218025052 bridge partner
TRANSCRIPT
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CONTENTS
VSL and Post-tensioning for Bridges --------------------------------- 3
Precast Segmental Erection
Balanced Cantilever Erection with Launching Gantry ------ 4Span by Span Erection with Launching Gantry -------------- 6
Balanced Cantilever Erection with Lifting Frames ---------- 8
Balanced Cantilever Erection with Cranes ------------------ 10
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
VSL SSI 2000 Stay Cable System ---------------------------- 26
Shatin T3 - Hong Kong (2004-2007)
Industrial Ring Road - Thailand (2005-2006)
Creve Coeur Lake - USA (1999-2003)
La Unidad Bridge - Mexico (2002-2003)
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From Post-tensioning to Bridge Partner
VSL is recognised as a world leader in specialist constructionengineering and associated technology and services. Today, VSLoperates as a worldwide network through 40 subsidiariesestablished on 6 continents. The Group is able to provide a fullrange of technical and construction services for bridge construction,including design evaluation, permanent works design, temporaryworks design and construction engineering, precastingmanagement and bridge construction.
Innovative solutions worldwide
VSL has contributed to some of the most prestigious and complexbridge structures around the world, ranging from large span staycable 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 isregarded as the most innovative ultra-high performance concretedevelopment in the last decade worldwide.
VSL has evolved from a specialist post-tensioning company into amulti disciplined bridge partner, capable of providing contractorsand engineers with construction and engineering services for highlycomplex and demanding projects. More importantly, the localisedorganisation of VSL provides clients with innovative practicaldesigns and construction solutions adapted to suit the local market.
Promoting highly efficient rates of construction
With extensive experience in large infrastructure and superstructureprojects, VSL has a proven record of developing project specificconstruction systems and methods that promote highly efficientrates of construction and facilitate programme surety, whilemaintaining and often improving essential safety and quality controlmeasures. Lateral thought processes encouraged within the designand production teams provide a suitable environment in which tonurture novel, and often remarkably simple solutions to demandingproblems. The exchange of knowledge within the VSL global networkenables the group's considerable experience to be fully utilised and
applied in a wide variety of engineering domains.
As a specialist bridge partner, VSL can bring the project team anextensive experience gained from erecting over 100,000 precastbridge deck elements (providing almost 5 million square metersof bridge surface), constructing multiple insitu bridges utilising VSLform travellers and incremental launching methods and also beinginvolved in the construction of over 100 stay cable bridges.
VSL is committed to offering clients a 'best for project' service thathas recently led to the development and successful implementationof various innovative Partnering and Alliancing arrangements that
have proved to be highly successful and mutually beneficial to allparties involved.
3
Taiwan High Speed Rail C215 - Taiwan(2000-2004)
Ilsun Bridge - Korea (2005-2007)
Shenzhen Western Corridor - Hong Kong(2004-2005)
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SPAN BY SPAN LIFTING FRAME CRANE PRECAST BEAM FULL SPAN PRECAST FALSEWORK INCREMENTAL LAUNCHLANCED CANTILEVER
Front Upper Cross BeamMain Truss
Rear Upper Cross Beam
Direction of Erection
Rear Lower Cross Beam Front Lower Cross BeamRear Support Leg
Segment Delivery on Completed Deck or at Ground Level
Stitching Beam
Closure Stitch Formwork Stressing Platform
N-1 N
LANCED CANTILEVER
PRECAST SEGMENTAL ERECTION
BALANCED CANTILEVER ERECTION WITH
VSL has over 20 years experience in thedesign and construction of precastsegmental balanced cantilever bridges.VSL in-house technical centres areprimarily involved in the design of erectionsystems and associated temporaryworks, and have also completed many
permanent works designs in closecooperation and conjunction withDesigners and Consultants.VSL has the capability and necessaryexperience to work with designers andcontractors to develop cost effectivedesigns that promote safe, effective
construction sequences and methodswhile achieving optimal productivity. VSLis recognised as a world leader in precastsegmental erection and has workedextensively with international contractorson technically demanding projects. VSL'shighly efficient erection systems enable
4
Telok Blangah - Singapore (1998-2001)61,440m 2 of deck, 1,460 segments
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FEATURES & ADVANTAGES
RM TRAVELLER FORM SYSTEM STAY CABLEHEAVY LIFTING
Front Support Leg
Pier Bracket
N+1
DescriptionSpan N-1
Stitch N to N-1
Curing of Stitch (Overnight)
Continui ty P.T.
Span N
Launch Gantry to Span N
Segment Erection Span N
Span N+1
Erect Pier Segment
Align Pier Segment
Place Reinforcement
Place Formwork
Cast Insitu Diaphragm
Curing Pier/Column Joint
Duration: 6 Shifts
1 2 4 5 63
Typical Erection Cycle
LAUNCHING GANTRY
contractors to minimise constructiondurations while optimising quality. VSLregularly achieves production ratesexceeding one cantilever per week.Within the VSL organisation, there is anextensive network of project managerial,technical and production staff.
