New agricultural building over 14 ha

The future livestock facilities will have room for up to 2,500 cows to produce around 70,000 to 75,000 litres of milk a day. The fresh milk will then be transported from the farm each day in three road tankers.

As the floor is horizontal, the incline within the wall formwork is created using supports produced by PASCHAL.

Expansion and addition

At present, the farming operation in Wiesenau already has dairy cattle housing for 1,250 animals, as well as two biogas facilities. After completion of the first construction phase, the 1,250 animals will be moved and space will be created for younger animals.
Biogas facility I has an installed electrical capacity of 526 kW per hour, while facility II has a capacity of 1052 kW per hour. The biogas facility in the current new building is designed to generate 330 kW and can provide energy for the entire operation.

Extensive construction activities in two construction phases

Since the laying of the first foundation stone in a celebration in April 2014, the construction activities on the 5 ha plot have been simultaneously running at full speed.
Bauerngesellschaft Ziltendorfer Niederung GbR is investing around 20 million euros in a completely new building with a biogas facility and the necessary infrastructure measures to be carried out in two construction phases.

To prepare for the actual construction measures, Oevermann Verkehrswegebau GmbH removed 52,000 m³ of farmland and installed 68,000 m³ of soil-improved recycled material for land levelling and modelling. In addition to the ground work, the company has also been commissioned with the necessary civil engineering work and the construction of around 50,000 m² of asphalt surfaces and roadways.

Vast dimensions

According to the drawings from the planning office of Matthias Thorwirth, three livestock buildings will be built, each 31.30 metres wide and 318.06 metres long.
A silo complex consisting of eight large storage tanks will also be added to the livestock facilities; the plan is to use these to store lucerne, grass and maize, all produced by the farm. Livestock and biogas facilities are to be seen as a cycle at the farming operation in Ziltendorf.

The milking house with adjacent staff rooms will be built in front of the livestock facilities, just like the buildings with waiting area and calving pen, a building for the calf hutches and calf pens and the straw barn planned in the immediate vicinity.

Concrete as the basis

Due to the mechanical and chemical loads, impermeable concrete will be used as the basis for all buildings and the necessary disposal channels.
This is because approx. 220 m3 of liquid manure are created each day in the three livestock buildings. Supply channels will be used to feed around 120 m3 of the manure to the new biogas facility and 100 m3 to the older biogas facilities. In addition, around 70 m3 of liquid manure will be produced on a daily basis in the new young cattle shed.

Preparations for the structural engineering measures began at the start of May 2014 in the form of supporting floor slabs for the three livestock facilities. Work is simultaneously being carried out on the main liquid manure channel with a length of 200 metres. La-Ge-Bau Wriezen GmbH is the building contractor in charge of this. The construction measures are being supervised and managed on site by Jürgen Bieniek, construction manager, and Rayk Rose, site office manager.

Over the course of construction, the formwork systems are delivered directly from the PASCHAL branch in Berlin to Wiesenau.
This articulated lorry was loaded with 19 tons and brought further LOGO.3 formwork panels to form around 400 m² of liquid manure channel interior walls.

Whenever possible, Karsten Grap, branch manager in Berlin, went to the site to oversee smooth delivery for himself.

Formwork planning with PPL

As the project progresses, the formwork planning is carried out with the formwork planning software PPL 10.0 by formwork consultant Harald Katt (PASCHAL branch in Berlin) and the rented formwork systems are then supplied accordingly.

It is currently planned to use the PASCHAL formwork systems Modular/GE, LOGO.3 steel, Circular Trapezoidal Girder Formwork for the concrete structures and PASCHAL Deck for the reinforced concrete slabs in the two-storey staff wing.

Circumferential reinforced concrete parapets

Along the outer contours of the floor slabs, the reinforced concrete parapets with a width of 20 cm and a height of 1.25 m are formed with 120 m² of Modular/GE as the construction progresses. After completion, the parapets will act as supports for the steel columns of the hall structure.

Main liquid manure channel

The main liquid manure channel with a width of 16.27 m and a length of 203 m will be installed in parallel with the concrete works for the livestock facilities.
La-Ge-Bau Wriezen GmbH also uses the LOGO.3 steel formwork system on a rental basis. An average of 800 m² of formwork will be provided for 3 to 4 months.
The floor of the inclined liquid manure channel is around 2.40 m to 3.25 m deeper than the upper edge of the ground. Given the high groundwater level and the highest possible groundwater level, all concrete structures are made from impermeable concrete of grade C25/35.
The concrete bases with a height of 1.25 m will be created with the Modular/GE formwork system.

The side walls of the main liquid manure channel are formed with the LOGO.3 formwork system on the inside and outside.
A combination of LOGO.3 panels with a height of 240 cm and a "horizontal" panel with a width of 55 cm is used here. The PASCHAL LOGO.3 formwork system in the steel design seen here is designed to withstand a fresh concrete pressure of 70 kN/m², complying with DIN 18281.

Sandwich construction

On the inside of the floor slab of the liquid manure channel and on the insides of the enclosing walls, a 2 mm thick HDPE plastic liner is welded in place and covered with a second concrete slab (18 cm thick) to protect against mechanical damage. Concrete stones are used laterally for mechanical protection.

Five concrete partition walls are built in the main liquid manure channel. These are formed with LOGO.3 steel to the full height of 220-303 cm.

The rotary milking parlour

200 m² of the Circular Trapezoidal Girder Formwork system are planned for the rotary milking parlour. Since the milker reaches his workstation on the parlour via a tunnel, the access route will be constructed in the form of a tunnel with two reinforced concrete stairwells. 350 m² of LOGO.3 steel are planned for this with a formwork height of 4.05 m.

The first concrete section with a height of 150 cm for the 25 cm thick reinforced concrete wall of the rotary milking parlour with a 22.00 m diameter will be formed with just under 210 m² of trapezoidal girder formwork.