Toronto Shangri-La Hotel … page 3

Kentucky Fast Rising Cores … page 6

Santa Ana Foothills High School … page 12

Connecticut US Navy Pier 31 … page 16

The Formwork Magazine

July 2011 · www.dokausa.com · www.doka.ca

Inspiring Innovation

Doka Xpress2

Keeping Toronto Safe � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 3

Fast rising cores for

Rising Sun Developing, Inc. � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 6

Radius serpentine concrete walls � � � � � � � � � � � � � � � � � � � � � � 8

Support from bidding to completion � � � � � � � � � � � � � � � � 10

Construction relies on the alignment

of the sun, Earth and moon � � � � � � � � � � � � � � � � � � � � � � � � � � � � 12

100% formwork needs covered

with a reliable partner � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 14

In the news � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 26

Editorial

Foldable Protection Screen

Circular wall formwork

US Navy Pier 31

Doka newsWatch our Super Climber in action on YouTube! Raising all wall formwork from one section to the next, with a push of a button, the Doka Super Climber is a modular, all-in-one system for high-rise structures. Visit www.YouTube.com/DokaNorthAmerica

Doka Executives visit with contractors at the World Trade Center site.

Index Page

As the 10th anniversary of 9/11 is upon us, it is hard not to take pause and reflect on that trag-edy. While that day will never be forgotten, the enthusiasm that surrounds the construction at the World Trade Center is something that has inspired our entire team. We are very proud to provide formwork solutions and services on Tower 2, Tower 4, and the Memorial project.

Although our economy is still struggling to rebound, there are many examples of growth and innovation that create optimism and signal good times ahead. In Toronto, our new foldable Xclimb 60 protection screen helped keep workers safe and protected from any weather, while also protecting pedestrians from falling debris. Formwork innovation also was key to meet the extremely tight construction schedule of a medical building as well as for the construction of a new naval submarine pier. Each of these projects, detail the role of form-work in performing quick, safe and reliable construction.

Working together, we can achieve great things. As many companies continue to cut their R&D efforts because of the economy, our charge is to continually innovate in response to your requests to ensure we can help you meet the changing needs of today’s construction world. Let’s continue to innovate to build a safer, smarter and more creative world together.

Andrew Mair Chief Executive Officer Doka USA, Ltd. / Doka Canada, Ltee

Dear Customers and Colleagues,

From left:• JosefKurzmann–MemberofUmdaschAG

Executive Board & CEO of Doka Division• AntonioRodrigues,Sr.–President,Roger

& Sons Concrete, Tower 4• AndrewMair–CEO,DokaNorthAmerica• AndreasJ.Ludwig–ChairmanoftheBoard,UmdaschAG

• J.JayMartino,Principal,JPCBuildersLLC, Tower 2

• RainerSpitzer–ManagingDirector,DokaEngineering & Sales

• GerdPechura–HeadofFinance,UmdaschAG

July 2011 3

Keeping Toronto Safe To keep the work area safe and protected from any weather, Doka's new foldable Xclimb 60 protection screen is used. The screen protects the people in the busy Toronto area from falling debris from the work site.

All work on the new deck can be done immediately with full edge protection allowing for a fast and safe work sequence on the overall construction project.

Doka Xpress4

The protection screen is wrapped around the entire perimeter of the building for four levels, and will climb up the 65 stories with hydraulics, no crane is needed. The top section of the screen was designed to fold down, which makes resetting of the slab formwork easier. The hinged top section of the protection screen is a big safety advan-tage in all stages of the project since the slab edges are protected with the screen as soon as the hinged section is set back in place after lifting up the slab formwork. In addition, the hinged section is completely sealed with rubber between the screens and also to the slab edges to keep heat in the required area.

In addition to the protection, Doka engineer-ing designed loading platforms built into

the screens to allow storage for the vertical formwork close to where the actual work is happening to reduce crane time.

One of the major challenges is the compli-cated slab edge outline. In the building’s design, the outside perimeter of the east side changes at every level. The edge of the building waves in and out irregularly. Then, starting on level 50, the slab edge in the cen-ter of the west side steps in and out every other level, approximately 19 ft.

