FormworkPress - MEVA Formwork Systems

FormworkPressProfessional Formwork News XII/2019

Rethinking formworkSpecial design for vertical louvre geometry – page 8

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FormworkPress XII/19

ContentsEditorial ....................................................................................................... 3 Information about MEVA .............................................................................. 4

Flexible solutions for the Mumbai Metro ....................................................... 6

Rethinking formwork requirements ................................................................ 8

Systematic flexibility ..................................................................................... 12

Smart formwork for bridge piers .................................................................. 14

ImprintSite photos show situations which do not always depict the final assembly of formwork with regard to safety regulations. Imprint: Edition XII/2019. Circulation: 2600 copies. Publisher: MEVA SchalungsSysteme GmbH, Industriestr. 5, D72221 Haiterbach. Layout: MEVA. Print: C. Maurer Druck + Verlag, D73312 Geislingen/Steige. Reprint and reuse of any editorial content only by copyright permission. We accept no liability for the content of external internet sites, nor for a violation of privacy or any other law arising from these.

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Florian F. Dingler, Owner and Managing Director of MEVA SchalungsSysteme GmbH

"At MEVA, when the limitations of an existing system

start to emerge, then it's time for a rethink."

Dear Reader

Similarities between individual design and production steps are not unusual in building projects. A closer look at the details, however, will soon confirm that every project is unique.

Special geometries, varying wall thicknesses, different surface grades and finishes often demand a high degree of versatility on the part of contractors. To maximise the range of tasks you can handle with your formwork, each MEVA system embodies an intelligent concept that offers a variety of combination options. With each formwork product, the connectors, braces, panel heights and widths are purposedesigned to accommodate a wealth of geometries.

MEVA's combi tie hole allows the use of three different tying methods in a single system. By permitting flexible alternation between one and twosided tying without the need for any additional accessories, our smart Mammut XT and StarTec XT formwork systems thus offer a significant efficiency boost. The level of improved performance has been verified by the independent constructionsector publisher ztv ZeittechnickVerlag.

Moreover, some jobs are so outoftheordinary that, to master the challenge, you have to completely reconsider your approach. At MEVA,

when the limitations of an existing system start to emerge, then it's time for a rethink. Drawing on our technical creativity, we develop convincing solutions for even the most idiosyncratic geometries – as demonstrated by an ongoing project in Stuttgart, with vertical louvre walls flanking the U6 line of the city's light rail system. The combination of one and twosided tying in a single cycle, the need for purposebuilt niche formwork and the stringent architectural concrete requirements made this project an intriguing challenge.

Tough tasks like this enable us to grow and push back the boundaries of the feasible. And the new ideas and concepts that often result allow MEVA, as formwork manufacturer and service partner, to supply you with even more innovative and efficient solutions. Which is why we will be more than happy if your project offers similar challenges.

Until then, let me hope that this issue of FormworkPress provides you with some interesting reading.

Best regards,

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News

Information about MEVA

The modernday world is characterised by a rapid process of change, which is particularly marked in technical fields. As a global innovator and pioneer of safe, efficient formwork solutions, MEVA gives high priority to knowledge and technical expertise.

Through training courses and visits to the MEVA plant, offered in German and English, the MEVA Academy furthers your understanding of formwork applications and the technical basics. The covered topics range from safety regulations and other useful background knowledge to practical tips.

Are you seeking to prepare for a particular challenge or would you like to brush up your expertise in certain areas? Then we will be glad to provide subjectspecific instruction and handson seminars to meet your particular requirements.

Numerous contractors from diverse trades and individuals from various higher education institutes have already attended continuing professional development courses at the MEVA Academy. Why not seize this opportunity and see for yourself?

The energy revolution is one of the burning issues of our time. Amid our efforts to build a sustainable future, environmental protection and the demand for innovative mobility concepts figure ever more prominently.

The various facets of MEVA's commitment to nature and humankind are pooled under the banner "connect the …". The focus of the "connect the future" project is on stateoftheart, ecofriendly technologies.

As early as last year, MEVA installed an electric vehicle charging station at the Haiterbach site with the aim of enhancing the sustainability and ecoefficiency of its own corporate mobility. All the recharging energy is renewably sourced, with some of it supplied directly from solar cells on the station roof.

