ZÜBLIN relies on BIM solution from ALLPLAN for a Reinforced Concrete Roof for Deutsche Bahn

Coordination of the complex formwork and reinforcement via the cloud-based BIM platform Allplan Bimplus

Munich, April 4, 2019 – They are the eye-catchers for the new station hall of the major Stuttgart 21 project: the chalice-shaped pillars. Not only because of their complex geometry, but also because of the effort involved in producing the custom-made formwork and reinforcement, they represent an enormous structural challenge for Ed. ZÜBLIN, who is realizing the project on behalf of Deutsche Bahn AG. In order to coordinate the installation of reinforcement and formwork in the reinforcement model, the construction company opted for the cloud-based BIM platform Allplan Bimplus.

“Something like this has never been built before,” says ZÜBLIN project manager Ottmar Bögel. The first of 28 chalice-shaped columns that will combine to hold the roof of Stuttgart’s new underground train station was completed in October 2018 – it is a work of art poured from concrete. Only recently, the second pillar was completed; from the middle of the year, three chalices are to be built parallel to each other. The one-of-a-kind structure is to be completed by late 2022.

Interaction of innovative procedures and digital processes

The process of creating the custom reinforcing bars is similarly complex. The complicated geometry of the chalice-shaped pillars is reflected in the reinforcement, which comprises approximately 11,000 different, partly three-dimensionally bent rebars, many of them unique. The steel is shaped in a bending facility established especially for this project mainly via interpolator between bending machine and reinforcement model. Quality control is performed using true-to-scale laser projection.

"The open BIM platform Allplan Bimplus can be used to effectively coordinate the installation of the reinforcement and formwork in the reinforcement model. Approximately 450 plans are required for each cup to map the sophisticated reinforcement layout," says Bögel. With Allplan Bimplus, the various planning teams work on a BIM model and can thus efficiently manage information, documents and tasks. In the case of the cup supports, the 3D model is used via a large screen in the container and as a mobile tablet solution directly on the construction site to support installation.

ZÜBLIN nominated for bauma Innovation Award 2019

ZÜBLIN has been nominated for the BAUMA INNOVATION AWARD 2019 in the category "Building, Construction Methods, Construction Processes" for the elaborate realization of the chalice roof for the Stuttgart underground station. The award is presented at the start of the leading trade fair for construction machinery (bauma, 8-14 April) in Munich.

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