Thecontractor,HardwallConstructionLtd.,was pleased that Doka provided a complete protection screen solution, which can take the changes in the building, is also able to hinge down and has loading platforms all the way around the building.

The Solution To keep workers and

pedestrians safe in busy downtown Toronto, Doka’s ProtectionScreenprovidesperimeter protection for the

working floor and three floors below, and allows sections to

fold down to fly in/out large table forms.

TheDokaHingedProtectionScreenhas

provided the jobsite with a safe and fast system.

It accommodates on-site material storage, public

safety and winter heating requirements.”

The Professional

Angelo Furgiuele, Hardwall Construction, Ltd.

The Factsjobsite

Shangri-La Hotel, Toronto, Canada

concrete contractor Hardwall Construction, Ltd.

products used Foldable Xclimb 60 Protection

Screen

July 2011 5

When the crane is ready to lift the large formwork tables, the top section of the screen is folded down with hydraulic cylinders.

The safely guided system allows you to keep a tight cycling schedule because wind loads that can force a crane to shut down will have no influence to the work sequence of the system.

The screens and fold down sections can be easily moved by using the portable hydraulic unit.

The Shangri La Hotel is scheduled to open in spring 2012.

Doka Xpress6

Fast Rising Cores For Rising Sun Developing, Inc.

The Factsjobsite

Pikeville College Osteopathic Medical Building, Pikeville, KY

square footage 82,000 sq. ft.

general contractor Codell Construction Co. concrete contractor

Rising Sun Developing, Inc.products used

Framed Formwork Frami, climbing formwork MF-240

Meeting the extremely tight construction schedule of an 82,000 sq. ft. medical building for an expansion to Pikeville College meant running two working crews and two cranes, six days per week.

The project, cut into the side of a moun-tain of rock, had to be excavated and pile drilled, which consumed an immense amount of the construction schedule. To get back on track, a quick system was needed to form three elevator cores and five levels of foundation work. Distinctive features include a 30 - 50 ft. high retaining wall, along with three cores at 187 ft. high.

The site has very little staging area and limited access to enable handling of the formwork and the steel for the project. For concrete contractor Rising Sun Developing, Inc., streamlining the forming process on their

cores, while staying on schedule, was the big-gest challenge. A fast and reliable system to use on their cores and walls was required.

The solution came in the form of the crane-lifted climbing formwork MF-240 and shaft platforms, as well as framed wall formwork Frami for three cores. The system offered fast and easy assembly with minimum crane time. One of the main advantages was the quick and easy adaptability to the changing pour heights. Additionally, the lightweight Frami system allowed Doka to stay under the maximum capacity of the crane as well as reduced the number

The MF-240 climbing system offered quick and easy

adaptability to the changing pour heights.

The project, cut into the side of a mountain of rock, had to be excavated and pile drilled.

July 2011 7

The Professionals : See what first-time Doka formwork users have to say:

The Solution To meet tight deadlines, minimal crane capacity and limited staging room, Doka’s Frami framed formwork, used with the MF 240 climbing system, was chosen to form three concrete elevator cores.

of crane picks. The fast stripping of the cores, achieved by using the Doka strip-ping corner, which can be integrated with all Doka wall systems, also gave the proj-ect a schedule boost.

The project team noted that the usability and speed of the formwork solution was evident as the large three cell core was completed in just six days.

Practical Tip

Stripping Corners

For fast stripping of cor-ners, use the Doka strip-ping corner. Strip from one location, one corner, at the top of the core with no need to loosen or retighten bolts. The core will come completely separated from the concrete, and the entire shaft can be lifted as one unit without further disas-sembly. The time savings are enormous.

With the MF-240 climbing system, the Frami wall forms can be easily rolled back or tilted to allow easy repositioning for cleaning of formwork or tying rebar.

In the last year of using Doka formwork, we have

increased our speed concerning our core formwork projects. This increased speed allows us to meet tighter deadlines and schedules, which allows us to improve our bottom line.”

Jason Akers, President, Rising Sun Developing Inc.

We were able to turn a large three cell core in six days,

pour to pour, and this was our first time using the Doka system.”

