USA ISSUE 02

RMD KWIKFORM EXPANDS OPERATIONS INTO USA

ALSO IN THIS ISSUE... CALIFORNIA RETROFIT, LOS ANGELES BRIDGE, PARASLIM, BASRA SPORTS CITY, CHIVAS BROTHERS AND SCUNTHORPE LEISURE CENTRE...

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EDITOR VIEWPOINT
Welcome to this, the second edition of Formula USA magazine, as Im sure you are all aware there have been some very exciting developments in the USA business since our last edition of this magazine Thanks to the extremely hard work and commitment of the team here, RMD Kwikform has acquired a significant foothold in the worlds largest construction market. The $35 million dollar acquisition of CMC Construction Services heavy forming and shoring assets represents one of the biggest opportunities and challenges in todays construction industry, and its a challenge the team at RMD Kwikform USA is very much looking forward to. The acquisition has given us a ready-made distribution network, customer base and an experienced sales team. The next step is to bring the RMD Kwikform experience, that our customers throughout the rest of the world are experiencing, to the USA. Building upon our existing relationships with international customers, and delivering the world class engineering support and custom product development we have become known for, will position us for success as we continue to build the business in North America. Building on our aforementioned strengths, combined with our global and local experience working with CMC Construction Services for the last five years, in the US market we will be concentrating on several key areas of business development; bridges, road and rail infrastructure, nuclear power, industrial and other key infrastructure projects such as airports and seaports. By delivering our proven world-class products such as Megashor and Alshor Plus, along with our vast engineering experience we will be able to meet and ultimately exceed the expectations of our customers in the USA. The challenge has indeed only just begun, but its a challenge I firmly believe we have the talent and experience to meet head on. In this issue of the magazine we look at two recent bridge projects in Los Angeles and Long Beach, California for you to read about as well as some interesting international projects we are working on from across the RMD Kwikform group. If you like these articles you can read more about our projects at http://formula. rmdkwikform.com/global/ or alternatively watch onsite video reports at http://www. rmdkwikform.tv/. Ill speak to you again in issue 3, until then enjoy the magazine John Richey USA Managing Director, RMD Kwikform

IN THIS ISSUE

USA EXPANSION

CALIFORNIA RETROFIT

LOS ANGELES BRIDGE

PARASLIM

BASRA SPORTS CITY

10

CHIVAS BROTHERS

12

WHOS WHO
EDITORIAL TEAM Editor - Roger Smith: roger.smith@rmdkwikform.com DESIGN AND PRODUCTION Edson Evers - Peter Haddock: peter@edsonevers.com

SCUNTHORPE CONTACT DETAILS

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WWW.RMDKWIKFORM.COM

UPDATE/USA AQUISITION

RMD KWIKFORM EXPANDS OPERATIONS INTO USA WITH $35m ACQUISITION

RMD Kwikform, the global formwork, falsework, safety and access provider, is pleased to announce that it has reached an agreement to acquire the heavy forming and shoring assets, including related distribution centers, of CMC Construction Services (CMC), a division of CMC Steel Fabrications, Inc., which is a subsidiary of Commercial Metals Company. The $35m acquisition enables RMD Kwikform to expand its geographical footprint into the worlds largest construction market. CMC has been one of the leading resellers of formwork and shoring solutions in the USA, primarily serving the civil engineering markets in Texas, Colorado and California, and has been a customer of RMD Kwikform since 2004. The acquisition represents an attractive opportunity to gain access to the largest construction market in the world via an existing client base and an established sales force, branch and distribution network. In addition to acquiring the heavy forming and shoring solutions of the business from CMC, RMD Kwikform has re-employed the majority of the management and staff associated with this business activity. The business will be based in Denver and will operate from distribution centers in Houston, Dallas, Denver and Los Angeles. Steven Dance, Managing Director of RMD Kwikform, commented, "This acquisition expands our international footprint and provides an attractive growth opportunity at a price that we believe represents excellent value. We are excited by the opportunity to leverage our expertise and experience to generate significant growth in the US over the coming years.

We are excited by the opportunity to leverage our expertise and experience to generate significant growth in the US over the coming years.

