Canada St. Joseph’s Seminary … page 7

Chicago 215 West Washington Complex … page 12

Florida Energy Plant … page 14

Colorado 4th Street Bridge … page 16

The Formwork Magazine

Jan. 2010 · www.dokausa.com

400 5th Ave., NYC

Doka Xpress2

Perimeter protection in NYC � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 3

Flexible climbing saves crane time � � � � � � � � � � � � � � � � � � � � 6

Architectural concrete finish in Canada � � � � � � � � � � � � � 7

Ahead of schedule with Framax Xlife � � � � � � � � � � � � � � � � � 8

Interview: Top 10 ways to improve

safety and efficiency � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 10

Success on two Chicago jobsites

with James McHugh Construction Co. � � � � � � 12 & 13

Revolutionary new load bearing

tower - Staxo 100 � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 14

Record-setting bridge � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 16

Services in formwork engineering � � � � � � � � � � � � � � � � � � � 18

In the news � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 20

Editorial

400 5th Avenue

Staxo 100

4th Street Bridge

Doka news

Huge pylons climbedUkraine – The industrial metropolis of Zaporozhye is being given a new cable-stayed bridge whose 492-foot tall, H-shaped twin pylons are being raised by Automatic climbing formwork SKE 50, in 40 casting sections. The massively sized cross-beam is being shored by Staxo 100 load-bearing towers.

Catwalks reduce hoists Italy – As part of the modernization of a cement plant, four 295-foot high towers were built using Automatic climbing formwork SKE 50. To make access to the workplaces as efficient as possible, the towers were linked to one another by catwalks. This made it possible to use three fewer building-site hoists.

Construction challenge solvedIsrael – Doka Israel supplies framed formwork Frami, large-area formwork Top 50, Dokaflex tables and Staxo load bearing towers for two new pharmaceutical factories in Israel. The floor area of the factories is 485,000 square feet. The manufacturing hall’s height of 30-feet presented a construction challenge.

Index Page

The latest reports show an increase in the industrial and infrastructure segments. For-tunately, these are industries in which Doka has proven exper-tise as, it is where we trace our roots more than 50 years ago.

Doka has supplied formwork for countless infrastructure, power-station and other civil engineering projects, continu-ally improving the formwork technology needed to safely and efficiently help in the construction of your projects. Despite the economic chal-lenges, we continue to invest in the enhancement of exist-ing products as well as the development of new formwork innovations. New products must afford users a quantifiable benefit. With 145-plus active patent rights, 50 patent ap-plications now being processed and a highly qualified research and development team, Doka unquestionably ranks as the most innovative company in the formwork industry at this time.

At the World of Concrete, Doka USA will unveil Doka Staxo 100, a high-performance load-bearing tower that is ideal for commercial or heavy civil construction. Other develop-ments in 2010 include growth of our Table Lifting System, a self-climbing lift system, eliminating the need for a crane, as well as Frami Xlife, a lightweight handset form with a new Xlife sheeting providing a smooth concrete finish.

We wish you the very best for a profitable and safe year.

Andrew Mair Chief Executive Officer Doka USA, Ltd.

Andrew Mair

January 2010 3

The Factsjobsite 400 5th Avenue, New York Citycustomer Navillus Concreteproducts used Xclimb 60 protection screen and loading platformstotal formwork used 22 of Doka’s Xclimb 60 protection screens and five loading platforms were selected, totaling 14,400 sq. ft. of protection around the perimeter of the building.

The Solution Doka’s Xclimb 60 was used to successfully construct this new 57-story hotel and residential building in crowded Manhattan. The room-high enclosure formwork provided complete protection, allowing workers to be more productive. The team was able to complete one entire floor every two days using Doka formwork.

Perimeter Protection on NYC High-Rise with Xclimb 60Working conditions on the high-rise were as safe as those on the ground level. One entire floor was completed every two days using the Xclimb 60 protection screen.

Doka Xpress4

Limited space With more than 5,540 high-rise buildings in a 305-square-mile radius, it can be very challenging to construct a new structure in New York City. Such is the case for a new 57-story, hotel and residential building located at 400 5th Avenue.

In order to accommodate the tight site and the varying floor heights, 22 of Doka’s Xclimb 60 protection screens and five loading platforms were selected and deliv-ered preassembled. Approximately 14,400 square feet of protection was used around the perimeter of the building. The room-high enclosure provided complete protechigh enclosure provided complete protec-

tion around the perimeter edges of the floor slabs where edge falsework and col-umn forming operations were performed.

Maximum safety “The Xclimb 60 protection screen’s modular panel system adapted well to the building’s design,” said Nick Zaraza, Doka Project Engineer. “The protection screen enclosed three floors plus seven feet above the work-ing deck at one time, protecting workers and preventing material from falling.”

Doka’s Xclimb 60 protection screen is structure-guided at all times, even while being repositioned. Positioning shoes guide being repositioned. Positioning shoes guide

Due to a considerable Due to a considerable increase in major increase in major

accidents in the New accidents in the New York high-rise industry during York high-rise industry during

the last couple of years, we we had no margin for error with had no margin for error with safety. The Doka Xclimb 60 safety. The Doka Xclimb 60 protection screen provided protection screen provided

a safe working environment a safe working environment and also ensured the safest and also ensured the safest

possible protection for possible protection for the public.”the public.”

The Professional

Gabriel McAuley, Gabriel McAuley, General Superintendent, Superintendent, Navillus ConcreteNavillus ConcreteNavillus Concrete

The protection screen enclosed four floors at one

time, protecting workers and preventing material from falling

off the work area.

