B R I D G E C O N S T R U C T I O N P A R TN E R
PRECASTSEGMENTALCONSTRUCTION
INSITUCONSTRUCTION
HEAVY LIFTING
STAY CABLECONSTRUCTION
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
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)
3
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 andapplied 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 thathave 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)
SPAN BY SPAN LIFTING FRAME CRANE PRECAST BEAM FULL SPAN PRECAST FALSEWORK INCREMENTAL LAUNCHBALANCED 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 Deckor at Ground Level
Stitching Beam
Closure Stitch Formwork Stressing Platform
N-1 N
BALANCED CANTILEVER
PRECAST SEGMENTAL ERECTIONBALANCED 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)61,440m2 of deck, 1,460 segments
FEATURES & ADVANTAGES
FORM 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)Continuity P.T.
Span NLaunch Gantry to Span NSegment Erection Span N
Span N+1Erect Pier SegmentAlign Pier SegmentPlace ReinforcementPlace FormworkCast Insitu DiaphragmCuring Pier/Column Joint
Duration: 6 Shifts1 2 4 5 63
Typical Erection Cycle
H 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
Taiwan C310 (1999-2001)96,120m2 of deck, 1,823 segments
Lai Chi Kok - Hong Kong (2004-2006)63,000m2 of deck, 1,771 segments
Shenzhen Western Corridor - Hong Kong(2004-2005) 90,800m2 of deck, 1,879 segments
Bayan Baru - Malaysia (2001-2003)31,063m2 of deck, 762 segments
Shatin T3 - Hong Kong (2004-2007)65,800m2 of deck, 1,806 segments
Pakse Bridge - Laos (1998-2000)16,284m2 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).
SPAN BY SPAN LIFTING FRAME CRANE PRECAST BEAM FULL SPAN PRECAST FALSEWORK INCREMENTAL LAUNCHBALANCED 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 ERECTIONSPAN 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
6
Deep Bay Link - Hong Kong (2004-2005)108,000m2 of deck, 3,014 segments
FEATURES & ADVANTAGES
FORM 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
Metro de Santiago - Chile (2004-2005)72,000m2 of deck, 2,156 segments
Deep Bay Link - Hong Kong (2004-2005)108,000m2 of deck, 3,014 segments
West Rail - Hong Kong (1999-2002)116,667m2 of deck, 8,642 segments
Bandra Worli - India (2002-2006)132,130m2 of deck, 2,332 segments
Penny's Bay - Hong Kong (2003-2004)16,240m2 of deck, 627 segments
Pusan - Korea (1993-1997)39,900m2 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.
SPAN BY SPAN LIFTING FRAME CRANE PRECAST BEAM FULL SPAN PRECAST FALSEWORK INCREMENTAL LAUNCHBALANCED 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 ERECTIONBALANCED CANTILEVER ERECTION WITH
VSL continually develops innovative liftingsolutions applicable to precast segmenterection. VSL strand lift ing units,incorporating multiple safety features areregularly utilised, providing a large rangeof lifting capacities whilst allowing precisealignment and placement of segments.
Extensive studies conducted by ourtechnica l cent res fac i l i ta te thedevelopment of project specific liftingsystems. Precast e lement del iveryusually governs the method adoptedand VSL have successfully operatedl i f t ing f rames su i tab le for use on
projects with considerable del iveryconstraints. VSL lifting frames are self-conta ined and incorporate safeunobstructed working platforms andaccesses to all necessary locations.Following assembly, installation andcommissioning by suitable cranes, VSL
8
West Tsing Yi - Hong Kong (2004-2005)14,000m2 of deck, 250 segments
FEATURES & ADVANTAGES
FORM 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
H LIFTING FRAMES
lifting frames can operate independently.VSL lift ing 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
Gopeng Flyover - Malaysia (2003-2004)12,240m2 of deck, 262 segments
Quarashia Bridge - Saudi Arabia(1989-1990) 12,820m2 of deck, 143 segments
Lai Chi Kok - Hong Kong (2004-2005)63,000m2 of deck, 1,771 segments
Kisosansen Bridge - Japan (1998-2001)90,000m2 of deck, 344 segments
Shenzhen Western Corridor - Hong Kong(2004-2005) 90,800m2 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 severallevels of safety features.