Jack Hammon, Superintendent, Rising Sun Developing, Inc.

Once we got started, the formwork never

had to hit the ground again until the core was topped out. This system offered advantages over other systems we could have used and they were noticeable on the job.”

David Robinette, Construction Manager, Codell Construction Company

I like your MF-240 platform and shaft system. It felt safer than any

other system that I have used. This was my first time using your

system and we finished on schedule, even with very bad weather. Also,

the drawings we received from your engineer were the most complete and

accurate drawings I have ever received.”

– Tim Newsome, Rising Sun Developing, Inc., Superintendent

Doka Xpress8

Radius Serpentine Concrete WallsFoothill High School Auxiliary Gymnasium is under way under the leadership of General Contractor Barnhart Balfour Beatty and Concrete Contractor Guy Yocom Construction, Inc.

Guy Yocom’s crew included excellent wall finishers that made the corded radius look like a smooth architectural finish. The Circular H20 Smooth radius forms were integrated with the corded radius and straight wall Frami Panels as required.

July 2011 9

GuyYocomhadpreviouslybeenatraditionalform user looking for a new formwork system to construct the north and south retaining walls, leading into radius walls with serpentine shaped construction.

The walls were running parallel at different heights, slopes, stepping conditions and in-tersection transitions. Many areas of the wall required an architectural finish that would be visible. Traditional lumber built radius forms typically involve excessive and experienced labor and costly lumber. Therefore, an innova-tive and fast radius system was required. In order to accomplish this goal, Frami formwork panels were selected as the best solution for inside and outside wall forms. The system adapts to all steps, height changes, transi-tions and sloping conditions on the project. The Frami Corded Radius System was very efficient for the serpentine radius changes as it incorporates fillers for the gain of the outside panels. The Frami panels were united withCircularH20radiusformsbystandardprofile adapters for clamp connections on the

tighter radius scope.

In addition to standard forming require-ments, special pilaster forms were de-signed and incorporated for use in other areas requiring pre-cast concrete tilt-up panels. The pilaster forms incorporated with these 42-ft.-high tilt-up panels includ-ed hinged corner pour windows for access during full height pouring and vibrating. Producingthedesiredfinishwasnoprob-lem, since the standard Frami system uses a special plywood facing.

Overall, 1,500 LF of formwork were used on the entire project for walls and pilasters rang-ing from 6 ft. to 42 ft. high.

For the concrete contractor, the biggest benefitwasthesavingstheyrealizedonlabor,schedule and materials. Support was pro-vided by Doka’s onsite field service team in order to drastically reduce the learning curve of using the new system.

The Factsjobsite Foothill High School Auxiliary Gymnasium, Santa Ana, CAgeneral contractor Barnhart Balfour Beattyconcrete contractor Guy Yocom Construction, Inc.products used Wall formwork Frami with Circular H20 Radius forms

The Doka forms use less manpower and have us ahead of the

form building schedule. For us, this means not only savings in labor, but also time. In this economy, the result will be a profitable project that gains respect for my crew and I.”

The Professional

Tony Molina, Superintendent, Guy Yocom Construction, Inc.

Even though this was the first time Guy Yocom Construction used the system, the learning curve was minimal and efficient production was achieved.

Doka Xpress10

Doka was brought in during the early stages, prior to bidding the project, to develop a suitable overall plan for construction. From thatpoint,DokaworkedwithPrecisionConcrete throughout the bid stage, includ-ing participating in discussions related to cycling, scheduling and overall proposed

durations for the equipment, based on expe-rience, to ensure a successful project.

Factors Affecting ConstructionThree of the structures were adjacent to one another, with each scheduled to start at different times. Furthermore, each structure

Construction on the new $117 million Douglas County Adult Detention and Law Enforcement Center is underway. The jail is being built on a 40-acre site with Turner/New South Construction and Concrete Contractor Precision Concrete Construction.

From the early stages of formulating a

construction plan, through the proposal-bid

phase, and finally now to the actual onsite construction,

JC[DokaAccountManagerSoutheast Area] has been with us every step of the way, often

providing expert solutions to potential issues before they

arise, saving hundreds of man-hours onsite.”

