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With the recently introduced DUO Lightweight Formwork, PERI has proved how more than just minor improvements are possible through a combination of new materials and a new component systematic. The top of the product specification list for the new development featured significantly extended fields of application, lightweight design with sufficient load-bearing capacity and simple handling.
For the new product, the PERI development had set itself some ambitious goals. This meant totally re-thinking the situation and, in this case, beginning with the material used.
Traditional formwork systems rely on long-proven materials namely wood, steel and aluminium for their supporting and load-bearing constructions. They still have a role to play and have specific strengths, among other things, accommodating high loads and large-scale applications. During the development (and for some time previous to this), PERI took into consideration the option of engineering plastics which allow much greater freedom in the design and, with the correct selection of materials, their physical properties can be tailored very precisely to match the field of application.
For the vast majority of the components of the new DUO formwork system, PERI uses a specially developed fibre-reinforced plastic which is resistant to moisture-related swelling and shrinkage, corrosion-proof and problem-free when coming into contact with concrete. The required mechanical properties can be adjusted through variable fibre content in the system components. Regarding the intended load-bearing capacity, significant weight savings are achieved as a result of using the plastic compared to steel or aluminium constructions. In addition, any minor damage to the surface of the formlining manufactured of the same material can easily be repaired. The formwork panels are matched to the size of the panel and can be quickly replaced on site using simple tools.
The fact that the components are so light is noticeable in many aspects. In the first instance, of course, with the handling: no part is heavier than 25 kg, and even two DUO panels connected together for standard wall heights of 270 cm, and weighing 53 kg, can easily be brought into position by two persons. Lightweight components make the handling easier, reduce the physical strain while simultaneously reducing the risk of accidents significantly. In terms of transport and logistics, fewer moving masses are involved and no equipment or cranes with high payloads are required – thus reducing energy and equipment costs.
PERI´s declared aim was to develop the individual system components for a broad range of applications. The components have been designed so that they can be very flexibly combined and used for different tasks. In this case that means: with DUO, walls, slabs and columns can be formed using the same components. More than two-thirds of all system components can be used for horizontal and vertical applications. The numerous identical parts for horizontal and vertical use not only provide an integrated operating and assembly logic, they also ensure procurement costs and storage space remain considerably smaller than is the case of separate formwork systems for walls and slabs. Sample invoices show that, with a smaller amount of standard equipment for forming walls, only around 20 % more investment is required in order to also realize slab formwork with the system – including tie technology, push-pull props and slab props, brackets and guardrails.
Just as important to the developers was to take advantage of the high degree of freedom with respect to design and shaping that the manufacturing process provides. As a result, there is only one connector for all components, the posts for the external and internal corners are identical, the push-pull prop connector also functions as the connection for the guardrail posts and serves to secure the bracing for the slab formwork.
A few years ago, PERI set a new standard in the market with the introduction of the MAXIMO Panel Formwork with ties inserted from one side only. Further development of the system is an on-going process as can now be seen at bauma 2016. System enhancements for MAXIMO form one of the focal points of PERI´s presentation in the wall formwork segment.
PERI MAXIMO has become a synonym for efficient forming operations. The single-sided tie technology contributes a large part to the significant time-savings that can be realized with MAXIMO. The well thought-out range of accessories extends the application possibilities and supports the special quality requirements with which the high-end formwork competes in its segment.
For large floor heights in high-quality residential construction projects or, for example, in underground garages larger formwork frame heights save time. MAXIMO Panel Elements, Multi-Purpose Panels, Inside, Outside as well as Shaft Corners are therefore now available in the new heights of 3.00 m and 3.60 m. Only 2 anchors are required for a panel height of 3.00 m while the MX 18 Anchor System is used for wall thicknesses up to 60 cm.
With the Bracket System MXK, the MAXIMO and TRIO formwork systems have been enhanced by the addition of a modular working platform. The bracket is mounted on horizontally-positioned formwork. Assembly of the lightweight and therefore easy to handle system components such as decking with or without access hatches, stopend rails and side mesh barriers, guardrail posts as well as solutions for internal and external corners is carried out without tools. Only those who prefer conventional planking and boards as decking must allow more time for correct installation using screws or nails. PERI provides this option in order to give the user freedom of choice and to offer an alternative depending on the availability on the construction site. Complete assembly on the ground including the securing devices results in a safe working platform in compliance with health and safety regulations immediately after placing the formwork. PERI also offers the Scaffold Bracket MXK in a version with an integrated push-pull prop connection that, depending on the formwork assembly, might otherwise project into the working area on the platform and thus present an obstacle for the construction crew.