5
aiwan C310 (1999-2001)6,120m 2 of deck, 1,823 segments
Lai Chi Kok - Hong Kong (2004-2006)63,000m 2 of deck, 1,771 segments
henzhen Western Corridor - Hong Kong004-2005) 90,800m 2 of deck, 1,879 segments
Bayan Baru - Malaysia (2001-2003)31,063m 2 of deck, 762 segments
hatin T3 - Hong Kong (2004-2007)5,800m 2 of deck, 1,806 segments
Pakse Bridge - Laos (1998-2000)16,284m 2 of deck, 384 segments
Delivery of segments alongcompleted deck to rear ofgantry minimises disruption toexisting traffic networks.
Necessary temporary worksrequire little groundimprovement and are generallyelevated, therefore causingminimal disruption to existingroads, structures or services.
Support craneage is reduceddue to temporary works beingrelocated by gantry.
Clear, unobstructed access toall work fronts is providedwithin gantry system.
Work can proceed on multiplework fronts within the gantry, i.epier segment erection,cantilever construction andclosure pour construction.
Temporary loads areintroduced directly into piers.
Fast rates of erection arepossible (up to 6 pairs ofsegments per shift areregularly achieved by VSL).
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SPAN BY SPAN LIFTING FRAME CRANE PRECAST BEAM FULL SPAN PRECAST FALSEWORK INCREMENTAL LAUNCHLANCED CANTILEVER
Main Truss
Direction of Erection
Rear Lower Cross Beam
Rear Support Leg
Segment Delivery atGround Level
Hanger Beams
WinchUpper Cross Beam
N-2 N-1 N
SPAN BY SPAN
PRECAST SEGMENTAL ERECTION
SPAN BY SPAN ERECTION WITH LAUNCHING
VSL has been involved in an extensivenumber of span-by-span precastsegmental projects in the Asia region andhas recently completed large segmentalinfrastructure projects in South America.Often in the face of demanding design,program and site constraints, VSL has a
proven ability to provide Consultants,Engineers and Contractors with innovative,practical and cost effective solutions,proving to be mutually beneficial to allparties involved.VSL erection systems are developed tooptimise permanent works design and
minimise additional temporary worksrequired during the construction stage.Within the VSL network, an extensive poolof suitably qualified personnel is availableto manage, supervise and operate the highcapacity erection gantries. Generally, insupport of the production teams, each
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Deep Bay Link - Hong Kong (2004-2005)108,000m 2 of deck, 3,014 segments
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FEATURES & ADVANTAGES
RM TRAVELLER FORM SYSTEM STAY CABLEHEAVY LIFTING
Front Lower Cross Beam
Front Support Leg
N+1
Description
Duration: 4-Day CycleTypical Erection Cycle
Launching of Gantry
Segment Placing
Segment Alignment / Gluing
Wet Joint Casting
Curing (Overnight)
Installation of External P.T.
Stressing of External P.T.
1
D/S N/S N/S N/S N/SD/S D/S D/S
2 43
GANTRY
project will have a project specific technicalteam responsible for providing details, andadvising on and monitoring the works toensure all necessary technical and safetyaspects are provided for. In addition,various VSL technical centres are utilisedto provide specific assistance if and when
required. Regular erection rates achievedare 1 span per 2.5 days with underslunggantries, and 1 span per 4 days withoverhead gantries. Being allowed tooperate 24-hour a day, VSL recentlyachieved in Chile a typical erection cycle of1 span every 24 hours .
7
etro de Santiago - Chile (2004-2005)2,000m 2 of deck, 2,156 segments
Deep Bay Link - Hong Kong (2004-2005)108,000m 2 of deck, 3,014 segments
West Rail - Hong Kong (1999-2002)16,667m 2 of deck, 8,642 segments
Bandra Worli - India (2002-2006)132,130m 2 of deck, 2,332 segments
enny 's Bay - Hong Kong (2003-2004)6,240m 2 of deck, 627 segments
Pusan - Korea (1993-1997)39,900m 2 of deck, 1,434 segments
Flexibility to use overhead orunderslung gantries.
Fast rates of erection arepossible due to use ofexternal post-tensioning (VSLhas achieved rates oferection exceeding 1 spanevery 24 hours).
Segment delivery is possiblealong completed deck to rearof gantry or at ground level.
Smaller crew size is requiredcompared to balancedcantilever construction.
Good access provided withinthe gantry to all work fronts.
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SPAN BY SPAN LIFTING FRAME CRANE PRECAST BEAM FULL SPAN PRECAST FALSEWORK INCREMENTAL LAUNCHLANCED CANTILEVER
Segment Delivery atGround Level
Alignment/SupportBracket
Stressing Platform
Stitching Beam
Closure Stitch Formwork
Lifting Spreader Beam
Stressing Platform
Rail Beam Lifting FrameUpper Cross Beam
N-2 N-1 N
LIFTING FRAME
PRECAST SEGMENTAL ERECTION
BALANCED CANTILEVER ERECTION WITH
VSL continually develops innovative liftingsolutions applicable to precast segmenterection. VSL strand lifting units,incorporating multiple safety features areregularly utilised, providing a large rangeof lifting capacities whilst allowing precisealignment and placement of segments.