Moreover, a new electric car has been added to the MEVA vehicle fleet. The red compact car is fully powered by electricity and thus emissionfree. Bearing the inscription "Nachhaltig beschleunigen" ("Sustainable acceleration"), it has now been on the road for some time as a travelling advert for emobility.

Sustainable accelerationMEVA Academy

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MEVA was set up in Germany in 1970. Since then, it has grown worldwide in tandem with its customers and partners. This year marks a special anniversary in Hungary, where MEVA has been operating in the market for 25 years.

Over this time, our simple, smart formwork solutions have proved their credentials on countless projects, such as the amphitheatre in Debrecen, the Central European University in Budapest, the Pancho Arena football stadium in Felcsút and the wellness centre in Makó. These and many other impressive facilities were built using MEVA's formwork systems.

At this year's MEVA Meets Friends event in Budapest, we were joined by over 140 guests to toast the subsidiary's 25th anniversary. Intriguing conversations with old and new acquaintances added sparkle and amped up the festive mood.

At the same time, practiceoriented product presentations offered ample opportunity for technical discussions. Our open conversations with customers and partners once again underlined our relationship of mutual trust. Such a dialogue helps us to understand your requirements and provide you

with support in the form of new, smart solutions. This solutionoriented approach is MEVA's hallmark and, from the very start, has enabled us to innovate efficient formwork systems to meet onsite challenges and demands.

This event gave us the chance to show our guests the fruits of previous discussions and our intensive development activities. Recently developed products such as Mammut XT, the new MevaDec or the new, even lighter AluFix handset formwork proved a particular attraction.

25th anniversary of MEVA Hungary

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Flexible solutions for the Mumbai MetroLarge cycles formed with the MBS wall formwork

Traffic and public transport are an ongoing issue in expanding megacities around the world. On their daily journey to work peo-ple often have to travel long distances, and those who drive themselves regularly have to contend with traffic jams. Expanding public transport promises to improve this situation. In the megacity of Mumbai with more than 15 million inhabitants the existing network is thus being extended.

To a large extent, the new metro lines are being built below existing roads. The stations are being built 20 metres below the surface. Nine out of the 26 stations planned are not, however, located under existing roads. Some are even situated in the immediate vicinity of culturally significant buildings such as the large Siddhivinayak temple.

The water stop is installed using two tie rods and two anchor sleeves as well as four cones for plastic tube in order to seal the tie hole.

Cone for plastic tubePlastic tube Water stop

Tie rod

Strictest safety requirementsOn the south side of the city the construction company CECITD Cem TPL is working on one of the new metro stations. The proximity to the temple, which is over 200 years old, means that the work is subject to a number of constraints to ensure that the temple is not damaged in the process.

Watertight outer wallsAfter successful completion of the excavation phase and corresponding work on the tunnels, watertight outer walls were poured with the help of MEVA’s formwork experts. One way to do this is to screw tie rods into the water stop from each side. The water stop is then left in the wall as a irrecoverable internal part after pouring. When using the water stop, two short anchor sleeves and four cones for plastic tube are also required in order to seal the tie hole (see figure below).

Efficient implementation for rapid construction progressUse was made of the smart MBS wall formwork, which can be precisely adapted to suit the building

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Project data

Æ Project Siddhivinayak metro station,

Mumbai (IND)

Æ Principal Mumbai Metro Corporation Limited

(MMRCL)

Æ Engineering Company MAPLE GC

Æ Contractor CECITD Cem TPL Joint Venture

Æ MEVA systems MBS wall formwork

Æ Engineering and support MEVA Formwork Systems Pvt. Ltd.,

Navi Mumbai, India

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layout and the freshconcrete pressure by positioning the girders and tie locations as required. For this project the lightweight K6 aluminium beams were delivered to the construction site just in time together with the 3S shuttering panels. They were assembled by the team from CECITD Cem TPL supported by MEVA formwork engineer Sarfaraz Solkar. The direct customer support on the spot provided by MEVA guarantees efficient and rapid construction progress in the long term.

