Sei sulla pagina 1di 28

B R I D G E C O N S T R U C T I O N P A R TN E R

PRECAST
SEGMENTAL
CONSTRUCTION
INSITU
CONSTRUCTION
HEAVY LIFTING
STAY CABLE
CONSTRUCTION
CONTENTS
VSL and Post-tensioning for Bridges --------------------------------- 3
Precast Segmental Erection
Balanced Cantilever Erection with Launching Gantry ------ 4
Span by Span Erection with Launching Gantry -------------- 6
Balanced Cantilever Erection with Lifting Frames ---------- 8
Balanced Cantilever Erection with Cranes ------------------ 10
Shatin T3 - Hong Kong (2004-2007)
Precast Beam Method -------------------------------------------- 12
Full Span Precast Method --------------------------------------- 14
Span by Span Erection on Falsework ------------------------ 16
Insitu Construction
Incremental Launching Method --------------------------------- 18
Form Traveller Method ------------------------------------------- 20
VSL Form Systems ----------------------------------------------- 22
Heavy Lifting Applications for Bridge Construction --------------- 24
Stay Cable Bridge Construction Industrial Ring Road - Thailand (2005-2006)

VSL SSI 2000 Stay Cable System ---------------------------- 26

Creve Coeur Lake - USA (1999-2003)

La Unidad Bridge - Mexico (2002-2003)


From Post-tensioning to Bridge Partner
VSL is recognised as a world leader in specialist construction
engineering and associated technology and services. Today, VSL
operates as a worldwide network through 40 subsidiaries
established on 6 continents. The Group is able to provide a full
range of technical and construction services for bridge construction,
including design evaluation, permanent works design, temporary
works design and construction engineering, precasting
management and bridge construction.

Innovative solutions worldwide Taiwan High Speed Rail C215 - Taiwan


(2000-2004)
VSL has contributed to some of the most prestigious and complex
bridge structures around the world, ranging from large span stay
cable bridges to conventional precast beam bridges. Recently,
the first full span bridge in Ductal® (Seonyu Footbridge, Korea)
has been designed and constructed by VSL, a structure that is
regarded as the most innovative ultra-high performance concrete
development in the last decade worldwide.

VSL has evolved from a specialist post-tensioning company into a


multi disciplined bridge partner, capable of providing contractors
and engineers with construction and engineering services for highly
complex and demanding projects. More importantly, the localised
organisation of VSL provides clients with innovative practical
designs and construction solutions adapted to suit the local market.

Promoting highly efficient rates of construction


With extensive experience in large infrastructure and superstructure
projects, VSL has a proven record of developing project specific
construction systems and methods that promote highly efficient
rates of construction and facilitate programme surety, while
maintaining and often improving essential safety and quality control
measures. Lateral thought processes encouraged within the design
and production teams provide a suitable environment in which to
nurture novel, and often remarkably simple solutions to demanding
problems. The exchange of knowledge within the VSL global network
enables the group's considerable experience to be fully utilised and
applied in a wide variety of engineering domains.
Shenzhen Western Corridor - Hong Kong
As a specialist bridge partner, VSL can bring the project team an (2004-2005)
extensive experience gained from erecting over 100,000 precast
bridge deck elements (providing almost 5 million square meters
of bridge surface), constructing multiple insitu bridges utilising VSL
form travellers and incremental launching methods and also being
involved in the construction of over 100 stay cable bridges.

VSL is committed to offering clients a 'best for project' service that


has recently led to the development and successful implementation
of various innovative Partnering and Alliancing arrangements that
have proved to be highly successful and mutually beneficial to all
parties involved.

Ilsun Bridge - Korea (2005-2007)

3
3
BALANCED CANTILEVER SPAN BY SPAN LIFTING FRAME CRANE PRECAST BEAM FULL SPAN PRECAST FALSEWORK INCREMENTAL LAUNCH

PRECAST SEGMENTAL ERECTION


BALANCED CANTILEVER ERECTION WITH

Telok Blangah - Singapore (1998-2001)


61,440m2 of deck, 1,460 segments

VSL has over 20 years experience in the permanent works designs in close construction sequences and methods
design and construction of precast cooperation and conjunction with while achieving optimal productivity. VSL
segmental balanced cantilever bridges. Designers and Consultants. is recognised as a world leader in precast
VSL in-house technical centres are VSL has the capability and necessary segmental erection and has worked
primarily involved in the design of erection experience to work with designers and extensively with international contractors
systems and associated temporary contractors to develop cost effective on technically demanding projects. VSL's
works, and have also completed many designs that promote safe, effective highly efficient erection systems enable

Rear Upper Cross Beam Front Upper Cross Beam


Main Truss
Rear Lower Cross Beam Front Lower Cross Beam
Rear Support Leg

Stitching Beam

Closure Stitch Formwork Stressing Platform


Segment Delivery on Completed Deck
or at Ground Level
Direction of Erection

N-1 N

4
FORM TRAVELLER FORM SYSTEM HEAVY LIFTING STAY CABLE

LAUNCHING GANTRY
FEATURES & ADVANTAGES

Delivery of segments along


completed deck to rear of
gantry minimises disruption to
existing traffic networks.

Necessary temporary works


require little ground
improvement and are generally
Taiwan C310 (1999-2001) Lai Chi Kok - Hong Kong (2004-2006) elevated, therefore causing
96,120m2 of deck, 1,823 segments 63,000m2 of deck, 1,771 segments minimal disruption to existing
roads, structures or services.

Support craneage is reduced


due to temporary works being
relocated by gantry.

Clear, unobstructed access to


all work fronts is provided
within gantry system.

Work can proceed on multiple


work fronts within the gantry, i.e
Shenzhen Western Corridor - Hong Kong Bayan Baru - Malaysia (2001-2003) pier segment erection,
(2004-2005) 90,800m2 of deck, 1,879 segments 31,063m2 of deck, 762 segments cantilever construction and
closure pour construction.

