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Hungary is investing more than 2.5 billion euros in a nationwide drive to expand and modernise its sewage disposal and treatment facilities. In the medium term, it is planned to build more than 20 wastewater treatment plants. With a construction volume of around 250 million euros, the giant Csepel sewerage project in the southern suburbs of Budapest, covering an area of around 50,000 m², is by far the biggest of these investments. Scheduled to go onstream in 2010, the plant will have a treatment capacity of up to 350,000 m³ of effluent a day, making it one of the biggest sewage treatment plants in the CEE area. Lead contractors for the reinforced concrete works are the Hungarian construction companies Hídépítő and Alterra. The contract volume comes to more than 40 million euros. Over 53,000 m³ of concrete is to be formed using high-performing, efficient formwork equipment from Doka. The unrivalled price/performance ratio, just-in-time-deliveries and comprehensive on-site service provided by Doka all combine to ensure cost-effective forming operations here.
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Around 150,000 m² of wall is being formed on the Csepel sewage treatment plant project in the south of the Hungarian capital Budapest, using Doka Top 50 extra-large panels.
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The 36 clarification basins will require the casting of more than 12,368 linear metres of water-impermeable wall, of between 2 and 9 metres in height. The total area of wall to be formed is around 150,000 m², with wall thicknesses varying between 25 and 65 centimetres. The concrete placed here must only be absolutely water-impermeable, but also able to withstand long-term sulphate attack.
The up to 9 m high basin walls are being poured in a single casting section, using Extra-large panels Top 50. Large numbers of repeat uses, high fresh-concrete pressure and rapid construction progress are among the central demands being made of the formwork equipment at this site. To optimise the site logistics, the Top 50 extra-large panels are being pre-assembled by the Doka “Ready-to-Use” Service and delivered to the site ready for immediate use. Doka’s just-in-time deliveries are another factor assisting the site logistics. Doka field service technicians help the crew to make expert use of the formwork equipment on the site. The lower walls are being poured using cost-saving Doka Frami hand-set formwork.
Besides this, the detailed preliminary planning work carried out by the Doka Formwork Experts has ensured streamlined forming operations, with the lowest possible commissioning quantities coupled with efficient materials-scheduling in each of the casting sections. The ongoing support and assistance given to this mega-site by the Doka Formwork Experts is another factor helping the project to run smoothly.
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The large-area formwork Top 50 is dependably shored against the huge pressure of the fresh concrete by Eurex 60 props. With its fast, easy handling, the Eurex 60 prop makes a big contribution towards speeding up formwork setup and striking. The prop can be quickly and exactly adjusted to the required height in 10 cm increments, with reference to numbered pegging holes. Fine adjustment is carried out steplessly and with millimetre precision. When the formwork is struck, the special design of the thread on these several-metre long props means that they can be quickly and easily released with only a few blows of the hammer, even when under heavy load. This ensures safe, fast shoring of the large-area formwork Top 50 in every phase of the forming operations.
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When it came to fixing the Eurex 60 props, the site crew got its first experience of using the unbeatable Doka Express anchor, and is very enthusiastic about all the many advantages of this innovative fixing solution. “The Express anchor is giving us some big time and cost savings. What we like most of all is how easy the anchor is to install, just using an ordinary hammer, and the fact that you can use it over and over again”, reports Contractors’ Supervisor Zoltán Hetényi of the P.A.M. Invest 2000, pointing out the benefits of the Express anchor for everyday work on the site.
In addition to the large areas of wall, there are also no fewer than 208 columns to be formed, ranging up to 4.1 metres in height. Using Column formwork KS here has ensured that work progresses swiftly and cost-efficiently. Setting up and striking this formwork is very easy and time-saving, simply by folding it open and shut, and this makes a major contribution towards speeding up the construction workflow. Like the Top 50 extra-large panels, these column formwork units come equipped with the Ladder system XS and with sturdy pouring platforms.
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The formwork equipment meets the most stringent specifications regarding not only efficiency but also safety standards. The Doka ladder system XS, featuring integral ladder cages, is in service on this site on both the 9 m high Extra-large panels Top 50 and the high-performing Column formwork KS. With its sturdy ladder cage, the Ladder system XS ensures safe – and thus fast – up-and-down access to and from the working platforms. It reduces the falling hazard to a minimum and greatly shortens the time spent climbing up and down. Thanks to the high safety standard of the Doka formwork and working platforms, around 40,000 m³ of concrete has so far been placed without incident. “With the XS ladder cage, the construction workers simply feel so much safer when climbing up or down. We shall certainly be using this well thought-out ladder system on other jobsites as well”, says Contractors’ Supervisor Zoltán Hetényi. The Doka safety solutions have also convinced the Hungarian labour inspectors. This massive site is being inspected every two weeks for compliance with the safety standards. To date, no shortcomings have been identified in the course of these inspections.
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| The Extra-large panels Top 50 are being dependably shored with Eurex 60 props. Swift construction progress is ensured by the rapid repositionability of the Eurex 60 props, and by the easy and reliable way they can be fixed using Doka Express anchors. |
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| Clarification basins with an oval groundplan can be constructed quickly and economically using the flexible circular formwork H20. |
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| The cost-effective Doka Frami hand-set formwork is being used for the lower walls. |
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