Advantage through flexible adaptationThe track bed in the newly built subway station is on the third basement level. Here, the first watertight concrete walls with a thickness of up to 1 m were poured over a length of 220 m. With 7.20 m, the third basement level is high enough to allow trains to enter and leave the station. With 6 m and 4.80 m, the floors above are lower and serve as the station concourse and arrivals level for the passengers. Using the flexible MBS wall formwork offers a significant advantage during the construction work. “Having set up the MBS for a pouring height of 7.20 m in the lower basement level, it can be simply shortened for the subsequent storeys,” explains Mahesh Dhanawade, the MEVA engineer responsible for the planning. “This enables us to offer the customer a clear advantage with our formwork system.”

Left: 20 metres below the surface, construction work has commenced on the new metro station. Above: The watertight outer walls are being formed using MEVA’s MBS wall formwork.

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Cover feature

Rethinking formwork requirementsSpecial MEVA design delivers solution to complex vertical louvre geometry

The three-kilometre extension currently under construction for the U6 line of Stuttgart's Stadtbahn light rail system will offer passen-gers a direct link from Gerlingen in the north-west of the city to the airport in the south. The route runs across the city and connects numerous districts. Once completed, the new extension will cut the journey time between Stuttgart city centre and the airport to only 30 minutes.

The extension project for the rail operator Stuttgarter Straßenbahnen AG (SSB) involves numerous construction companies. Of these, Züblin was awarded the biggest contract, which is for the ramp, tunnel and terminus structure at Stuttgart Airport. Faced with the task of building a highly complex vertical louvre wall, the contractor decided to call on MEVA's design expertise. The architecturally idiosyncratic wall structure is located at the Airport/Exhibition Centre terminus.

Premiere for wall conceptThe process of designing and constructing the vertical louvre walls required a good deal of subtlety and ingenuity. "As this is the first time our company has built a wall of this kind, it was very difficult to predict the required effort," explains Züblin site manager Heiko Wagner. "But thanks to MEVA's support, it's been a very successful premiere." MEVA's engineers started by converting an undimensioned initial sketch from the tendering procedure into a detailed 3D model showing the exact angles, niches and spacings.

Project requirementsRising to a height of up to 9.30 m, the vertical louvre walls are located at the upwardly open light rail terminus between the conference hotel to the north and airport to the south. The planned wall height varies in response to a nearby footpath and cycle track. The composition features an overlapping sequence of 4 m wide louvres. The walls project at the top and are tapered in thickness, a narrowing effect achieved by the rear face form

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work. To speed up and streamline site operations, provision was also made for interlinking the special formwork panels.

Starting from the bottomA total of 18 pour cycles are required to build the complex vertical louvre walls. The elaborate geometry was already reflected in the steelfixing operations, the shape of the louvre walls being traced out by the precise reinforcement layout at ground level. 15 cm high kickers were then cast to simplify subsequent assembly of the tall formwork units and support frames.

Three-part niche formworkTo achieve the required overlapping configuration with singlesided formwork, a special solution was needed to form the gaps between the individual louvres. This function was performed by a MEVAdesigned niche formwork assembly that allowed efficient and straightforward creation of the required geometries. As the concept included the later illumination of the niches between the louvres, more than just a rectangular boxout was needed. A further recess had to be incorporated at the rear to accommodate the electrical fittings. A niche kicker was also required at ground level to take account of the varying angles formed with the joints between the precastconcrete track blocks. Then, as the largest of the three units, came the front niche formwork. Development of the ingenious technical solution called for a fair amount of creative engineering. Given the spatial constraints, the team opted for a steel assembly.

Detail solutionSeveral factors play a role in ensuring the reliable positioning of the niche formwork between the louvres. First, it is screwed through the frame to the front wall formwork. Tightfitting timber board is then incorporated into the boxout to resist the fresh concrete pressure. A special Lshaped metal bracket is also fitted into the niche formwork, with the longer leg secured to the frame of the louvre formwork. In case of differences in pour height and fresh concrete pressures between two louvres, this provides horizontal stability by transferring the pressure to the frame. To facilitate removal of the niche formwork after casting, it is additionally fitted with hinged corners and designed with a trapezoidal shape with a narrower rear face. As a result, once the front part is free, the unit can be easily removed without friction. The hinged corners also allow the sides to be folded in, which further simplifies the stripping process (see diagram on p. 11).