January 2010 5

the screen’s vertical profiles up the side of a structure, permitting safe, fast and efficient repositioning under any weather condition. Even in wind speeds up to 45 miles per hour, an entire screen unit can be repositioned safely in one lift. Further, crews typically work much faster inside the protection screen because they cannot see how high up they are, and are not required to tie-off, so they tend to move about more freely.

Eliminate crane timePortable hydraulic components can be added to the Xclimb 60 protection screen to allow easy repositioning making it indepen-dent of the crane. Designed for exceptional

climbing safety, this cost-effective system, when combined with the protection screen, provides full high-rise perimeter protection for the working floor and three floors below. The guided system connects to the wall with a self-locking mechanism and provides for fast, safe repositioning of site material.

Construction started December 2008 and the screens were installed in June2009. In 2010, when the building is com-pleted, New York City will have a new addition to its already breathtaking skyline. Doka’s customized solution ensures in-creased production for the crews without sacrificing safety or efficiency.

Forming Efficient Solutions.

The Xclimb 60 protection screen has been successfully used in Chicago on the Legacy project and is increasingly becoming popular on many high-rises worldwide, increasing productivity while ensuring worker safety.

Doka Xpress6

When construction of the Obel Tower began in 2006 in Belfast, Northern Ireland, it made much news as it is designed to overtake the skyline as one of the tallest skyscrapers in the city. Located on Donegall Quay beside the Lagan River, the residential apartment building will also include com-mercial space and will measure 265 feet in height once complete in 2010.

Fernwave Ireland Ltd. was hired to perform the cast-in-place concrete work and they turned to Doka for a single-source formwork solution. One of the key challenges identi-fied early in the project was the need to maximize efficiency since space is at a pre-mium on the waterfront site. In fact, there is room for only one tower slewing crane and the only viable option is crane-independent formwork. Doka suggested the use of their

Dokaflex tables, Xclimb 60 protection shield, SKE 50 brackets and their unique Table Lift-SKE 50 brackets and their unique Table Lift-ing System (TLS).

For the central 265 foot cast-in-place core of the building, 22 automatic self-climbing of the building, 22 automatic self-climbing Doka SKE 50 brackets were selected, allow-ing the team to maintain a weekly schedule for each slab deck. The shaft formwork is for each slab deck. The shaft formwork is comprised of panels as well as stripping comprised of panels as well as stripping corner units. These formwork boxes can be corner units. These formwork boxes can be lifted from level to level without further dis-assembly. Since crane capacity is extremely assembly. Since crane capacity is extremely limited and ideally, floor-slab forming should be crane-independent, the tables are being lifted from level to level with two TLS table lifting systems. The 1,969-square-foot floor slabs are being formed with 150 Dokaflex slabs are being formed with 150 Dokaflex special tables. The TLS Table Lifting System special tables. The TLS Table Lifting System takes the floor-slab formwork quickly from takes the floor-slab formwork quickly from one floor to the next without the need for one floor to the next without the need for a crane. Further, the Xclimb 60 protection a crane. Further, the Xclimb 60 protection shield also climbs automatically, as well as shield also climbs automatically, as well as provides full-enclosure protection for the four topmost floors as the tower rises. four topmost floors as the tower rises.

“We are using automatic climbers for the cast-in-place core and the TLS enables cast-in-place core and the TLS enables crane-independent lifts of the Doka tables crane-independent lifts of the Doka tables so we can successfully limit crane usage as so we can successfully limit crane usage as well as ensure we maintain a one-week cycle well as ensure we maintain a one-week cycle for the deck slabs,” said Ronan McHugh, for the deck slabs,” said Ronan McHugh, Project Manager for Fernwave. Project Manager for Fernwave.

The Factsjobsite

Obel Tower, Obel Tower, Belfast, Northern Ireland

customer Fernwave Ireland Ltd.

products used 22 automatic self-climbing 22 automatic self-climbing

Doka SKE 50 brackets, 150 Doka SKE 50 brackets, 150 Dokaflex special tables, Dokaflex special tables,

Xclimb 60 protection shield, Xclimb 60 protection shield, and the Table Lifting System and the Table Lifting System

The Solution The customer was able to The customer was able to

complete this project on complete this project on time and on schedule due to time and on schedule due to the use of Doka’s formwork the use of Doka’s formwork

solutions. solutions.

It’s very much on It’s very much on account of the fact account of the fact

that we are using TLS that we are using TLS units that we’ve been able units that we’ve been able

to maintain this tight weekly to maintain this tight weekly cycle right through the cycle right through the

floor-slab phase of floor-slab phase of construction. The TLS units construction. The TLS units

keep our shifting times short keep our shifting times short and allow us to reap the and allow us to reap the

benefit of continuous and benefit of continuous and speedy workflows.”speedy workflows.”

The Professional

Ronan McHugh, Ronan McHugh, Project Manager, Project Manager, Fernwave Fernwave Ireland Ltd.Ireland Ltd.

The central CIP core of the The central CIP core of the Obel Tower is being climbed Obel Tower is being climbed

with 22 Doka SKE 50 automatic with 22 Doka SKE 50 automatic climbers.

