TEMPORARY structures from Pilosio, a leading Italian manufacturer of building scaffolding, wall formworks and slabforms and retaining systems, are currently being used in the construction of three major buildings near the Grand Mosque in Makkah, Saudi Arabia.

Pilosio’s partner in this operation is the scaffolding and formwork division of Arabian Roots, a major building products distributor in Saudi Arabia.

The order – believed to be the largest in Pilosio’s history – follows an earlier success with a contract at the new Jeddah international airport.

Under the Makkah contract, Pilosio is supplying a huge quantity of Magnum Plus model vertical formwork, Simplex table and Linear flooring systems as well as MP multidirectional structures for the construction the three major buildings intended to serve the northern area of the Al Haram mosque.

On completion of construction, the first building will comprise 17 floors covering an overall area of 106,000 sq m. It will be 111 m tall, of which 80 m will be above ground. The 20-storey, second structure will comprise a total area of 154,000 sq m, with a height of 120 m, 97 m of which will be above ground. The 15-floor third building will comprise a built-up area of 72,000 sq m and will rise to 101 m (87 m above ground).

A wide range of formwork and support structures are being used on the project to facilitate construction, given the scale of the development.

Magnum Plus, a modular system of formwork for large areas, is the ideal solution for construction sites of large sizes and helps in obtaining a high level of productivity even under the most difficult conditions, says a spokesman for Pilosio.

The system is made up of a 240 by 300 cm base or reinforced panel, equal to 7.2 sq m, with four throughputs for opposing tie-rods and two connecting blocks. A few connection accessories enable large reinforced areas to be constructed and transported as a whole, in addition to facilitating single-side castings up to 7.5-m high, upward castings at height, wall and pillar castings 9 to 10 m high, and any other structures cast on site.

“Magnum formwork comes under Class 7 in accordance with prEN 15113-1. The maximum resistance to concrete casting pressures is 60 kN per sq m in the basic version and 100 kN per sq m for the reinforced version. The system is designed and made at Pilosio factories in accordance with the prEN 15113-1/206 ‘Vertical formwork – Part 1 performance requirements, general design and assessment’,” he says.

Highlighting some of the strengths of the Magnum Plus, the spokesman says: “The system ensures great modularity of the panels, which can be used both vertically and horizontally, and provides undersize compensation elements for precise positioning. The 240 by 300 cm base panel is the most robust of Pilosio’s formwork (411 kg), with specifications that allow use at up to 60/80 kN per sq m in the basic version, and up to 100 kN per sq m for the reinforced version.”

Other main advantages of the system are the high productivity of the large-size panel, the presence of a tie-rod every 1.8 sq m, a connecting block every 3.6 sq m, and a throughput with taper bushing. It is possible to cast with self-compacting concrete and combine Magnum with the Minimag panels, using the adjustable clamp. Additional benefits lie in the possibility of reinforcing the sloping panels, with a large range of accessories for every requirement (hinged corners, service shelves, sealing panels, support brackets and opposing beams) and three different options to reinforce the corner nodes, depending on the needs of the construction site.

Another Pilosio product used on site is the Simplex Table, a modular table for casting single-slab flooring. The tables are recommended for laying cast slabs of varying sizes and with lowered perimeter and internal beams. They are made up of two base frames connected diagonally and completed with brackets and screw-adjustable bases. The first and second order is provided with PL20 beams, while the counter cast surface comprises multilayer wood or a construction panel. Each table is transported by transfer wagons, while a rocker arm is used to move from one floor to the next with a single crane lift.

Linear, a semi-traditional system, is being used for the casting of floors on site with high-capacity props that support a primary and secondary order of wooden beams with protected ends. The system is suitable for floors cast in a single block, reinforced or lightweight concrete and also for traditional floors with beams. The counter cast surface can be in “yellow” panels or in various types of multilayers between 21 or 27 mm thick, depending on the architectural requirement and the degree of finish required.

The formwork system is made up of a number of elements: props of various diameters and capacities in accordance with the EN 1065 regulations, PL20 wooden beams in lengths of 330, 390, 490, 590 cm and protected at the ends, four-way head, intermediate head, drop head, 30 cm square for lowered beams and raised and corner beams of 25 cm for joining the floor.

Meanwhile, also used in the construction of the three buildings are MP support structures, comprising components of the MP multidirectional scaffolding with a series of specific accessories for slabs, beams or any other elements cast at heights. The choice of sizes of components available enables the construction of structures of any dimensions, the spokesman points out. The tower with a square base of 0.83 by 0.83 m or 1.15 by 1.15 m enables capacities of up to 5 kN for individual vertical mounting or a total of 20 kN for each tower.

“The extreme modularity of this type of structure allows any construction site problem of capacity or geometry to be solved,” says the spokesman. “It is possible to increase the capacity by doubling the uprights, to construct structures with a curvilinear or triangular base or any other shape to get around obstacles and even create supports for items with negative or positive inclinations. Using bases or adjustable brackets, the towers can also be used as a temporary counterbalance for works to stabilise structures under construction. Service stairs can also be provided for easy access at height.”