Extensive studies conducted by ourtechn ica l cen t r es f ac i l i t a t e thedevelopment of project specific liftingsys tems . Precas t e lement del iveryusually governs the method adoptedand VSL have successfully operatedl i f t ing f rames sui table for use on
projects with considerable deliveryconstraints. VSL lifting frames are self-contained and incorporate safeunobstructed working platforms andaccesses to all necessary locations.Following assembly, installation andcommissioning by suitable cranes, VSL
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West Tsing Yi - Hong Kong (2004-2005)14,000m 2 of deck, 250 segments
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FEATURES & ADVANTAGES
RM TRAVELLER FORM SYSTEM STAY CABLEHEAVY LIFTING
Hanger Beams
1st pair of field segments erected by crane.Segments are suspended from hanger beams
or lifting frames when there is a wet joint.
Pier Segment Erection by Crane
N+1 N+2
Segment Erection - Pair 2-3
Segment Erection - Pair 6-7
Segment Erection - Pair 8-9
Segment Erection - Pair 10-11
Segment Erection - Pair 12-13
Remove Lifting Frames
Segment Erection - Pair 4-5
Wet Joint Curing
Wet Joint Construction
Segment Erection - Pair 1
Duration: 13 Shifts1 2 4 5 6 7 8 9 10 11 12 133
Erect & Assemble Lifting Frames &Brackets on Pier Head
DescriptionTypical Erection Cycle
LIFTING FRAMES
lifting frames can operate independently.VSL lifting systems incorporate twoprimary hydraulic systems providing bothlifting and self-launching mechanisms.When high lifting speeds are required,generally greater than 20 meters per hour,tandem lifting units or winch systems have
been utilised. VSL technical centrestypically work with engineers toincorporate necessary lifting system tiedown into the permanent works, to ensuresuitable load introduction into thepermanent works and also provide stageby stage analysis, geometry control and
precamber calculation. VSL's experiencedsupervisory teams regularly achieveerection cycles of two pairs of segmentsper shift.
9
openg Flyover - Malaysia (2003-2004)2,240m 2 of deck, 262 segments
Quarashia Bridge - Saudi Arabia(1989-1990) 12,820m 2 of deck, 143 segments
ai Chi Kok - Hong Kong (2004-2005)3,000m 2 of deck, 1,771 segments
isosansen Bridge - Japan (1998-2001)0,000m 2 of deck, 344 segments
Shenzhen Western Corridor - Hong Kong(2004-2005) 90,800m 2 of deck, 1,879 segments
Relatively simple temporaryworks requirements.
High rates of erection.
Large segments can be erected.
Optimised crew cycles.
Multiple levels of segmentalignment and adjustmentare possible.
Strand lifting units can beadopted and provide several
levels of safety features.
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SPAN BY SPAN LIFTING FRAME CRANE PRECAST BEAM FULL SPAN PRECAST FALSEWORK INCREMENTAL LAUNCHLANCED CANTILEVER
Segment Delivery atGround Level Alignment/Support Bracket
Hanger BeamsStitching Beam
Closure Stitch Formwork
Stressing Platform
N-2 N-1 N
CRANE
PRECAST SEGMENTAL ERECTION
BALANCED CANTILEVER ERECTION WITH
Erection using suitable mobile craneagehas frequently been executed by VSL,particularly in relation to balanced cantileverconstruction. When site and groundconditions are suitable, this method oferection has proved highly effective and canfacilitate considerable rates of erection.
VSL project teams provide detailedcraneage studies helping to optimise craneusage while minimising disruption to thesurrounding environment. In particular, VSLhas assisted contractors to develop andimplement temporary traffic managementschemes. VSL technical centres work with
production team to develop additionaltemporary works, in particular piersegment supports and accessrequirements. VSL is capable of offeringstage-by-stage analysis and detailedprecamber calculation. With careful projectdesign and management, cranes of varying
10
West Rail - Hong Kong (1999-2002)8,330m 2 of deck, 617 segments
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FEATURES & ADVANTAGES
RM TRAVELLER FORM SYSTEM STAY CABLEHEAVY LIFTING
1st pair of field segments erected by crane.Segments are suspended from hanger beams
if there is a wet joint to be cast.
Pier Segment Erection by Crane
N+1 N+2
Description
Duration: 8 Shifts
1 2 4 5 6 7 83
Installation ofPier Segment Support Brackets
Installation of Pier Segment
Segment Erection - Pair 1-3
Segment Erection - Pair 4-6
Segment Erection - Pair 7-9
Segment Erection - Pair 10-12
Typical Erection Cycle
CRANES
types and capacities have been utilised byVSL to achieve the best operating results.Typical erection rates are up to 6 segmentsper day.