Tight site and limited crane capacity Unique formwork solutionUnique formwork solutionUnique formwork solution required on the Obel Tower on the Obel Tower

January 2010 7

The chapel includes a curved wall; apThe chapel includes a curved wall; ap-proximately 20-foot high windows and re-cesses for Stations of the Cross figures on the two straight walls; textured-concrete the two straight walls; textured-concrete rustication strips; and a 6.5-foot high header beam over the entrance doors. The header beam, spanning more than The header beam, spanning more than 36 feet at 30 feet from the ground, will be poured monolithically with the 36-foot-high west walls.

Several factors influenced the level of Doka’s product design including the high concrete pressure required by the con-tractor; tie-holes and panel sizes pretractor; tie-holes and panel sizes pre-determined by the architect; and 5-ton, 36-foot-high formwork panels that have to be accurately positioned and plumbed to pour the wall without any vertical breaks.

To accommodate the size and height of To accommodate the size and height of the panels, Doka custom-designed C10 the panels, Doka custom-designed C10 lifting channels to withstand the high bendlifting channels to withstand the high bend-

Practical Tip

Planning key to Planning key to architectural concrete

Architectural concrete sur-Architectural concrete sur-Architectural concrete surfaces are often very tricky to achieve as the concrete appearance is generally based on the specific project architect’s wishes. In order to achieve the desired results, it is critical to have a meeting of the minds with all involved parties at the very early stages of the project.

ing loads and evenly distribute the panel ing loads and evenly distribute the panel weight. The panels were hoisted into posiweight. The panels were hoisted into posi-tion using the steel channels as strong-tion using the steel channels as strong-backs. A separate curb slab was poured to backs. A separate curb slab was poured to ensure that the 36-foot high panels would ensure that the 36-foot high panels would be easily plumbed and leveled.be easily plumbed and leveled.

One of the most challenging aspects of One of the most challenging aspects of the chapel’s design was the curved walls the chapel’s design was the curved walls featuring architectural reveals and tie-featuring architectural reveals and tie-holes. Doka designed special steel conholes. Doka designed special steel con-necting parts that fit seamlessly together necting parts that fit seamlessly together with the formwork system to achieve with the formwork system to achieve precise panel joints and an accurate precise panel joints and an accurate curve. To meet the specific requirements curve. To meet the specific requirements for the architectural tie-holes and panel for the architectural tie-holes and panel sizes, Doka supplied its Top 50 formwork sizes, Doka supplied its Top 50 formwork system. Due to the high pressure, H20 system. Due to the high pressure, H20 beams for the Top 50 formwork system beams for the Top 50 formwork system were placed close together. The outer were placed close together. The outer layer of plywood was to be screwed only layer of plywood was to be screwed only from the back of the form and two layers from the back of the form and two layers of plywood were required. of plywood were required. of plywood were required.

Desired Concrete Finish AchievedSt. Joseph’s SeminarySt. Joseph’s Seminary in Edmonton, Alberta, in Edmonton, Alberta, in Edmonton, Alberta, in Edmonton, Alberta, St. Joseph’s Seminary in Edmonton, Alberta, St. Joseph’s SeminarySt. Joseph’s Seminary in Edmonton, Alberta, St. Joseph’s SeminaryCanada, required a specific architectural design. Doka Canada, required a specific architectural design. Doka Canada, required a specific architectural design. Doka developed and custom-designed special formwork to developed and custom-designed special formwork to developed and custom-designed special formwork to meet the distinguishing aspects of the chapel. meet the distinguishing aspects of the chapel. meet the distinguishing aspects of the chapel.

The Factsjobsite St. Joseph Seminary, Edmonton, Albertacustomer Dawson Wallace Construction Ltd.products used Custom-designed C10 lifting channels, special steel connecting parts, Top 50 formwork, H20 beams and Staxo 100total formwork used 5,971 sq. ft.

The Solution The use of Doka formwork The use of Doka formwork allowed the finished product to match the architect’s design to match the architect’s design exactly, resulting in a chapel that will meet the growing that will meet the growing needs of its seminarians and the community.the community.

Doka Xpress8

The Factsjobsite

Martha Jefferson Regional Medical Center,

Charlottesville, Virginiacustomer

Cleveland Cement Contractors

products used Framax, MF 240 and

shaft platformstotal formwork used

12,000 sq. ft. of Framax, 12 MF 240 climbing platforms along with four telescopic

shaft platforms

General contractor M.A. Mortenson and concrete contractor Cleveland Cement Contractors sought the assistance of Doka to meet the challenging schedule. With more than 2,000 lineal feet of foundation wall ranging from 17 feet to 34 feet high as well as varying footing heights, pilaster sizes and spacing, a formwork system was needed that would allow for cycling the forms in a fast and efficient manner.

Capable of 1,650 psf, Doka’s Framax form-ing system with the X-Life plywood face provides a superior concrete finish. Fur-ther, using hinged pilaster corners allowed the contractor to maintain an aggressive schedule, while achieving the high produc-tion rates required for the foundation wall.

Flexible SolutionsDoka’s Framax forming system with MF 240

Months Ahead of ScheduleThe Martha Jefferson Regional Medical Center in Virginia is currently under a fast paced construction schedule to replace an existing facility.

Capable of 1,650 psf, Doka’s Framax forming system with the X-Life plywood face provides a superior concrete finish. Further, using hinged pilaster corners allowed the contractor to maintain an aggressive schedule while achieving the high production rates required for the foundation wall.

January 2010 9

9710-303-01

The Solution Doka helped to form the unique foundation walls and elevator and stair cores in an aggressively tight schedule. With early planning and collaboration, Doka was able to help the contractor increase production and shave approximately 74 days off the tight core wall schedule.schedule.

