Project support at the very highest level for the new Henninger Turm

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With a height of around 140 m, the new Henninger Turm is one of the tallest residential towers in Germany. A total of 210 apartments are expected to be ready for occupancy at the beginning of 2017. The former grain storage silo of the Henninger brewery, which was demolished in 2013, has been re-created with the bright northern facade and in particular the cantilevering circular section – the so-called "Barrel" – as highlights of the new structure. At its top, the 39th floor includes a restaurant whilst the observation deck in the floor below provides an impressive panoramic view of the Frankfurt skyline. The high-rise shaft encloses a 5-storey base structure complete with parking facilities along with extensive range of service and retail outlets.

Comprehensive project support

Already in the tendering phase, PERI, in close coordination with the project team of Ed. Züblin AG, developed a workflow concept with formwork, scaffolding and related services from a single source. Using this, the implementation planning could be easily updated and further optimized to exactly match site demands – on the basis of clearly defined tasks, safety requirements and a predefined budget. In addition to the technical and scheduling feasibility, great emphasis was simultaneously placed on corresponding cost efficiency.

PERI engineers supported the rapid construction progress with formwork, scaffolding and service expertise of the very highest level. The project-specific customized climbing formwork solution on the basis of ACS and RCS self-climbing technology as well as the realization of the 40 m high, cantilevering barrel-shaped section at a height of 100 m, were important components of a well thought-out implementation and safety concept. In particular, the 3D planning with PERI CAD software along with the project support provided on the jobsite by a project coordinator and the availability of an experienced supervisor for the formwork assembly, ensured efficient and cost-effective use of materials from the beginning onwards.

High-rise construction in 8-day cycles

For safe and efficient working operations, the top four floors under construction were always enclosed on three sides by means of the RCS Climbing Protection Panel. Here, the rail-mounted enclosure cantilevered up to 2.22 m away from the exterior of the building which meant that the offset balconies could be climbed over without any problems. Four material landing platforms were integrated into the enclosure which were raised along with the corresponding protection panel units. Climbing was carried out with crane support as well as without through the help of mobile RCS climbing hydraulics. On the north side of the building, the RCS Rail Climbing System was used together with TRIO Panel Formwork as rail-guided climbing formwork. Thanks to the hydraulically-operated ACS Self-Climbing Formwork, no crane was likewise required for the construction of the elevator shafts.

Barrel-shaped structure at a height of 100 m

The 40 m high barrel-like construction positioned above the thirtieth floor has an external diameter of around 25 m. For the structural work of this very distinctive circular section, a working and scaffolding platform with an up to 8 m cantilever was formed at a height of 100 m on the basis of modular, rentable standard system components. The PERI concept took into consideration, on the one hand, the required load distribution in the core and external walls for all construction stages and, on the other, provided the well thought-out assembly and dismantling concept with the maximum level of safety as a high proportion of the assembly work was carried out on the ground. The reinforced concrete walls were formed with RUNDFLEX and TRIO while the PROKIT safety system served as anti-fall protection on the open slab edges. Subsequent scaffolding requirements on the circular structure for the final facade assembly operations with PERI UP Flex Modular Scaffolding supplemented the PERI complete solution.

Base structure with parking garage ramp

Execution of the base section was carried out in parallel with the high-rise construction. This accelerated the construction progress but still accordingly required that the formwork and scaffolding planning as well as site logistics be taken into consideration. One particular challenge was the construction of the six-storey high parking garage ramp. RUNDFLEX Wall Formwork was used to realize the inner ramp with its 4 m diameter and large-sized wall openings; the crane-movable internal and external platforms were project-specifically planned and formed using system components taken from the VARIOKIT Engineering Construction Kit and SCS Climbing System. Moreover, not only the load-bearing concept but also the safe access to the main and finishing platforms were taken into account by the PERI engineers in the project solution.

2013: dismantling operations with PERI UP

For 50 years, the original Henninger Turm in the Sachsenhausen district of Frankfurt served as a grain storage silo for the Henninger brewery and was the tallest building in the city for many years reaching a height of 120 m. In 2013, work began to gradually dismantle the former landmark. Already during the demolition work at the top on the revolving restaurant called "The Barrel", PERI UP Flex served as a 16 m high working and safety scaffold. Here, the cantilever-mounted RCS Climbing Rails formed a stable basis for the working and assembly levels at a height of over 100 m.