The Professional

Brian McCormick, General Superintendent, Precision Concrete Construction

Support From Bidding To Completion

July 2011 11

The Factsjobsite Douglas County Adult Detention and Law Enforcement Center, Douglasville, GAsquare footage approximately 500,000 sq. ft.general contractor/architect GC joint venture, Turner/New South JV / HOKconcrete contractor Precision Concrete Constructionproducts used Framax large area wall formwork, Frami Framed formwork, Pre-assembled Dokamatic Tables

The Solution Doka wall, slab, climbing, and safety solutions together with support and services every step of the project.

has varied floor elevations. A strict Class A exposed finish were also required in multiple areas, as were different elevated slab de-signs, and shoring heights exceeded 21 ft. In addition, there were crane capacity/access problems, poor site soil conditions, multiple severe weather storm systems that hit the area, and more than 75 percent of the slab-on-grade left out due to the underground not being completely designed.

Formwork Solution In order to meet pours exceeding 21 ft. in height, Doka’s formwork solution included more than 4,000 sq. ft. of Framax large area wall formwork for the foundation and retaining walls. Further, Frami Framed formwork was used for the columns, which were hinged at one corner to allow them to be quickly and easily opened for clean-ing and resetting. Approximately 3,000 sq. ft. of columns, some as high as 18 ft., were poured every other day during a four month schedule. More than 80,000 sq. ft. of pre-assembled Dokamatic Tables were alsoutilizedastheyprovidedacompletefloor for each building, allowing the tables to cycle straight up vertically, without any horizontalrepositioning.Finally,morethan4,000 Eurex 20-550 supporting props were utilizedwiththeDokamaticTablestosup-

port the tall shoring.

Safety First To ensure safety measures along with high productivity, several hands-on product dem-onstrations were held at the Southeast Doka branch facility to clearly show the speed, level of expertise, and quality of the solu-tions recommended.

“Once the project started, we held regular site safety meetings with the general con-tractor, providing them a step-by-step guide on safe use of all of products onsite. Bi-weekly “Toolbox Talk” meetings were held onsite with the entire labor force in order to answer questions as well as highlight any unsafe working conditions found during rou-tine project site visits. In addition, frequent weekly project site visits were conducted to provide specific advice on safe operation of Doka equipment onsite — first hand,” stated JCThomas,DokaAccountManager.

“The productivity of the Doka systems was an integral reason they were able to secure the order. Doka is considered as a partner onthisproject–withalleffortsfocusedonon-time completion of the project,” stated MillardFarmer,Superintendent,PrecisionConcrete.

The entire project, consist-ing of five buildings, started in January 2011 is expected to be completed in December 2012.

The Dokamatic Table helps save on labor and crane time. The system is optimized for minimal forming times on me-dium and large deck projects and deals easily with varying requirements in terms of slab thickness and geometry.

Doka Xpress12

This U.S. Navy project, Pier 31, is located at the Naval Submarine Base (NSB) in New London, Groton, Conn. The scope of work includes the demolition of an existing pier, construction of a new 550-ft. long x 67-ft. wide naval submarine pier with associated utilities, fender system and other amenities.

Since the cycle can only occur during a low tide twice per month, timing of concrete placement and formwork cycles is crucial for productivity

The Factsjobsite Pier 31 Replacement, Navy Submarine Base New London, Groton, CTsquare footage 40,000 sq. ft.general contractor/architect American Bridge Companyconcrete contractor American Bridge Company

Construction Relies On The Alignment Of The Sun, Earth And Moon

July 2011 13

The pier is supported on 116 concrete filled steel pipe piles, each 36 in. in diameter. Of this total, 61 will be driven and secured with drilled rock sockets, while the remain-ing piles are friction. The pier is constructed of a complex honeycombed cast-in-place concrete substructure of pile caps, duct banks and mechanical chases and will be topped with a cast-in-place concrete deck. American Bridge (AB) is self-performing the demolition, piling, precast erection, cast-in-place concrete and fender system, along with other miscellaneous items.

