-
played, showing the versatility of
the Top 50 system.
In addition, the booth will
feature Conesco Doka's "Ready-
to-Use" pre-assembly service. Pho-
tos will be available of formwork
that has been pre-assembled at
our warehouse and delivered to
the site, saving the contractor
weeks on his schedule and on site
labor costs.
With these highlights, Conesco
Doka is looking forward to drawing
a capable and informed trade pub-
lic coming to meet its system sup-
plier, Conesco Doka, with a healthy
mixture of curiosity, requests and
suggestions from actual practice.
The novel end-reinforcement of the new Doka beam H20 top increases
the lifespan of the beam several times over. The beam will be used with
Formwork News 1| 2004
Dokaflex 1-2-4 floor-slab systems, the new Dokamatic table and Doka
timber-beam formwork.
Imprint:
“Formwork News” is a publication of the International Doka Group. Publisher: International Doka Group, Reichsstrasse 23, A 3300 Amstetten, Austria.
Editor-in-chief: A. Zehetner, Layout design: COMO Werbe & PR GmbH, A 4020 Linz, Reprography: Nureg Reproduktionen, Nuremberg, Germany. Printers:
Fr. Ant. Niedermayr, Grafische Kunstanstalt, Regensburg, Germany. In some cases the site photos show the situation during formwork assembly and are
therefore not always complete from the point of view of safety. 5
Scott Candler filtration project, Atlanta
Covering a site of 60 acres (24.3 ha)
the Scott Candler filtration con-
tract includes updating existing
plant and facilities, new structures,
raw water and fresh water piping
and installation of plant in the filter
and ozone buildings.
Archer Western is also using
extensive quantities of Doka’s Alu-
Framax system, particularly for the
sedimentation beams, columns
and edge forms because its light
weight allows ‘hand-set’ installa-
tion and positioning, eliminating
the need for a crane.
Efficient four-day cycle “The main advantage of the
Framax system is the minimum use
of walers and stiffeners as we just
for wall construction clamp the panels together,” said
Lynn.
On a project where construction
Extensive water penetrations on the Scott Candler filtration project joints are not typical and ever
in Atlanta, Georgia where, according to the Project’s Superinten- changing, Lynn highlighted a fur-
dent, there is not a wall without a pipe penetration, led the main ther benefit of the clamping sys-
contractor Archer Western Contractors Ltd. to use Doka Framax tem, allowing simple reconfigura-
formwork system to ensure versatility. tion.
Use of the Framax system en-
sured an efficient four-day cycle for
“A serious consideration through- system that allowed versatility to wall construction. Typically, a non-
out construction of the new plant meet the ever-changing shapes.” stop pour could comprise 50-60 ft
and upgrading of the existing facili- Forming the ‘backbone’ of the (15.2-18.1 m) long walls with three
ties is that it must remain opera- formwork system according to 40 ft (12.2 m) long ‘T’ intersection
tional throughout all phases of con- Lynn Walker, the contractor is rely- walls up to 30 ft (9.1 m) high.
struction,” said Senior Project Su- ing on the Framax 135 cm x 270 cm “Time is money,” he said, “And
perintendent Lynn Walker. (4.43 ft x 8.9 ft) panels to cover though it’s difficult to compare
large areas, particularly in the one framed gangform system to
He continued, “Another problem filter building. Here for example, another, one thing is for sure - the
is that throughout construction of the larger panels are being used Framax system is so much quicker
the new facility there are so many to cover areas of up to 1680 ft2 and easier to erect compared to
water penetrations in virtually (156 m2) and for the 30 ft (9.14 m) other systems. And that’s what it
every wall, we needed a formwork tall columns in a single form. takes to work efficiently.”
Archer Western Contractors Ltd,
is constructing more than
1 million ft2 (92,900 m2) of walls
and columns, using almost 62,000 ft2
(5760 m2) of Doka Framax form-
work system.
“The formwork and service provid-
ed by Conesco Doka has helped us
to achieve our goal of pouring
80,000 cubic yards (61,200 m3) of
concrete in one year,” says Senior
Project Supervisor Lynn Walker.
Metro tunnel extension project in Largo, Maryland
Conesco Doka systems keep
Maryland metro project on track
A formwork system supplied by Conesco Doka has reduced
pouring cycle times by a third on the $ 215 million WMATA
(Washington Metropolitan Area Transit Authority) Metro tunnel
extension project in Largo, Maryland.
With around 300 pours to complete
and an aggressive construction
schedule to keep, the LGS Joint
Venture needed a forming system
that could accommodate the wide
range of tunnel heights and widths
as well as the radius sections.
dule of a pour every three days.
Greg Johannes, Project Manager
for LGS JV, was pleased with the
results, stating that “ the com-
pletely hydraulic system really sim-
plified the stripping, driving, and
setting operation throughout the
constantly changing tunnel align-
ment. It was well worth the addi-
tional cost to fully automate the
system. It was the only way we
could pick up time on the sched-
ule.”
