Press Release | Weil der Stadt (Hausen), August 12, 2024: The energy transition in Germany requires significant grid expansion to ensure sustainable power supply. In southern Germany, where population density and industrial concentration are high, the demand for electricity is increasing. To guarantee power supply under the changing conditions of the energy transition and to prevent overloads, the transmission system operator TransnetBW is upgrading the transmission network between Karlsruhe-Daxlanden and Eichstetten am Kaiserstuhl from 220 to 380 kilovolts—known as the Badische Rheinschiene grid enhancement project.

Some of the tower foundations for the high-voltage pylons in this project are being concreted using round column formwork from Robusta-Gaukel. For these pylon bases, the structural design requires a foundation slab, upon which the cylindrical reinforced concrete structure is built.

Custom-sized round column formworks ensure precise and secure concreting of pylon foundations, even under challenging conditions such as constructing power lines over long distances and across varied terrain profiles. The formwork has a height of 2000 mm and a diameter of 2100 mm, with precise length gradations in 50 cm increments and a maximum concrete pressure resistance of 120 kN/m². The special feature: to enable formwork assembly without a crane, the formwork is designed as a hand-set formwork and divided into six segments. Each segment weighs only about 40 kg and can be carried by one to two people.

The formwork assembly is simple and quick, thanks to its quick-release system with Robusta's bolt-on set and wing nut, requiring no separate tools. Centering pins ensure precise alignment of the formwork halves, optimizing the quality of the concrete surface. The formwork’s stability allows for multiple reuses.

The hollow wall concreting consoles are temporarily mounted on the formwork, creating a concreting platform on-site quickly and easily. This approach provides a stable working platform with back protection, ensuring a safe concreting process. Handling is done without a crane.

For comfortable and safe work, the standing surface of the hollow wall concreting console is positioned about 50 cm below the top edge of the formwork. The consoles can be hooked in at any desired position.

The required foundations for the new power line are being constructed by SCHLEITH GmbH. This renowned family-owned company, specializing in civil engineering, structural engineering, and special foundation work, was contracted by CTeam Consulting & Anlagenbau from Ummendorf, which acts as the general contractor for TransnetBW GmbH from Stuttgart in the Badische Rheinschiene grid enhancement project.

In addition to round column formworks, SCHLEITH GmbH also ordered hollow wall concreting consoles from Robusta-Gaukel. Jochen Bruder, senior site manager at SCHLEITH GmbH Baugesellschaft, reports: “We are impressed by the robust quality of the formworks from Robusta-Gaukel. Each formwork can be reused multiple times, contributing to the sustainability of our large-scale project.”

As a specialist in innovative safety and formwork solutions on construction sites, Robusta-Gaukel is proud to contribute to the development of infrastructure for reliable energy supply in Germany through this project.

For special formworks like the large round column formwork used in the power line project, Robusta-Gaukel draws on a wealth of experience. The company produces formworks tailored to specific application conditions. These special formworks are used for concrete structures on construction sites and in precast plants with exposed concrete quality. Special formworks can be realized as individual pieces or in combination with standard, wall, and slab formworks. The advantage here: planning and production of the formwork structure are handled in-house.

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About ROBUSTA-GAUKEL
ROBUSTA-GAUKEL GmbH & Co. KG has stood for well-engineered products that withstand the rigors of use on construction sites around the world since 1965. The focus is on the development of innovative products to optimize construction processes and improve safety on the construction site. The specialist for assembly, anchoring, safety technology and formwork as well as complex special solutions has its headquarters in Weil der Stadt/Hausen and currently employs around 90 people at two locations. Its customers include numerous well-known European construction companies and groups.