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Bridge Construction Partner
Bridge Construction Partner
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)
3
3
BALANCED CANTILEVER SPAN BY SPAN LIFTING FRAME CRANE PRECAST BEAM FULL SPAN PRECAST FALSEWORK INCREMENTAL LAUNCH
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
Stitching Beam
N-1 N
4
FORM TRAVELLER FORM SYSTEM HEAVY LIFTING STAY CABLE
LAUNCHING GANTRY
FEATURES & ADVANTAGES
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
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.
Launching of Gantry
Segment Placing
Curing (Overnight)
Front Lower Cross Beam
Installation of External P.T.
N+1
Stressing of External P.T.
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BALANCED CANTILEVER SPAN BY SPAN LIFTING FRAME CRANE PRECAST BEAM FULL SPAN PRECAST FALSEWORK INCREMENTAL LAUNCH
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
Stitching Beam
Alignment/Support
Stressing Platform
Bracket
8
FORM TRAVELLER FORM SYSTEM HEAVY LIFTING STAY CABLE
LIFTING FRAMES
FEATURES & ADVANTAGES
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
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
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
N-2 N-1 N
10
FORM TRAVELLER FORM SYSTEM HEAVY LIFTING STAY CABLE
CRANES
FEATURES & ADVANTAGES
Temporary works
requirements are minimised.
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
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
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
Support Tower
Beam Delivery at Ground Level
Direction of Erection
N-2 N-1 N
12
FORM TRAVELLER FORM SYSTEM HEAVY LIFTING STAY CABLE
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.
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
N-1 N N+1
14
FORM TRAVELLER FORM SYSTEM HEAVY LIFTING STAY CABLE
N-2 N-1 N
Temporary Support
16
FORM TRAVELLER FORM SYSTEM HEAVY LIFTING STAY CABLE
Minimised engineering
requirements are possible.
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
Description 1 2 3 4
Erection of Segments
17
BALANCED CANTILEVER SPAN BY SPAN LIFTING FRAME CRANE PRECAST BEAM FULL SPAN PRECAST FALSEWORK INCREMENTAL LAUNCH
INSITU CONSTRUCTION
INCREMENTAL LAUNCHING METHOD
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
Lateral Restraint
Scaffolding for Access
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FORM TRAVELLER FORM SYSTEM HEAVY LIFTING STAY CABLE
Rybny Potok - Czech Republic (2005) Caguanas River Bridge - Puerto Rico
58m of span length, 10,858m2 of surface (1981) 385m of bridge length
Stress P.T.
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BALANCED CANTILEVER SPAN BY SPAN LIFTING FRAME CRANE PRECAST BEAM FULL SPAN PRECAST FALSEWORK INCREMENTAL LAUNCH
INSITU CONSTRUCTION
FORM TRAVELLER METHOD
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
N N+1
20
FORM TRAVELLER FORM SYSTEM HEAVY LIFTING STAY CABLE
INSITU CONSTRUCTION
VSL FORM SYSTEMS
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
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.
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BALANCED CANTILEVER SPAN BY SPAN LIFTING FRAME CRANE PRECAST BEAM FULL SPAN PRECAST FALSEWORK INCREMENTAL LAUNCH
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
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.
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
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
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
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