Practical Tip

MF 240 Climbing MF 240 Climbing Formwork

Using the unique roll-back feature and 8-foot wide working platforms allows safe and quick cleaning of the face of the forms before the next casting step and also allows vertical, horizontal or tiltable form adjustment, if needed.

“roll-back” climbing platforms were chosen for the exterior, and “flipper-leg” telescopic for the exterior, and “flipper-leg” telescopic shaft platforms for the interior, of the 12 elevator and stair cores. Doka supplied ap-proximately 12,000 square feet of Framax, 12 MF 240 climbing platforms along with four telescopic shaft platforms for the four telescopic shaft platforms for the elevator and stair cores, which had vary-ing heights ranging from 60 to 90 feet. The chosen systems provided flexibility, as the two sets of core forms had to be modified two sets of core forms had to be modified for reuse on 12 different cores and the founfor reuse on 12 different cores and the foun-dation form package had to accommodate variable single- and double-pilaster sizes. variable single- and double-pilaster sizes. Also, the bias cut stripping corners allowed Also, the bias cut stripping corners allowed the interior core forms and shaft platforms the interior core forms and shaft platforms to strip as a single unit very quickly, minito strip as a single unit very quickly, mini-mizing the number of crane picks.

Doka’s solution to working around the Doka’s solution to working around the

tremendous amount of steel embeds on tremendous amount of steel embeds on the project was to design custom hanger the project was to design custom hanger brackets to allow positioning of the MF 240 brackets to allow positioning of the MF 240 climbing platforms at the doorway open-ings in the elevator and stairway walls as they changed from lift to lift. This allowed they changed from lift to lift. This allowed the contractor to jump the forms straight the contractor to jump the forms straight up the core walls without rebuilding the forms or platforms, thereby eliminating forms or platforms, thereby eliminating construction delays.

Speedy Progress Speedy Progress Several formwork planning meetings were held to review solutions that would were held to review solutions that would streamline the construction process to streamline the construction process to minimize project delays and pick up time on the schedule. The result for the owner is an excellent foundation to a hospital that will serve the community for decades to will serve the community for decades to come. come.

Framax Xlife wall formwork and the MF 240 climbing system provided the contractor with a flexible solution & increased productivity on this medical center.

Doka Xpress10

Top Ways to Improve Safety and Efficiency in 2010 Michael Schaeffer, National Sales Manager with National Sales Manager with National Sales Manager with responsibility for Northeast/MidAtlantic Areas at Doka responsibility for Northeast/MidAtlantic Areas at Doka responsibility for Northeast/MidAtlantic Areas at Doka USA Ltd., has been in the industry for more than 17 USA Ltd., has been in the industry for more than 17 USA Ltd., has been in the industry for more than 17 years. years.

Selecting the right formwork Selecting the right formwork greatly affects the schedule, greatly affects the schedule,

labor requirements, quality labor requirements, quality and total cost of a project.

An experienced formwork professional, An experienced formwork professional, Schaeffer’s career also includes engi-neering, sales, operations and executive management experience. Today, his main responsibilities for Doka USA, Ltd. include companywide sales, area management, companywide sales, area management,

product management as well as market-ing support. He is a frequent author and speaker. To help our customers with some common design and field issues, we’ve assembled the following Frequently Asked Questions, answered by Michael Shaeffer.Questions, answered by Michael Shaeffer.

January 2010 11How does the selection of formwork affect the overall job? The selection of formwork greatly affects the schedule, labor requirements, quality and total cost of a project. A contractor ulti-mately has two choices: an inexpensive but labor-intensive forming material, or a system that costs more but provides high produc-tivity, built-in safety features and is more labor-efficient.

When should I start considering formwork? At the very early design stage of the project. This allows you to prepare a more accurate bid, and also get information on sizing structural concrete members to meet standard form dimensions. Your supplier can also offer insight into the most economical formwork means and methods.

Should I purchase a system or rent one? This decision should be based on the dura-tion of the project and the overall strategy of the company. Typically, if a form system has to be rented for more than 8 to 10 months, purchasing the system might be more economical. Purchasing brings additional costs such as maintenance and storage, but some formwork companies offer services for customers who purchase their equipment.

How can I ensure workers feel safe on the job site? Your formwork structure should be outfit-

ted with equipment that meets OSHA requirements for fall protection. On platforms where people will be working, there are systems available to secure guardrails or protection screens (like Doka’s Xclimb 60 Protection Screen) to protect workers from falls. Further, a worker needs a safe, easy way to climb from one area to the next, so it is impor-tant to have proper ladders installed. If safety equipment features are easy to use, then workers will use them. With every-one following safe practices, not only will there be fewer accidents (or none at all), but also benefits in increased productivity and efficiency.

What do I need to know when assembling formwork?One of the common mistakes made is not following the engineering drawings for assembling and setting up formwork. Cutting corners or not following set-up instructions can lead to accidents. You should also have the proper ties in place to secure the formwork to guarantee safety and accuracy. Consider having the formwork preassembled at the supplier’s shop, which will save you time in the field and provide safety advantages. Because formwork technol-ogy is constantly changing, you should take advantage of training offered by your formwork supplier on the proper and safe utilization of forming equipment.

In head-to-head comparison, Frami proves to be the optimal solution over hand-set forming systems in several areas, includ-ing labor, material savings, and safety.

Following engineering drawings for assembling and setting up formwork is critical to avoid accidents.