Temporary loads are


introduced directly into piers.

Fast rates of erection are


possible (up to 6 pairs of
segments per shift are
regularly achieved by VSL).

Shatin T3 - Hong Kong (2004-2007) Pakse Bridge - Laos (1998-2000)


65,800m2 of deck, 1,806 segments 16,284m2 of deck, 384 segments

contractors to minimise construction


durations while optimising quality. VSL
regularly achieves production rates
exceeding one cantilever per week.
Within the VSL organisation, there is an
extensive network of project managerial,
technical and production staff.

Typical Erection Cycle Duration: 6 Shifts


Description 1 2 3 4 5 6
Span N-1
Curing of Stitch (Overnight)
Continuity P.T.
Span N
Launch Gantry to Span N
Front Support Leg
Segment Erection Span N
Stitch N to N-1
Span N+1
Erect Pier Segment
Pier Bracket Align Pier Segment
Place Reinforcement
Place Formwork
N+1 Cast Insitu Diaphragm
Curing Pier/Column Joint
5
BALANCED CANTILEVER SPAN BY SPAN LIFTING FRAME CRANE PRECAST BEAM FULL SPAN PRECAST FALSEWORK INCREMENTAL LAUNCH

PRECAST SEGMENTAL ERECTION


SPAN BY SPAN ERECTION WITH LAUNCHING

Deep Bay Link - Hong Kong (2004-2005)


108,000m2 of deck, 3,014 segments

VSL has been involved in an extensive proven ability to provide Consultants, minimise additional temporary works
number of span-by-span precast Engineers and Contractors with innovative, required during the construction stage.
segmental projects in the Asia region and practical and cost effective solutions, Within the VSL network, an extensive pool
has recently completed large segmental proving to be mutually beneficial to all of suitably qualified personnel is available
infrastructure projects in South America. parties involved. to manage, supervise and operate the high
Often in the face of demanding design, VSL erection systems are developed to capacity erection gantries. Generally, in
program and site constraints, VSL has a optimise permanent works design and support of the production teams, each

Winch
Rear Support Leg Upper Cross Beam
Main Truss
Rear Lower Cross Beam

Hanger Beams

Segment Delivery at
Direction of Erection Ground Level

N-2 N-1 N

6
FORM TRAVELLER FORM SYSTEM HEAVY LIFTING STAY CABLE

GANTRY
FEATURES & ADVANTAGES

Flexibility to use overhead or


underslung gantries.

Fast rates of erection are


possible due to use of
external post-tensioning (VSL
has achieved rates of
erection exceeding 1 span
Metro de Santiago - Chile (2004-2005) Deep Bay Link - Hong Kong (2004-2005) every 24 hours).
72,000m2 of deck, 2,156 segments 108,000m2 of deck, 3,014 segments

Segment delivery is possible


along completed deck to rear
of gantry or at ground level.

Smaller crew size is required


compared to balanced
cantilever construction.

Good access provided within


the gantry to all work fronts.

West Rail - Hong Kong (1999-2002) Bandra Worli - India (2002-2006)


116,667m2 of deck, 8,642 segments 132,130m2 of deck, 2,332 segments

Penny's Bay - Hong Kong (2003-2004) Pusan - Korea (1993-1997)


16,240m2 of deck, 627 segments 39,900m2 of deck, 1,434 segments

project will have a project specific technical required. Regular erection rates achieved
team responsible for providing details, and are 1 span per 2.5 days with underslung
advising on and monitoring the works to gantries, and 1 span per 4 days with
ensure all necessary technical and safety overhead gantries. Being allowed to
aspects are provided for. In addition, operate 24-hour a day, VSL recently
various VSL technical centres are utilised achieved in Chile a typical erection cycle of
to provide specific assistance if and when 1 span every 24 hours.

Typical Erection Cycle Duration: 4-Day Cycle


1 2 3 4
Description
D/S N/S D/S N/S D/S N/S D/S N/S

Launching of Gantry

Segment Placing

Segment Alignment / Gluing


Front Support Leg
Wet Joint Casting

Curing (Overnight)
Front Lower Cross Beam
Installation of External P.T.
N+1
Stressing of External P.T.
7
BALANCED CANTILEVER SPAN BY SPAN LIFTING FRAME CRANE PRECAST BEAM FULL SPAN PRECAST FALSEWORK INCREMENTAL LAUNCH

PRECAST SEGMENTAL ERECTION


BALANCED CANTILEVER ERECTION WITH

West Tsing Yi - Hong Kong (2004-2005)


14,000m2 of deck, 250 segments

VSL continually develops innovative lifting Extensive studies conducted by our projects with considerable delivery
solutions applicable to precast segment t e c h n i c a l c e n t r e s f ac i l i t a t e t h e constraints. VSL lifting frames are self-
erection. VSL strand lifting units, development of project specific lifting c o n t a i n e d an d i n c o r p o r a t e s a f e
incorporating multiple safety features are s y s t em s . P r ec as t e l em e n t d e l i v e r y unobstructed working platforms and
regularly utilised, providing a large range usually governs the method adopted accesses to all necessary locations.
of lifting capacities whilst allowing precise and VSL have successfully operated Following assembly, installation and
alignment and placement of segments. l i f t i n g f r am es s u i t ab l e fo r u s e o n commissioning by suitable cranes, VSL

Upper Cross Beam


Rail Beam Lifting Frame

Stitching Beam

Alignment/Support
Stressing Platform
Bracket

Lifting Spreader Beam Stressing Platform


Closure Stitch Formwork
Segment Delivery at
Ground Level
N-2 N-1 N

8
FORM TRAVELLER FORM SYSTEM HEAVY LIFTING STAY CABLE

LIFTING FRAMES
FEATURES & ADVANTAGES

Relatively simple temporary


works requirements.

High rates of erection.

