Tapered Rectangular Conical Structure

Shin Seoncheong, South Korea – Tapered Rectangular Chimney

Global Chimneys Co. Ltd. hired Gleitbau GmbH of Salzburg Austria, to slipform this new chimney structure. The sliding operation was performed during 2017. The tapered rectangular shape makes for a unique and spectacular tower-like structure, made possible by the latest advances in slipform technology. The overall height is 148 m and the base dimensions of 20 m x 20 m taper off to 12 m x 12 m at the top. The wall thickness reduces from 0.90 m at the bottom to 0.35 m at the top.

Tapered Concrete Pier

Tapered Rectangular Chimney – Height of 148 m.

Gleitbau GmbH is a leading slipform contractor in North America and around the world, executing more than 100 slipform projects per year. The company was founded in 1961 and became an industry leader during the 1970s and 1980s through its offshore work in the North Sea. Gleitbau GBG typically supplies the slipform system, engineering, concrete mix design, geometry control and technical supervision, mostly to general contractors. Heavy lifting services are also provided, many times in conjunction with slipforming. For more information, please contact Michael Veegh.

Flour Silo by Vertical Slipforming

Saalemühle Alsleben GmbH – New Flour Silo

Alsleben a.d. Saale, Germany – General contractor Industriebau Wernigerode GmbH hired Gleitbau GmbH of Salzburg Austria, to slipform the new flour silo Nr. 3 for agricultural company Saalemühle Alsleben. The work was executed during 2015 and 2016. Constructed in two phases, the bulkier lower section was slipformed to a height of 19.49 m, followed on top by a more slender section slipformed to a height of 47.16 m.

Slipform construction of a flour silo

New Flour Silo Nr. 3 built for Saalemühle Alsleben GmbH.

Gleitbau GmbH is a leading slipform contractor in North America and the world, executing approximately 100 slipform projects every year. The company was formed in 1961 and became the industry leader during the 1970s and 1980s through its offshore work in the North Sea. Gleitbau GmbH typically supplies the slipform system, engineering, concrete mix design, geometry control and technical supervision, mostly to general contractors. Heavy lifting services are also provided, many times in conjunction with slipforming. For more information, please contact Michael Veegh.

LNG Tank

Port of Tahkoluoto, Finland

LNG Tank

LNG Tank slipformed by Gleitbau GmbH.

Finland’s first Liquefied Natural Gas (LNG) Terminal is being built by Skangas at the oil and chemical harbor of the Port of Tahkoluoto in Pori, on the west coast of Finland. The estimated completion date for the terminal is fall of 2016. Total LNG storage capacity will be 30,000 cubic meters.

LNG Tank

Tank during slipforming showing radial guide ropes.

The LNG tank has a final height of 35 m and an outside diameter of 42 m. The walls of the tank were slipformed truly round with the help of radial wire ropes coming together at the geometric center of the tank. Additional ground-based lasers ensured the tank was constructed true and vertical and also confirmed perfect roundness. By adding enough lasers around the perimeter, there were no deviations from perfectly round to speak of. This is an important step in achieving the desired accuracy in tank geometry. High precision is required in the wall geometry as the steel dome has to accurately fit the inside of the tank. These steel roofs are normally assembled on the ground and lifted in place with hydraulic heavy lifting techniques or with internal air pressure. Welders then attach the roof to a steel ring embedded in the concrete wall. A final concrete layer is poured over this steel dome to complete the tank structure.

LNG Tank

Steel roof being lifted into place.

The general contractor on the project is a partnership of Neste Jacobs Oy, KVL-Tekniikka Oy and FCC Industrial. Concrete subcontractor Destia Ltd. hired Gleitbau GmbH for slipforming the tank walls. Slipforming was completed in 2014. Safety during construction was a high priority and slipforming proved to be very safe once again, as during slipforming the formwork is supported at numerous points at all times and is never released from the structure below.

Gleitbau GmbH is a leading international slipform contractor, working in North America and around the world. Formed in 1961, the company executes 80 to 100 slipform projects every year. The typical scope of work includes the supply of the slipforming equipment, engineering, concrete mix design, geometry control and onsite supervision of the slipforming operation, mostly for general contractors. For more information please contact Michael Veegh.

