Case Study: Steel Formwork System Delivered 200+ Reuses on German Bridge Project

01. The Challenge

A major infrastructure contractor in Germany was constructing the 1,500-meter Rader High Bridge replacement over the Kiel Canal—a steel composite structure requiring extensive in-situ concrete work for foundations, abutments, and 40-meter-high pier shafts . They faced three critical challenges:

• Complex pier geometries — 13 "standard piers" ranging from 21 to 41 meters in height, each cycle requiring dramatically different formwork dimensions 

• High concrete pressure — tall pier pours generated up to 100 kN/m² lateral pressure, exceeding most formwork systems' capacity 

• Safety at height — working at significant heights demanded completely enclosed, stable working platforms

They needed a formwork system with extreme load capacity, durability for 200+ uses, and adaptability to varied pier geometries.

02. The Solution: Steel Formwork System

The project deployed high-capacity steel formwork systems across multiple applications:

• SCF 60 self-climbing steel formwork for the 44-meter pier shafts — hydraulically climbing with fully enclosed working platforms 

• Custom 3D-curved steel formwork boxes for geometrically complex pier heads

• MANTO and RASTO steel panel formwork for foundations and abutments 

Key technical advantages:

• Load capacity up to 100 kN/m² — withstands full hydrostatic concrete pressure 

• 200–300 reuse cycles — industrialized steel formwork far outlasts timber alternatives 

• Hot-dip galvanized finish — corrosion resistance for long-term durability 

• Crane-operated climbing system — safe access and formwork repositioning at height 

03. Measured Results

Outcome: The construction management team confirmed: "All formwork systems met our expectations. They are efficient, easy to handle, and offer a high level of site safety. Everything fit!" 

04. Why Steel Formwork for Infrastructure?

For bridge piers, high-rise cores, and heavy civil works:

• Highest load capacity — 100 kN/m² max concrete pressure 

• 200–300 reuse cycles — lowest cost-per-use over project lifecycle 

• Climbing formwork compatible — safe work at height

Ready to power your next infrastructure project?

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