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PROJECTS/CALIFORNIA RETROFIT

RMD KWIKFORM KEEPS TRAFFIC MOVING IN LONG BEACH, CALIFORNIA

RMD Kwikform supplies a custom falsework solution for the renovation of a busy Californian off ramp. RMD Kwikform North America has provided a unique falsework solution to prop the existing 10th Street Off Ramp over Long Beach Freeway and Shorline Drive in Long Beach, California, allowing contractors Riverside Construction to perform a seismic retrofit. RMD Kwikform project team discusses the project: For this project RMD Kwikform utilized its patented Megashor shoring and Superslim Soldiers to devise a falsework solution permitting Riverside Construction to carry out the seismic retrofit of the 10th Street Off Ramp. The off ramp was supported directly under three existing steel bridge piers, made possible by the diversity of Megashor, and then reinforced by Superslim Soldiers acting as ledgers or braces. The bridge deck was then propped and raised using RMD Kwikforms Hydraulic Jack units, accompanied by Riverside Constructions own jacks. Once the bridge deck had been elevated, the jacks were locked in position granting access to the bearings that were then accessible and replaced. For the second stage of RMD Kwikforms involvement in the retrofitting, the construction of the new reinforced concrete cap to the pier heads, the bridge deck was lowered back into position. The Megashor Legs supporting the bridge deck were partially dismantled, all without repositioning the Megashor legs, including the lower ledgers. The propping falsework of each bridge pier was explicitly designed with minimum dismantling in mind, so it could also be reused multiple times on subsequent piers, boosting productivity and saving time and money as part of RMD Kwikforms ideology. Once the Megashor legs had been partially dismantled, the space created made way for the installation of temporary steel beams, secondary timber joists and plywood for the construction of the new reinforced concrete cap to the bridge pier heads. This project is a great example of the philosophy RMD Kwikforms reputation is established on; engineering expertise and excellent customer service through formulating unique and innovative solutions delivered to the customers parameters, within budget and on schedule. A project spokesperson for Riverside Construction remarked: Having never worked with RMD Kwikform before there were no previous experiences to go on, only a reputation. As a business partner RMD Kwikform delivered on, and lived up to, their fine reputation for providing ingenuitive engineering expertise and solutions efficiently and thoroughly. If there were any problems RMD Kwikform would be on site to resolve them and would have the project back on track without delay. RMD Kwikform is reliable and thats something of great importance in this line of business as meeting a deadline can be make or break.

As a business partner RMD Kwikform delivered on, and lived up to, their fine reputation for providing ingenuitive engineering expertise and solutions efficiently and thoroughly.

WWW.RMDKWIKFORM.COM

PROJECTS/LOS ANGELES BRIDGE

RMD KWIKFORM REHABILITATES BRIDGE TO ACCOMMODATE EXTRA TRAIN LINE

RMD Kwikform supplied falsework to a Los Angeles bridge, allowing regular traffic to continue as a rail line was added.
Contractors Griffith Company called upon RMD Kwikform North America to design a shoring solution for the rehabilitation of a bridge implemented in June 2010. The unique solution is designed to enable both road and rail traffic to continue over and underneath the Slauson Avenue Bridge in Los Angeles, United States of America, while an additional rail line is added to the existing main line track. In order for an additional rail track to be added to the two already running underneath the Slauson Avenue Bridge, two of the seven bents supporting it needed to be removed and replaced, all while the bridge was functioning normally. Thus a unique and proficient falsework solution was required if this was to be achieved. Vicken Dakessian, RMD Kwikform regional manager explained: The existing train tracks ran underneath Bents 6 and Bent 7 supporting the bridge. However, as the main line tracks travel between them at an odd angle to the axis of the bridge it was not possible to accommodate an additional track without replacing the existing bents. Each of the two bents the train tracks passed between were composed in different ways and in different positions. The engineering team at RMD Kwikform therefore had to tackle each of the challenges separately, formulating different shoring solutions to suit the project needs. RMD Kwikform prides itself on its engineering prowess and premiere customer service by working closely with its clients to deliver an engineering solution as efficiently and comprehensively as possible, on budget and on time and this project was no different. RMD Kwikforms engineers were able to work with contractors Griffith Company and were able to devise a method of overcoming the complexities of the job at hand. Bent 6 was made up of a Steel Pier Cap Beam set on top of two concrete columns that were replaced. The Megashor Towers that

RMD Kwikform prides itself on its engineering prowess and premiere customer service by working closely with its clients to deliver an engineering solution as efficiently and comprehensively as possible, on budget and on time and this project was no different.
supported the two 52 foot long W27x217 header beams and had to first be put into place before the columns could be removed. Eight Megashor legs fitted with Hydraulic units were put in place to support the weight of the bridge and traffic overhead. Two layers of cribbage beams were additionally utilized to distribute the load of the bridge equally among the Megashor towers, while the existing columns were used to cope with the lateral seismic forces also absorbed through the cribbing.

