Free-standing UNIFIX facade scaffolding supports a demanding construction process
Sophisticated scaffolding solutions were required for the construction of a new large-scale production hall for serial timber construction. For a hall measuring approximately 40.0 x 140.0 m and with an eaves height of 12.0 m, working and safety scaffolding needed to be erected in multiple construction phases.
The particular challenge was that anchoring was only possible in the area of the base plate or foundation. This required an economical yet structurally sophisticated solution for the free-standing scaffolding structures with a platform height of up to 14.0 m.
Selected for this project was the user-friendly UNIFIX facade scaffolding system from the scaffolding manufacturer ALFIX from Saxony. This system is available in both aluminium (Z-8.1-997) as well as steel (Z-8.1-947) and is approved by building authorities. The modular system proved to be the convincing choice thanks to its high degree of flexibility and its well-designed, tool-free modular connection system. These features allowed the scaffolding to be extended quickly, cost-effectively, and with a particular focus on user needs, adapting to the specific requirements as construction progressed.
Well-designed structural concept for maximum structural stability
The free-standing working scaffolding was designed by the ALFIX project team as a recurring basic construction structure and erected by the executing contractor HEPP GmbH after the start of construction. Two bays, each 3.0 m wide, were combined with a transverse support bay of the same width. This support bay was connected to the outer standards of the facade scaffolding at intervals of 4.0 m using scaffold tubes. This produced a compact, load-optimised triangular structure that safely transferred wind and traffic loads via short lever arms.
UNIFIX steel assembly frames were used in some of the heavily loaded support towers, while the actual facade scaffolding was constructed nearly exclusively using aluminium components. This material-optimised construction ensured high load-bearing capacity while simultaneously reducing dead weight, resulting in a significant economic advantage in terms of transport, logistics, and assembly.
Construction process optimally supported
The scaffolding was continuously extended in three phases which corresponded to the progress of the construction project. In the first phase, the scaffolding was erected completely free-standing on the gable and along approximately 40 metres of the hall facade. This was necessary to allow large-scale timber components to be lifted into place and installed by crane without obstruction. The open scaffolding structure facilitated a smooth construction process and enabled an efficient installation of the facade elements.
In order to ensure the uninterrupted construction process, hall doors and large building openings were bridged using system-independent aluminium lattice girders and kept permanently clear, allowing for material transport and operations inside the hall to remain unrestricted throughout all construction phases.
Intelligent ballasting for each construction phase
Particular attention had to be paid to the structural stability analysis of the free-standing structures. Depending on the stage of the construction, it was necessary to consider different load cases: from the entirely free-standing scaffolding to the open facade, and finally to the later closed building facade.
The ballasting was, therefore, individually tailored to the requirements of the respective construction phase. A total of approximately 60 tonnes of ballast was used, consisting of concrete weights and IBC containers. The weights were placed partly directly within the facade scaffolding and partly within its extended support bay. This differentiated planning allowed for the economical optimisation of the required ballast quantity while simultaneously ensuring a high level of safety.
Safe access throughout the entire construction site
To ensure safe access to all work areas, a total of eight identical stairway towers were assembled. The construction, composed entirely of aluminium components including UNIFIX platform stairs, corresponding UNIFIX assembly frames and handrails, met the requirements of the Technical Rules for Operational Safety (TRBS) which stipulate that safe access must be provided at least every 50 metres.
A total of 47 stair flights provided safe and convenient access to all levels. The scaffolding was further equipped with approximately 2,100 linear metres of internal guardrails and a roof edge protection scaffold to safeguard workers during operations in the roof area.
Collaborative planning, efficient execution
The scaffolding concept was developed in close collaboration between the executing contractor HEPP GmbH and the ALFIX Technical Department. As early as in the planning phase, the structural concept, simulated using drawings and 3D visualisations, the construction sequence and the structural stability verifications were meticulously coordinated. In particular, the varying construction phases ranging from free-standing scaffolding to open and finally fully enclosed building facades, required precise structural analysis and ballasting planning tailored precisely to the progress of construction. The result was a technically sophisticated and cost-effective scaffolding solution that met the project’s specific requirements at all times.
With a total scaffolding area of 6,510 m², 8 stairway towers, 47 stair flights, approximately 2,100 linear metres of internal guardrails and 60.0 tonnes of installed ballast, the construction project impressively demonstrates the performance of the UNIFIX facade scaffolding system.
The combination of lightweight, high load-bearing capacity, a well-designed modular system, and a tool-free connection system enabled efficient assembly and flexible adaptation to the construction progress. At the same time, the high aluminium content significantly reduced logistical effort, as the overall transport tonnage was able to be kept comparatively low despite the large quantities of materials required.
Inquiries regarding individual construction projects or special designs can be submitted directly using the contact form on the ALFIX website. The ALFIX GmbH team is available to provide consultation and support during the planning phase using drawings, 3D visualisations (see https://autode.sk/4pkYBUV) and material lists, as well as the preparation of structural stability analyses and the selection of suitable system components for the planned project.