Mill Building

Jazan B-Mill, Saudi Arabia

mill building with silos

Jazan B-Mill – Silos slipformed by Gleitbau GmbH

Shown here are two silos that form part of the Jazan B-Mill complex, a flour mill with attached silos that has a production capacity of 600 tons per day. The owner is GSFMO (Ministry of Agriculture of Saudi Arabia).

The general contractor for the concrete work was CEM Estero S.p.a. of Italy, operating from its offices in Riyadh. The contractor hired Gleitbau GmbH to slipform these two silos in late 2015. The slipform height was 28.3 m. Each silo shell was completed in under a week, by working around the clock, pouring concrete 24 hours a day.

Gleitbau GmbH is a leading slipform contractor in North America and the world, executing about 100 slipform projects every year. The company was formed in 1961 and became the industry leader during the 1970s and 1980s through its offshore work in the North Sea. Gleitbau GmbH typically supplies the slipform system, engineering, concrete mix design, geometry control and technical supervision, mostly to general contractors. Heavy lifting services are also provided, many times in conjunction with slipforming. For more information, please contact Michael Veegh.

Solar Tower

Negev Desert, Israel

Solar Tower

Ashalim Solar Thermal Station with 240 m Tower. Photo by Megalim Solar Power Ltd.

The world’s tallest solar tower at 787 ft will be built this year in the Negev Desert, Israel. 50,600 computer-controlled mirrors surrounding the tower will track the sun and point the energy to the top of the tower, where superheated steam will be produced for driving a turbine. When finished, the tower and mirrors will be able to produce 121 MW of power. The $800 million project is being built by a joint venture company owned by Brightsource Energy (25%), GE Alstom (25%) and NOY Infrastructure & Energy Investment Fund (50%).

The developer-builder of this project, Megalim Solar Power Ltd, hired Gleitbau GmbH to slipform the tower shaft to a height of 200 m. After that, the 2500 ton boiler will be added to complete the tower.

Gleitbau GmbH is a leading slipform company in North America and the world, executing from 80 to 100 slipform projects every year. The company was formed in 1961 and is active in most construction sectors. For more information, please contact Michael Veegh.

Silo Construction

Silo Work – Guacolda, Chile

silo

Slipforming of two silos in Guacolda, Chile – 2014

Guacolda power plant in northern Chile. Züblin International GmbH, Chile SpA hired Gleitbau GmbH to slipform these two silos, which are 40 m tall. They represent a typical application for slipforming technology. Recent advances in slipforming allow for much more complex shapes to be built, such as conical structures with parabolic curves from bottom to top.

Gleitbau is a leading slipform contractor in North America and the world, performing up to 100 slipform projects every year. The company was formed in 1961 and is active in most construction sectors.

silo

Silo shell completed by Gleitbau – 2014

Bridge Pylons

St. Petersburg, Russia

bridge pylons

Petrovsky Fairway Cable-Stayed Bridge, St. Petersburg, Russia

Pictured here are the bridge pylons for the Petrovsky Fairway cable-stayed bridge, which is a crucial link in the St. Petersburg Western High Speed Diameter Project. This is the largest PPP road construction project in the world today and the first urban high-speed toll motorway in Russia.

Elba Yaritim Sondazh Inshaat, the general contractor on this project, hired Gleitbau GmbH to slipform the two bridge pylons. The pylons are approximately 114 m tall with outside dimensions of roughly 5.0 m x 6.0 m per leg. The pylons were completed in 2014. Slipforming was chosen because of the speed of construction and the resulting structural durability, as the towers have no construction joints or form-tie holes.

Anchorage Area

The cable anchorage area required the installation of welded steel boxes, which nowadays is the preferred method for defining the intricate stay pipe and bearing plate geometry for each cable.

The slipform was stopped at the underside of the first welded box, to insert steel supports into the wet concrete. These supports were then used for leveling and orienting the box in relation to the bridge.

At that point, the inside form was abandoned and slipforming continued with the outside form only, which ran flush with the ends of the stay pipes. These pipes were cut at compound angles to match the concrete surface.

As the slipform climbed, steel boxes were added. Bolts were used initially for connecting and adjusting the boxes, followed by final welding.

This particular design anchored the stay cables inside the tower. No cable saddles were used. The entire pylon was slipformed at an average speed of 3m / day, including the anchorage area.