Choosing a system that provides high productivity and has built-in safety features will lead to greater savings than inexpensive labor-intensive systems.

Doka Xpress12

Chicago has taken great strides to be a green city. One such example is 215 West – a 50-story, $150-million modern luxury apartment complex. Construction of 215 West was finished in October 2009, three months ahead of schedule thanks to the integration of unique formwork solutions.

James McHugh Construction Co. chose approximately 1,000 square feet of Top 50, 3,500 square feet of custom steel, 2,600 square feet of preassembled SKE 50 platform, and 35 SKE Climbing Brack-ets, all from Doka. The Top 50 forming equipment provides easy and efficient forming sequences. The system can be configured for fast and safe stripping of the formwork, after which the interior forms can be immediately reconfigured and rapidly re-set into the next casting. The Top 50 modular gang form system can be assembled in any configuration for a wide range of applications. The 3,500-square-foot custom steel solution 3,500-square-foot custom steel solution

enabled the team to complete one floor every three days and allowed the team to ensure no mistakes were made.

A lot of reveals were necessary to accomA lot of reveals were necessary to accom-plish the two different finishes – a flat slab and downturn beam. These two finishes were used interchangeably for each floor. As such, the stripping needed to be As such, the stripping needed to be smooth and the formwork had to be able to roll back so workers could safely climb to the next level. The formwork was used to ensure a quality exterior that included exposed beams and columns and also helped the contractor to switch between the parking garage and the typical floors at the 14th floor. Further, the form system platform had built-in handrails and was enclosed, allowing the workers to remain efficient and safe.

Doka preassembled the custom steel and platforms before delivering them to the site, which saved time and labor costs. which saved time and labor costs.

The Factsjobsite

215 West, Chicagocustomer

James McHugh James McHugh Construction Co.products used

Top 50, SKE 50, SKE Top 50, SKE 50, SKE climbing brackets and climbing brackets and

custom steeltotal formwork used 1,000 sq. ft. of Top 50, 1,000 sq. ft. of Top 50,

3,500 sq. ft. of custom steel, 3,500 sq. ft. of custom steel, 2,600 sq. ft. of preassembled 2,600 sq. ft. of preassembled SKE 50 platform and 35 SKE SKE 50 platform and 35 SKE

climbing brackets

The Solution Construction of 215 West Construction of 215 West

was finished in October was finished in October 2009, three months ahead 2009, three months ahead

of schedule thanks to of schedule thanks to the integration of unique the integration of unique

formwork solutions. formwork solutions.

Formwork + Four Workers = 3 Day Cycle

Doka’s formwork Doka’s formwork solutions allowed the solutions allowed the

contractor to utilize only contractor to utilize only four workers for a typical four workers for a typical floor. If another formwork floor. If another formwork

system had been used, system had been used, the contractor would have the contractor would have

needed at least 10 workers needed at least 10 workers and would not have been and would not have been

able to complete one floor able to complete one floor every three days.”every three days.”

The Professional

Kevin Morley, Kevin Morley, Carpenter Carpenter Superintendent, Superintendent, Superintendent, James McHugh James McHugh James McHugh Construction Construction Co.

January 2010 13

The Factsjobsite Alta Tower at Kinzie Station, Alta Tower at Kinzie Station, Chicagocustomer James McHugh James McHugh Construction Co.products used Top 50, SKE 50, Frami, Top 50, SKE 50, Frami, Framax and custom steeltotal formwork used The tower portion of the The tower portion of the project utilized more than 5,000 square feet of custom steel as well as 24 SKE brackets. For the garage, 43 MF-240 brackets were used and more than 7,000 sq. ft. of Top 50 formwork. Top 50 formwork.

The Solution The Alta tower, a 41-story The Alta tower, a 41-story building with 428 units, on the Kinzie Station project the Kinzie Station project was able to be constructed was able to be constructed quickly and efficiently with the use of Doka Formwork. the use of Doka Formwork. Throughout construction, Throughout construction, Doka helped James McHugh Construction Co. stay on time and on budget while time and on budget while achieving a three- to four-day work cycle.work cycle.

Doka didn’t just provide us with formwork equipment,

but rather a reliable solution that exceeded our expectations.”expectations.”

The Professional

Joey Payne, Joey Payne, Superintendent, Superintendent, James McHugh James McHugh Construction Co.Construction Co.

The tower portion of the project utilized The tower portion of the project utilized The tower portion of the project utilized more than 5,000 square feet of custom steel as well as 24 SKE brackets. For the garage, 43 MF-240 brackets were used and more than 7,000 square feet of Top 50 formwork. Top 50 was used for K Sta-tion’s garage to match the slope of the tion’s garage to match the slope of the ramp, columns and walls. The bottoms of the Top 50 forms were easily cut to the ramp’s slope, which eliminated the need for wedge-shaped wood fillers required for wedge-shaped wood fillers required in a traditional stepped formwork system. SKE 50 was ideal because the contrac-tor needed a crane-independent climbing tor needed a crane-independent climbing system to meet the schedule.

To form the custom-fabricated exterior To form the custom-fabricated exterior beam forms, the contractor utilized Frami, the fastest assembling wall system in the the fastest assembling wall system in the market, for the interior of the beams. The entire perimeter of formwork was set up in one shot so the slab, spandrel beams and columns all could be poured together, which also saved time. which also saved time. which also saved time.