Based on experiences gained from AB’s workonPier6atthislocation,revisedconstruction methods were incorporated to ensure smoother flow of work, allow the abil-ity to multitask and provide more productive

flexibility. To meet these challenges, AB and Doka worked together to engineer, design and fabricate a structural false-work deck system to support the live loads to place the cast-in-place concrete substructure mono-lithically. One key element of the solution was procuring enough false-work materials to construct a platform for more than half the pier. This will provide the opportunity to gang-form much of the structure, reducing installation time and labor costs. As portions of the work are completed, the false-work will be lowered onto floats and reused to complete the remainder of the pier.

“ThiswasacomplicatedPierwithachal-lenging formwork system due to the under-side of the pier affected by the tidal waters. This tidal sequence made it challenging to come up with the right system to be practi-caltostrip,”saidKevinMoynihan,ProjectManager, American Bridge Co.

Forming Against The TideThe Deck tables are located right at the tide line. American Bridge can only cycle the Deck at low tides, which occur twice per month, known as “spring tides” when the sun, earth and moon all form a straight line. Another challenge, were the tables and support system needed to be engineered to handle a wide range of pile deviations 6 in. to 8 in. in any direction. Additionally, the pier has concrete duct banks that run in both directions along the entire pier. Since these locations aren’t typical, the customer chose Frami with its lightweight and versatile design, due to the ability to efficiently change the configuration of the formwork from bay to bay.

When complete, the pier will service our troops for years to come.

Approximately 24,000 ft. of custom tables were used with about 3,500 Doka H20 timber beams to form just more than half of the total pier soffit.

We used wooden floats to float out the 21-ft. x 73-ft. form panels

from the underside of the pier. Where we could not use a float, we installed Styrofoam on the Doka panels so they would float out on their own.”

The Professional

Kevin Moynihan, Project Manager, American Bridge Co.

Wooden floats were used to carry formwork to the underside of the pier.

Doka Xpress14

However,withastrongcommitmenttoenergy efficiency and the environment, they did not want a building that uses today’s traditional heating systems nor is straddled with high ongoing maintenance costs. The result is their new South Campus.

As with most projects, schedule and equipment availability were key elements outlined for the success of this project. The design also required innovative solutions

as the building had no typical levels, so the formwork needed to be designed to be flexible to adapt to the changing slab layout. In response to these challenges as well as based on prior experience with the customer, Doka was selected to supply all formwork.

The new building includes a large overhang on the perimeter of level four that needed to be supported from the main floor. Doka’s

100% Formwork Needs CoveredBow Valley College sought to double their capacity to 20,000 students.

The Factsjobsite

Bow Valley College Campus, Calgary, Alberta, Canada

square footage 51,775 sq. ft.

general contractor Stuart Olson

architect Graham Edmunds Cartier

Architectureconcrete contractor

Stuart Olson / Con-Forte JV Ltd.

products used Starter Block Unit D22, Climbing Bracket D22,

Folding Platform K, Climbing Formwork MF240, Framax S Xlife, Dokaflex S,

Preassembled Dokamatic Tables, Staxo 100, Eurex 60

550s, Shaft Platforms

July 2011 15

This project was completed using 100% Doka products for the concrete work.

layout, a new design was needed for every level.However,Dokawasabletocreateasolution that involved reusing as much as possible from the previous level to save time and money.

Safety requirements were also a large factor on this job, and Doka’s protection platforms, handrail posts and formwork bracing equipment helped ensure a safe project. The first of its kind in the Calgary Community, this project offers students a fantastic learning environment. The owner was very pleased with the time and labor savings they were able to achieve during construction.

Load-bearing tower Staxo 100 is a high performance shoring system with integrated ladder and high shoring capacity.

From wall, slab, and shoring systems to safety and climbing solutions, Doka is providing efficient concrete solutions at Bow Valley College Campus.

solution was its Staxo 100 with a total height of approximately 46 ft. Staxo 100, in conjunction with Eurex 60 550 was also used to accomplish the massive trans-fer beams (8 ft. deep x 5 ft. wide) on the roof. Doka’s WS10 wailing was used for the stringers in order to take the load and adapt it to the slope of the ramp and the curve of the ramp wall.