Large segments can be erected.

Gopeng Flyover - Malaysia (2003-2004) Optimised crew cycles.


12,240m2 of deck, 262 segments
Multiple levels of segment
alignment and adjustment
are possible.

Strand lifting units can be


adopted and provide several
levels of safety features.

Lai Chi Kok - Hong Kong (2004-2005) Quarashia Bridge - Saudi Arabia
63,000m2 of deck, 1,771 segments (1989-1990) 12,820m2 of deck, 143 segments

Kisosansen Bridge - Japan (1998-2001) Shenzhen Western Corridor - Hong Kong


90,000m2 of deck, 344 segments (2004-2005) 90,800m2 of deck, 1,879 segments

lifting frames can operate independently. been utilised. VSL technical centres precamber calculation. VSL's experienced
VSL lifting systems incorporate two typically work with engineers to supervisory teams regularly achieve
primary hydraulic systems providing both incorporate necessary lifting system tie erection cycles of two pairs of segments
lifting and self-launching mechanisms. down into the permanent works, to ensure per shift.
When high lifting speeds are required, suitable load introduction into the
generally greater than 20 meters per hour, permanent works and also provide stage
tandem lifting units or winch systems have by stage analysis, geometry control and

Typical Erection Cycle Duration: 13 Shifts


Hanger Beams Description 1 2 3 4 5 6 7 8 9 10 11 12 13
Erect & Assemble Lifting Frames &
Brackets on Pier Head
1st pair of field segments erected by crane.
Segment Erection - Pair 1
Segments are suspended from hanger beams
or lifting frames when there is a wet joint. Wet Joint Construction

Wet Joint Curing

Segment Erection - Pair 2-3


Pier Segment Erection by Crane
Segment Erection - Pair 4-5

Segment Erection - Pair 6-7

Segment Erection - Pair 8-9

Segment Erection - Pair 10-11

Segment Erection - Pair 12-13


N+1 N+2
Remove Lifting Frames
9
BALANCED CANTILEVER SPAN BY SPAN LIFTING FRAME CRANE PRECAST BEAM FULL SPAN PRECAST FALSEWORK INCREMENTAL LAUNCH

PRECAST SEGMENTAL ERECTION


BALANCED CANTILEVER ERECTION WITH

West Rail - Hong Kong (1999-2002)


8,330m2 of deck, 617 segments

Erection using suitable mobile craneage VSL project teams provide detailed production team to develop additional
has frequently been executed by VSL, craneage studies helping to optimise crane temporary works, in particular pier
particularly in relation to balanced cantilever usage while minimising disruption to the segment supports and access
construction. When site and ground surrounding environment. In particular, VSL requirements. VSL is capable of offering
conditions are suitable, this method of has assisted contractors to develop and stage-by-stage analysis and detailed
erection has proved highly effective and can implement temporary traffic management precamber calculation. With careful project
facilitate considerable rates of erection. schemes. VSL technical centres work with design and management, cranes of varying

Stressing Platform
Stitching Beam Hanger Beams

Closure Stitch Formwork


Segment Delivery at
Alignment/Support Bracket Ground Level

N-2 N-1 N

10
FORM TRAVELLER FORM SYSTEM HEAVY LIFTING STAY CABLE

CRANES
FEATURES & ADVANTAGES

Temporary works
requirements are minimised.

Fast rates of erection are possible.

Multiple work fronts are possible.

Optimised crew size.

Minimal engineering requirements.

Cranes are generally readily


available in the market.

Cranes can be utilised to


execute other activities.

Shatin T3 - Hong Kong (2004-2007)


65,800m2 of deck, 1,806 segments

Lai Chi Kok - Hong West Rail - Hong


Kong (2004-2006) Kong (1999-2002)
West Link - Australia (2004-2005) 63,000m2 of deck, 8,330m2 of deck,
86,000m2 of deck, 3,013 segments 1,771 segments 617 segments

types and capacities have been utilised by


VSL to achieve the best operating results.
Typical erection rates are up to 6 segments
per day.

1st pair of field segments erected by crane. Typical Erection Cycle Duration: 8 Shifts
Segments are suspended from hanger beams Description 1 2 3 4 5 6 7 8
if there is a wet joint to be cast.
Installation of
Pier Segment Support Brackets

Installation of Pier Segment


Pier Segment Erection by Crane

Segment Erection - Pair 1-3

Segment Erection - Pair 4-6

Segment Erection - Pair 7-9

N+1 N+2
Segment Erection - Pair 10-12
11
BALANCED CANTILEVER SPAN BY SPAN LIFTING FRAME CRANE PRECAST BEAM FULL SPAN PRECAST FALSEWORK INCREMENTAL LAUNCH

PRECAST SEGMENTAL ERECTION


PRECAST BEAM METHOD

N-S Link - Jakarta (1989-1991)


2,000 beams

VSL has considerable experience in the erection system to be adopted. VSL has In addition to the erection of primary
erection of various precast beam structures. utilised a variety of launching girders, beam structural members, VSL has also been
Methods of erection have been developed launchers and lifting frames, capable of responsible for the complete construction
following extensive studies relating to site receiving precast beams directly behind, of bridge decks including placement of
constraints. Generally, the delivery of below or in parallel to the erection system. precast planks, and insitu works. VSL's
precast beams to the erection front is the I beams, U beams and T beams have been experienced project specific
determinant that influences the method of erected extensively. management, supervisory and technical

Rear Lower Cross Beam


Rear Upper Cross Beam Main Truss Front Lower Cross Beam
in Lifting Position Front Upper Cross Beam
in Lifting Position
Rear Support Leg

Support Tower
Beam Delivery at Ground Level

Direction of Erection

N-2 N-1 N

12
FORM TRAVELLER FORM SYSTEM HEAVY LIFTING STAY CABLE

FEATURES & ADVANTAGES

Fast rates of erection.