To meet K Station’s unique architectural To meet K Station’s unique architectural To meet K Station’s unique architectural challenges, Doka provided stripping bars and hinged yokes, which allowed the inte-rior beam forms to be hinged up and over the exterior beam forms. This approach the exterior beam forms. This approach allowed the interior forms to remain out of the way so the column forms could be hinged open and the entire side of form-work could be rolled back for cleaning, work could be rolled back for cleaning, oiling and for climbing to the next level.

Additionally, custom steel formwork was Additionally, custom steel formwork was fabricated with the large, vertical reveals fabricated with the large, vertical reveals built-in, which allowed for the horizontal reveals to be permanently attached to the panels, extending their useful life. Also, the column form joint at the interior was fabri-cated with an integral vertical rail allowing for the use of Framax quick-acting clamps, for the use of Framax quick-acting clamps, saving considerable time from the tradisaving considerable time from the tradi-tional bolt and nut connection. In addition, tional bolt and nut connection. In addition, Doka fabricated custom platform channels resembling a “Z-shape” to accommodate the unusual shape of the columns. the unusual shape of the columns. the unusual shape of the columns. the unusual shape of the columns. the unusual shape of the columns.

Exceeding Expectations again and again… Chicago’s skyline will soon experienceChicago’s skyline will soon experienceChicago’s skyline will soon experience a noticeable change, with the construction of the noticeable change, with the construction of the noticeable change, with the construction of the 8-acre Kinzie Station (K Station).8-acre Kinzie Station (K Station).8-acre Kinzie Station (K Station).8-acre Kinzie Station (K Station).

Doka Xpress14

Doka is the first Doka is the first forming company that forming company that

has lived up to the has lived up to the promises made in the 12 promises made in the 12

years I have been in heavy years I have been in heavy civil construction.”

The Professional

Jorge Jorge Mendez, Civil Mendez, Civil Superintendent, Superintendent, Superintendent, Zachry Zachry ConstructionConstruction

The Factsjobsite

West County Energy Center, West County Energy Center, Palm Beach County, Florida.

customer Zachry Construction

products used Staxo 100, Framax and Staxo 100, Framax and

Dokamatic tablesDokamatic tablestotal formwork used

Approximately 236,000 cubic Approximately 236,000 cubic feet of shoring was used feet of shoring was used

to support a table area of to support a table area of 8,000 sq. ft. Approximately 8,000 sq. ft. Approximately 35,000 sq. ft. of formwork 35,000 sq. ft. of formwork

was used onsite. was used onsite.

The Solution A combination of A combination of

Dokamatic Tables and the Dokamatic Tables and the ground breaking Staxo 100 ground breaking Staxo 100

load-bearing towers to aid in load-bearing towers to aid in the construction of 40-foot the construction of 40-foot

tall, 10-foot thick slab sitting tall, 10-foot thick slab sitting on eight piers and one shear on eight piers and one shear

wall, while spanning over wall, while spanning over a base mat with two a base mat with two

different elevations

New Shoring System Debuts in Florida Staxo 100,Staxo 100, Doka’s new revolutionary load bearing Doka’s new revolutionary load bearing Doka’s new revolutionary load bearing Doka’s new revolutionary load bearing tower is speeding up progress on a Power Plant tower is speeding up progress on a Power Plant tower is speeding up progress on a Power Plant tower is speeding up progress on a Power Plant upgrade with contractor, Zachry Construction.upgrade with contractor, Zachry Construction.upgrade with contractor, Zachry Construction.

When Florida Power and Light decided When Florida Power and Light decided to build a new 2,400-megawat natural gas fired power plant in Palm Beach County, they turned to the alliance of Zachry Construction and Black & Veatch

Engineering. The steam turbine pedestal Engineering. The steam turbine pedestal that was to be constructed at the West County Energy Center would be the first “G” class three-on-one combined cycle in the nation.

January 2010 15

Forming Efficient Solutions.

The groundbreaking Staxo 100 system provides tie-off points built into every frame, can be ganged or hand-set, contains integrat-ed couplers with no loose parts, and has optimal load capacity to provide major time and labor savings and a safe working environment.

Key to success was finding solutions that would aid construction of the com-plex pedestal featuring a 40-foot tall, 10-foot thick slab sitting on eight piers and one shear wall, while spanning over a base mat with two different elevations. The solution was Framax set on top of preassembled Dokamatic tables to pour the 150-foot by 42-foot slab. Doka’s new Staxo 100 load-bearing towers were the choice for the necessary shoring.

Staxo 100 is Doka’s new shoring system with an integrated ladder. Already used in Europe, it will be unveiled at the 2010 World of Concrete and this is its first use in the United States. The product can handle extremely high leg-load capacity of up to 90 kips per leg and is designed for opti-mum adaptability to different layouts, floor shapes and loads. Staxo 100 frames come in three different heights, which make it suitable for a wide range of elevations.

According to Nick Zaraza, Doka Project Engineer, the crew was able to assemble the Staxo 100 towers faster than the crane operator was able to set them. An

8-foot wide walkway was also integrated around the perimeter to give the workers plenty of room during pouring.

The Dokamatic tables arrived to the site preassembled and were easily reused. Further, the system enabled the 10-foot by 10-foot columns to be formed at full height, allowing the construction team to avoid interference with massive rebar on the inside. The combination of the Dokamatic tables and Staxo 100 solutions allowed 90 percent of the work to be per-formed on the ground at a safe level.

“Having the first-ever built-in ladder sys-tem was a huge advantage as it allowed access to different levels of the deck,” said Zaraza. “The tie-off points, which are incorporated into the frame, allowed the workers to quickly and safely maneuver up the towers to relieve the crane and set the Dokamatic tables. Further, the preas-sembled Dokamatic tables saved valuable man-hours.”