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PROJECTS/LOS ANGELES BRIDGE

Devising a solution that involves keeping a bridge open and performing its regular duties while major rehabilitative work is being performed on it is no easy task, and RMD Kwikform was able to provide an efficient and effective means of achieving this goal.
After the new columns were repositioned and constructed, the eight girders comprising the bridge were then raised to remove the original Pier Cap Beam. A replacement Pier Cap Beam was then put into place once bearing pads to mount it on were installed on the newly constructed columns. The bridge was then lowered into place onto the new Pier Cap Beam, and the Megashor and other equipment used to support the bridge was removed. The next part of the project that is due to commence in the coming weeks will be the removal of the single large concrete column and pier cap from which Bent 7 was constructed. This will also entail supporting the remaining bridge structure above while this process takes place. All the materials used to comprise Bent 7 have to be removed before the new footing column and cantilever pier cap are constructed. This is why we have designed two separate temporary supports, one 28ft to the left of the pier centre line and another 30ft to the right. As an added complication to this already technically demanding aspect of the rehabilitation of the Slauson Avenue Bridge, the left hand temporary support is required to extend over the existing active main line rail tracks. This means that four 100ft long W36x282 header beams will be used to support the girders making up the bridge. In turn, the beams will be supported by fourteen Megashor legs, fitted with hydraulic units; eight legs positioned at the center line of bridge, while four legs set on a common footing were positioned under the south most bridge girder. Meanwhile on the north side of the train track two Megashor legs will be positioned in order to provide additional support. To overcome the seismic lateral forces, RMD Kwikforms engineers have devised a solution

that involves attaching four Megashor Legs, set at 45 degrees from vertical to the header beams and anchoring them to the footings. The right hand temporary support will be set up in much the same method as the left hand support with seven 64ft long W27x250 header beams supported by sixteen Megashor towers arranged in a similar fashion. Seven of these Megashor Towers will be set at the same 45 degree angle attached from vertical to the header beams and again anchored to the footer to resists seismic forces, maintaining the structures integrity.

A project team spokesperson for contractors, the Griffith Company commented: RMD Kwikforms engineers worked closely with the team heading up the project and a solution was formulated that suited the Griffith Companys budget and time frame while delivering an outstanding solution to the engineering problems that faced the project. Devising a solution that involves keeping a bridge open and performing its regular duties while major rehabilitative work is being performed on it is no easy task, and RMD Kwikform was able to provide an efficient and effective means of achieving this goal.

WWW.RMDKWIKFORM.COM

PRODUCTS/PARASLIM

HOW PARASLIM HELPED CHANGE COMPOSITE BRIDGE CONSTRUCTION

By Ian Fryer, RMD Kwikform Engineering Director and inventor of Paraslim.
It was in the 1980s when the popularity of composite bridges first took off. There had always been composite structures for varying reasons, but as the industry developed there was a greater need for more radical change. The drive for efficiency, shorter construction times, and a move towards offsite fabrication played an important role in the need to advance composite bridge construction. This was further enhanced by the industrys desire to reduce onsite labor cost and the level of operative skill required. All of these factors added up to the increase in popularity of composite bridge construction and led it to gradually become the preferred option over in-situ concrete bridge casting. Composite bridges by their very nature however still required a level of in-situ concrete forming to produce the concrete deck slab. Initially this engineering and equipment challenge focused on improving the methods of constructing the cantilever deck sections at the edge of the bridge. The development and use of various methods, all of which had their own technical, practical and safety challenges created a major opportunity for a new more modern method of construction. It was at this point that engineers at RMD Kwikform in Aldridge accelerated their development of an entirely new system that

The drive for efficiency, shorter construction times, and a move towards offsite fabrication played an important role in the need to advance composite bridge construction.
would be launched into the market in 1995 as Paraslim. At the time, the six strong design team were given a completely free range to look at the development of the new system. This was important as the industry itself, being already well established, had very clear ideas about how systems should work and be brought into the market. What the team was able to do by adopting this method was to design a modular system where each triangular frame was supported directly from the top flange of the bridge girders by a single diagonal tie. Similar systems pre-existed in the US market but suffered from safety and access issues, as equipment had to be removed piecemeal from the beneath the bridge once the deck cantilever had been cast. With the vertical load carried by the diagonal tie at a single point, rotational stability of the triangular frame was affected by horizontal support from the webs of the bridge girders.