Likewise new in the programme is the Concreting Platform MX featuring a practical robust construction of galvanized components and a stable surface comprised of a steel grating. The 2.40 m x 1.00 m covering has an integrated safety catch and guardrails can simply be folded down for storage and transportation.
Instead of stopend ties, walers and wingnut counterplates, stopends from 15 cm up to 40 cm can be immediately closed with the stopend waler. The waler can be continuously adjusted for walls ranging from 15 cm to 40 cm, and can be used with both MAXIMO and TRIO elements.
In order that users can continue using MAXIMO in climatically unfavorable areas with prolonged cold spells, PERI has developed the electrically-operated Heating Element MXH. The dimensions have been matched to suit the MAXIMO formwork elements and are available in the standard dimensions of 2.70 m and 2.40 m high or 1.20 m wide with 2 extension panels respectively.
Installation of the heating elements is carried out horizontally. Recesses and detailed solutions ensure that all functions of the MAXIMO formwork elements remain unrestricted. The use of BFD Alignment Couplers, assembly of the Scaffold Bracket MXK and the use of MX Tie Technology is also possible with mounted heating elements. Attaching the heating elements takes place horizontally and requires only two screws at each corner. The adjustable temperature range for heating operations is +20° C to +80° C.
Powder coating on the outside and galvanized insides of the frames have already provided very high level of corrosion protection and easy cleaning of the MAXIMO panel elements. A new addition is CAVITIX, a cavity sealing option for the inside of the frame construction. Through the protective film inside the frame, humidity and condensation can also no longer attack this particular area.
With the development stage now reached and presented at bauma 2016, the claim that PERI MAXIMO is one of the most comprehensive systems for high-end formwork on the market has been confirmed once again. Independent measurements confirm the efficiency and economical working operations with MAXIMO.
In many areas of formwork technology, PERI already relies on modular solutions. The lightweight Bracket System MXK bears on the principle in order to realize safe working platforms on MAXIMO and TRIO formwork elements. Through the modular design, customized configurations are possible.
A bracket alone is not a working platform but it does define what is actually possible. The PERI Scaffold Bracket MXK is hooked into the struts of the horizontally-positioned MAXIMO or TRIO panel formwork without requiring tools while still on the ground and forms the basis for any configurations depending on the particular requirements and the availability of materials on the construction site.
Apart from the scaffold bracket itself, the MXK system also includes scaffold decks with working areas made of steel or coated wood along with side mesh barriers lengthwise to the panel formwork. The lengths of the platforms are adapted to suit the standard widths of the MAXIMO and TRIO panel formwork elements in each case whereby the decks are also available with access hatches for multi-storey structures. For those who prefer to work conventionally with wood can nail or screw wooden planks to the bracket to form the decking. With PERI Guardrail Posts, not only can the PMB Side Mesh Barrier be used but also simple boarding. For open edges and transitions to adjacent working platforms, PERI offers swivel-mounted end guardrails. An interesting additional detail: the MXK Bracket is also available in a second version complete with an integrated Push-Pull Prop Connection. As a result, the push-pull props do not project into the working areas on the platforms. This not only keeps all ways free of obstructions but also increases working safety. The system is rounded off by means of an adapter for the internal corners, decking for external corners and a filler platform for length compensation.
After installation of the scaffold bracket, the remaining components are also mounted on the ground. The scaffolding platform is simply hooked in followed by the side mesh barrier and end guardrails, or according to the required set up arrangement of the guardrail posts. The only physical effort worth mentioning is required for mounting planks as the work surface if wood is the preferred material for the decking. The entire pre-assembly procedure on the ground is carried out without a crane whereby the components can easily be brought into position manually. After installing the formwork, the working platforms remain mounted on the formwork elements throughout the entire construction-site operations.
Simple craneless pre-assembly on the ground and the complete system provide advantages when dealing with the workload as well as for work safety. Those using MAXIMO and TRIO formwork systems also save on investment costs because the MXK system is compatible with both.
Building with concrete is still a climate-related task. Especially in those regions with a long cold season, PERI now ensures that concrete construction operations can be carried out regardless of the outside temperature. With the MXH Heating Elements, MAXIMO can now be expanded to provide a high-performing and efficient Heated Formwork.
In the Scandinavian countries and elsewhere, outside temperatures impose natural limits on concrete construction. The hydration requires temperatures that remain stable above a certain minimum value. PERI now provides a cost-effective way for the MAXIMO formwork system to create an ideal micro-climate for concrete components. The required heating element for this is called PERI MXH.