Relatively simple erection


gantry, or crane erection.

Beam delivery possible


along completed deck to
rear of gantry, thus
Palau Island Bridge - Palau (2003-2005) Cebu Coastal Road - Philippines (2001-
minimising disruption to
4,000m2 of deck, 52 beams 2002) 24,000m2 of deck, 320 beams
existing traffic networks.

Small works crew size.

Geometry control is minimised.

Precast beam production is


relatively simple and requires
low levels of mechanisation.

Sarasin Bridge - Phuket, Thailand East Coast Parkway - Singapore (1981)


(1991-1992) 7,800m2 of deck, 182 beams 68,250m2 of deck, 180 beams

Tutong Lumut Coastal Highway - Brunei Saraburi - Thailand (1994-1995)


(2001-2003) 6,100m2 of deck, 210 beams

teams facilitate rates of erection often Tandem lifting of full span precast beams
exceeding one span per day. with cranes has also been adopted
With the precast beam method, strand and facilitating the lifting of large loads often
winch lifting units are utilised, providing exceeding 100 tonnes in weight and 40m
safe and precise placement of precast in length.
elements, allowing multiple degrees of
alignment and efficient rates of erection.

Typical Erection Cycle Duration: 2-Shift Cycle (Hours)


Shift - 1 Shift - 2
Description (10 Hour Shift) (10 Hour Shift)

Lift and place 1st beam (outer most) with


precast plank on top

Lift and place 2nd beam with precast plank


on top

Lift and place 3rd beam with precast plank


on top
Front Support Leg
Lift and place 4th beam with precast plank
on top

Reposition the intermediate planks into


final position

N+1 Move gantry to center viaduct then launch


to next span
13
BALANCED CANTILEVER SPAN BY SPAN LIFTING FRAME CRANE PRECAST BEAM FULL SPAN PRECAST FALSEWORK INCREMENTAL LAUNCH

PRECAST SEGMENTAL ERECTION


FULL SPAN PRECAST METHOD

Taiwan High Speed Rail C215- Taiwan


(2000-2004) 260,000m2 of deck, 602 spans

The full span precast method of erection erection, with specific references labour and necessary plant requirements.
is particularly suited to projects including the Taiwan High Speed Rail Other than access to the pier heads, very
comprising multiple spans of similar Project and the Singapore MRT. little temporary works are required and
length which have minimal horizontal radii. Full span precast elements can be follow up activities are minimised.
Typically rail networks are most suitable constructed in a static casting yard under Rapid rates of erection are achievable, and
for this method of erection. VSL has factory conditions which facilitate improved VSL has obtained erection rates of 2 spans
considerable experience in this field of safety and quality while also optimising per day. Delivery of precast elements along

Launching Carrier
Delivery of Precast Span along Completed Deck Rear Lifting Frame Front Lifting Frame Front Trailer
by Launching Carrier
Lifting Winches
Rear Trailer

Rear Fixed Leg


Direction of Erection
Rear Mobile Support

N-1 N N+1

14
FORM TRAVELLER FORM SYSTEM HEAVY LIFTING STAY CABLE

FEATURES & ADVANTAGES

Very high rate of production,


with very high quality.

Minimal follow up works.

Full span production in factory


environment allows
improvements in quality of
Taiwan High Speed Rail C215 - Taiwan Seven Mile Bridge - USA (1980-1982)
precast elements.
(2000-2004) 260,000m2 of deck, 602 spans 130,000m2 of deck, 265 spans

Delivery of elements to rear of


gantry is possible along
completed deck therefore
minimising disruption to
existing traffic networks.

Reduced on site activities,


improves safety and
environmental concerns.

Minimal additional temporary


Taiwan High Speed Rail C215 - Taiwan MRT - Singapore (1985-1989) works are required.
(2000-2004) 260,000m2 of deck, 602 spans 114,000m2 of deck, 1,000 spans

Taiwan High Speed Rail C215 - Taiwan MRT - Singapore (1985-1989)


(2000-2004) 260,000m2 of deck, 602 spans 114,000m2 of deck, 1,000 spans

the completed deck reduces disruption to


existing traffic networks and helps
minimise ground improvement works that
would otherwise be required to transport
large elements at ground level.

Typical Erection Cycle Duration: 1-Day Cycle (Hours)


Description 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
Delivery New Span from Yard to
Erection Site
Support Beam
Erection of New Span

Return Launching Carrier to Yard

Launching Carrier Available for


Yard Handling
Load New Segment into
Launching Carrier
Front Mobile Support
Load Transfer from Temporary to
Permanent Bearings
Front Fixed Leg
Prepare Permanent Bearings
for Grouting
N+2 N+3
Grout Permanent Bearings
15
BALANCED CANTILEVER SPAN BY SPAN LIFTING FRAME CRANE PRECAST BEAM FULL SPAN PRECAST FALSEWORK INCREMENTAL LAUNCH

PRECAST SEGMENTAL ERECTION


SPAN BY SPAN ERECTION ON FALSEWORK

Deep Bay Link - Hong Kong (2004-2005)


108,000m2 of deck, 3,014 segments

V S L h as ad o p t e d t h e f a l s e w o r k incorporated to enable temporary segment segments. VSL engineering and


s u p p o r t m e t h o d o n m an y p r e c as t support, alignment and load transfer onto production staff conduct extensive logistic
segmental projects. piers. Typically, segments are loaded onto studies relating to site access, segment
Dependent upon the imposed loading and the falsework support using suitable handling and temporary foundation needs.
the effective height, conventional scaffold craneage. However, if access is limited, Modular support systems are adopted to
support or heavy shoring systems are VSL has also developed alternative minimise relocation durations and to
utilised. Hydraulic systems are solutions for the handling and loading of optimise erection rates. Long span support

Relocation of Falsework Support

Span Jack Span Jack


Falsework Support Stressing Platform

Segment Delivery at Ground Level

N-2 N-1 N
Temporary Support
16
FORM TRAVELLER FORM SYSTEM HEAVY LIFTING STAY CABLE

FEATURES & ADVANTAGES

Minimised engineering
requirements are possible.