The project includes the cut and cover construction of 4.83km (3 miles) of Elsewhere on the project, the
double tunnel box, with straight sections poured in 15.24m segments and LGS JV used the Doka Framax
curves in 7.62m chords. gang forming system backed with
Doka Support “A” frames to form
T he design build project in-
cludes the cut and cover con-
struction of 3 miles of double 12 ft.
commodate the wide range of tun-
nel heights and widths as well as
the radius sections.
the 18 ft. high walls of the West
Service Room and double cross-
over areas; and Framax with D-22
high x 14-15 ft. wide tunnel box, The system supplied by Conesco support frames for the 12 ft. high
with the straight and curved sec- Doka comprised a traveller sys- walls of the Triple Box area.
tions poured in 50 ft. segments. tem, with independently-control- LGS decided to gang-form the
There is also a series of flared sec- led front and rear wheel drive and continuous column footings for
tions, triple box sections, service braking systems, front and rear Triple Box, and Conesco Doka sup-
and operations buildings, plus an steering, and vertical height and plied a Quad-8 forming system
aerial structure and freeway cross- width adjustment. with custom support brackets and
ing. With approximately 300 pours The 50 ft. long roof and side 8” steel channels. The system was
to complete and an aggressive con- forms could be “crabbed” in two 25 hung from the 24” diameter sup-
struction schedule to keep, the LGS ft. sections as needed in the curved port struts spanning the tunnel
(Lane Construction Corp., Granite sections. This allowed the LGS JV width. With this system the LGS
Construction Co. and Slattery- to pour two 25 ft. chords at a time JV were able to strip and set an en-
Skanska Inc.) Joint Venture need- using one 50 ft. traveller, thereby tire 50 ft. long footing in just two
ed a forming system that could ac- saving a day on the original sche- 25ft. gangs.
Formwork News 1| 2004
Conesco Doka Ltd. Little Ferry Branch Atlanta Branch California Office
Little Ferry Headquarters 208 Gates Road, 105A Boulderbrook Circle, 6901 Central Avenue,
Little Ferry, NJ 07643 Lawrenceville, GA 30045 Riverside, CA 92504
214 Gates Road,
Tel: (800) 631-1978 Tel: (888) 618-4700 Tel: (909) 509-0023
Little Ferry, Fax: (201) 329-6229 Fax: (770) 962-5238 Fax: (909) 509-0024
NJ 07643
Tel: (800) 631-1978 Chicago Branch Maryland Office
Fax: (201) 641-6254 1032 Moen Avenue, 6537 Mid Cities Ave.,
E-Mail: dest@conescodoka.com Rockdale, IL 60436 Unit 11,
Tel: (815) 730-6700 Beltsville, MD 20705
Fax: (815) 730-8178 Tel: (301) 595-1808 7
Fax: (301) 595-7395
For the Doka address nearest you, please see our web-site: http://www.conescodoka.com
Mesa Performing Arts Center, Mesa, Arizona
Conesco Doka delivers fine performance
at Arizona´s largest arts center
Doka Top 50 formwork has provided the ideal solution to a tough not a concern. All forms above
architectural challenge at the new $ 94m Mesa Arts Center in the grade level were climbed on Doka
state of Arizona. Located on a 2.83ha site in downtown Mesa, the MF240 rollback units. These pro-
62,640m2 development includes four theatres, five galleries, 14 vided a safe working platform for
studios and classrooms, meeting spaces, a lecture hall, internal carpenters and reinforcing steel in-
performance spaces and administrative offices. stallers, as well as a trailing work
level for finishing and patching op-
erations.
According to Peter Franceschina,
Western Regional Manager for
Conesco Doka, “The biggest chal-
lenge was coping with the pre-
determined sizes of the form liner
sheets and handling the reduction
in wall lengths due to the sloping
walls. Furthermore, the horizontal
construction joints were not level
but perpendicular to the sloped end
walls. This meant that the rollback
platforms also had to be sloped.”
Scheduled to open in spring
2005, the Mesa Arts Center will be
the largest arts centre in the State
of Arizona.
Layton Company of Arizona used Top 50 with articulated steel walers to
achieve outer radii of 21.63m, 29.55m and 31.69m on the curved,
battered walls.
T he largest three theatres are a
complex design that combines
canted, curved and conventional
sloped inwards at either 4, 5 or 6
degrees. For the curved, battered
wall at the opposite end to the
cast-in-situ concrete walls with flytowers, Layton Company of In total, Conesco Doka supplied
sloping flat roofs and stringent Arizona used Top 50 with articulat- approximately 1400m2 of formwork
finishing requirements. ed steel walers to achieve outer to the project, including some
To meet the demands, general radii of 21.63m, 29.55m and Framax for the foundation and
contractor Layton Company of 31.69m. The two remaining walls straight theatre walls.
Arizona opted for Doka equipment. were also formed with Top 50,
Each theatre has a back-of-stage with one wall inclined at 4, 5 or 6
Formwork News 1| 2004
scenery “flytower” formed using degrees to match the flytower.
Doka Top 50 gangs, with an elas- In total, Conesco Doka supplied
tomeric form liner moulded onto approximately 1400m2 of form-
the plywood facing providing the work to the project, including
woodgrained exterior finish. The some quantities of Framax for the
towers range from 34m to 54m high foundation and straight theatre
8 and each incorporates one wall walls where concrete finish was