Another design challenge was the archi-tectural finish desired in the south stair core from the main floor to level eight. Doka met this challenge with its Framax panels and an overlay of architectural ply-wood. With the constantly changing slab

Doka Xpress16

Frami Xlife wins Most Innovative Product Award

USADoka USA Ltd.214GatesRoadLittleFerry,NJ07643Tel. (201) 329-7839Tel.(877)DOKA-USAFax (201) 641-6254E-Mail: usa@doka.comwww.dokausa.com

CanadaDoka Canada Ltd./Ltee5404 - 36th Street S.E.Calgary,AlbertaT2C1P1 CanadaTel. (403) 243-6629Fax (403) 243-6787E-Mail: canada@doka.comwww.doka.ca

FrAMI XLIFE WINS MoST INNoVATIVE ProDUCT An award program showcased annuallyattheWorldofConcrete,theMIPawardrecognizesnewandinnovativeprod-uctsintheindustry.TheMIPprogramallowsattendees a chance to vote for products they judge as innovative. Frami Xlife won the attendees' choice award in the form-work category. The system is an ideal wall formwork solution for foundations, high-rise shear walls and cores, high-rise columns, low wall and footing portions of heavy con-struction projects. Frami Xlife is light enough to be man-handled, yet strong enough for crane-assisted forming, while producing a smooth concrete finish.

DokA NorTH AMErICA IS NoW oN FACE-Book! Visit us and become a fan of our page by clicking the "like" button. Send us your contact information via the contact us form and receive free carpenter pencils. www.facebook.com/DokaNorthAmerica

Doka locations worldwide.

Imprint: “Doka Xpress” is a publication of Doka USA, Ltd. Publisher:DokaUSA,214GatesRoad,LittleFerry,NJ07643.Editorial: Diana Sanicki, Marketing, Doka USA, Ltd. Layout Design:PixelatePhotography&Design,Ltd.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.

Doka in the US and Canadanews, dates, media, awards

SEE US AT THE ASCC ANNUAL CoNFErEN-CE & THE ASBI CoNVENTIoN The American Society of Concrete Contractors (ASCC) Annual conference will be held September 14-18,2011inGrandRapids,Michigan.Register for the event at www.ascconline.org.

Visit our booth at the 23rd annual American Segmental Bridge Institute (ASBI) conven-tionheldattheMarriott,WardmanPark,November 7 - 8, 2011 in Washington, D.C.

GET THE LATEST NEWS

New York (Northeast Area)Doka USA, Ltd.208GatesRoadLittleFerry,NJ07643Tel.(877)DOKA-USA

Chicago (Midwest Area)Doka USA, Ltd.22901 West Winchester DriveChannahon, IL 60410Tel. (815) 521-3700

Atlanta (Southeast Area)Doka USA, Ltd.105A Boulderbrook CircleLawrenceville,GA30045Tel. (888) 618-4700

Baltimore (Mid-Atlantic Area)Doka USA, Ltd.3665 Benson AvenueBaltimore, MD 21227Tel. (410) 368-8390

Los Angeles (Far West Area)Doka USA, Ltd.6901 Central AvenueRiverside, CA 92504Tel. (951) 509-0023

Houston (Southwest Area)Doka USA, Ltd.10822 Mahaffey RoadTomball, TX 77375Tel. (821)516-2211

Saskatchewan/Manitoba officeDoka Canada Ltd./LteeTel. (866) 923-6629

Toronto office (Eastern Canada)Doka Canada Ltd./Ltee12673 Coleraine DriveBolton, Ontario L73 3B5CanadaTel. (416) 999-5893

Edmonton/Northern Alberta officeDoka Canada Ltd./LteeTel. (866) 923-6629

Vancouver officeDoka Canada Ltd./Ltee120, 4401 Blauson BlvdAbbotsford,BCV3G0A4CanadaTel. (604) 432-9455

www.facebook.com/ DokaNorthAmerica

facebook.com/DokaNorthAmerica

youtube.com/DokaNorthAmerica

www.dokausa.comwww.doka.ca

linkedin.com/company/doka

LIkE US oN FACEBook

Like us on Facebook and receive free carpenter pencils!

twitter.com/Doka_USA