TECHNICAL | CONCRETE
Above: Special steel formwork arrived in hall for casting tunnel short sections - segments PHOTO CREDIT: PERI
To that end, in the enormous casting factory,
multiple production lines will be performing the same tasks, each contributing segments to form full elements to come out at the end of each of their chains of activities. At the end of the casting lines, the open cells through
each completed full element are then sealed off with specially designed bulkheads. The elements are then moved out of the factory toward the awaiting drydocks. The drydocks are lined up to receive the factory
output and the deep trenches were constructed as part of a specially built basin in a new harbour with breakwater. Within the drydocks the sealed-off elements are fitted out to work with flotation pontoons. When ready, and scheduled for the construction sequence, a drydock is flooded and the awaiting element is floated. Gates are at the ends of each drydock. They open, and then the main gate that holds back the sea is open to give the passage to the floating element. Out at sea, the elements are tugged to holding zones and then, to schedule, submerged and placed in a
26 | July 2023
specially prepared trench. One by one, the giant hollow concrete elements will be added to the extending line of the tunnel. Only when sealed and watertight will the bulkheads – now internal structures in the extending line of the tunnel – be removed. That is the overall cycle. Getting the concreting cycle working effectively on
so many production lines is key to the success of the venture. Inside the factory, casting the concrete is an enormous physical and logistical task. To that end, formwork plays an important role. Peri developed a formwork concept for the central
production of the standard tunnel elements. The main contractor building the tunnel, portals,
ramps, and seabed trench to hold the long tube, is Fehmarn Link Contractors (FLC), a joint venture of Vinci, Per Aarsleff, Wayss & Freytag, Max Bogl, CFE, Soletanche Bachy, BAM. The JV is supported by Cowi as consultant and subcontractor Dredging International. For the volume of work to be done, Peri has supplied
more than 10,000 tonnes of special formwork. Each steel assembly has been designed to cast one of the
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