There are so many things to consider when building a bridge, and the costs quickly add up. The use of formliners can be a cost-effective design alternative.
The applications for elastic formliners in bridge construction are diverse. Their flexibility allows them to be used for concrete elements even in complex areas, such as in bridge construction. Not only do they offer an economical means of producing concrete parts, but they also contribute to efficiency due to their reusable nature, thereby reducing construction time.
A significant advantage lies in the consistent quality of results ensured by formliners. The precise reproduction of surface textures and patterns results in a homogeneous concrete surface that is less prone to cracks and other structural issues, which is crucial for the long-term safety and durability of bridge constructions. Additionally, formliners offer high design versatility, capable of meeting various aesthetic requirements, whether by mimicking natural stone textures or creating modern, textured surfaces.
Whether for new construction or restoration, formliners often present a cost-saving alternative to working with other building materials, particularly when heritage preservation regulations are involved.
During the renovation of the Höllenbrach Bridge (Image 1), a listed circular arch bridge spanning the Höllenbach and Landstraße 409 on the A1 between Remscheid and Wermelskirchen, extensive measures were taken due to weathering and age-related damage affecting the edges of its 22 bridge arches. These deteriorations posed risks to pedestrians and drivers below. For feasibility and cost reasons, architects opted to replace existing natural stone blocks with sight concrete resembling natural stone. The challenge: differing textures on the visible and underside surfaces of the bridge deck.
To faithfully replicate the original appearance, models of the differing textures of the arch corners were initially created and submitted to the heritage authority for approval. After approval, the form liners were produced. In the precast plant, the angular edge stones were individually cast and then assembled on-site piece by piece like building blocks: 64 sight concrete blocks form a 25-meter-long bridge deck.
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