11
hatin T3 - Hong Kong (2004-2007)5,800m 2 of deck, 1,806 segments
West Link - Australia (2004-2005)6,000m 2 of deck, 3,013 segments
West Rail - HongKong (1999-2002)8,330m 2 of deck,617 segments
Lai Chi Kok - HongKong (2004-2006)63,000m 2 of deck,1,771 segments
Temporary worksrequirements are minimised.
Fast rates of erection are possible.
Multiple work fronts are possible.
Optimised crew size.
Minimal engineering requirements.
Cranes are generally readilyavailable in the market.
Cranes can be utilised toexecute other activities.
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SPAN BY SPAN LIFTING FRAME CRANE PRECAST BEAM FULL SPAN PRECAST FALSEWORK INCREMENTAL LAUNCHLANCED CANTILEVER
Front Upper Cross Beamin Lifting Position
Support Tower
Rear Upper Cross Beamin Lifting Position
Direction of Erection
Rear Lower Cross BeamFront Lower Cross Beam
Rear Support Leg
Beam Delivery at Ground Level
Main Truss
N-2 N-1 N
PRECAST BEAM
PRECAST SEGMENTAL ERECTION
PRECAST BEAM METHOD
VSL has considerable experience in theerection of various precast beam structures.Methods of erection have been developedfollowing extensive studies relating to siteconstraints. Generally, the delivery ofprecast beams to the erection front is thedeterminant that influences the method of
erection system to be adopted. VSL hasutilised a variety of launching girders, beamlaunchers and lifting frames, capable ofreceiving precast beams directly behind,below or in parallel to the erection system.I beams, U beams and T beams have beenerected extensively.
In addition to the erection of primarystructural members, VSL has also beenresponsible for the complete constructionof bridge decks including placement ofprecast planks, and insitu works. VSL'sexperienced project specificmanagement, supervisory and technical
12
N-S Link - Jakarta (1989-1991)2,000 beams
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FEATURES & ADVANTAGES
RM TRAVELLER FORM SYSTEM STAY CABLEHEAVY LIFTING
Front Support Leg
N+1
Description
Typical Erection Cycle Duration: 2-Shift Cycle (Hours)Shift - 1
(10 Hour Shift)Shift - 2
(10 Hour Shift)
Lift and place 1 st beam (outer most) withprecast plank on top
Lift and place 2 nd beam with precast plankon top
Lift and place 3 rd beam with precast plank
on top
Lift and place 4 th beam with precast plankon top
Reposition the intermediate planks intofinal position
Move gantry to center viaduct then launchto next span
teams facilitate rates of erection oftenexceeding one span per day.With the precast beam method, strand andwinch lifting units are utilised, providingsafe and precise placement of precastelements, allowing multiple degrees ofalignment and efficient rates of erection.
Tandem lifting of full span precast beamswith cranes has also been adoptedfacilitating the lifting of large loads oftenexceeding 100 tonnes in weight and 40min length.
13
alau Island Bridge - Palau (2003-2005)000m 2 of deck, 52 beams
Cebu Coastal Road - Philippines (2001-2002) 24,000m 2 of deck, 320 beams
arasin Bridge - Phuket, Thailand991-1992) 7,800m 2 of deck, 182 beams
East Coast Parkway - Singapore (1981)68,250m 2 of deck, 180 beams
utong Lumut Coastal Highway - Brunei001-2003) 6,100m 2 of deck, 210 beams
Saraburi - Thailand (1994-1995)
Fast rates of erection.
Relatively simple erectiongantry, or crane erection.
Beam delivery possiblealong completed deck torear of gantry, thusminimising disruption toexisting traffic networks.
Small works crew size.
Geometry control is minimised.
Precast beam production isrelatively simple and requireslow levels of mechanisation.
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SPAN BY SPAN LIFTING FRAME CRANE PRECAST BEAM FULL SPAN PRECAST FALSEWORK INCREMENTAL LAUNCHLANCED CANTILEVER
N-1 N N+1
Delivery of Precast Span along Completed Deck by Launching Carrier
Direction of Erection
Rear Trailer
Front Trailer
Rear Fixed Leg
Rear Mobile Support
Front Lifting FrameRear Lifting Frame
Lifting Winches
Launching Carrier
FULL SPAN PRECAST
PRECAST SEGMENTAL ERECTION
FULL SPAN PRECAST METHOD
The full span precast method of erectionis particularly suited to projectscomprising multiple spans of similarlength which have minimal horizontal radii.Typically rail networks are most suitablefor this method of erection. VSL hasconsiderable experience in this field of
erection, with specific referencesincluding the Taiwan High Speed RailProject and the Singapore MRT.Full span precast elements can beconstructed in a static casting yard underfactory conditions which facilitate improvedsafety and quality while also optimising
labour and necessary plant requirements.Other than access to the pier heads, verylittle temporary works are required andfollow up activities are minimised.Rapid rates of erection are achievable, andVSL has obtained erection rates of 2 spansper day. Delivery of precast elements along
14
Taiwan High Speed Rail C215- Taiwan(2000-2004) 260,000m 2 of deck, 602 spans
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FEATURES & ADVANTAGES
RM TRAVELLER FORM SYSTEM STAY CABLEHEAVY LIFTING
N+2 N+3
Front Mobile Support
Front Fixed Leg
Support Beam
DescriptionTypical Erection Cycle Duration: 1-Day Cycle (Hours)
5 6 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 237
Delivery New Span from Yard toErection Site
Erection of New Span
Return Launching Carrier to Yard
Launching Carrier Available for
Yard HandlingLoad New Segment intoLaunching Carrier
Load Transfer from Temporary toPermanent Bearings
Prepare Permanent Bearingsfor Grouting
Grout Permanent Bearings
the completed deck reduces disruption toexisting traffic networks and helpsminimise ground improvement works thatwould otherwise be required to transportlarge elements at ground level.
