Roof renovation of the Dresden Central Train Station using ALFIX MODUL MULTI 4.0
After nearly three years of intensive planning, technical support, and logistical coordination, a demanding scaffolding project has been successfully completed: the extensive scaffolding erected for the roof renovation of Dresden Central Station. In close cooperation with the scaffolding company Bindig Gerüstbau GmbH and the executing construction company PFEIFER Structures GmbH, a complex scaffolding concept was implemented that was required to take into account the ongoing train operations and daily public traffic at all times.
Dresden Central Train Station is one of the most important transport hubs in eastern Germany and is particularly known for its striking hall construction. As part of a comprehensive modernisation in the early 2000s, the building received an impressive roof structure designed by the British architect Norman Foster, which includes a translucent membrane made of PTFE-coated fibreglass fabric which spans the historic steel truss girders from the 19th century. This light-permeable roof connects the historic listed building with modern engineering architecture, and continues to characterise the station’s appearance.
At the same time, the structure places specific demands on maintenance and regular upkeep. After many years of operation, age-related wear and tear become apparent, especially in the drainage areas of the membrane. Weather conditions, in particular harsh winters, had placed additional strain on the roof membrane. With this in mind, a comprehensive renewal of the roof membrane was carried out, in which the existing areas were gradually replaced and further developed. New structural details and additional skylights are intended to ensure that snow and ice loads can be removed more effectively, and that the roof remains winter-proof in the long term.
Technical support and regional cooperation
From on-site coordination and site measurement surveys to structural planning, detailed 3D modelling, and short-term material requirements planning, ALFIX GmbH provided technical support for the scaffolding project throughout the entire construction period. The company’s physical proximity to the site enabled particularly close project management and rapid response times when reacting to changing requirements on the construction site.
In close cooperation with Bindig Gerüstbau GmbH as well as the executing construction company PFEIFER Structures GmbH, economical solutions were developed to enable the renovation work to be carried out during ongoing railway operations.
The comprehensive plans in IFC format were the basis of the scaffolding planning, which detailed the complex roof geometry of the station hall in particular. However, all areas where the planned scaffolding was to be erected within the station hall needed to undergo precise surveying and digitisation on-site. This involved taking numerous elements—such as benches, vending machines, cashpoints, waste bins, and display boards—into account when planning, as the intention was to avoid dismantling existing fixtures for the renovation work. This detailed inventory was crucial to prevent collisions early on, and to precisely adapt the scaffolding structures to the specific conditions of the site.
One particular challenge was posed by the organisation of the construction process. Many scaffolding sections were only able to be erected at night or on weekends, when train services were restricted or suspended. At the same time, storage space around the train station was severely limited, which resulted in material deliveries often needing to be made at unusual times and with precise coordination. Despite these complex circumstances, all project participants succeeded in completing the individual construction phases on schedule.
Versatile scaffolding solutions for diverse requirements
The scaffolding structures primarily served the purpose of roof renovation, however other functions were also fulfilled, such as: working and service scaffolding for roof work, support scaffolding and platforms for material storage, facade scaffolding on the exterior as protective scaffolding and fall protection, and emergency stairs and access systems for escape routes and site access.
The robust ALFIX MODUL MULTI 4.0 modular scaffolding system proved particularly well-suited to the diverse requirements of the scaffolding structures at Dresden Central Station due to its high flexibility. This system stands out with its high load-bearing capacity, flexible grid dimensions, as well as its quick and safe assembly. The construction is based on technically sophisticated prefabricated components that are combined in a modular system using U-shaped ledgers and tube ledgers along with vertical standards. This enables a high performance to be achieved by a small component size, which significantly simplifies transport, handling, and assembly on the construction site. Thanks to screwless connections, the scaffolding can be assembled easily and economically. The metric system provides a particular advantage, with lengths and widths in 0.50 m increments and modular panels spaced at equal intervals, allowing for a precise adaptation to different building shapes. In combination with diverse connection options and systematically combinable bay widths from 0.36 m to 3.07 m, even complex spatial structures can be implemented economically. This provides a decisive advantage in projects with demanding spatial needs, as was required at Dresden Central Station.
Funnel-shaped scaffolding in the station hall
One of the most technically demanding tasks involved scaffolding the so-called “funnel-shaped” drainage areas within the station hall. Each of the supporting structures of the hall’s arches includes a funnel-shaped drainage point in the roof membrane. In order to renovate these areas, each column had to be scaffolded with specially designed funnel-shaped scaffolding.