Modular support system can


be relocated with ease and
relatively quickly.

Work can proceed on multiple


West Rail - Hong Kong (1999-2002) Penny's Bay - Hong Kong (2003-2004)
work fronts.
116,667m2 of deck, 8,642 segments 16,240m2 of deck, 627 segments

Production crew size is fully


utilised and optimised.

Good access is provided to all


work fronts.

Deep Bay Link - Hong Kong (2004-2005) Penny's Bay - Hong Kong (2003-2004)
108,000m2 of deck, 3,014 segments 16,240m2 of deck, 627 segments

West Link - Australia (2004-2005) East Rail - Hong Kong (2000-2003)


86,000m2 of deck, 3,013 segments 58,320m2 of deck, 4,449 segments

structures are often developed to cater for


road or rail crossings. Support structures
incorporate access and working platforms
and may include suspended containments
to manage falling debris. Typical erection
rates are up to one span every three days.

Typical Erection Cycle Duration: 4-Day Cycle (Days)

Description 1 2 3 4

Installation of Scaffold Support

Erection of Segments

Alignment and Gluing

Post Tensioning Operations

N+1 Load Transfer onto Permanent Bearings

17
BALANCED CANTILEVER SPAN BY SPAN LIFTING FRAME CRANE PRECAST BEAM FULL SPAN PRECAST FALSEWORK INCREMENTAL LAUNCH

INSITU CONSTRUCTION
INCREMENTAL LAUNCHING METHOD

Kemena Bridge - Malaysia (2003-2005)


32-53m of span length, 4,947.6m2 of surface

The principle of the incrementally superstructure is then jacked forward a construction can be used for bridges
launched bridge consists of building the distance equal to the length of this having constant cross sectional shape
superstructure segments in a casting yard segment. This process is repeated until throughout their length. The bridge should
located behind the bridge abutment. Each the bridge is in its final position. Additional be straight or have a constant horizontal
segment is matchcast against the previous continuity prestress is then installed and and vertical curvature.
one and prestressed to the section of the temporary bearings are replaced by the The incrementally launched bridge has
superstructure already built. The entire permanent bearings. This form of several advantages. It eliminates the

Casting Bed
Direction of Launch

Monolithic or Stressed Connection


Vertical Reaction Beams to 1st Segment
Pulling Jack Launching Nose
Launching Bearings

Lateral Restraint
Scaffolding for Access

N N+1 N+2 N+3

18
FORM TRAVELLER FORM SYSTEM HEAVY LIFTING STAY CABLE

FEATURES & ADVANTAGES

Concentrated work front optimises


craneage requirements.

Site constraints such as poor


ground and access restriction
can be minimised.

Minimal temporary works.


Brides Glens Bridge - Ireland (2003-2004)
45.9-65m of span length, 3,200m 2 of surface
Seven-day cycle is achievable if
overtime is allowed.

Require only a moderate


investment in specialised
equipment such as launching
nose, launching jacks,
conventional jacks, launching
bearings and guides.

Rybny Potok - Czech Republic (2005) Caguanas River Bridge - Puerto Rico
58m of span length, 10,858m2 of surface (1981) 385m of bridge length

Tampanies Sengkang Flyover - Singapore (2002-2003)


24.5-63m of span length, 10,623.85m2 of surface

traditional scaffolding required for a precasting yard. The precasting work is


supporting the formwork. This is particularly thus more easily supervised, giving a high
valuable for projects with high piers, in quality of workmanship. However, it should
urban areas, spanning over deep water, be noted that the post-tensioning
over roads and over railways. Most of the requirements for the launching operations
construction operations take place in the usually result in higher quantities when
same location, which may be organised as compared with other construction methods.

Duration: 8-Day Cycle (Days)


TYPICAL CONSTRUCTION SEQUENCE Typical Construction Cycle

Cast segment (A), Description 1 2 3 4 5 6 7 8

(A) install launching nose, Launch Segment


install pulling units
Strip and Clean Forms

Install Base and Web Rebar


Pull segment (A) forward
Install Web Forms
(A) using pulling jacks attached
to reaction beam Concrete Base and Webs

Install Inner Forms

Construct segment (B), Install Top Slab Rebar


repeat stage Y and Z for Concrete Top Slab
(B) (A) remaining segments
Curing

Stress P.T.
19
BALANCED CANTILEVER SPAN BY SPAN LIFTING FRAME CRANE PRECAST BEAM FULL SPAN PRECAST FALSEWORK INCREMENTAL LAUNCH

INSITU CONSTRUCTION
FORM TRAVELLER METHOD

Taiwan High Speed Rail - Taiwan (2002-2003)


80-100m of span length, 22 cantilevers

Developed from our earlier form traveller casting lengths can be adopted to suit craneage during assembly, erection and
systems, VSL has produced a engineers' designs. relocation. Unobstructed working
standardised modular form traveller Mechanical and hydraulic systems built in platforms and access are incorporated into
system, applicable to most contemporary to the form traveller system ensure the form system.
bridge designs. This highly flexible precise control of the bridge during Reinforcement and concreting operations
system allows efficient use on bridges construction. The lightweight modular have been optimised by minimising
with different cross sections. A variety of system requires minimal support obstruction caused by the form traveller.

Main Frame

Front Transverse Truss


Form Traveller Anchoring Jack Form Traveller

Rail Beam Stitching Beam


Outer Roller Beam

Closure Stitch Formwork


End Span Falsework
Lower Front Transverse Beam
Lower Rear Transverse Beam

N N+1

20
FORM TRAVELLER FORM SYSTEM HEAVY LIFTING STAY CABLE

FEATURES & ADVANTAGES

VSL modular form travellers


are readily available and can
be obtained quickly without
major re-engineering required.