... continued on page 10

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North/south differenceApart from delivering complex detail solutions, MEVA’s engineers had to devise smart concepts to meet challenges of a more general nature. The vertical louvre walls exhibit varying geometries on the northern and southern sides: the louvres are arranged in opposing directions and the rearside taper also differs in response to the adjacent landscaping. While the 140 m long southern side is built with an inclined rear face, a channel is formed on the shorter, 93 m long northern side. The special shapes necessitated the use of customdesigned precision formwork that can be reused as the works progress. “Our procedures vary according to the area we’re working in,” explains site manager Heiko Wagner, referring to the additional complication of the north/south difference. “At the start, this required extreme concentration. But we got the hang of it after we’d done it two or three times. And you soon notice how MEVA’s designs are geared to onsite practice and making operations as easy as possible.”

When one becomes twoAs the vertical louvre walls not only have different rear faces, but also project upwards beyond the excavation pit, the use of singlesided formwork is not possible over the full height. MEVA’s experts thus developed an intelligent solution to combine single and doublesided operations. The STB 450 support frame and Mammut 350 heavyduty formwork are used to cast the lower section against the pit wall. Here, the system’s ability to accommodate fresh concrete pressures of up to 100 kN/m² over the full surface is particularly beneficial as unlimited pour speeds are possible for heights of up to 4 m. Due to the different rear faces, the singlesided area has a wall thickness of approx. 1 m on the northern side and 1.3 m on the southern side. The singlesided area of the northern wall is also larger and is supported by three Triplex braces to resist the accordingly higher forces. The southern wall, on the other hand, only needs two of MEVA’s modular heavyduty braces. In the upper part of the vertical louvre walls, singlesided is replaced

... from page 9

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by doublesided formwork. This approx. 2.5 m tall section is supported by a MEVA steel frame assembly. As the overall height of the vertical louvre walls is constant, the height difference between the singlesided sections on the northern and southern sides is offset by fitting a support plate to the steel frame assembly.

Bold approach to innovationWith the steel frame acting in a similar way to a dry tie, the formwork in the entire area of this frame requires no through ties. “Twosided tying was originally planned,” points out Züblin project manager Christian Hoffmann. “To achieve a uniform appearance over all the concrete surfaces, this would have meant adding a regular pattern of blank cones to the singlesided area and involved an enormous effort.” MEVA’s proposal to work with a steel frame paved the way for a formwork assembly that essentially amounts to two singlesided arrangements. The absence of tie holes with this solution automatically eliminates the need for blank cones, thereby vastly simplifying and speeding up operations. It also allows the achievement of a more even and uniform surface finish. The idea won over Züblin’s experts and also appealed to the principal Stuttgarter Straßenbahnen AG. A delighted Christian Hoffmann was quick to praise the creative formwork designers at partner MEVA: “Their proposals added real value to our project.”

Smooth and textured architectural concreteEliminating the need for blank cones was also useful in meeting the stringent architectural concrete requirements placed on the project. To achieve extrasmooth and uniform concrete surfaces, the special formwork was fitted with alkus allplastic facings at the MEVA plant. The facings were screwed down from behind to avoid screw marks on the surface. Joints and angles were welded with the same synthetic material used for the facings. This prevents the escape of cement paste and thus delivers very highquality results. The smooth surfaces formed by the alkus allplastic facing are bounded by a soft woodgrain finish at the louvre edges, achieved through the incorporation of textured formliners. Inchperfect flushfitting of the facings in the special formwork helped to enhance the harmonious appearance of the wall composition.

Following the success of the first concreting operations, works to the vertical louvre walls are set to continue until the end of 2019. “Thanks to MEVA’s special design expertise, we now have a formwork solution tailored to our requirements,” says site manager Wagner. “Which is a real blessing on such a complex project.” Project manager Hoffmann adds: “For us, the convincing solutions to a whole string of design challenges will be a massive help in delivering the project successfully.”

Project data

Æ Project Special design for vertical louvre walls

at Airport/Exhibition Centre light rail terminus, Stuttgart (GER)

Æ Principal Stuttgarter Straßenbahnen AG (SSB)

Æ Contractor Züblin AG

Æ MEVA systems Mammut 350 wall formwork STB 450 support frame Triplex heavyduty brace Special design

Æ Engineering and support MEVA SchalungsSysteme GmbH,

Haiterbach, Germany

Right: Niche formwork detail showing, among other things, the hinged corners that simplify the stripping process.

