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Vienna International Airport (VIE) has been enjoying double-digit growth in passenger numbers, making it urgently necessary to build a new terminal. The Skylink Project is a EUR 400 m investment to construct a brand-new terminal, complete with a pier. From 2008, VIE will be able to handle up to 24 m passengers a year. Doka is the system supplier responsible for the entire formwork concept of what is currently the biggest project in Austria.
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As well as the new South Pier, with 17 aircraft stands, the Skylink Project also comprises a terminal with check-in desks, luggage reclaim and services zones. In a recent interview, VIE press spokesman Hans Mayer put this construction project at the heart of a series of major investments to be completed by 2008. By then, VIE will have invested around 854 m. euros in extending the aprons, in new multi-storey car parking, a new air traffic control tower, expanding the existing baggage handling facility and in building the Handling Centre West, with some 50 % of the total outlay going into the Skylink Project.
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The formwork planning was dictated by two crucial factors: the dimensions of the terminal and the pier, and the extremely short period allowed for building the structure shell, from October 2005 until the end of December 2006. As well as large commissioning quantities, these plans also called for flexible, versatile formwork systems.
The new pier is 450 m long and 33 m wide, and the sickle-shaped terminal has a length of 270 m and a width of 55 m. Both buildings are 20 m high; with their frequent changes from extremely high floor-slabs to standard heights, they make very great demands of the formwork technology used.
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Used here in conjunction with a large number of Staxo load-bearing towers, Dokamatic and Dokaflex tables – 9550 m² of them – are demonstrating their unrivalled adaptability. An edge floor-beam on the new terminal building has to be formed at a height of 24 m above the ground. This edge beam rests on centrifugally cast concrete columns and in turn will bear a pre-cast concrete floor which is to be fixed into place at a later stage. The drop-beam formwork of Framax Xlife panels is supported from ground level by Staxo load-bearing towers. The site crew are using Dokamatic tables to provide an intermediate working platform at a height of 18 m. The Dokamatic tables are mounted quickly and safely to the Staxo towers with easy-to-use plug-and-bolt connections. The tall Staxo towers have to be secured against the high wind loads that occur here. Eurex 60 floor props are the ideal solution for this, and can be attached to the steel primary beam of the Dokamatic table in a few simple steps. Diagonally mounted on the inside of the structure, they provide the necessary bracing against tensile and compressive forces.
In other casting sections, the Dokamatic tables double as shoring and working platforms for the forming operations on the slab edges. The edge floor-beam and parapet are being cast in one single pour. Due to the curving shape of the terminal, the formwork solution for this requires the use of 90 cm wide and 2.70 m high Framax Xlife panels with circular forming plates.
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The Skylink consortium also opted for Doka framed formwork Framax Xlife for building the lift and stairwell shafts. The formwork concept very much reflects the huge deadline pressure: Ready-to-use sets of formwork have been commissioned for all the shafts, because the handling and modifications that would otherwise be needed would take too much time. The Doka Vienna Branch has to keep over 11,000 m² of Framax Xlife framed formwork ready for delivery in accordance with an exact just-in-time delivery schedule.
An interesting cost-cutting solution that is proving itself again here is the Framax stripping corner I. There are 176 of them, in heights of 135, 270 and 330 cm, in use on the site, surprising even construction veterans again and again with their great efficiency. The stripping spindle pulls the inside corners of the shaft formwork together in such a way as to leave approx. 6 cm of stripping play. The crane is only needed for lifting the whole shaft formwork in one piece; there is no need to measure up again.
The new South Pier will not be the last word on the Skylink Project for a long time. There are already plans for a further pier finger to the north, and for another terminal extension. Says Skylink project manager Mario Wunderlich: “When you’ve got a project on this scale with such a tight timetable, you really need a formwork supplier you can depend on. With Doka, the teamwork is functioning superbly, and their exact formwork planning and just-in-time deliveries are helping us meet the deadline.”
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| The edge floor-beam and parapet are being cast in one single pour. Owing to the curving shape of the terminal, the Framax Xlife panels are combined with circular forming plates. |
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| As well as the new South Pier, with 17 aircraft stands, the Skylink Project also comprises a terminal with check-in desks, luggage reclaim and services zones. |
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