Long-span bridge structures


with access constraints can be
easily accommodated.
Deep Bay Link - Hong Kong (2004-2005) H-3 North Halawa Valley Viaduct -
71.5m of span length, 28 cantilevers Hawaii (1990-1992)
Craneage capacity
requirements are minimised.

Crew efficiency between 1 pair


of form travellers is optimised.

Sinu Bridge - Columbia (2005) Ma Wan - Hong Kong (1999)


150m of main span length, 2 cantilevers 48m of main span length, 15 cantilevers

Chenur Bridge - Malaysia (2002-2004) Angara River Bridge - Russia (2000-2005)


140m of main span length, 7 cantilevers 105m of main span length, 5 cantilevers

Typical cycles of 5 days per pour are asymmetrical construction resulting in


regularly achieved. If required, steam curing optimal usage of labour resources. Project
can also be incorporated into the form specific forms are also developed to
system resulting in typical cycles of 4 days construct the pier head.
per pour. VSL technical centres continually
work with engineers to optimise post-
tensioning arrangements, often facilitating
Typical Construction Cycle Duration: 5-day cycle, 12 hours per day
Day 1 Day 2 Day 3 Day 4 Day 5
Description 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7

Removal of stop end form and form ties


End span constructed using Form Traveller Installation of strand
Stressing of cantilever P.T.
Stripping of outer, inner, bottom form
Launching and fixation of rail beam

Bridge Abutment Launching and fixation of main frame


Cleaning of form panels
Rolling back of inner web forms
Adjust / Close outer and bottom forms
Placing P.T. ducts / inserts for bottom slab / webs
Launch inner web forms, adjust / close inner web forms
Placing reinforcement / P.T. ducts / insert for upper deck
and cantilever wing
Final survey / check of level / alignment
Temporary Support
Pour concrete
Curing - Traveller #1
Curing - Traveller #2
Traveller #1 Traveller #2
BALANCED CANTILEVER SPAN BY SPAN LIFTING FRAME CRANE PRECAST BEAM FULL SPAN PRECAST FALSEWORK INCREMENTAL LAUNCH

INSITU CONSTRUCTION
VSL FORM SYSTEMS

Photos of this page:


Stonecutters Bridge - Hong Kong

VSL has considerable experience in a operation, VSL is also able to provide complete establishment and operation of
wide variety of insitu form system ranging detailed design, supply and operation of the casting yard including reinforcement
from self climbing form systems utilised precast cells required for precast and concreting operations.
for pier and pylon construction to large segmental bridge decks, precast beams, VSL form systems are generally modular,
span underslung movable scaffold and also full span precast elements. light weight and provide clear unobstructed
support systems. Recently, on the Taiwan High Speed Rail access to all necessary working areas.
To complement any precast erection Project, VSL was responsible for the Mechanised VSL Form Systems facilitate

22
FORM TRAVELLER FORM SYSTEM HEAVY LIFTING STAY CABLE

Tsing Ma Bridge - Hong Kong Tsing Ma Bridge - Hong Kong Taiwan High Speed Rail C215 - Taiwan
Pier climbform Pier climbform Pretensioning bed and form

Kisosansen Bridge - Japan Kisosansen Bridge - Japan Taiwan High Speed Rail C215 - Taiwan
Match cast short line cells Match cast short line cells Pretensioning bed and form

Pakse Bridge - Laos Metro de Santiago - Chile Metro de Santiago - Chile


Match cast long line Match cast long line Match cast long line

Ahnpyung Bridge - Korea Bandra Worli - India


MSS Match cast short line cells

casting of highly complex structures with The VSL Climb Form System will generally
variable geometric properties, and achieve an optimal cycle of three days per
produce high quality finishes often four meter lift, however, due to the modular
required by clients. arrangement of the system, variable lift
VSL managed casting yards regularly heights can be accommodated with
achieve precast segmental production rates relative ease up to a maximum lift height
of up to one segment per day, per cell. of six meters.

23
BALANCED CANTILEVER SPAN BY SPAN LIFTING FRAME CRANE PRECAST BEAM FULL SPAN PRECAST FALSEWORK INCREMENTAL LAUNCH

HEAVY LIFTING APPLICATIONS FOR BRIDGE

Bridge at Miraflores - Spain (2005)


Two lowering operations of main arch (1,360t each)

For economic or technical reasons, Unique Solutions The extensive experience of VSL
today's bridge structures are often personnel and VSL's exceptional track
VSL will plan lifting, horizontal jacking, or
assembled from large, heavy, pre- record provide further assurance of
lowering operations and design the
fabricated elements. For projects in which reliable performance.
necessary temporary structures to suit the
cranes or other conventional handling
requirements of the projects. Sound Flexibility
equipment cannot be used because of
engineering, clear thinking, the ability to
excessive weight, dimensions or space VSL's range of equipment provides the
innovate, and years of successful
limitations, VSL Heavy Lifting will often capability to lift or lower single loads
experience provide a guarantee of reliable
provide the most effective solution. well in excess of 10,000t and includes
and cost-effective solutions.
a large range of hydraulic jacks, pumps,
VSL Heavy Lifting provides contractors,
controls units, monitoring devices, and
engineers and owners with a broad
modular lifting/jacking frames. Thus,
range of advantages, including: Safety
VSL has both the capability and flexibilty
Economy and efficiency, through The safety of personnel and components to perform virtually any project requiring
custom designed solutions. are VSL's first priority. Specialised lifting, lowering or horizontal jacking.
hydraulic lifting equipment is designed
R e l i a b i l i t y, b as e d u p o n s o u n d The VSL Service Package
for the highest level of reliability, and all
e n g i n e e r i n g an d t h r e e d ecad es
equipment is rigorously tested and VSL offers a complete range of services
of experience.
serviced through VSL's quality control for the planning, engineering, equipment
The highest level of safety through the and maintenance program. VSL field supply and execution of any heavy lifting
use of advanced and reliable services are also based upon a total project. VSL Heavy Lifting services
hydraulic equipment. commitment to safety. provided throughout the world include:

24
FORM TRAVELLER FORM SYSTEM HEAVY LIFTING STAY CABLE

CONSTRUCTION
FEATURES & ADVANTAGES

Economy and efficiency through


custom designed solutions.