15
aiwan High Speed Rail C215 - Taiwan000-2004) 260,000m 2 of deck, 602 spans
aiwan High Speed Rail C215 - Taiwan000-2004) 260,000m 2 of deck, 602 spans
aiwan High Speed Rail C215 - Taiwan000-2004) 260,000m 2 of deck, 602 spans
Seven Mile Bridge - USA (1980-1982)130,000m 2 of deck, 265 spans
MRT - Singapore (1985-1989)114,000m 2 of deck, 1,000 spans
MRT - Singapore (1985-1989)114,000m 2 of deck, 1,000 spans
Very high rate of production,with very high quality.
Minimal follow up works.
Full span production in factoryenvironment allowsimprovements in quality ofprecast elements.
Delivery of elements to rear ofgantry is possible alongcompleted deck thereforeminimising disruption toexisting traffic networks.
Reduced on site activities,improves safety andenvironmental concerns.
Minimal additional temporaryworks are required.
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SPAN BY SPAN LIFTING FRAME CRANE PRECAST BEAM FULL SPAN PRECAST FALSEWORK INCREMENTAL LAUNCHLANCED CANTILEVER
Segment Delivery at Ground Level
Stressing PlatformSpan Jack Span Jack
N-2 N-1 N
Falsework Support
Temporary Support
Relocation of Falsework Support
FALSEWORK
PRECAST SEGMENTAL ERECTION
SPAN BY SPAN ERECTION ON FALSEWORK
V S L has adop ted the f a l s ew orks uppor t me thod on many p recas tsegmental projects.Dependent upon the imposed loading andthe effective height, conventional scaffoldsupport or heavy shoring systems areutilised. Hydraulic systems are
incorporated to enable temporary segmentsupport, alignment and load transfer ontopiers. Typically, segments are loaded ontothe falsework support using suitablecraneage. However, if access is limited,VSL has also developed alternativesolutions for the handling and loading of
segments. VSL engineering andproduction staff conduct extensive logisticstudies relating to site access, segmenthandling and temporary foundation needs.Modular support systems are adopted tominimise relocation durations and tooptimise erection rates. Long span support
16
Deep Bay Link - Hong Kong (2004-2005)108,000m 2 of deck, 3,014 segments
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FEATURES & ADVANTAGES
RM TRAVELLER FORM SYSTEM STAY CABLEHEAVY LIFTING
N+1
Description
Typical Erection Cycle Duration: 4-Day Cycle (Days)
1 2 43
Installation of Scaffold Support
Erection of Segments
Alignment and Gluing
Post Tensioning Operations
Load Transfer onto Permanent Bearings
structures are often developed to cater forroad or rail crossings. Support structuresincorporate access and working platformsand may include suspended containmentsto manage falling debris. Typical erectionrates are up to one span every three days.
17
West Rail - Hong Kong (1999-2002)16,667m 2 of deck, 8,642 segments
Penny ' s Bay - Hong Kong (2003-2004)16,240m 2 of deck, 627 segments
eep Bay Link - Hong Kong (2004-2005)08,000m 2 of deck, 3,014 segments
Penny ' s Bay - Hong Kong (2003-2004)16,240m 2 of deck, 627 segments
West Link - Australia (2004-2005)6,000m 2 of deck, 3,013 segments
East Rail - Hong Kong (2000-2003)58,320m 2 of deck, 4,449 segments
Minimised engineeringrequirements are possible.
Modular support system canbe relocated with ease andrelatively quickly.
Work can proceed on multiplework fronts.
Production crew size is fullyutilised and optimised.
Good access is provided to allwork fronts.