The heating elements are available in the standard heights of 2.70 m and widths of 2.40 m and 1.20 m; furthermore, there are four matching extension elements with heights of 1.20 m and 0.60 m. Recesses for BFD Alignment Couplers for connecting the formwork elements and Scaffold Brackets MXK are integrated so that the full functionality of MAXIMO, including the use of MX Tie Technology, is maintained even when using the MXH. The heating elements are mounted horizontally on the corresponding MAXIMO formwork elements while fastening takes place by means of a pair of screws for each corner. The power supply is provided by a countersunk notch for electrical connection.
During operations, a set-point temperature control in a range from +20 °C to +80 °C is possible. As a result, PERI has thus expanded the MAXIMO formwork system to a system for all seasons which is certainly interesting not only for colder regions but also for time-critical projects that have to be realized in shorter winter periods in temperate climate zones.
SKYMAX is the name of the new slab formwork from PERI presented at bauma 2016 and the performance profile is very impressive. Achieving more with only the minimum of components and, in the process, ensuring ergonomic and safe work operations were the mission of the development team. This resulted in a system completely mounted from below with a particularly flexible prophead – mission successful. One of the main features of SKYMAX: a single prophead is sufficient as it can be used in all positions.
The essential characteristics of SKYMAX initially seem unspectacular. Standard formwork panels have dimensions of 1.00 m x 2.00 m, and can be used with PEP Ergo Props up to a height of 3.50 m, even higher with the grid-compatible PERI UP Flex Modular Scaffolding. With the usual support, 30 cm thick slabs and evenness in accordance with Table 3, Line 7 of the relevant DIN 18202 can be realized whereby slab thicknesses of 55 cm are possible through additional props under the panels in the centre. However, taking a closer look reveal the details of the construction along with the simple handling during assembly and dismantling of the formwork as well as the easy realization of slab tables with a minimum of effort.
Formwork assembly always takes place entirely from below. The panels are swivelled upwards one after the other and then supported. The users always remain in the safest possible position, namely on the installation area – a clear benefit regarding work safety. In the same way, that is to say from below, compensation elements and the SKYMAX Guardrails are installed, which are likewise mounted on one side and then swung into position. The formwork can subsequently be safely accessed. The support itself shows another interesting detail. Due to the special shape of the prophead and the interlocking feature of the panel construction, changes in the installation direction as well as and moving the panels against each other are easily possible. One and the same prophead can be used for all relevant positions – at panel intersections, directly on rising walls and in corners or for a centrally-positioned prop of adjacent panels. Even when changing the direction of the panels, no other prophead is required.
In addition to the standard SKYMAX Prophead, PERI offers a drophead which allows early striking. A longitudinal beam for a prop grid arrangement of 2.00 m x 2.00 m supplements the system. And with an additional beam, panels can be mounted on site to form slab tables of up to 4.00 m x 6.00 m. This is a particular advantage as in this way slab tables can be quickly realized as needed and with an absolute minimum of effort and costs, and only minimized transportation and logistics costs.
Restriction to functionally practical components is not only highlighted through the example of the universally applicable prophead, it also continues throughout the entire system. This relieves storage requirements, logistics and the cost balance. More workplace safety, workload reduction through the swivel-type assembly and manageable range of components are good arguments why SKYMAX is worth taking an even closer look at.
They are increasingly being seen more often: spectacular buildings featuring freeform architecture which, through a clear design language, places extremely high demands on the formwork technology. The new design possibilities are based on 3D drawings that can work together with freeform contours.
In recent years, PERI has planned and manufactured freeform formwork for a number of outstanding reference projects of renowned architects. The Stuttgart Mercedes-Benz Museum from Ben von Berkel, London Aquatics Centre from Zaha Hadid, or the Museum of Tomorrow in Rio de Janeiro designed by Santiago Calatrava are just a few examples where PERI contributed to the success of the projects.
Buildings with curved structural elements in all directions can only be realized with customized special formwork. PERI engineers plan this architecture-specific formwork units on the basis of a 3D model. During the planning, the conformity between the architectural model and formwork unit is checked again and again on the basis of photo-realistic, three-dimensional images and simulations. In the process, PERI integrates the highest possible proportion of cost-reducing system components even during the development of these unique pieces. One of the particularly difficult challenges often involves the precise arrangement of the subsequently visible joint and tie configuration. Here, the required steps of the formwork assembly on the jobsite are always precisely taken into consideration. As a result, the 3D formwork sections can be pre-assembled as special formwork at the factory with millimetre accuracy and subsequently put together on the construction site in a similarly straightforward way as for standard systems.
For such challenges, PERI has developed an extensive portfolio of services: from 3D planning, cut-to-size formlining and the assembly of complex formwork units through to just-in-time delivery. The diverse international project experience has led to a high level of detail and standardization in the execution of such formwork projects which offers PERI customers a large number of advantages. This ranges from larger element sizes, improved element connections, higher permissible concrete pressures and concreting heights through to visually pleasing joint-free element transitions.