Engineering Director for RMD Kwikform, Ian Fryer who drove the development comments: The Paraslim system works in the same way as when you are carrying a heavy box in your arms. The stiff box represents the triangular frame, with your arms held diagonally being the diagonal Paraslim ties. The near end of the box reacts against your body in the same way as the Paraslim system reacts against the bridge girder and provides rotational stability for the box. THE EUREKA MOMENT The eureka moment came with development of the all-new Paraslim tie system. Sheathed with a tapered stripping device, the tie was extended upwards through the deck concrete and this, combined with the ability to gang the frames together into crane handlable modules, enabled the equipment to be struck and removed from above with the need to go below the concrete slab. Attachment of the single tie to the top flange of the bridge girders posed further technical challenges. Initially fabricated steel brackets were welded by a manual metal arc process to the top flange of the girders. Heat generated by this method however risked damage to the girder paint finish and less costly and more reliable methods were sought. Following rigorous testing of various different solutions, the RMD Kwikform engineering

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PRODUCTS/PARASLIM

team sourced an M24 drawn-arc weld stud to effect the anchorage. In order to achieve efficiency gains by using the system, weld studs were designed to be connected to the bridge girder during the manufacturing process. By using methods identical to those employed for the top flange shear studs, an already established method readily accepted by all parties, the overall solution fitted well with the girder manufacture process. M24 weld studs are load tested to above full working load in the factory, thus providing an additional quality measure. Once this hurdle had been overcome, development of the complete system could be finalized. RMD Kwikform engineers drew on the established Superslim Soldier to make up the top member of the diagonal frame, with new adjustable components developed to form the other two smaller sides of the triangular frame. The modular nature of the Superslim system meant that the top member of the system could be varied in length up to 4.5m to suit the bridge profile and the centers of frames could be altered to suit the applied loading. It was using this base of the trusted Superslim steel beam product, that ultimately enabled the team to make a system that was both affordable and readily accepted by the market. The real endorsement of this came with the systems very first real life use onsite. This involved the construction of a composite bridge for Jackson Civil Engineering over the West Coast Main Line in Peterborough. Following this early success on a high risk and high profile project, the Paraslim system rapidly took off and quickly established itself as the preferred method for composite bridge construction.

A key element behind the successful introduction of Paraslim was the approach of the industry as a whole to the safe implementation of the system with training and support key to its development. As the industry continues to embrace change it will be the development of future systems like Paraslim that will make a clear difference to the market.
As the system was continually developed and used onsite, further benefits were soon realized. The short stiff load path almost eliminated deflection and so grout loss was massively reduced, leading to a much improved quality in finished construction and reduced repair costs. For the contractor onsite, Paraslim could be pre-assembled into modules at ground level as a non project critical path activity. Once the bridge girders were erected, modules could quickly be craned into place and levelled ready for steel fixing. This meant that just two joiners, assisted by one site engineer could erect and level up to 60 linear meters of Paraslim equipment in a single shift, a huge improvement over under slung systems. Further project benefits were soon realised with contractors electing to assemble the Paraslim equipment in its entirety onto the bridge girders at site level, prior to lifting the

girders into place. Although larger cranes were required, critical path activity was reduced and the Paraslim equipment could immediately form a ready-made access and material platform at high level. These elements allowed for an access up and down the bridge at no extra cost, increasing safety and reducing overall project time delivery. Erection and dismantling in modules by crane almost eliminated work at height, thus pre-empting introduction of the work at height regulations by a number of years. Now in its 15th year, Paraslim has become the preferred method of construction for composite bridges in the UK and Ireland and has gained popularity in other markets across the globe. Where it was revolutionary in its introduction Paraslim continues to be the market leader and continues in its own innovative path with the recent move towards offsite preassembly. Again supported by the industry and endorsed by major players like Costain who has adopted preassembled Paraslim as its composite bridge product of choice Paraslim continues to support the drive for efficient and safe construction. Ian: I think a key element behind the successful introduction of Paraslim was the approach of the industry as a whole to the safe implementation of the system with training and support key to its development. As the industry continues to embrace change it will be the development of future systems like Paraslim that will make a clear difference to the market.

