Fire station, Leverkusen

The tender to build and operate the large complex of the fire station in Leverkusen for a period of 25 years was won by the Dresden branch of BAM Deutschland AG. Most of the walls were designed to make use of precast concrete elements – a total of 13 000 m², with 8000 m² in the form of cavity wall elements. A class 3 fair-face concrete finish was required in most places and the architects specified the joint patterns for walls and floors, with no post-treatment of surfaces. The joints between the precast concrete wall elements also had to satisfy the tough specification for the appearance of the concrete surfaces. Precast concrete elements are normally supplied with a first-rate surface finish. However, on some building sites, “bizarre” methods are sometimes used to seal the joints prior to pouring the in situ concrete: makeshift boards across the joints or foam injected into the gaps – all intended to prevent cement slurry from escaping.

Joint pattern shows what FLUXX can do

“Such slipshod methods not only result in poor-quality joints with an often substandard appearance, but the work involved and the materials consumed are totally disproportionate to the outcome,” says Dipl.-Ing. Stefan Spohr, owner of Krefeld-based MST distributor SpohrTec Schalungen. It was he who convinced the decision-makers at BAM of the benefits of using the FLUXX products from Mayer Schaltechnik to produce flawless joints. He continues: “Since Mayer Schaltechnik launched the FLUXX system in 2011, the use of timber battens and foam for sealing joints between cavity wall elements to prevent cement slurry leaking out has become a thing of the past. The bars are available in 1 m and 1.5 m lengths. They are simply fixed in the butt joints between the cavity wall elements with plastic locking anchors. Building with precast concrete wall elements has thus been rationalised enormously.” The bars made from galvanised and red powder-coated steel can be reused an “infinite” number of times and produce excellent joints in record time. To remove the bars, the plastic locking anchor is simply turned further until it breaks off, which leaves the FLUXX bar ready for the next joint.

Even with a wall height of 6 m, an elevating work platform was all that was needed to erect the precast concrete elements and fit the FLUXX bars in the joints. BAM site manager Tobias Theves has another bit of practical advice: “The FLUXX bar is an excellent product for achieving excellent joints with minimum input. However, to satisfy the highest demands regarding joint tightness, the self-adhesive FLUXX F6 foil tape, which is designed for the system and also available from Mayer Schaltechnik, should be attached to the bars so that leaking cement slurry really is ruled out completely.”


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