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Systematic flexibility

Upon completion in 2020, the Crowne Plaza currently under construction in Adelaide, South Australia will be the Australian city's tallest building. The 138 m high-rise, which is being erected by the local Kyren Group, will house the Crowne Plaza Hotel with 329 guest rooms located from the third to the 20th floor.

The floortofloor heights in the building vary according to use. For example, the bottom levels, which accommodate retail and parking facilities, have somewhat higher ceilings than the hotel area. At the same time, the plan area of the building core narrows with increasing building height. The Crowne Plaza scheme thus called for particularly flexible formwork solutions capable of adapting to the required geometries. The formwork experts at Mitcon duly opted for use of the efficient and reliable systems offered by MEVA. The local partner Novatec was able to provide these on site in the shortest possible time.

MEVA's efficient solutions meet wideranging demands for Crowne Plaza

Hydraulically skywardsThe building core was erected using the MAC automatic climbing system. Its highperformance hydraulics eliminate the need for a crane, which is consequently freed up for the other site operations. The building's smaller floorplates from the 11th floor upwards entail a corresponding reduction in building core size. The formwork was adjusted accordingly through the removal, in stages, of several shafts. Additionally, Novatec supplied the GT50 SGF climbing safety screens.

Tailored climbing systemAs the MAC system is purposedesigned for every project, special provision was made for removing the beams and hydraulic units. With the formwork adaptations already factored into the design, the relevant components were easy to disassemble on the job to accommodate the change in floorplan. The system was similarly reconfigured on the 22nd storey, with the elimination of additional lift shafts. The rearrangements also involved removal of some

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Through the staged removal of formwork the MAC automatic climbing system was adapted to the required layouts.

Project data

Æ Project Crowne Plaza, Adelaide (AUS)

Æ Contractor Kyren Group (construction) Mitcon (formwork)

Æ MEVA systems MevaDec slab formwork MAC automatic climbing system

Æ Engineering and support MEVA Formwork Systems Pte Ltd,

Singapore and Novatec Formwork Systems, Australia

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of the beams. The scope of the adaptations are shown in the drawings on the right.

Impressive flexibilityMitcon's Nick Bairstow was full of praise for the system's flexibility: "We were able to set up the MAC system in under 12 days. And the preassembled components saved us a lot of time. As a result, everything ran smoothly and even the rearrangement operations were troublefree."

Efficient slab formwork The floor slabs for all the 37 storeys were cast in tandem with the building core. Here too, varying requirements necessitated a flexible solution for efficient slab shuttering. By selecting the MevaDec modular formwork, Mitcon enjoyed all the benefits of a system that combines different slabforming methods.

Primary-and-secondary-beam method (HN)For the lower section of the highrise, the brief called for slab soffits with a exposed surface finish meeting architectural concrete requirements. The MevaDec HN method provides for the use of primary and secondary beams to create a base for the loose facings. At the same time, the system's provision for changing the direction of the primary beams allows continuous adaptation to different layouts. It was thus possible to form each of the 1,550 m² slab areas in two cycles while simultaneously achieving the required ceiling finish.

Drop-head-beam-panel method (FTE)The floor slab plan area was reduced by half from the 11th storey upwards. As woodfinish fairfaced concrete was no longer required for these surfaces, the project team switched to the dropheadbeampanel method. Here, the MevaDec slab formwork panels were placed between the primary beams. Moreover, use of the MevaDec drop head further accelerated progress on site. The drop head allows the primary beams to be lowered to facilitate removal of the panels, which can then be immediately reused on the next level. At the same time, the props with the drop head automatically remain in place for reshoring purposes. The ready availability of primary beams and panels for the next cycle thus serves to reduce onsite inventory.

"In some cases, reshoring was simultaneously needed on eight levels," says a satisfied Nick Bairstow. "In that way, the drop head really simplified our work. All in all, we safely met our targets. Which was also thanks to the major contribution made by MEVA's formwork systems."

