Civil lessons learned at construction of

Straddle Type monorail of São Paulo – line

15 silver
Rodolfo Szmidke - rszmidke@metrosp.com.br
Tatiana de C. C. S. da Fonseca – tatiana.fonseca@metrosp.com.br
 Monorail of São Paulo – line15 silver

• Conceived in 2009

• Opening in 2014: 2 stations, maintenance and servisse yard, 2.9 km long

• Currently (2021): 10 stations in operation, 13 km of extension

Structure characteristics of Monorail

120m

• Permanent way with 120 m long modules separated by

structural joints

• Module composed of 5 columns and 4 precast beams

joined together by concrete and prestressing

• Beam span – 30m (usual)

• Joint cover elements (finger plates and locking pivots)

Structure characteristics of Monorail

• Permanent way with 120 m long modules separated by

structural joints

• Module composed of 5 columns and 4 precast beams

joined together by concrete and prestressing

• Beam span – 30m (usual)

• Joint cover elements (finger plates and locking pivots)

Structure characteristics of Monorail

30m

• Permanent way with 120 m long modules separated by

structural joints

• Module composed of 5 columns and 4 precast beams

joined together by concrete and prestressing

• Beam span – 30m (usual)

• Joint cover elements (finger plates and locking pivots)

Structure characteristics of Monorail

• Beam span – 30m (usual)

• Permanent way with 120 m long modules separated by

structural joints

• Module composed of 5 columns and 4 precast beams

joined together by concrete and prestressing

• Joint cover elements (finger plates and locking pivots)

Structure characteristics of Monorail
Structure characteristics of Monorail
Structure characteristics of Monorail
Pathological Manifestations
• Characteristics of reinforced and prestressed concrete

• Bubbles
• Cracks
• Detachments

• Specific or critical aspects of the monorail system

• Deficiencies in finger plate and locking pivot performance

• Discomfort due to lack of alignment and leveling of the
permanent way
• Dimensional deviations

Challenges for detection and/or treatment

• Short deadline for performing repair activities – 3 hours of window night access

• Restrictions on modifications in the original sections

• Difficulty in accessing the damaged region – walkways helps a lot!

 Pathological Manifestations - Bubbles

• Cause

Trapping air during the concreting process

• Impacts

Aesthetic prejudice
Decreasing of covering
Wear of tires

• Treatment

Application of polymeric mortar in bubbles with a diameter greater than

12.7 mm in the lateral bearing tracks, and from 37.5mm in Other cases

• Improvement

Improvement of fresh concrete vibration methods

Cheking with percussion along the way to discover hidden bubbles
 Pathological Manifestations - Bubbles

• Cause

Entrapped air during the concreting process

• Impacts

Aesthetic prejudice
Decreasing of covering
Wear of tires

• Treatment

Application of polymeric mortar in bubbles with a diameter greater than

12.7 mm in the lateral bearing tracks, and from 37.5mm in other cases

• Improvement

Improvement of fresh concrete vibration methods

Cheking with percussion along the way to discover hidden bubbles
 Pathological Manifestations - Bubbles

• Cause

Trapping air during the concreting process

• Impacts

Aesthetic prejudice
Decreasing of covering
Wear of tires

• Treatment

Application of polymeric mortar in bubbles with a diameter greater than

12.7 mm in the lateral bearing tracks, and from 37.5mm in Other cases

• Improvement

Improvement of fresh concrete vibration methods

Cheking with percussion along the way to discover hidden bubbles
 Pathological Manifestations - Bubbles

• Cause

Trapping air during the concreting process

• Impacts

Aesthetic prejudice
Decreasing of covering
Wear of tires

• Treatment

Application of polymeric mortar in bubbles with a diameter greater than

12.7 mm in the lateral bearing tracks, and from 37.5mm in Other cases

• Improvement

Improvement of fresh concrete vibration methods

Cheking with percussion along the way to discover hidden bubbles
 Pathological Manifestations - Cracks

