Budget-friendly design

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.

There are many uses for elastic structure formliners. As they are so flexible, they can be used for concrete parts of complicated structures, such as bridges. 

New-builds or restoration projects: As they can be used again and again, the forms are often a cost-saving alternative to working with other construction materials. This especially applies when complying with conservation regulations. 

This led to special requirements when renovating the Höllenbrachbrücke Bridge: This listed arch bridge cut across Höllenbach and Landstraße 409 on the A1 between Remscheid and Wermelskirchen. 

As part of comprehensive renovation work, the edges of the 22 bridge arches were replaced due to weather damage and aging: They had begun to crumble, and had become a danger to pedestrians and motorists using the Landstraße underneath the bridge. For reasons of both feasibility and cost, the architects decided to replace the existing stone blocks with exposed concrete with a natural stone effect. The challenge: The visible parts and underside of the bridge’s arch had varying levels of texture. 

In order to replicate the original look as closely as possible, the two different textures were modelled and presented to the Preservation Office. Once approved, the formliners were created. In the precast plant, the angular edge blocks were poured individually, then finally assembled on site like Lego blocks. 64 visible concrete blocks form a 25 metre-long bridge arch.

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