Ground floor 10th floor level

11th 21st floor level

22th 36st floor level

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Smart formwork for bridge piers

Public transport will play a major role in future mobility. Linking up villages and small set-tlements will be an important factor in this respect. In the small Danish towns of Lundby and Vordingborg, work is proceeding on the development and expansion of the relevant infrastructure. Here, MEVA's formwork systems were used to build new footbridges over railway lines. CG Jensen, the contractor responsible for the projects, was faced with different tasks at the two locations.

Extension of existing piersThe job in the village of Lundby was to extend existing round piers, 2.7 m tall and made of reinforced concrete, in order to build a higher bridge. These piers had been cast with boarded formwork. To raise them to a height of 4 m, the experts at CG Jensen decided to use MEVA's modular MEP shoring tower. This was assembled around the circular piers and served as a scaffold.

Combination of boarded and panelised formwork for guaranteed stability

Boarded and panelised formwork To recreate the shape of the existing piers, an exact copy was first made of the boarded formwork. Two semicircular timber forms were then fixed to AluStar wall formwork panels. The assembled boarded formwork thus ensured the continuation of the required shape. At the same time, stability was guaranteed by MEVA's proven panelised formwork system, which is structurally certified under GSV (German Concrete Formwork Quality Protection Association) standards. Though a genuine lightweight – with the largest (270 x 90 cm) panel weighing only 65 kg – the performancetoweight champion can accommodate a fresh concrete pressure of 60 kN/m².

Wall formwork on MEPWith the formwork assembled on the MEP shoring towers, it was possible to extend the existing piers to the required height. For reliable positioning and fixing of the individual panels, the contractor used a mobile working platform that allowed easy movement between the piers.

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Left: The semicircular boarded formwork was fixed to the formwork systems. MEVA's smart systems guarantee safety and make the planning process much easier. Right: The formwork was subsequently assembled on top of the MEP shoring tower.

Project data

Æ Project Footbridges at railway stations in

Lundby and Vordingborg (DNK)

Æ Contractor CG Jensen A/S

Æ MEVA systems AluStar wall formwork Mammut 350 wall formwork MEP shoring tower

Æ Engineering and support MEVA SchalungsSysteme GmbH,

Køge, Denmark

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Foundation formwork set by handThe job in Vordingborg, further south, was to construct completely new bridge piers. The foundations were built using the lightweight AluStar wall formwork system. Its low weight offered obvious benefits due to the possibility, in many cases, of setting the formwork by hand. Another useful feature was the ergonomic grip profile on the rear face, which simplified handling.

Large-area piers with Mammut 350The bridge piers in Vordingborg also had to be provided with a recognisable boarded formwork finish. However, the plan shape here was slightly different from that of the polygonalround piers in Lundby. As a result, further boarded formwork units were produced and fixed to Mammut 350 formwork, which served as a carrying construction. As in Lundby, the MEVA system solution with its closed hollow frame profile allowed reliable prediction of the fresh concrete load capacity. The heavyduty formwork is able to accommodate pressures of up to 100 kN/m². Mammut 350 thus allows unlimited pour speeds up to a height of 4 m. Thanks to the large contact areas of up to 8.75 m², extensive wall areas can be efficiently formed with only few panels.

"The works performed with MEVA's formwork systems ran very smoothly," says site manager John Rasmussen. "At the same time, the MEP shoring tower and the wall formwork delivered impressive quality, handling and flexibility."

You can rely on us wherever you are.With 40 offices on 5 continents, we are on the spot wherever you need us.

MEVA Schalungs-Systeme GmbH

Tel. +49 7456 692-01Fax +49 7456 [email protected]

Industriestrasse 572221 HaiterbachGermany

www.meva.net 3318

GB

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A-Pfaffstätten Tel. +43 2252 20900-0AUS-Adelaide Tel. +61 8 82634377Benelux, Gouda Tel. +31 182 570770BH-Riffa Tel. +973 3322 4290CDN-Toronto Tel. +1 416 8278714CH-Seon Tel. +41 62 7697100DK-Køge Tel. +45 56 311855F-Sarreguemines Tel. +33 387 959938GB-Tamworth Tel. +44 1827 60217H-Budapest Tel. +36 1 2722222IND-Mumbai Tel. +91 22 27563430

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