• Cause

Transient Efforts
Efforts in service
Hydration heat

• Impacts

Aesthetic prejudice
Vulnerability to the entry of aggressive agents

• Treatment

Openings from 0.2 mm and 0.6 mm – application of calcium acetate and

waterproofing
Openings above 0.6 mm – epóxi injection

• Improvement

Adequacy of concrete strength required for transitory phases

Temperature control during concreting
 Pathological Manifestations - Cracks

• Cause

Transient Efforts
Efforts in servisse
Hydration heat

• Impacts

Aesthetic prejudice
Vulnerability to the entry of aggressive agents

• Treatment

Openings from 0.2 mm and 0.6 mm – application of calcium acetate and

waterproofing
Openings above 0.6 mm – epóxi injection

• Improvement

Adequacy of concrete strength required for transitory phases

Temperature control during concreting
 Pathological Manifestations - Cracks

• Cause

Transient Efforts
Efforts in servisse
Hydration heat

• Impacts

Aesthetic prejudice
Vulnerability to the entry of aggressive agents

• Treatment

Openings from 0.2 mm and 0.6 mm – application of calcium acetate and

waterproofing
Openings above 0.6 mm – epóxi injection

• Improvement

Adequacy of concrete strength required for transitory phases

Temperature control during concreting
 Pathological Manifestations - Cracks

• Cause

Transient Efforts
Efforts in servisse
Hydration heat

• Impacts

Aesthetic prejudice
Vulnerability to the entry of aggressive agents

• Treatment

Openings from 0.2 mm and 0.6 mm – application of calcium acetate and

waterproofing
Openings above 0.6 mm – epóxi injection

• Improvement

Adequacy of concrete strength required for transitory phases

Temperature control during concreting
 Pathological Manifestations - Detachments

• Cause

Shock during the movement of beams in the factory

Shock during the positioning of the beams on the columns
Repairs to the bearing strip lifting handles region

• Impacts

Aesthetic prejudice
Decrease in coverage
Damage to passenger comfort

• Treatment

Sides - Recomposition with cementitious mortar

Top – Recomposition with sulfoaluminate concrete

• Improvement

Greater control in the beam movement process

Relocation of lifting handles to minimize intersection with bearing strip
 Pathological Manifestations - Detachments

• Cause

Shock during the movement of beams in the factory

Shock during the positioning of the beams on the columns
Repairs to the bearing strip lifting handles region

• Impacts

Aesthetic prejudice
Decrease in coverage
Damage to passenger comfort

• Treatment

Sides - Recomposition with cementitious mortar

Top – Recomposition with sulfoaluminate concrete

• Improvement

Greater control in the beam movement process

Relocation of lifting handles to minimize intersection with bearing strip
 Pathological Manifestations - Detachments

• Cause

Shock during the movement of beams in the factory

Shock during the positioning of the beams on the columns
Repairs to the bearing strip lifting handles region

• Impacts

Aesthetic prejudice
Decrease in coverage
Damage to passenger comfort

• Treatment

Sides - Recomposition with cementitious mortar

Top – Recomposition with sulfoaluminate concrete

• Improvement

Greater control in the beam movement process

Relocation of lifting handles to minimize intersection with bearing strip
 Pathological Manifestations - Detachments

• Cause

Shock during the movement of beams in the factory

Shock during the positioning of the beams on the columns
Repairs to the bearing strip lifting handles region

• Impacts

Aesthetic prejudice
Decrease in coverage
Damage to passenger comfort

• Treatment

Sides - Recomposition with cementitious mortar

Top – Recomposition with sulfoaluminate concrete

• Improvement

Greater control in the beam movement process

Relocation of lifting handles to minimize intersection with bearing strip
 Pathological Manifestations – Dimensional deviatations

• Cause

Deviations in the manufacture of guide beams and execution of

closure pours (width, leveling and superelevation)

