ZŁOTE TARASY / GOLDEN TERRACES – industrial scaffolding

Warsaw, Poland

THE CHALLENGE

Złote Tarasy is a shopping mall, office space and entertainment complex and the central part of this construction is covered with a large glass roof. It is undulating in an irregular way, supported on poles reminiscent of tree crowns, and underneath it there is a commercial space cascaded on multi-level terraces.

During the construction of the facility, it was necessary to create a supporting structure for this roof, which was also to act as a working platform for welding roof components and for finishing works such as painting, sealing, glazing, etc.

  • A modular scaffold was proposed, and due to the high load values, the support points had to be strengthened by using a steel grating that transmits the load to the scaffolding stands.
  • The  Multiserwis Design Studio performed the necessary design activities, and the Scaffolding Services Department in Poland took care of the implementation.

THE SOLUTION

Prefabricated elements of the roof were supported by points on the scaffolding, in strictly defined places.

The supporting structure was made of modular scaffolding:

  • Number of spatial scaffolding: ~ 93,000 m3.
  • Working platform area: ~ 9,000 m2.
  • 4 km of lattice girders.
  • 50 tons of I-sections supporting the roof.

At the stage of the dome construction, the magazines mentioned that it was “the greatest construction of the Third Polish Republic”.

Planning

Detailed documentation was obtained from the Ordering Party, as well as information on the Client’s needs in the performance of the task. Then the service was efficiently planned, and project documentation was prepared.

The most difficult element in designing the scaffolding for the dome was to construct it in such a way, as to transfer the load from the roof structure directly to the scaffolding stands (over 700 supports!). The maximum vertical load with concentrated force was 30 kN, which with a simultaneous surface load of 2.0 kN / m2 and the considerable height of the scaffolding was a serious problem to be solved.

The nature of the project, its complexity and degree of difficulty required the preparation of a technical design of the scaffolding containing over 60 detailed drawings in the formats from A4 to A0 and complete static calculations, considering the spatial work of the scaffolding.

Getting ready

Qualified staff was assembled to perform the service. The appropriate amount of scaffolding material (which was a load for about 40 trucks) and steel sections was secured, and the stages of transport were planned.

The basic element of the roof structure is a steel spatial frame, commonly known as a “ladder”. The dome consists of 126 ladders of various geometry (the dimensions of the ladder projections were mostly about 6mx15m, and the average weight of the ladder was about 4 tons). The ladders were mounted using tower cranes equipped with special slings, enabling precise setting of the levels of the support points. The support points were supports placed on the scaffolding and their coordinates were precisely determined and checked by a surveyor.

Execution

The complicated shape of the roof made it necessary to use a scaffolding working platform at various levels, from 1.5 to 3 m below the level of the roof structure. This resulted in the necessity to provide an appropriate communication route between the platform faults and to secure individual faults with protective rails. For this purpose, the scaffolding structure includes:

  • 4 basic staircases that are also escape routes,
  • auxiliary communication risers and staircases constituting transitions between the scaffolding working levels and the ceilings,
  • 4 lifts with a capacity of 600 kg are provided for the transport of small elements of the roof.

The height of the scaffolding was variable, and ranged from 4.0 to 33.0 m.

The pace of construction and the small area of ​​works carried out in the city center required strict compliance with health and safety rules and regulations, which the employees performed in an exemplary manner.

 

THE RESULT

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This  project has shown that the company can face various challenges. The fruitful cooperation between the company and the Investor contributed to the implementation of another project that became a pride among construction facilities.

The structure was designed and made on time. The technical design contained a number of documents and instructions giving guidelines for the safe performance of works.

The location of the construction site in the main center of Warsaw and required precise logistics planning due to area limitations.

The scaffolding for the assembly of the atrium roof was not the only task of the company within this project. The company also performed scaffolding works during the assembly of external facades (the total area was approximately 45,000 m2). The scaffoldings set up by the company were used to make other works on facades, such as panels made of stone and metal. Some of the facades were over 50 meters high.

Another challenge was the scaffolding at the top of the office building – the so-called The Eye. The scaffolding was assembled on steel beams spread against the ceilings on the 18th floor of the skyscraper: the height of the foundation was 76 m, and the last working level was at a height of 90 m. The entire scaffolding was tightly covered, which made it possible to carry out assembly works on the facade in winter.

The use of scaffolding made it possible to implement a facility that blends in perfectly with the surroundings and is a characteristic element of the center of Warsaw.

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