WWW.RMDKWIKFORM.COM

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PROJECTS/BASRA SPORTS CITY

RMD KWIKFORM SCORES IN IRAQ WITH BASRA SPORTS CITY STADIUM PROJECT
Equipment and engineers from formwork and falsework specialist, RMD Kwikform is supporting the dreams of up to 65,000 Iraqi football fans, after being selected by construction specialist Abdullah A. Al Jiburi Contracting Company, to support it in the construction of the new Basra Sports City Stadium in Iraq.
Constructed for the Iraq Ministry for Sports and Youth, ground works for the impressive new complex which is set to host the 21st Gulf Cup, commenced onsite in September 2009. Abdullah A. Al Jiburi Contracting Company then started bringing in RMD Kwikform Kwikstage and Rapidshor shoring, to support the main concrete construction of the stadium, in January 2010. With 1,000s of beams, 100s of columns and numerous slabs for the 8 level, 65,000 seater football stadium required, over 3,000 tons of equipment were shipped onto site. In addition to RMD Kwikforms Kwikstage and Rapidshor shoring, column, wall and beam formwork, including steel Superslim soldiers and GTX timber beams, were also supplied to the project. Due to the tight deadline of just 32 months from the commencement of the project, to completion, getting the formwork and falsework solution design, support and project sequencing right, were all key to Abdullah A. Al Jiburi Contracting Company, as project manager Abdul Hussain explains: Being such a high profile and socially important project for Basra and the country as a whole, we needed to make sure that before we reached the formwork and falsework stage, we had the right equipment, designs and support to ensure its smooth construction. Because we have worked with RMD Kwikform on a number of projects, we know they have the resources that are setup to support our team on the ground and can therefore react quickly to any changes in sequencing or design. Due to the large scale of the project, we required a sizable fleet of equipment. Logistically identifying the correct amount of equipment, getting it to site quickly and setting up a storage facility was therefore quite a complex challenge. Here again we have benefitted from input on the project and in the past from RMD Kwikform, who share best practice techniques on equipment management that help to save both time and money. With concrete works already well under way and expected to last until late 2011, the landmark Basra Sports City stadium, which looks similar in design to the Beijing Olympics Stadium, is set to release the passion of a nation when it hosts the 21st Gulf Cup (Khaleeji 21) in December of 2012. Commenting on its work in Iraq and being awarded the contract for the Basra Sports City Stadium, Regional Export Sales Manager for RMD Kwikform, Alexis Potter said: As a business we have been working in Iraq for a number of years pre and post war, but it is our partnership with Abdullah A. Al Jiburi Contracting Company that has now been in operation for over 2.5 years, that has led to increasing success within Iraq.

From a business perspective, in the delivery of this project, we will be privileged to achieve an important goal for RMD Kwikform, in that we will have played a part in a landmark project that will put a very proud nation back on the sporting excellence map.
Having worked with Abdullah A. Al Jiburi Contracting Company on infrastructure and water projects, including supplying formwork and shoring for Basrah Water Towers, Al Nassyryah Bridge and Jumhuria Intersection, we have built up a true partnership approach to supporting successful project delivering in Iraq. It is this partnership and our proven engineering experience in delivering large stadia work, like the Sydney Olympics, that ultimately led to us being awarded the prestigious Basra Sports City Stadium job. With any job of this scale however you will face numerous challenges. For this particular project the most important element of our service delivery was how we were able to support the customer on the ground. When we first tendered for the project we recognized that this was critical to its delivery.

