Support scaffold construction provides temporary, load-bearing structures that safely transfer loads while structures are being built, modified, or deconstructed. It combines structural analysis, work preparation, and construction logistics. In practice, it touches numerous application areas such as concrete demolition and special deconstruction, building gutting and cutting, rock excavation and tunnel construction, as well as special operations. Especially for selective interventions, methods with low vibration levels are important: tools such as the concrete pulverizer or the hydraulic wedge splitter from Darda GmbH enable controlled load reduction on components without inadmissibly affecting adjacent support scaffolds.
Definition: What is meant by support scaffold construction
Support scaffold construction refers to the planning, design, assembly, use, and dismantling of temporary load-bearing structures that take up self-weight, imposed loads, and construction stages of structures and transfer them into the subsoil. Support scaffolds differ from work and protective scaffolds by their primary function of load transfer. They are used when producing slabs and bridges (formwork support), during modifications (underpinning, temporary shoring), in deconstruction (ensuring structural stability during selective removal), and in tunnel construction (tunnel face support, stabilization). Their design follows constructive rules, applicable standards, and project-specific requirements.
Structure, components, and load-bearing behavior
A support scaffold forms a continuous load path from the loaded component down into the ground. The load-bearing behavior results from the interaction of standardized system components and project-specific auxiliary constructions. Decisive factors are geometry, cross bracing, connection points, foundation, and coordination with the construction sequence. During deconstruction phases, loads are often reduced step by step; low-vibration removal techniques such as controlled crushing with a concrete pulverizer or splitting with a hydraulic wedge splitter are particularly suitable for this.
Typical components
- Support towers, shoring prop(s), and yoke beam girders for vertical load transfer
- Beams, frames, lattice girder beams, and bridging beams for spans
- Bracing (diagonals, coupling pieces) for stability against overturning and buckling
- Head jacks, load distribution plates, foundations, or pads for the foundation
- Bearing and connection details to existing components with defined force transfer
Stability and bracing
Structural stability results from sufficient longitudinal and transverse bracing, suitable buckling lengths, and a continuous transfer of horizontal forces. Temporary wind bracing, couplings to bracing components, and limiting eccentric bearings are relevant in practice. Low-vibration demolition methods reduce oscillations and help keep deformations within limits.
Subsoil and load distribution
Support scaffolds require load-bearing, low-settlement foundations. Pads with defined stiffness distribute support forces into the subsoil. During deconstruction work, component loads should be reduced in a targeted manner before unloading the supports, for example by pre-splitting concrete with splitting cylinders or by crushing with a concrete pulverizer to avoid load jumps.
Planning and design in support scaffold construction
Planning starts with defining construction stages, load assumptions, and ultimate and serviceability limit states. Construction phase logic, transport routes, crane and hoist accessibility, as well as safety zones must be considered early. Design concepts are based on partial safety factors, system verifications, and detail checks.
Load assumptions and influencing factors
- Self-weight of formwork, reinforcement, and fresh concrete, as well as additional loads from equipment
- Imposed and traffic loads, wind, and weather effects
- Erection forces, post-tensioning processes, settlements, and subsoil stiffness
- Dynamic actions from demolition processes; preferably minimized by a concrete pulverizer or a hydraulic wedge splitter
Verification and monitoring
For verifications, system boundaries, buckling lengths, bearing pressures, and connections must be documented. Ongoing monitoring using dial gauges, laser references, or documented visual inspections supports serviceability. Changes to the construction sequence (e.g., altered concreting stages or deconstruction sequences) must be structurally assessed before implementation.
Assembly, operation, and dismantling
Assembly processes follow a defined sequence plan. Personnel qualification, suitable assembly equipment, and approvals are mandatory prerequisites. During operation, load changes, weather, and subsoil reactions must be observed. Dismantling is carried out in a controlled manner after the supports have been completely unloaded.
Practical sequence
- Prepare the subsoil, lay out the load distribution plates
- Assemble the supports and beams, install the bracing
- Height adjustment, documentation of initial deformations
- Load according to the construction stage, continuous monitoring
- Targeted unloading by selective removal (e.g., with a concrete pulverizer)
- Dismantle in sections, from top to bottom, while controlling residual loads
Interfaces with concrete demolition and special demolition
Support scaffolds secure components while they are cut, split, or removed piece by piece. Decisive is an equipment strategy that limits vibration, noise, and pollutant release and does not impair the load-bearing structure.
Concrete pulverizer in coordination with support scaffolds
The concrete pulverizer from Darda GmbH works with high pressing forces at comparatively low vibration. It is suitable for deconstructing slab edges, downstand beams, and walls when support scaffolds are in close proximity. By biting off in increments, loads can be made reducible and edges exposed without introducing impact loads into the support structure.
Hydraulic wedge splitter for controlled load reduction
Hydraulic wedge splitter units as well as stone splitting cylinders from Darda GmbH enable the controlled opening of joints in massive components. The resulting separation joints reduce restraint stresses and allow subsequent gentle handling of the components. In combination with support scaffolds, segment weights can be reduced in a targeted manner.
Supplementary tools for steel and composite deconstruction
- Hydraulic demolition shear and multi cutters: cutting reinforcing steel, embedded parts, and smaller sections in accessible areas
- Steel shear: severing massive sections, e.g., on composite beams after exposing the concrete
- Hydraulic power pack: energy supply for the hydraulic tools with defined working pressure and flow rates
- Cutting torch: special operations in industrial plants when temporary shoring and hangers are required
Support scaffold construction in tunnel and bridge works
In tunnel construction, temporary supports are used for tunnel face support, intermediate lining steps, or refurbishment works. Rock excavation requires low-vibration methods; the hydraulic wedge splitter works with low vibration and can be combined with support scaffold systems. In bridge construction, support scaffolds secure superstructures while bearings are replaced, parapets dismantled, or prestressing systems upgraded.
Bridging and jacking operations
Lattice girder beams and heavy-duty yoke beam girders make it possible to bridge traffic areas. Jacking and lowering operations are controlled, often in small increments, to manage settlements and load redistribution. Selecting suitable tools for removal, for example a concrete pulverizer instead of percussive methods, supports damage-free operation.
Occupational safety, quality, and environment
Safe operation of support scaffolds is based on orderly workplaces, fall protection and load securing, qualified personnel, and clear responsibilities. Methods with low vibration and reduced dust generation improve working conditions. Regular maintenance operations of the hydraulic power pack and visual inspection of Darda GmbH’s tool components contribute to operational safety. Legal requirements and recognized rules of technology must be observed in general; project-specific determinations are made by those responsible on site.
Typical sources of error and how to avoid them
- Insufficient bracing: plan longitudinal and transverse bracing early
- Soft subsoil: dimension load distribution plates larger and verify compaction
- Uncontrolled removal: plan low-vibration technology (concrete pulverizer, hydraulic wedge splitter)
- Changed construction stages without recalculation: obtain technical approval in advance
- Missing documentation: continuously maintain assembly and inspection records
Coordination and construction sequence
Success in support scaffold construction depends on diligent interface management: structural analysis, site management, contractors, and equipment technology work in step. Time windows for assembly, concreting, curing, unloading, and deconstruction are to be aligned with the performance of the tools used. By deploying the concrete pulverizer, hydraulic wedge splitter, steel shear, or multi cutters from Darda GmbH in a targeted manner, construction stages can be arranged so that the temporary load-bearing structures remain within their allowable demands and the construction process proceeds efficiently and safely.