Prefabrication of formwork and reinforcement sections

The Swedish Transportation Administration is building two 371m long parallel road bridges over a busy roundabout in Malmö. The contractor, PEAB, is building under a strict time schedule and has engaged CN3 to optimize the construction with the use of 3D Production Models. The 3D model integrates the design requirements of Centerlöf & Holmberg and the practical knowhow of the contractor and the suppliers. This Integrated Project Delivery approach contributes to high constructability and increased productivity.

The reinforcement design has been divided in to 6 main groups, that are assembled in the factory to form large sections. This reduces the man-hours on site significantly. In their normal production setup PEAB would be able to finish 4 meters of bridge per day – by using prefabricated formwork and reinforcement sections, they were able to increase the speed to 7 meters per day.

Formwork structures have been made in the 3D model, as a basis for prefabrication off site. The formwork is assembled in sections and mounted on site.
The prefabricated reinforcement sections were virtually packed in shipping containers in the 3D model, to minimize the number of containers used.
Structural foundations and columns have also been fully detailed in the 3D model and the interface between supports and the bridge have been thoroughly visualized for precise and productive production on site.

By prefabricating formwork and reinforcement sections, the contractor has been able to reduce the construction period with 40% and minimize the waste of reinforcement steel to below 0,1%.

CLIENT: Trafikverket
ENGINEER: Centerlöf & Holmberg
PHASE: Design and construction

ICT and design management
Value engineering
Advanced modelling
Fabrication automation
Prefab planning