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PROJECTS/BASRA SPORTS CITY

11

We therefore took time to find the right person to support the customer at site level. The individual we recruited had over 15 years of experience in formwork and shoring, with a proven track record of working on largescale projects in the Middle East region. In showing this commitment to the customer, we have been able to develop a good working relationship with the site team from the very start of the project. Where our site operative comes into his own is the management of equipment flow and availability. On a project of this type, when you are transitioning from dock, to site, to erection, to dismantling, storage and handling, the logistics can be incredibly complex. That is not to mention dealing with lost and damaged items that typically occur on any construction site. Part and parcel of this process is to gain the trust and respect of the individuals working onsite handling equipment. This is why with any project of this type, it is advisable to assist with training erection staff on the best use of equipment and erection techniques. Not only do you save them valuable time, so they can achieve set goals, you also help to improve site safety and therefore individuals can see you are thinking of them, not just the job. By having a formwork specialist educating teams on the ground on how to follow drawings and sequencing, the project benefits can be substantial. Because the Basra Sports City Stadium is a large government project, with a very high profile, these factors are being watched and analyzed constantly. So for Abdullah A. Al Jiburi Contracting Company, where working with RMD Kwikform really comes into its own is our focus on health and safety. No matter where the location, we adhere to our own global health and safety system, which is based on industry leading standards and practices. ENGINEERING DESIGN CHALLENGES For RMD Kwikforms engineers, dealing with a large-scale project of this kind, overcoming the challenges of the structures construction were key to its timely delivery. One of the more challenging elements of the project involved supporting large beams at level 7 and 8 off the much lighter main concourse level, comprising of cast in-situ beams and hollow core precast concrete planks. Alexis: For this particular part of the structure, the engineering team had to

create solutions that could support numerous operations. These included the casting of a 1.4m deep beam at level 7, including a beam cantilever just over 9.0m in length. A sloping raker beam from the edge of the cantilever was also required up to level 8 to act as a tie to secure the overall frame. The falsework system therefore had to be designed for cumulative loading from levels 7 and 8 off the lighter structure below. In order to achieve this, Rapidshor falsework with a maximum leg capacity of 80 kN per leg used in conjunction with Superslim soldier spreader beams, was used as the primary support system up to the underside of level 7. On completion of level 7, with the primary support system remaining undisturbed, the raker beams up to level 8 were supported off a framework of Kwikstage Propping and Superslim Soldiers, an integral feature in resisting sliding forces induced by the sloping soffit. Beam side forms, soffits and columns at these levels were formed using steel Superslim Soldiers, GTX timber beams and recoverable Rapid Bar Ties. At all times throughout this crucial stage, the input of our site operative was critical as he ensured all

phases were erected safely and in accordance with our designs. With the formwork and shoring phase of the project on schedule for completion in late 2011, the overall complex is due to be opened to the public in late 2012, ready for the 21st Gulf Cup in December 2012. Alexis concluded: From a business perspective, in the delivery of this project, we will be privileged to achieve an important goal for RMD Kwikform, in that we will have played a part in a landmark project that will put a very proud nation back on the sporting excellence map. Once completed the stadium will be surrounded by water and accessible to patrons by bridge. The 360-acre complex, designed to be one of Iraqs major sports centers, will also contain a smaller stadium, practice facilities, a training complex, a swimming center, and other facilities. For more information on this and other projects from RMD Kwikform visit www.rmdkwikform.com/ae

WWW.RMDKWIKFORM.COM

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PROJECTS/CHIVAS BROTHERS

RMD KWIKFORM FALSEWORK PROVIDES SPIRITED SUPPORT TO RENOWNED WHISKY PRODUCER CHIVAS BROTHERS
Formwork and falsework specialist, RMD Kwikform supplies 13,435 Superslim Soldiers from around the world to help specialist contractor Bluevale Structures safeguard valuable stocks belonging to Scotch whisky company, Chivas Brothers in Scotland.
Housed in bonded warehouses at Mulben and Keith, the heart of whiskys famous Speyside region, countless oak casks of maturing Scotch whisky are currently being protected by 13,435 Superslim Soldier beams from RMD Kwikform, the largest ever UK movement of the product, completed in record time. The 608 tons of falsework have been assembled into long push pull props to support the walls of 31 individual warehouses. These props are the first and crucial stage in an important warehouse refurbishment process. In order for structural work to be undertaken safely, added protection for the warehouse walls was also required. This was also put in place to negate the potential impact of severe winds predicted for later in the year, which could have put at risk the valuable maturing stock destined for markets around the world. Commenting on the need for speed and the importance of the refurbishment project, Chivas Brothers Bill Lamb said: As a World renowned Scotch whisky and premium spirit producer, Chivas Brothers under the ownership of Pernod Ricard is responsible for the production of a whole range of brands. These include the worlds most prestigious Scotch whisky, Chivas Regal, which has the ultra premium Chivas Regal 25 year old at its pinnacle, and the worlds No 2 Scotch whisky brand, Ballantines. What this essentially means is that we are the custodians of a tradition of producing the finest products that was started by the Chivas Brothers in the 19th century. Because we produce 250 million bottles of spirit a year, in order to keep production at the level the market demands, at any one time we have to store and have access to in the region of 6 million casks of product in special bonded warehouses. To minimize disruption, we chose to build a new structure around the original. Our main concern throughout this process is obviously keeping the casks and product safe at all times.