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SPAN BY SPAN LIFTING FRAME CRANE PRECAST BEAM FULL SPAN PRECAST FALSEWORK INCREMENTAL LAUNCHLANCED CANTILEVER
Launching Nose
Casting Bed
Vertical Reaction Beams
Scaffolding for Access
Pulling Jack
Direction of Launch
Monolithic or Stressed Connectionto 1 st Segment
Launching Bearings
Lateral Restraint
N N+1 N+2 N+3
INCREMENTAL LAUNCH
INSITU CONSTRUCTION
INCREMENTAL LAUNCHING METHOD
The principle of the incrementallylaunched bridge consists of building thesuperstructure segments in a casting yardlocated behind the bridge abutment. Eachsegment is matchcast against the previousone and prestressed to the section ofsuperstructure already built. The entire
superstructure is then jacked forward adistance equal to the length of thissegment. This process is repeated untilthe bridge is in its final position. Additionalcontinuity prestress is then installed andthe temporary bearings are replaced by thepermanent bearings. This form of
construction can be used for bridgeshaving constant cross sectional shapethroughout their length. The bridge shouldbe straight or have a constant horizontaland vertical curvature.The incrementally launched bridge hasseveral advantages. It eliminates the
18
Kemena Bridge - Malaysia (2003-2005)32-53m of span length, 4,947.6m 2 of surface
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FEATURES & ADVANTAGES
RM TRAVELLER FORM SYSTEM STAY CABLEHEAVY LIFTING
(A)(B)
(A)
(A)
TYPICAL CONSTRUCTION SEQUENCE
Cast segment (A),install launching nose,install pulling units
Pull segment (A) forwardusing pulling jacks attached
to reaction beam
Construct segment (B),repeat stage and for remaining segments
Description
Typical Construction Cycle Duration: 8-Day Cycle (Days)
1 2 4 5 63 7 8
Launch Segment
Strip and Clean Forms
Install Base and Web Rebar
Install Web Forms
Concrete Base and Webs
Install Inner Forms
Install Top Slab Rebar
Concrete Top Slab
Curing
Stress P.T.
traditional scaffolding required forsupporting the formwork. This is particularlyvaluable for projects with high piers, inurban areas, spanning over deep water,over roads and over railways. Most of theconstruction operations take place in thesame location, which may be organised as
a precasting yard. The precasting work isthus more easily supervised, giving a highquality of workmanship. However, it shouldbe noted that the post-tensioningrequirements for the launching operationsusually result in higher quantities whencompared with other construction methods.
19
ybny Potok - Czech Republic (2005)8m of span length, 10,858m 2 of surface
Brides Glens Bridge - Ireland (2003-2004)45.9-65m of span length, 3,200m 2 of surface
Caguanas River Bridge - Puerto Rico(1981) 385m of bridge length
ampanies Sengkang Flyover - Singapore (2002-2003)4.5-63m of span length, 10,623.85m 2 of surface
Concentrated work front optimisescraneage requirements.
Site constraints such as poorground and access restrictioncan be minimised.
Minimal temporary works.
Seven-day cycle is achievable ifovertime is allowed.
Require only a moderateinvestment in specialisedequipment such as launching
nose, launching jacks,conventional jacks, launchingbearings and guides.
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SPAN BY SPAN LIFTING FRAME CRANE PRECAST BEAM FULL SPAN PRECAST FALSEWORK INCREMENTAL LAUNCHLANCED CANTILEVER
Front Transverse Truss Anchoring Jack
Rail Beam
Main Frame
Lower Rear Transverse Beam
Stitching Beam
Closure Stitch Formwork End Span Falsework
Form Traveller
Lower Front Transverse Beam
Outer Roller Beam
Form Traveller
N N+1
INSITU CONSTRUCTION
FORM TRAVELLER METHOD
Developed from our earlier form travellersystems, VSL has produced astandardised modular form travellersystem, applicable to most contemporarybridge designs. This highly flexiblesystem allows efficient use on bridgeswith different cross sections. A variety of
casting lengths can be adopted to suitengineers' designs.Mechanical and hydraulic systems built into the form traveller system ensureprecise control of the bridge duringconstruction. The lightweight modularsystem requires minimal support
craneage during assembly, erection andrelocation. Unobstructed workingplatforms and access are incorporated intothe form system.Reinforcement and concreting operationshave been optimised by minimisingobstruction caused by the form traveller.
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Taiwan High Speed Rail - Taiwan (2002-2003)80-100m of span length, 22 cantilevers
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FEATURES & ADVANTAGES
RM TRAVELLER FORM SYSTEM STAY CABLEHEAVY LIFTING
Bridge Abutment
Temporary Support
End span constructed using Form Traveller
Description
Typical Construction Cycle
Removal of stop end form and form ties
Installation of strand
Stressing of cantilever P.T.
Stripping of outer, inner, bottom form
Launching and fixation of rail beam
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
Final survey / check of level / alignment
Pour concrete
Curing - Traveller #1
Curing - Traveller #2
Traveller #1 Traveller #2
Placing reinforcement / P.T. ducts / insert for upper deckand cantilever wing
Duration: 5-day cycle, 12 hours per dayDay 1 Day 2 Day 3 Day 4 Day 5
8 1 2 3 4 5 6 79 10 11 12 8 1 2 3 4 5 6 79 10 11 12 8 1 2 3 4 5 6 79 10 11 12 8 1 2 3 4 5 6 79 10 11 12 8 1 2 3 4 5 6 79 10 11 12
RM TRAVELLER
Typical cycles of 5 days per pour areregularly achieved. If required, steam curingcan also be incorporated into the formsystem resulting in typical cycles of 4 daysper pour. VSL technical centres continuallywork with engineers to optimise post-tensioning arrangements, often facilitating
asymmetrical construction resulting inoptimal usage of labour resources. Projectspecific forms are also developed toconstruct the pier head.
