When HCH Miller Park Joint Venture (Huber, Hunt and Nickels, Clark, Hunzinger) was awarded the contract for Miller Park, the new home of the Milwaukee Brewers, they had concerns about several important aspects of the concrete construction.

The first problem area was the 2,500 foot long, twenty foot tall perimeter wall for the service level of the ball park. They needed an architectural finish with a minimum of joints and tie holes to finish. To address this concern, Symons® by Dayton Superior proposed using 20' high by 10' wide Max‑A‑Form panels. The steel face of the forms provided the required finish, and the large size of the panels reduced the number of joints. In addition, the strength of the system allowed the contractor to use a high rate of pour even with just five Taper Ties per panel. The low number of ties saved the contractor time and labor in the setting and stripping operations and in patching tie holes.

A more complex area of the stadium design was the support beams for the rolling roof panels. The 1050' long, sixteen foot deep beams were supported by eight 150' tall steel towers as they curved together around the outfield. Solid baffle walls on top of each tower acted as stiffener beams between the support beams which varied in length and were not solid, but had a series of empty cores between the beams that gave the design a distinctive “waffle” look. In addition, the beams were not parallel to each other. Each roof section had a different pivot point behind home plate, and the radius and orientation of each one’s support beam reflected this slight, but important, difference.

Because of the complexity of the architectural plan, the design of the core elements presented a particular forming challenge. Each core was an untrue rectangle with fractional dimensions and slight curves on two sides. No two sides of any core had the same dimensions, and none of the corners had a 90 degree angle. In addition, the curved walls had to be within a 1∕8" tolerance using flat forms. These unusual challenges made precision difficult, but absolutely essential for this crucial element.

Symons proposed a scheme to form the cores almost entirely with standard Max‑A‑Form panels and stripping corners with Flex‑Form® fillers. The Flex‑Form fillers provided forming dimensions down to two inches, and all-steel 1" and 1½" Steel‑Ply® fillers provided dimensional adjustments down to ½". Quarter inch plywood strips provided even finer adjustments. Built on the ground with eight foot tall Max‑A‑Form and Flex‑Form pieces, the plans called for the core dimensions to be modified between each of the thirteen pours and lifted into place. The plans specified just four ties per row of panels, which simplified setting and stripping procedures in the tight spaces available inside the cores. The ties were spaced two feet down from the top of core wall and two feet up from the bottom to avoid densely configured rebar cages.

The only areas that could not be formed with standard parts were the corners at the intersec‑ tions of the support beams and the two outer tower caps. To avoid time-consuming job-built corners in these areas, the contractor chose to order custom stripping corners. Symons manufactured several sets of corners that were similar to standard stripping corners, but with‑ out stiffeners. These special corners could be “flexed” to meet the design requirements and keep the tight schedule on track.

The contractor was pleased with the thorough forming plans provided by Technical Services. Superintendent Dan Simonides reported that the forms set up and stripped well for all thirteen pours, and he was very satisfied with the productivity possible even on the complex support beams.

Flex-Form® System

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Max-A-Form® Forming System

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Steel-Ply® Concrete Forming System

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