The project began in early 2008 and is ex-pected to be completed in February 2010.

Staxo 100 is Doka’s revolutionary new shoring system with the first-ever built-in ladder system allowing quick access to different deck levels.

Doka Xpress16

I will be using Doka I will be using Doka formwork on future formwork on future

projects. Doka’s projects. Doka’s customer service and customer service and

expertise with segmental expertise with segmental formwork is one of the best in formwork is one of the best in

the industry.”the industry.”

The Professional

Mike McNish, Mike McNish, Project Manager, Project Manager, Project Manager, Flatiron Constructors Constructors IntermountainIntermountain

The Factsjobsite

4th Street Bridge, 4th Street Bridge, Pueblo, Colorado

customer Flatiron Constructors Flatiron Constructors

Intermountainproducts used

Top 50, custom support Top 50, custom support walers, pier tables and walers, pier tables and

10k Shoring Systemtotal formwork used

4,060 sq. ft. of Top 50 in 4,060 sq. ft. of Top 50 in conjunction with custom conjunction with custom

support walers, 6,032 sq. ft. support walers, 6,032 sq. ft. of 10k shoring and of 10k shoring and

one set of formwork for one set of formwork for four pier table forms

The 4th street bridge consists of cast-in-place post-tensioned

segmental box girders built from above in balanced cantilever

with form travelers.

January 2010 17

The Solution The use of Doka formwork has ensured efficiency and safety while saving time and money. During construction of the first main span cantilevers, the contractor achieved a production rate of approximately two segments every five days. Had the team used any other formwork, production would have been a six-day cycle.

The contractor, Flatiron Constructors Intermountain, was hired to perform cast-in-place concrete segmental construction of the bridge. The new 4th Street Bridge is constructed of twin 1,140-foot concrete segmental bridges consisting of cast-in-place post-tensioned segmental box gird-ers built from above in balanced cantilever with form travelers.

The use of Doka Top 50, custom support walers, pier tables and 10k Shoring System helps to ensure efficiency and safety while saving time and money. The contractor is using 4,060 square feet of Top 50 in con-junction with custom support walers, 6,032 square feet of 10k shoring and one set of formwork for four pier table forms.

Custom walers were selected in conjunc-

tion with Doka’s Top 50 forming equip-ment, which is designed to provide easy and efficient forming sequences for large-area projects. The system can be con-figured for fast and safe stripping of the formwork, after which the interior forms can be immediately reconfigured and rapidly reset into the next casting. This ease of maneuverability is critical since the bridge’s shape and forming needs will consistently change during the construc-tion process. The Top 50 system’s adapt-ability to any type of architectural require-ment, form facing or formwork pressure tie-hole pattern, also comes in handy on this project. A proven load-bearing tower made of steel, Doka’s 10k Shoring System allows the shoring of slabs at a wide range of heights. It is especially effective for heights exceeding 18 feet.

Doka Forms Record Segmental BridgeSince December 2007, the Colorado Department of Transportation (CDOT) has been constructing the new 4th Street Bridge — a large, innovative project in Pueblo, Colo.

Using the Top 50 system easily adapted to the consistently changing shape of the bridge.

Doka Xpress18

Services in Formwork EngineeringAs construction projects continue to require shorter timeframes and reduced budgets, contractors demand efficient formwork solutions. But, getting the job done on time also means having a reliable partner in the field.

Doka Field Service Technicians support the crew as they come to

grips with specialized formwork systems and familiarize everyone

with the safe, correct routines – for maximum efficiency

right from the word go. With professional site support

designed to match the various phases of construction, Doka

delivers solutions for customers from start to finish.

January 2010 19

EngineeringProviding the right formwork solution, coupled with the right services, at the right time – that’s the goal of Doka’s engi-neering staff. The pooled knowledge and expertise of all Doka’s engineers and the complete ingenuity with which they for-mulate cost-effective formwork solutions has put Doka among the very top compa-nies in the field of formwork technology. This experience includes constructing This experience includes constructing high-rises in record time, highly demand-ing exposed concrete projects, techni-cal challenges calling for professional logistical know-how and building bridges anywhere in the country.

Field ServiceThe Doka field service technicians are expe-The Doka field service technicians are expe-rienced formwork craftsmen who introduce your team to our formwork systems and your team to our formwork systems and assist you in the supervision of the formwork assembly. Complicated and outstanding formwork jobs are no problem. No mat-formwork jobs are no problem. No mat-ter if it is automatic climbing formwork, a ter if it is automatic climbing formwork, a formwork traveler for tunnels, or on-site formwork traveler for tunnels, or on-site assembly of a special formwork component, Doka’s field service technicians are ready to give you advice and support.

Pre-assembly ServiceWhen you are faced with limited space on When you are faced with limited space on the site, the need for a very fast start-up the site, the need for a very fast start-up , inexperienced jobsite personnel or com, inexperienced jobsite personnel or com-

plicated formwork design, you may elect to have Doka pre-assemble any or all of to have Doka pre-assemble any or all of the formwork. From building Top 50 gang the formwork. From building Top 50 gang forms and custom parabolic pier forms forms and custom parabolic pier forms to custom column and beam formwork, to custom column and beam formwork, our competent engineers and assembly teams help build formwork especially for teams help build formwork especially for your project in your local Doka branch. your project in your local Doka branch. This service affords for just-in-time This service affords for just-in-time delivery, reduced on-site storage, and fast-tracks the speed of your formwork fast-tracks the speed of your formwork process.