The latest PERI freeform formwork project is the V & A Museum of Design in Dundee, Great Britain, which has been designed by the Japanese architect, Kengo Kuma. Currently, over 3,000 freeform formwork units are being planned at the company headquarters in Weissenhorn and produced in the formwork assembly facility. At bauma 2016, PERI will be providing insights into the design of such freeform formwork.
Surface appearance is one of the key elements for architectural concrete. PERI now provides two options in one and the same formwork panel sheet. Matt or glossy: only a matter of the assembly.
High demands mostly require special solutions. With the FinPly Maxi large-sized formwork panel – presented for the first time at bauma 2016 – PERI offers an attractive cost-effective solution that combines two contrasting fields of application in one product.
What has been previously only been available in smaller formats, has now been transferred by PERI to larger surfaces: manufactured from high quality and strong plywood material, the FinPly Maxi features the absorbent wood surface of the base material on one side while the other side is smoothly coated with phenolic resin. Depending on the assembly, this results in a matt or glossy finish after striking.
As areas of use, PERI provides for applications with particularly high requirements regarding architectural concrete with large concreting widths or heights, or large-dimensioned freeform formwork units. Element transitions can be smoothly realized with the new large-sized formwork panel producing an attractive finish, a quality criterion in particular for special architectural objects where the image factor plays an important role.
The dual application possibilities of FinPly Maxi makes the new development from PERI a good investment – acquisition and storage costs are thus significantly reduced due to the different surfaces.
The new prop family, PEP Alpha, is classified as Class D in accordance with EN 1065 whereby the two prop types, PEP Alpha D-300 and D-350, cover around 80 % of the usual range of applications for steel tube props according to PERI´s own market observations.
The D-300 version reaches extension lengths of 1.80 m to 3.00 m while the larger D-350 model covers the 2.00 m to 3.50 m range. The required load-bearing capacity according to EN 1065 Class D is maintained through to the full extension length and significantly exceeds this with smaller extension lengths. For the PEP Alpha D-300, PERI confirms a load capacity of up to 41.4 kN, with up to 37.5 kN for the D-350. These are exceptional practice-oriented values which show a very positive increase compared with the norm. In comparison with the proven PEP Ergo props, also from PERI, the PEP Alpha props have a more simple design. They do without, among other things, details such as the possibility to repair the prop in favour of a more favourable price.
The PERI UP Flex Shoring Tower MDS shares its best features with the PERI UP Flex scaffolding system: it can be assembled extremely quickly and offers a high level of constructional safety for users. With a new head frame, it is even more versatile.
Since it was unveiled three years ago, the PERI UP Flex Shoring Tower MDS has proven itself in many applications. With significant weight savings, it is exceptionally light compared to conventional constructions with a similar range of applications. No component weighs more than 16 kg which saves the energy of site personnel and significantly improves the otherwise very strenuous manual handling.
In addition, the erection procedure is simplified through the special assembly logic. The decks are transported upwards on the inside, i.e. in the area of the shoring tower already protected, and then mounted on the respective higher-positioned ledgers without tools from a safe working position. Following the same principle, the guardrails are mounted in advance from the lower level in each case. As a result, every new level is already secure before it even being accessed. The reduced weight and assembly without tools accelerate assembly and dismantling significantly.
With an extended range of accessories, PERI has opened up new areas of application for the PERI UP Flex Shoring Tower MDS. The most important new component is the new Head Frame MDS 150 which has allowed the MDS standard grid to be extended from 1.25 m to 1.50 m. This means the MDS can be used under formwork systems with larger grid dimensions, e.g. SKYDECK slab panels or slab tables. In addition, a new head spindle is now part of the product portfolio. For ensuring fast horizontal moving, a new connection for the Shoring Tower MDS is available which serves for mounting the proven transportation wheel from the PERI programme.
A weather protection roof makes the jobsite more independent of weather and precipitation but it is not always easy to use and also very often subjected to high operational demands.
PERI has been working on the solution – with a motor and heating. The PERI Weather Protection Roof LGS on the basis of the LGS Lattice Girder System has long since found its place in many construction projects as a lightweight construction with large spans and safe operability. The advantage of having a large-sized cover, however, makes planning difficult and unwanted loads such as snow and ice to a potential problem. For winding and unwinding the sheeting, PERI now offers with a solution complete with an electric motor which significantly simplifies the operation. A concept for heating the keder sheeting will also be presented: integrated heating wires ensure that snow accumulation is avoided during the colder season.