H-3 North Halawa Valley Viaduct -Hawaii (1990-1992)
Ma Wan - Hong Kong (1999)48m of main span length, 15 cantilevers
henur Bridge - Malaysia (2002-2004)40m of main span length, 7 cantilevers
Angara River Bridge - Russia (2000-2005)105m of main span length, 5 cantilevers
nu Bridge - Columbia (2005)50m of main span length, 2 cantilevers
eep Bay Link - Hong Kong (2004-2005)1.5m of span length, 28 cantilevers
VSL modular form travellersare readily available and canbe obtained quickly withoutmajor re-engineering required.
Long-span bridge structureswith access constraints can beeasily accommodated.
Craneage capacityrequirements are minimised.
Crew efficiency between 1 pairof form travellers is optimised.
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SPAN BY SPAN LIFTING FRAME CRANE PRECAST BEAM FULL SPAN PRECAST FALSEWORK INCREMENTAL LAUNCHLANCED CANTILEVER
INSITU CONSTRUCTION
VSL FORM SYSTEMS
VSL has considerable experience in awide variety of insitu form system ranging
from self climbing form systems utilisedfor pier and pylon construction to largespan underslung movable scaffoldsupport systems.To complement any precast erection
operation, VSL is also able to providedetailed design, supply and operation of
precast cells required for precastsegmental bridge decks, precast beams,and also full span precast elements.Recently, on the Taiwan High Speed RailProject, VSL was responsible for the
complete establishment and operation ofthe casting yard including reinforcement
and concreting operations.VSL form systems are generally modular,light weight and provide clear unobstructedaccess to all necessary working areas.Mechanised VSL Form Systems facilitate
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Photos of this page:Stonecutters Bridge - Hong Kong
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RM TRAVELLER FORM SYSTEM STAY CABLEHEAVY LIFTINGFORM SYSTEM
casting of highly complex structures withvariable geometric properties, and
produce high quality finishes oftenrequired by clients.VSL managed casting yards regularlyachieve precast segmental production ratesof up to one segment per day, per cell.
The VSL Climb Form System will generallyachieve an optimal cycle of three days per
four meter lift, however, due to the modulararrangement of the system, variable liftheights can be accommodated withrelative ease up to a maximum lift heightof six meters.
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sing Ma Bridge - Hong Konger climbform
Tsing Ma Bridge - Hong KongPier climbform
isosansen Bridge - Japanatch cast short line cells
Kisosansen Bridge - JapanMatch cast short line cells
akse Bridge - Laosatch cast long line
Metro de Santiago - ChileMatch cast long line
hnpyung Bridge - KoreaS S
Taiwan High Speed Rail C215 - TaiwanPretensioning bed and form
Taiwan High Speed Rail C215 - TaiwanPretensioning bed and form
Bandra Worli - IndiaMatch cast short line cells
Metro de Santiago - ChileMatch cast long line
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SPAN BY SPAN LIFTING FRAME CRANE PRECAST BEAM FULL SPAN PRECAST FALSEWORK INCREMENTAL LAUNCHLANCED CANTILEVER
HEAVY LIFTING APPLICATIONS FOR BRIDGE
For economic or technical reasons,today's bridge structures are oftenassembled from large, heavy, pre-
fabricated elements. For projects in whichcranes or other conventional handlingequipment cannot be used because ofexcessive weight, dimensions or spacelimitations, VSL Heavy Lifting will oftenprovide the most effective solution.
VSL Heavy Lifting provides contractors,engineers and owners with a broadrange of advantages, including:
Economy and efficiency, throughcustom designed solutions.
R e l i a b i l i t y, b a s e d u p o n s o u n d
engineer ing and three decadesof experience.
The highest level of safety through theuse of advanced and reliablehydraulic equipment.
Unique Solutions
VSL will plan lifting, horizontal jacking, orlowering operations and design thenecessary temporary structures to suit therequirements of the projects. Soundengineering, clear thinking, the ability toinnovate, and years of successfulexperience provide a guarantee of reliableand cost-effective solutions.
Safety
The safety of personnel and componentsare VSL's f irs t priority. Specialisedhydraulic lifting equipment is designedfor the highest level of reliability, and allequipment is r igorously tested andserviced through VSL's quality controland maintenance program. VSL fieldservices are also based upon a totalcommitment to safety.
The extensive experience of VSLpersonnel and VSL's exceptional trackrecord provide further assurance of
reliable performance.Flexibility
VSL's range of equipment provides thecapability to lift or lower single loadswell in excess of 10,000t and includesa large range of hydraulic jacks, pumps,controls units, monitoring devices, andmodular lifting/jacking frames. Thus,VSL has both the capability and flexib iltyto perform virtually any project requiringlifting, lowering or horizontal jacking.
