Flexible and compliant use of ALFIX facade scaffolding system and ALFIX MODUL MULTI modular scaffolding system
Both the facade scaffolding and the modular scaffolding from ALFIX are characterised by their very high load-bearing capacity attained by using high-strength construction steel and implementing sophisticated product details. Among other things, our clever design reduces the wall thickness which allows for the construction of lighter scaffolding components, which decreases the dead load of the scaffolding and offers the scaffolder greater flexibility – even for tall, slim constructions such as smokestacks. Thanks to our well-thought-out solutions, traffic loads are sometimes better able to be distributed since the dead weight is comparatively lower than with standard scaffolding solutions despite the overall height. Less tonnage is moved with the same handling, which provides a benefit to the user.
The scaffolding of smokestacks for the purposes of renovation, demolition, or reconstruction (for example, as a transmission mast) is constantly in demand in Germany and internationally, and is one of the tasks that is handled by the ALFIX project team. Whether preparing visualisations as technical drawings or as 3D CAD models, creating parts lists, or developing verifiable structural analyses, the ALFIX technical team provides comprehensive and detailed preliminary planning right through to the preparation of the assembly plans.
Total renovation of a smokestack in Switzerland
For this project, a smokestack at the energy centre on Josefstrasse in Zurich was scaffolded by Albfix GmbH using the ALFIX facade scaffolding system. With a height of approximately 77.0 m, some individual bays were arranged radially on the structure which has a diameter of 8.50 m. Due to the modular division of the bay lengths in 0.50 m grid dimensions, the choice was made to use 12 bays measuring 2.07 m (W06, LK3) using steel floors, which would perfectly align with the curved shape of the smokestack. The inner and outer posts of the assembly frame were connected every 2.0 m using tubes and couplers to create extremely durable tension rings made of scaffolding components. When combined with the anchoring, tension resistant and pressure resistant anchors were formed to absorb the resulting wind loads and forces and transfer them into the construction. Due to the smokestack’s great height and the resulting dead load and wind loads, the anchoring points were planned and implemented using injection anchors according to the project-specific structural analysis. An external stair tower constructed using aluminium platforms was included to enable comfortable access to the different levels.
Smooth dismantling of a smokestack in Finland
For the dismantling of a smokestack at a hospital in Kiljava, Finland, scaffolding was erected by the company SUOMI Teline OY. Since the diameter of the stack measured 2.80 m, it could easily be enclosed using the ALFIX MODUL MULTI 4.0 modular scaffolding system in system lengths of 3.07 m. Due to the narrow diameter of the smokestack, a square design using W09 components was used. An external stair tower with aluminium platforms was required, planned, and constructed in order to enable comfortable access to all working levels of the 38.0 m high construction. Since the anchor base of this stack was masonry, it was necessary to carry out structural analysis measurements and installation of injection anchors every 2.0 m in the corner areas to ensure secure and reliable anchoring. The cylindrical design of the building paired with square scaffolding resulted in small uncovered areas in the corners, which were then bridged using the appropriate ALFIX steel decks with integrated lift-off protection in order to provide a safe access for the trades.
Efficient smokestack removal and restoration in Thuringia
Instead of a complete demolition or a comprehensive restoration, in practice smokestacks are occasionally partially dismantled, followed by an overhaul of the remaining stack. Such was the case with this project in Thuringia, Germany. Commissioned by the Thuringian State Office for Building and Transport, the scaffolding company Gothaer Gerüstbau scaffolded the 42.0 m high smokestack in Nordhausen which had a diameter of 3.70 m which tapers towards the top. In addition to the stable W06 working scaffolding, certain levels were equipped with stable load-bearing platforms in order to enable the materials to be easily loaded, and for the efficient removal of demolition materials from the site using a crane. The load-bearing cantilevers or load platforms using U-ledgers and standards were designed to meet the client’s requirements. Depending on the installation direction of the diagonal braces (upwards to transfer the tensile forces, downwards to transfer the compressive forces), different traffic loads can be assigned to the load levels. Anchoring was provided in the subsoil at 4.0 m intervals in the node areas using suitable injection anchors.
Detailed structural design proof was provided for all projects, as the construction heights for these projects deviate from the standard system configuration. As well, the condition of the subsoil significantly influences the stability and the load-bearing capacity of the scaffolding construction. Parts lists are always generated in collaboration with the client, taking into account the client’s existing components, which not only enables efficient planning but also facilitates practical implementation. This holistic approach ensures both the safety and stability of the construction, while providing a targeted focus on the specific requirements of each client and each construction project.