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13

In order to meet our very tight refurbishment deadline, we had to ensure extra support was given to the walls of the warehouse structures. We had a very tight window for this part of the process to be completed, so that we could get to work on the refurbishment in the summer months. It was therefore essential that the propping stage was finished very quickly indeed. That said, we also wanted a solution that was well engineered, safe, could do the job of protecting our product and that was ultimately well priced. That is why, following a competitive tender, we awarded the job to RMD Kwikform and Bluevale Structures, while also employing our own engineering consultant, Blyth and Blyth to assist with the process. In order to support the warehouse structures, push pull prop sets were designed by the engineering team at RMD Kwikform under the guidance of project co-ordinator, Neil Hawkins with the Superslim soldiers driven up from Aldridge in convoys to RMD Kwikforms Glasgow branch. Once at the branch, the falsework was unloaded into a special compound created on site for Bluevale Structures, where a team of eight erectors worked seven days a week to pre-assemble individually designed three-prop sets. These props were then transported directly to each warehouse and fixed into position using prepositioned tilt plates, with 38 prop sets used to support each warehouse. The pre-assembly process carried out by RMD Kwikform, improved quality control and Health and Safety factors, while also reducing site installation time by more than 50%. Commenting on the speed, design input and logistical challenge faced by RMD Kwikform to supply the Superslim Soldiers, RMD Kwikform project co-ordinator, Neil Hawkins said: When the initial inquiry and competitive tender came in, we soon realized that the scale of the job meant we did not have enough equipment in the UK to cope with the rapid deployment and scale of demand. However we were not going to let that stop us from winning the job, as we were able to call upon our colleagues across our global business for support. Initially we took stocks from the UK then from Ireland and Spain finally shipping in containers from the Middle East.

Being able to deliver this project is proof that RMD Kwikform can rapidly respond to the needs of our customers, no matter what the challenge.
Putting supply to one side, the additional challenge with the project was brought about by the variations in the ground geometry around the perimeter of each warehouse, together with the position of extensive adjacent buried services. These variables conspired to affect the position and levels for the pad foundations onto which each triple prop set was to be founded. This meant that the length of every single set of props had to be individually designed, detailed and the relevant soldier lengths required to make up the required length sourced and delivered to site. In order to reduce the time it would take to produce the 1200 drawings required for the project, the RMD Kwikform engineering team customized its AutoCAD software to semi-automate this process completing the task in a fraction of the normal time. Harry Wylie, owner of main contractor Bluevale Structures comments, Commercially, with a job of this kind you need to make sure that the method you use is appropriate and cost effective. The key to RMD Kwikform winning the business was its ability to offer a one system approach, but

most importantly its ability to supply all of the equipment. Without this we would have had to work with a number of companies using different products with different capabilities, which under the tight deadline would have been extremely difficult to manage. Following a site survey from WES consulting and thanks to the swift response from RMD Kwikform, we were able to start work onsite sooner than expected, preparing each building for the prop set installation by casting concrete fixing points and fitting tilt plates to the structure, supplied in advance of the props arrival. Working directly from the raw site survey issued by WES Consulting, RMD Kwikform engineers at its head office in Aldridge methodically issued the 1200 drawings required to complete the project to the Glasgow branch. Here the components and stock were managed and reports issued for additional requirements, streamlining the logistics and delivery schedules to branch, and once assembled, out to site. Concluding, Neil said: Being able to deliver this project is proof that RMD Kwikform can rapidly respond to the needs of our customers, no matter what the challenge. The effort and support from the UK team and our colleagues across the globe enabled us to play an important role in supporting both Chivas and Bluevale Structures. From a personal point of view it has a also been a very exciting project to manage.