Reconditioning serviceAfter using Doka at your job site, we After using Doka at your job site, we provide professional reconditioning ser-vice for your Doka material throughout vice for your Doka material throughout the United States. Specially trained staff the United States. Specially trained staff take over the cleaning and repair of every take over the cleaning and repair of every single piece and make them fit for your single piece and make them fit for your next job according to our high quality standards.standards.

TrainingYour place or ours, Doka offers training Your place or ours, Doka offers training seminars throughout the year focusing seminars throughout the year focusing on either your specific needs and project or general forming practices and safety handling. From classroom style interactive teaching to hands-on training, Doka’s exteaching to hands-on training, Doka’s ex-perienced staff of engineers, field service personnel and account representatives are ready to educate contractors to help them build safer, faster and more cost-them build safer, faster and more cost-effectively than ever before. effectively than ever before.

We have convenient We have convenient locations across the locations across the

U.S. & Canada and we U.S. & Canada and we maintain a complete rental-equipment stock so that we equipment stock so that we

can ensure short delivery can ensure short delivery times and preassembly times and preassembly

support. This dedication to support. This dedication to quality and services adds quality and services adds

up to economical and fast up to economical and fast forming, which means forming, which means increased capacity for increased capacity for

contractors. Our approach contractors. Our approach is integral. The combination is integral. The combination of highly efficient formwork of highly efficient formwork and services tailored to the and services tailored to the

project specifics ensures project specifics ensures successful work and successful work and

enhances the customer’s enhances the customer’s competitiveness.”

The Professional

Bob Kent, Bob Kent, Vice President Vice President Vice President of Engineeringof Engineeringof Engineering

Doka Xpress20

Revolutionary new load-bearing tower Staxo 100

USADoka USA Ltd.214 Gates Road214 Gates RoadLittle Ferry, NJ 07643Tel. (201) 329-7839Tel. (201) 329-7839Tel. (877) DOKA-USATel. (877) DOKA-USAFax (201) 641-6254E-Mail: usa@doka.comwww.dokausa.comwww.dokausa.com

CanadaDoka Canada Ltd./Ltee5404 - 36th Street S.E.Calgary, Alberta T2C 1P1 CanadaTel. (403) 243-6629Tel. (403) 243-6629Fax (403) 243-6787E-Mail: canada@doka.comE-Mail: canada@doka.com

WORLD OF CONCRETE 2010 Doka USA and Doka Canada will be participating in the World of Concrete Show, held Febru-ary 2- 5, 2010.

Unveiling new products and displaying wall, slab, climbing and safety solutions, Doka will demonstrate how to decrease costs and improve overall jobsite effi-ciency in 2010. Stop by booth C5413 and learn how to form efficient solutions!

VOTE STAXO 100 FOR MOST INNOVATIVEPRODUCT Staxo 100, a groundbreaking load-bearing tower from Doka, will be unveiled at the WOC 2010 show. Hav-ing the first-ever built-in ladder system, Staxo 100 provides tie-off points built into every frame, can be ganged or hand-set, contains integrated couplers with no loose parts, and has an optimal load capacity to provide major time and labor savings and a safe working environment. The prod-uct has also been nominated as a Most Innovative Product under the formwork category. Vote for Staxo 100 by visiting www.worldofconcrete.com

Doka branches in the world

Imprint: “Doka Xpress” is a publication of Doka USA, Ltd. “Doka Xpress” is a publication of Doka USA, Ltd. “Doka Xpress” is a publication of Doka USA, Ltd. Publisher: Doka USA, 214 Gates Road, Little Ferry, NJ 07643. Gates Road, Little Ferry, NJ 07643. Gates Road, Little Ferry, NJ 07643. Editorial: Diana Sanicki Marketing, Doka USA, Ltd. Diana Sanicki Marketing, Doka USA, Ltd. Diana Sanicki Marketing, Doka USA, Ltd. Layout Design: Constructive Communication, Inc. Constructive Communication, Inc. Constructive Communication, Inc. 400 5th Ave. Photo Credits: Joe Woolhead

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.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.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.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.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.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

DOKA OFFERS CUSTOMER TRAININg Schedule a formwork training seminar at any Doka facility or at your location by contacting your local branch office. Learn safe formwork handling and get solutions to make 2010 an efficient and successful year.

BAUMA 2010 Bauma, the world’s largest trade fair for construction industry, will take place April 19-25, 2010 in Munich Germany. The event only occurs every three years. Doka’s exhibition hall will have a total of three levels, showcasing cutting-edge innovations as well as Doka’s extended service and product portfolio.

Visit Doka’s Booth C5413 at the World of Concrete

New York (Northeast Area)Doka USA, Ltd.208 Gates RoadLittle Ferry, NJ 07643Tel. (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, GA 30045Tel. (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./LteeBox 961Weyburn, SK S4H 2L2CanadaTel. (306) 861-3211

Toronto OfficeDoka Canada Ltd./Ltee5153 Preservation CircleMississauga, Ontario L5M 7T4CanadaTel. (416) 999-5893

Edmonton OfficeDoka Canada Ltd./Ltee233, 6030 - 88th StreetEdmonton, AB T6E6G4CanadaTel. (780) 490-1966

Vancouver OfficeDoka Canada Ltd./Ltee120, 4401 Blauson BlvdAbbotsford, BC V3G 0A4Canada