• Impacts

Damage to passenger comfort

Wear of rolling stock

• Treatment

Concrete surface roughing to meet tolerances

• Improvement

Controls for the manufacture of beams and execution of closure

pours
Production quality monitoring
 Pathological Manifestations – Dimensional deviatations

• Cause

Deviations in the manufacture of guide beams and execution of

closure pours (width, leveling and superelevation)

• Impacts

Damage to passenger comfort

Wear of rolling stock

• Treatment

Concrete surface roughing to meet tolerances

• Improvement

Controls for the manufacture of beams and execution of closure

pours
Production quality monitoring
 Pathological Manifestations – Dimensional deviatations

• Cause

Deviations in the manufacture of guide beams and execution of

closure pours (width, leveling and superelevation)

• Impacts

Damage to passenger comfort

Wear of rolling stock

• Treatment

Concrete surface roughing to meet tolerances

• Improvement

Controls for the manufacture of beams and execution of closure

pours
Production quality monitoring
 Pathological Manifestations – Dimensional deviatations

• Cause

Deviations in the manufacture of guide beams and execution of

closure pours (width, leveling and superelevation)

• Impacts

Damage to passenger comfort

Wear of rolling stock

• Treatment

Concrete surface roughing to meet tolerances

• Improvement

Controls for the manufacture of beams and execution of closure

pours
Production quality monitoring
 Pathological Manifestations – Dimensional deviatations

• Cause

Deviations in the manufacture of guide beams and execution of

closure pours (width, leveling and superelevation)

• Impacts

Damage to passenger comfort

Wear of rolling stock

• Treatment

Concrete surface roughing to meet tolerances

• Improvement

Controls for the manufacture of beams and execution of closure

pours
Production quality monitoring
 Pathological Manifestations - Deflections above the limit
• Cause

Prestressing

• Impacts

Damage to passenger comfort

Wear of rolling stock

• Treatment

Recomposition of "valleys" with sulfoaluminate concrete

• Improvement

Deflection monitoring in three steps: concreting, factory prestressing and

module prestressing
 Pathological Manifestations - Deflections above the limit
• Cause

Prestressing

• Impacts

Damage to passenger comfort

Wear of rolling stock

• Treatment

Recomposition of "valleys" with sulfoaluminate concrete

• Improvement

Deflection monitoring in three steps: concreting, factory prestressing and

module prestressing
 Pathological Manifestations - Deflections above the limit
• Cause

Prestressing

• Impacts

Damage to passenger comfort

Wear of rolling stock

• Treatment

Recomposition of "valleys" with sulfoaluminate concrete

• Improvement

Deflection monitoring in three steps: concreting, factory prestressing and

module prestressing
 Pathological Manifestations - Deflections above the limit
• Cause

Prestressing

• Impacts

Damage to passenger comfort

Wear of rolling stock

• Treatment

Recomposition of "valleys" with sulfoaluminate concrete

• Improvement

Deflection monitoring in three steps: concreting, factory prestressing and

module prestressing
 Finger plate – Unlevelling and opening between Plates

• Cause

Lack of dimensional preciousness

• Impacts

Damage to passenger comfort

Wear of rolling stock
Noise
Bolts break

• Treatment

Realignment by adding shims or thinning plates

• Improvement

Stricter factory inspections focusing on dimensional control of parts and

assembled assembly (tolerance of 1 mm)
Second inspection after galvanization of components
 Finger plate – Unlevelling and opening between Plates

• Cause

Lack of dimensional preciousness

• Impacts

Damage to passenger comfort

Wear of rolling stock
Noise
Bolts break

• Treatment

Realignment by adding shims or thinning plates

• Improvement

Stricter factory inspections focusing on dimensional control of parts and

assembled assembly (tolerance of 1 mm)
Second inspection after galvanization of components
 Finger plate – Unlevelling and opening between Plates