Gleitbau GmbH is a leading slipform contractor with projects all over the world, including North America. The company was formed in 1961 and completes between 80 – 100 slipform projects every year. The scope of work normally includes the supply of custom slipform equipment, engineering, geometry control and supervision of the slipforming operation. For more information, please contact Michael Veegh.

bridge pylons

Bridge pylons being slipformed

Cable Car Towers

Cable Car Transportation Complex, Vietnam

cable cars tower

Conical tower slipforming with 15 degree incline, by Gleitbau GmbH.

Shown above are the three-legged towers for the Queen Cable Car aerial tramway installation in Ha Long, Vietnam. This record-setting cable car system is part of the Ocean Park Project in the Bai Chay area. The project aims to boost tourism in Ha Long Bay.

Completed in 2015, the aerial tramway sports massive 230 passenger cabins and concrete support towers up to 185 m tall. The individual tower legs start out with a diameter of either 4.0 m or 5.0 m, tapering all the way to the top. They also maintain a constant wall thickness of 0.35 m along their height. The maximum inclination is 15 degrees from vertical.

To build the record-setting cable car towers, the owner and general contractor, Sun Group of Vietnam, hired Gleitbau GmbH for slipforming the conical legs of the towers. Gleitbau GmbH slipformed two towers with three legs each, and also provided the heavy lifting services required for erecting the precast strut triangles, which stabilize the tower legs.

Gleitbau GmbH is a world leader in slipform construction, executing between 80 to 100 slipform projects every year. They work all over the world, including North America, providing customized slipform equipment, engineering, geometry control and supervision to general contractors and owners. For more information, please contact Michael Veegh.

cable car towers

Conical tower slipforming and heavy lifting of precast strut triangles for stabilizing the tower legs.

High Rise Building Cores

High Rise in Paris, France

High Rise Construction

High Rise Construction – Slipforming of the Building Core – 180 m tall / 590 ft

High rise construction can greatly benefit from the use of vertical slipforming. Shown above is the new Palais De Justice currently being built in Paris, France. Most tall buildings have one or more concrete cores that provide lateral strength to the building. They also house the stairs and elevators. These cores can be rapidly built by using the slipform method of construction. Doorways and openings are easily added by inserting block-outs into the slipform as it rises. The above high rise core was slipformed by working day shifts only. However, slipforming is most efficient when working around the clock, 24 hours per day, using two or three shifts. Typical speeds are 3m to 5m per day, but up to 10m per day can be achieved if workers are well coordinated and not limited by material supply or concrete quality.

Slipforming is extremely safe, as the slipform setup always remains connected to the structure. The two work platforms provide a safe and predicable environment for the workers. The lower platform is used for finishing the concrete to the desired surface quality. Tarpaulins can also be suspended from the lower platform. These shield the fresh concrete from direct exposure to the sun and wind during the initial curing period.

Gleitbau GmbH was hired by Bouygues Travaux Publics of France to provide the slipform equipment and onsite supervision for this project, including geometry control. Gleitbau GmbH is a world leader in concrete slipform construction and works on projects all over the world, including North America. You can contact Michael Veegh for more information on slipform construction. Gleitbau will gladly provide a technical review and slipform pricing for your upcoming high rise project.

High Rise Construction

Close-Up of Slipform Equipment with Two Work Levels

 

Caisson Construction

Port of Piraeus, Greece

Slipformed Caisson

Slipformed caissons for the West Pier 3 expansion, Port of Piraeus, Greece – 2016

40 large concrete caissons were slipformed for the Port of Piraeus, West Pier 3 expansion project, just south of Athens. The individual caisson boxes were built on a large, semi-submersible barge. After slipforming was completed, the barge was lowered into the water and the caissons floated away to their final locations. The overall caisson dimensions are 24.8 m x 13.1 m, with a height of 19.5 m. The wall thickness varies between 0.3 m and 0.4 m.

Vertical slipform construction is eminently suited for offshore and marine structures because of the high degree of durability that can be achieved with the slipform process. There are no construction joints because slipforming is a continuous process that does not stop until the structure is completed. There is also no need for form ties and rebar bolsters when using this construction method, resulting in an extremely durable structure.

Gleitbau GmbH was hired by J/V Routsis S.A. – Tekal S.A. to provide the equipment and supervision for the slipform operation, including the geometry control. Work is expected to be completed in 2016. Gleitbau is an industry leading slipform company and works on projects all over the world, including North America.

Slipformed Caisson

Aerial view of the slipform operation, taking place on top of a semi-submersible barge.