Paul Williams, Divisional Operations Director for RMD Kwikform*, explores how the temporary works industry plays a vital role in delivering rail and metro projects. He also highlights what considerations contractors need to give to formwork for such builds.

01 December 2020

From the Dubai Metro expansion project in the UAE to the Riyadh Metro project in Saudi Arabia, which is currently the largest metro project in the world, large-scale rail expansion is set to take off in a dramatic way over the next decade in the Middle East.

The region’s most ambitious project – The Gulf Railway, which will stretch over 2,000 km – is now expected to be completed by 2023, costing an estimate of $250 billion. There’s no doubt that the future growth of rail infrastructure in the region is an exciting one.

Any rail or metro project presents unique challenges for the construction industry. Works on these highly complex jobs include the construction of tunnels and access roads, underground and over ground stations, bridges and viaducts, and extensive groundworks support.

 

Bridges

When constructing bridges for rail projects, there are several factors to consider: What type of bridge is it? Where is it located? What is the height and length? Having a clear understanding of every facet of the bridge build will ensure that the right formwork solution can be engineered and supplied.

For example, a temporary road bridge may use only standard formwork components, whereas a bridge spanning a live rail line will tend to require a bespoke design and debris protection. For permanent bridges with multiple piers and span – often running over live roads or railways – a composite construction method is a safe and fast solution. As horizontal steel beams are connected to permanent structures, the amount of concrete to form the bridge deck will be reduced.

In addition, it is important to consider the delivery of equipment and how this will affect surrounding areas. By opting for pre-assembled formwork modules, installation is far quicker, which ultimately reduces road closure and rail suspension times.

 

Tunnels

There are many crucial factors to consider when faced with tunnel construction. What are the ground and groundwater conditions? What is the length, diameter, depth and shape of the tunnel? Logistically, how will you ensure that the excavation is safe and efficient?

When thinking about formwork and shoring requirements, this too is based on many factors. Is the tunnel crown curved? Or does it have a flat soffit? For short-length tunnels passing beneath a rail embankment, a standard formwork and shoring system will usually be adequate. For one that extends over several kilometres, a more complex engineered temporary works solution will be necessary.

As always, construction cycles and overall project deadlines are a key consideration when it comes to tunnel construction. Will the entire tunnel be cast as one section? Or will the slab, walls and roof be cast separately? The construction sequence has a direct impact on the formwork and shoring as special solutions are often required for such applications.

A hydraulic traveller system on castor wheels is a productive solution when it comes to moving the traveller and casting concrete; once the concrete has cured, the system can be struck and moved to the next pour.

 

Stations

In recent years, the development of rail infrastructure in the Middle East has seen the design and development of architecturally grand stations. Exposed concrete is now often a feature, which places greater emphasis on the quality of the concrete finish. These demands necessitate detailed design of the formwork to ensure compliance with the architect’s specifications.

Wall forming will inevitably be a part of key works on any above or below ground station project - whether it’s a load or non-load bearing wall or a retaining wall. With simultaneous construction and tight programme times, it’s important to look at the simplest, yet safest solution to cast the station walls in the most efficient way.

When it comes to reviewing which temporary works equipment you need, consider a system that will allow for flexibility and versatility, particularly when it comes to walls of varying heights. Panel systems are often the best choice as they are easily installed, easily struck once concrete has cured, and they can be reused.

 

Megashor for Dubai Metro

Of all the infrastructure developments undertaken in the UAE, the Dubai Metro is one of the most important public transport projects in terms of its strategic implications: creating a high-speed link to the new Al Maktoum International Airport in Jebel Ali, which is designed to carry 27,000 passengers per hour on each of the two lines.

RMD Kwikform secured the contract to supply a temporary support solution for the construction of the metro’s elevated tracks. Using RMD Kwikform’s Megashor system allowed the contractor to support the precast viaduct sections in multiple locations during the construction cycle.

The Dubai Metro was undertaken by members of a joint venture company – VFR Joint Venture, made up of the two post-tensioned pre-stressing specialists, VSL and Freyssinet, together with Italian contractor Rizzani.

RMD Kwikform’s expertise contributed to the successful completion of the 52-km Red Line, which features 29 stations running along it, as well as another 22 km of track and 18 stations for the Green Line. The consortium had up to a dozen sections of the route under construction at any one time, with RMD Kwikform called upon to supply Megashor towers to site.

RMD Kwikform was chosen based on the firm’s ability to complete the scope of work against tight project timeframes. The Megashor support system offers a load-carrying capacity of 720 kN per leg, which was a major benefit to carry the heavy load of the U-shaped precast concrete sections to the tracks. The Megashor system was designed to be used wherever the main contractor was unable to use its standard launching system.

 

* RMD Kwikform (www.rmdkwikform.com) provides formwork, falsework and shoring solutions to the worldwide construction industry. With operations globally, supported by a network of distributors and agents, as well as specialist export teams, RMD Kwikform can provide a truly local service, backed up by significant international experience.  

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