Suitable for any heights and


any kind of loads.

High level of safety as load is


always secured mechanically.
Infiernillo II Bridge - Mexico (2000) Industrial Ring Road - Thailand (2005-
Lifting of 3 arched steel trusses (600t each) 2006) Lifting of 500t bridge deck segment
Reliability based on 35 years of
solid experience.

High flexibility with lifting units


from 10t to 600t capacity.

Lifting levels and loads with


extremely tight tolerances are
monitored and maintained with
highly precise computer-aided
control system.

Lanjaron Viaduct - Spain (2001) Weser Bridge Hehlen - Germany Very high capacity to the
Launching over deep valley with fishing line principle Crane assisted launching over the river selfweight ratio.

Dreirosen Bridge - Basel Switzerland


Lifting and floating in of 4 steel trusses (540t each)

Loire River Bridge - France VSL Heavy Lifting Equipment (from left)
Lifting of centre span (2,400t) Hydraulic pump, lifting unit, strand coiler

Feasibility studies and preliminary Design, manufacture and supply of The planning of a heavy lifting operation
consultation for lifting, horizontal special equipment and temporary should be started as early as possible.
jacking and lowering operations. structures, if required. Early involvement of VSL specialists will
result in a handling scheme that
Project design and planning, L eas i n g an d o p e r a t i o n o f V S L
optimises the project's economy,
equipment specification, scheduling equipment and execution by VSL
efficiency and schedule.
and budgeting. or others.

25
BALANCED CANTILEVER SPAN BY SPAN LIFTING FRAME CRANE PRECAST BEAM FULL SPAN PRECAST FALSEWORK INCREMENTAL LAUNCH

STAY CABLE BRIDGE CONSTRUCTION


VSL SSI 2000 STAY CABLE SYSTEM

La Unidad Bridge - Mexico (2002-2003)


Main span length: 240m

Industrial Ring Road - Thailand (2005-2006) Sucharskiego Bridge - Poland (2000-2001) Europa Bridge - Portugal (2000-2002)
Main span length: 398m & 326m Main span length: 230m Main span length: 185.6m

The VSL SSI 2000 Stay Cable System is resistance, excellent corrosion In the basic configuration the system
acknowledged as being one of the protection, easy monitoring and incorporates greased and sheathed
leading systems currently available. The maintenance. Installation and monostrands contained within a
system is based around the proven VSL replacement is carried out using strand continuous external HDPE stay pipe, with
strand and wedge anchorage technology by strand method which has the benefit no grouting in the cable. Additional
and is designed to meet the most of requiring very little space and which enhancements can be offered including;
stringent criteria offering high fatigue utilises relatively light weight equipment. metalisation (galvanising) of the

26
FORM TRAVELLER FORM SYSTEM HEAVY LIFTING STAY CABLE

FEATURES & ADVANTAGES

High fatigue resistance.

Compatible with modern


construction methods;
compact anchorages fully
prefabricated in workshop,
single strand installation with
light equipment, easy force
Wadi Leban Bridge - Saudi Arabia Neva Bridge - Russia (2002) monitoring and adjustment.
(1997) Main span length: 405m Main span length: 382m

Full encapsulation of strand


inside the anchorage.

Faster installation and erection


cycles, reduced maintenance.

Designed to receive in the


future vibration damping
systems if necessary.

Ability to remove and to replace


individual strands if necessary.
Peldar Bridge - Colombia (2003) US Grant Bridge - USA (2003)
Main span length: 120m Main span length: 267m
Factory applied individual
protection treatment, up to 100
years design life in the most
aggressive environments.

Yichong Yiling Bridge - Hubei, China Safti Bridge - Singapore (1995)


(2001) Main Span Length: 348m Main span length: 99m

Taney Bridge - Ireland (2002) Batam Tonton - Indonesia (1997) Uddevalla Bridge - Sweden (1998)
Main span length: 109m Main span length: 350m Main span length: 414m

monostrands for additional corrosion In addition to the design, supply and supply of the necessary temporary works
protection, coloured HDPE stay pipes, installation of the stay cable system, VSL and construction equipment.
helical ribbing on the stay pipes to reduce is able to offer clients a full range of
risk of wind rain induced cable vibrations, specialist bridge construction services from
and the VSL Friction Damper one of the stage by stage construction analysis to the
most efficient and robust forms of cable actual construction of the entire
damping available. superstructure including the design and

27
YOUR BRIDGE PARTNER
HEADQUARTERS
VSL International Ltd.
Scheibenstrasse 70 - Bern - CH-3014 - Switzerland
Phone: +41 32 613 30 30 Fax: +41 32 613 30 55
www.vsl.com