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PROJECTS/SCUNTHORPE LEISURE CENTRE

PYRAMID MEETS DOME RMD KWIKFORM HELPS B & K STRUCTURES ERECT A GEODESIC DOME STRUCTURE FOR SCUNTHORPE LEISURE CENTRE

RMD Kwikforms engineering team has designed ten specialist pyramid support towers to help contractor B & K Structures construct an innovative wood and steel geodesic dome for the impressive 21m leisure center project in Scunthorpe.
The new leisure center, will transform the lives of local residents creating one of the UKs most lively and interesting facilities that will complement the adjacent Central Park, which will also be refurbished as part of the scheme. Erecting the structure, which once completed is self-supporting, thanks to a steel spine, was a complex task, requiring specialist systems that could provide pinpoint node support, without compromising or slowing down the erection procedure. Having worked with RMD Kwikform on a number of previously successful projects, the B & K Structures project team made contact with RMD Kwikform engineers at the earliest design phase, to devise a practical support system that would meet the tight deadline Commenting on this and the structure itself John Booth, B & K Structures contract manager said: The really exciting part of this project is the nature of the structure that will house the new leisure center. It is truly unique in its design, consisting of five interconnected untrue geodesic domes to form a roof over the facility. Once completed it will look very impressive as if a number of different sized pods have been connected together. By working with RMD Kwikform engineers that we were able to model the complex erection sequence including the horizontal, vertical and tangential loads placed upon the structure at different points. By understanding the pressures and moments these loads would exert on the dome we were able to determine where to place support structures, how they would be loaded and what we needed to do to build in additional strength in order to reduce the number we required. RMD Kwikform engineers worked hand in hand with the B & K Structures team to design a special pyramid topped support structure, using specially fabricated parts mounted on a Rapishor tower. This design ultimately reduced the original need to support up to 168 different node points at one time, enabling the structure to be supported at just 10 points at any one time. RMD Kwikforms Chris Holland explains: Flexibility was the key to the design of the system. In order to achieve the level of support required, we had to make sure we were able to design a system that could be altered and adjusted to support node points at different angles and heights. This was achieved through the design and fabrication of an adjustable pyramid shaped head support that could be mounted onto Rapidshor shoring towers. Because Rapidshor is one of our core products we could reduce the overall cost of the system, while also

RMD Kwikform engineers worked hand in hand with the B & K Structures team to design a special support structure, using specially fabricated parts.
allowing B & K structures to achieve the very precise heights required for each tower. Due to the strength of Rapidshor the towers themselves, we were able to use just a small amount of space, while providing enough strength and support for the roof to rest on. The tower systems were able to take loads of up to 20 tons from the steel node point, through the pyramid assembly, tower legs and into the ground below, without damaging the wooden sections of the structure, Chris added. While the core structure was erected in waves using the ten RMD Kwikform Rapidshor pyramid support structures, which were moved back as the dome took shape, cedar clad and insulated prefabricated sections were installed by a separate team, to allow for the roof structure to be assembled and sealed. Now well on the way to completion, the leisure center, once open will support the local community, helping them to enjoy sport and leisure activities in a truly exciting environment.

FORMULAMAGAZINE/ISSUE02

CONTACT DETAILS

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USA
DENVER HEAD OFFICE
9351 Grant St, Suite 200 Thornton, Colorado, 80229 Off: (303) 252 7000 Fax: (303) 252 7319 Email: usa@rmdkwikform.com

LOS ANGELES

2631 South Riverside Avenue Bloomington, CA 92316-3236 Off: (909) 873 0909 Fax: (909) 875 0910 Email: usa@rmdkwikform.com

HOUSTON

102 Bennington Street Houston, Texas, 77022 Tel (713) 692 5945 Fax (713) 692 2188 Email: usa@rmdkwikform.com

DALLAS

2323 Irving Boulevard Dallas, Texas, 75207 Off: (214) 631 6699 Fax: (214) 637 1145 Email: usa@rmdkwikform.com

DENVER

6665 N. Washington Street Denver, Colorado, 80229 Off: (303) 287 7531 Fax: (303) 288 1344 Email: usa@rmdkwikform.com

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