The VSL Service Package
VSL offers a complete range of servicesfor the planning, engineering, equipmentsupply and execution of any heavy liftingproject. VSL Heavy Lifting servicesprovided throughout the world include:
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Bridge at Miraflores - Spain (2005)Two lowering operations of main arch (1,360t each)
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FEATURES & ADVANTAGES
RM TRAVELLER FORM SYSTEM STAY CABLEHEAVY LIFTINGHEAVY LIFTING
CONSTRUCTION
Feasibility studies and preliminaryconsultation for lifting, horizontal
jacking and lowering operations.
Project design and planning,equipment specification, schedulingand budgeting.
Design, manufacture and supply ofspecial equipment and temporarystructures, if required.
Leas ing and operat ion of VSLequipment and execution by VSLor others.
The planning of a heavy lifting operationshould be started as early as possible.Early involvement of VSL specialists willresult in a handling scheme thatoptimises the project's economy,efficiency and schedule.
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fiernillo II Bridge - Mexico (2000)ifting of 3 arched steel trusses (600t each)
Industrial Ring Road - Thailand (2005-2006) Lifting of 500t bridge deck segment
anjaron Viaduct - Spain (2001)aunching over deep valley with fishing line principle
Weser Bridge Hehlen - GermanyCrane assisted launching over the river
reirosen Bridge - Basel Switzerlandfting and floating in of 4 steel trusses (540t each)
VSL Heavy Lifting Equipment (from left)Hydraulic pump, lifting unit, strand coiler
oire River Bridge - Franceifting of centre span (2,400t)
Economy and efficiency throughcustom designed solutions.
Suitable for any heights andany kind of loads.
High level of safety as load isalways secured mechanically.
Reliability based on 35 years ofsolid experience.
High flexibility with lifting unitsfrom 10t to 600t capacity.
Lifting levels and loads withextremely tight tolerances aremonitored and maintained withhighly precise computer-aidedcontrol system.
Very high capacity to theselfweight ratio.
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SPAN BY SPAN LIFTING FRAME CRANE PRECAST BEAM FULL SPAN PRECAST FALSEWORK INCREMENTAL LAUNCHLANCED CANTILEVER
STAY CABLE BRIDGE CONSTRUCTION
VSL SSI 2000 STAY CABLE SYSTEM
The VSL SSI 2000 Stay Cable System is
acknowledged as being one of theleading systems currently available. Thesystem is based around the proven VSLstrand and wedge anchorage technologyand is designed to meet the moststringent criteria offering high fatigue
resistance, excellent corrosion
protection, easy monitoring andmaintenance. Installation andreplacement is carried out using strandby strand method which has the benefitof requiring very little space and whichutilises relatively light weight equipment.
In the basic configuration the system
incorporates greased and sheathedmonostrands contained within acontinuous external HDPE stay pipe, withno grouting in the cable. Additionalenhancements can be offered including;metalisation (galvanising) of the
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La Unidad Bridge - Mexico (2002-2003)Main span length: 240m
dustrial Ring Road - Thailand (2005-2006)Main span length: 398m & 326m
Sucharskiego Bridge - Poland (2000-2001)Main span length: 230m
Europa Bridge - Portugal (2000-2002)Main span length: 185.6m
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FEATURES & ADVANTAGES
RM TRAVELLER FORM SYSTEM STAY CABLEHEAVY LIFTING STAY CABLE
monostrands for additional corrosion
protection, coloured HDPE stay pipes,helical ribbing on the stay pipes to reducerisk of wind rain induced cable vibrations,and the VSL Friction Damper one of themost efficient and robust forms of cabledamping available.
In addition to the design, supply and
installation of the stay cable system, VSLis able to offer clients a full range ofspecialist bridge construction services fromstage by stage construction analysis to theactual construction of the entiresuperstructure including the design and
supply of the necessary temporary works
and construction equipment.
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Wadi Leban Bridge - Saudi Arabia997) Main span length: 405m
Neva Bridge - Russia (2002)Main span length: 382m
eldar Bridge - Colombia (2003)ain span length: 120m
US Grant Bridge - USA (2003)Main span length: 267m
ichong Yiling Bridge - Hubei, China001) Main Span Length: 348m
Safti Bridge - Singapore (1995)Main span length: 99m
aney Bridge - Ireland (2002)ain span length: 109m
Uddevalla Bridge - Sweden (1998)Main span length: 414m
Batam Tonton - Indonesia (1997)Main span length: 350m
High fatigue resistance.
Compatible with modernconstruction methods;compact anchorages fullyprefabricated in workshop,single strand installation withlight equipment, easy forcemonitoring and adjustment.
Full encapsulation of strandinside the anchorage.
Faster installation and erectioncycles, reduced maintenance.
Designed to receive in thefuture vibration dampingsystems if necessary.
Ability to remove and to replaceindividual strands if necessary.
Factory applied individualprotection treatment, up to 100years design life in the mostaggressive environments.
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HEADQUARTERSVSL International Ltd.
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www.vsl.com
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YOUR BRIDGE PARTNER