AMERICAS EUROPE ASIA


ARGENTINA AUSTRIA PORTUGAL BRUNEI VIETNAM
VSL Sistemas Especiales de Grund-Pfahl- und Sonderbau GmbH VSL Sistemas Portugal VSL Systems (B) Sdn. Bhd. VSL Vietnam Ltd.
Construcción Argentina S.A. HIMBERG Pre-Esforço, Equipamento BRUNEI DARUSSALAM HANOI
BUENOS AIRES Phone: + 43-2235 87 777 e Montagens S.A. Phone: + 673-2-380 153 / 381 827 Phone: + 84-4-8245 488
Phone: + 54-11-4326-06 09 Fax: + 43-2235 86 561 S. DOMINGOS DE RANA Fax: + 673-2-381 954 Fax: + 84-4-8245 717
Fax: + 54-11-4326-26 50 Phone: + 351-21-445 83 10
BELGIUM Fax: + 351-21-444 63 77 HONG KONG HO CHI MINH CITY
CHILE N.V. Procedes VSL S.A. VSL Hong Kong Ltd. Phone: + 84-8-8106 817
VSL GEO Fax: + 84-8-9102 596
VSL Sistemas Especiales de BERCHEM WANCHAI
Sistemas de Aplicação em Geotecnia SA
Construcción S.A. Phone: + 32 3 230 36 34 Phone: + 852-2590 22 88
S. DOMINGOS DE RANA
SANTIAGO Fax: + 32 3 230 89 65
Phone: + 351-21-445 83 10
Fax: + 852-2590 02 90 AUSTRALIA / PACIFIC
Phone: + 56-2-233 10 81 VSL Australia Pty. Ltd.
Fax: + 351-21-445 83 28 Intrafor Hong Kong Ltd.
Fax: + 56-2-233 67 39 CZECH REPUBLIC SYDNEY
WANCHAI
VSL Systemy (CZ), s.r.o. Phone: + 61 2 9 484 59 44
COLOMBIA SPAIN Phone: + 852-2836 31 12
PRAGUE Fax: + 61 2 9 875 38 94
CTT Stronghold Fax: + 852-2591 61 39
Sistemas Especiales de Phone: + 420-2-67 07 24 20
BARCELONA
Construcción Ltda. Fax: + 420-2-67 07 24 06 BRISBANE
Phone: + 34-93-289 23 30 INDIA
BOGOTA Phone: + 61 7 3265 64 00
Fax: + 34-93-289 23 31
Phone: + 57-1-633 21 09 FRANCE VSL India PVT Ltd. Fax: + 61 7 3265 75 34
Fax: + 57-1-633 21 09 VSL France S.A. CHENNAI
VSL-SPAM, S.A.
TOULOUSE Phone: + 91-44 4225 11 11 MELBOURNE & SOUTHERN
BARCELONA
MEXICO Phone: + 33 (0)5 61 00 96 25 Fax: + 91-44 4225 10 10 Phone: + 61 3 979 503 66
Phone: + 34 93 846 70 07
VSL Corporation Mexico S.A de C.V Fax: + 33 (0)5 61 00 96 51 Fax: + 61 3 979 505 47
Fax: + 34 93 846 51 97
MEXICO INDONESIA
Phone: + 52-5-396 86 21 GERMANY PT VSL Indonesia NEW ZEALAND
Fax: + 52-5-396 84 88 VSL Systems GmbH SWEDEN JAKARTA Phone: + 61 2 9 484 59 44
BERLIN Internordisk Spännarmering AB Phone: + 62-21 570 07 86 Fax: + 61 2 9 875 38 94
UNITED STATES Phone: + 49 30 53 01 35 32 VÄSTERHANINGE Fax: + 62-21 573 12 17
VStructural LLC Fax: + 49 30 53 01 35 34 Phone: + 46-8-5007 3820
BALTIMORE, MD Fax: + 46-8-753 49 73 JAPAN
Phone: + 1-410-850-7000 GREAT BRITAIN VSL Japan Corporation
Fax: + 1-410-850-4111 VSL Systems (UK) Ltd. SWITZERLAND TOKYO
BEDFORDSHIRE VSL (Switzerland) Ltd. Phone: + 81-3-3346-8913
VENEZUELA Phone: + 44 (0) 1480 404 401 SUBINGEN Fax: + 81-3-3345-9153
Gestión de Obras y Construcciones C.A. Fax: + 44 (0) 1480 404 402 Phone: + 41-32 613 30 30
CARACAS Fax: + 41-32 613 30 15 KOREA
Phone: + 58-212 941 86 75 NETHERLANDS VSL Korea Co. Ltd.
Fax: + 58-212 941 86 75 VSL (Suisse) SA SEOUL
VSL Benelux B.V.
VOUVRY Phone: + 82-2-553 8200
OEGSTGEEST
Phone: + 41 24 48157 71 Fax: + 82-2-553 8255
Phone: + 31-71-576 89 00
Fax: + 41 24 48157 72
MIDDLE EAST Fax: + 31-71-572 08 86
MAINLAND CHINA
UNITED ARAB EMIRATES
NORWAY VSL Engineering Corp. Ltd.
VSL Middle East LLC
VSL Norge A/S HEFEI
DUBAI, UAE
STAVANGER Phone: + 86-551-3822918
Phone: + 9714-296-6399
Phone: + 47-51 58 81 25 Fax: + 86-551-3822878
Fax: + 9714-296-6552
Fax: + 47-51 58 81 26
MALAYSIA
VSL Engineers (M) Sdn. Bhd.
AFRICA KUALA LUMPUR
EGYPT Phone: + 603-7981-47 42
Matrix Engineering Company Fax: + 603-7981-84 22
CAIRO
Phone: + 20-2-344 19 00 PHILIPPINES
Fax: + 20-2-346 04 57 VSL Philippines Inc.
PASIG CITY
SOUTH AFRICA Phone: + 632 672 17 03
Tsala-RMS Construction Solutions (Pty) Ltd. Fax: + 632 672 13 95
Johannesburg
Phone: + 27 11 878-6820 SINGAPORE
Fax: + 27 11 878-6821 VSL Singapore Pte. Ltd.
SINGAPORE
Phone: + 65-6559 12 22
Fax: + 65-6257 77 51

TAIWAN
VSL Taiwan Ltd.
TAIPEI
Phone: + 886-2-2759 6819
Fax: + 886-2-2759 6821

THAILAND
VSL (Thailand) Co. Ltd.
BANGKOK
Phone: + 66-2-237 32 88 / 89 / 90
Fax: + 66-2-238 24 48