• Cause

Lack of dimensional preciousness

• Impacts

Damage to passenger comfort

Wear of rolling stock
Noise
Bolts break

• Treatment

Realignment by adding shims or thinning plates

• Improvement

Stricter factory inspections focusing on dimensional control of parts and

assembled assembly (tolerance of 1 mm)
Second inspection after galvanization of components
 Finger plate – Badly filling the box

• Cause

Concrete consolidation problems

• Impacts

Noise
Cracks in the base plate
Bolts break

• Treatment

Drilling holes in the boxes and filling with epoxy resin

• Improvement

Changed the design with the inclusion of holes to expel air and allow
insertion of the vibrator
 Finger plate – Badly filling the box

• Cause

Concrete consolidation problems

• Impacts

Noise
Cracks in the base plate
Bolts break

• Treatment

Drilling holes in the boxes and filling with epoxy resin

• Improvement

Changed the design with the inclusion of holes to expel air and allow
insertion of the vibrator
 Finger plate – Badly filling the box

• Cause

Concrete consolidation problems

• Impacts

Noise
Cracks in the base plate
Bolts break

• Treatment

Drilling holes in the boxes and filling with epoxy resin

• Improvement

Changed the design with the inclusion of holes to expel air and allow
insertion of the vibrator
 Finger plate – Lack of achievement of the bond strength

• Cause

Unlevelling plates
Friction between componentes

• Impacts

Lost of torque
Bolts break

• Treatment

Torque application to bolts defined in a previous experimental study and in a

controlled manner
Replacement of damaged bolts

• Improvement

New type of bolts

Requirement of prior experimental study to determine adequate torque
Use of digital torquemeter with torque x angle
 Finger plate – Lack of achievement of the bond strength

• Cause

Unlevelling plates
Friction between componentes

• Impacts

Lost of torque
Bolts break

• Treatment

Torque application to bolts defined in a previous experimental study and in a

controlled manner
Replacement of damaged bolts

• Improvement

New type of bolts

Requirement of prior experimental study to determine adequate torque
Use of digital torquemeter with torque x angle
 Finger plate – Lack of achievement of the bond strength

• Cause

Unlevelling plates
Friction between componentes

• Impacts

Lost of torque
Bolts break

• Treatment

Torque application to bolts defined in a previous experimental study and in a

controlled manner
Replacement of damaged bolts

• Improvement

New type of bolts

Requirement of prior experimental study to determine adequate torque
Use of digital torquemeter with torque x angle
 Locking Pivot

• Cause

Clearance between the core and the locking pivot sleeves

• Impacts

Damage to passenger comfort

Risk of shock between the teeth of the finger plate top plates

• Treatment

Replacement of internal cores to reduce clearance

• Improvement

Detailed inspection of the clearance between the inner core and the sleeves
 Locking Pivot

• Cause

Clearance between the core and the locking pivot sleeves

• Impacts

Damage to passenger comfort

Risk of shock between the teeth of the finger plate top plates

• Treatment

Replacement of internal cores to reduce clearance

• Improvement

Detailed inspection of the clearance between the inner core and the sleeves
 Locking Pivot

• Cause

Clearance between the core and the locking pivot sleeves

• Impacts

Damage to passenger comfort

Risk of shock between the teeth of the finger plate top plates

• Treatment

Replacement of internal cores to reduce clearance

• Improvement

Detailed inspection of the clearance between the inner core and the sleeves
 Conclusion

• As they constitute a path for a system that requires precision, the execution and fabrication of beams and
joint elements require greater control;

• Pathological manifestations that are occasionally neglected in usual concrete structures can be critical when
dealing with guide beams;

• Due to the conditions for access, inspection and treatment of structures, it is essential that aspects related to
maintenance are taken into account when designing projects;

• The application of torque x angle methodology with analysis of torque curves allowed greater success in
achieving the necessary joining force;

• The lessons learned recorded and the improvements made enabled an improvement in the quality of
execution of the permanent way, which can be applied to new projects, including through consulting;
Thank You!
Obrigado!