Several constraints had to be reliably taken into account. The train tracks themselves had to be integrated into the planning as a contact area, while at the same time adhering strictly to the prescribed track closures. Simultaneously, the severely limited contact areas required a precisely coordinated and economic scaffolding concept. In addition, the complex steel truss structure of the hall’s construction placed high demands on the planning and execution, which were successfully met through a tailor-made technical solution. Finally, the required scaffolding volume was achieved by special cantilevers using MODUL brackets and MODUL lattice girders. For each individual funnel-shaped scaffold, detailed 3D planning was carried out beforehand in order to identify material requirements, penetrations, and collisions early on. The design of the funnels-shaped scaffolds in load class 3, with a permissible surface load of 200 kg/m², ensured the necessary load-bearing capacity and safety. Due to the work being carried out while train traffic continued, all structures were fully clad with protective netting in order to guarantee maximum safety for operations and personnel.
Pedestrian tunnel to ensure safe foot traffic
Extensive safety measures were also required outside the station hall. In the course of planned crane operations, there was an increased risk of falling loads, particularly on the south side of the train station. For the effective protection of pedestrians, a pedestrian tunnel approximately 100.0 metres long was constructed. This tunnel was also carried out using the further developed ALFIX MODUL MULTI 4.0 system and was designed and built with a clearance height of 2.30 m and a comfortable width of 2.50 m. The tunnel ran parallel to the station building and ensured safe access to the station hall and the adjacent shops at all times. In this way, foot traffic was ensured in a reliable and highly safe manner throughout the construction phase.
Gable scaffolding as suspended structures
Another multi-faceted planned construction phase involved the gable areas of the side halls, in particular the gable of the large central hall. Here, scaffolding was designed as suspended scaffolding, some of which was affixed to steel cables in the end phase, while others were securely fastened to the support structure using lashing straps during pre-assembly. In order to not exceed the defined suspension points with the permissible loads, the tensile forces of the steel cables had to be measured using special measuring instruments and adjusted accordingly to maintain a continuous load distribution on the steel structure. These scaffolds served primarily as fall protection for the roof workers. The uppermost level was accessible and was also designed for load class 3 (200 kg/m²). Since all structures had to be entirely enclosed with netting, especially due to the high volume of foot traffic, additional horizontal loads resulted. These were specifically concentrated at the base and top, and transferred in a controlled manner into the support structure using vertical system-free lattice girders. In this way, the delicate glass surfaces of the hall arches could be protected effectively, while at the same time ensuring that the highest safety standards were met.
Load platform for assembly work
For the assembly of the central large gable scaffold, an additional load-bearing platform was erected as a temporary support structure on the roof of the central hall (not shown). A particular challenge was in creating a substructure which could reliably retain the permissible surface load of 200 kg/m². With the help of the space-oriented modular scaffolding ALFIX MODUL MULTI 4.0, a generously-sized platform was able to be constructed, with which the concentrated loads occurring during crane lifting were evenly distributed across the roof. Numerous system-independent lattice girders in longitudinal and transverse directions, as well as additional vertical diagonals with broad levelling plates, ensured that high point loads were avoided. A further challenge was that existing air conditioning and ventilation systems in the roof area had to be built over. Thanks to close coordination between scaffolding company, construction trades, and testing engineers, it was possible to implement a technically sophisticated and economically efficient solution.
Freestanding stairway towers as escape routes
For the roof work, safe escape and rescue routes had to be provided at appropriate intervals in order to ensure rapid rescue in case of danger and to provide accessibility to all work areas. For this purpose, a total of six stairway towers were planned and constructed. Due to the historic building structure of sandstone and steel, the structure could only be minimally attached to the building itself, resulting in the need for some stairway towers to be partially freestanding. The upper level of each tower was extended to become a rescue platform, on which a stretcher was placed for emergencies. To prevent unauthorised access, the stairway towers were constructed as closed structures up to a height of approximately 4.0 metres. Each stairway tower was planned individually, to optimally consider features such as passageways, delivery zones, and pedestrian flows, while simultaneously ensuring safe and functional access.
Successful completion of an extraordinary project
The completion of the construction work marks the end of a project that presented significant technical and organisational challenges. The combination of precise digital planning, innovative scaffolding technology, and close collaboration between all project partners made it possible to safely carry out construction works on one of the most significant transport buildings in Saxony during ongoing railway operations. The ALFIX MODUL MULTI 4.0 modular scaffolding system once again demonstrated its strengths: high adaptability, efficient assembly processes, and reliable load-bearing capacity, even for extensive construction projects.
The ALFIX Technical Team provides competent and practical support for its clients. Using structural calculations, 3D visualisations, as well as the creation of detailed assembly plans with the corresponding parts lists, we can guarantee a safe and efficient implementation. Individual inquiries regarding construction projects can be submitted at any time using the Contact section of the ALFIX website.