SPAN BY SPAN LIFTING FRAME CRANE PRECAST BEAM FULL SPAN PRECAST FALSEWORK INCREMENTAL LAUNCHBALANCED CANTILEVER
Segment Delivery atGround LevelAlignment/Support Bracket
Hanger BeamsStitching Beam
Closure Stitch Formwork
Stressing Platform
N-2 N-1 N
CRANE
PRECAST SEGMENTAL ERECTIONBALANCED 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)8,330m2 of deck, 617 segments
FEATURES & ADVANTAGES
FORM 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 of Pier 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
H CRANES
types and capacities have been utilised byVSL to achieve the best operating results.Typical erection rates are up to 6 segmentsper day.
11
Shatin T3 - Hong Kong (2004-2007)65,800m2 of deck, 1,806 segments
West Link - Australia (2004-2005)86,000m2 of deck, 3,013 segments
West Rail - HongKong (1999-2002)8,330m2 of deck,617 segments
Lai Chi Kok - HongKong (2004-2006)63,000m2 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.
SPAN BY SPAN LIFTING FRAME CRANE PRECAST BEAM FULL SPAN PRECAST FALSEWORK INCREMENTAL LAUNCHBALANCED 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 ERECTIONPRECAST 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
FEATURES & ADVANTAGES
FORM 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 1st beam (outer most) withprecast plank on top
Lift and place 2nd beam with precast plankon top
Lift and place 3rd beam with precast plankon top
Lift and place 4th 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
Palau Island Bridge - Palau (2003-2005)4,000m2 of deck, 52 beams
Cebu Coastal Road - Philippines (2001-2002) 24,000m2 of deck, 320 beams
Sarasin Bridge - Phuket, Thailand(1991-1992) 7,800m2 of deck, 182 beams
East Coast Parkway - Singapore (1981)68,250m2 of deck, 180 beams
Tutong Lumut Coastal Highway - Brunei(2001-2003) 6,100m2 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.
SPAN BY SPAN LIFTING FRAME CRANE PRECAST BEAM FULL SPAN PRECAST FALSEWORK INCREMENTAL LAUNCHBALANCED CANTILEVER
N-1 N N+1
Delivery of Precast Span along Completed Deckby 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 ERECTIONFULL 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) 260,000m2 of deck, 602 spans
FEATURES & ADVANTAGES
FORM 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 forYard Handling
Load 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
Taiwan High Speed Rail C215 - Taiwan(2000-2004) 260,000m2 of deck, 602 spans
Taiwan High Speed Rail C215 - Taiwan(2000-2004) 260,000m2 of deck, 602 spans
Taiwan High Speed Rail C215 - Taiwan(2000-2004) 260,000m2 of deck, 602 spans
Seven Mile Bridge - USA (1980-1982)130,000m2 of deck, 265 spans
MRT - Singapore (1985-1989)114,000m2 of deck, 1,000 spans
MRT - Singapore (1985-1989)114,000m2 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.
SPAN BY SPAN LIFTING FRAME CRANE PRECAST BEAM FULL SPAN PRECAST FALSEWORK INCREMENTAL LAUNCHBALANCED CANTILEVER
Segment Delivery at Ground Level
Stressing PlatformSpan JackSpan Jack
N-2 N-1 N
Falsework Support
Temporary Support
Relocation of Falsework Support
FALSEWORK
PRECAST SEGMENTAL ERECTIONSPAN BY SPAN ERECTION ON FALSEWORK
VSL has adopted the fa lseworksuppor t method on many precas 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)108,000m2 of deck, 3,014 segments
FEATURES & ADVANTAGES
FORM 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
K
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)116,667m2 of deck, 8,642 segments
Penny's Bay - Hong Kong (2003-2004)16,240m2 of deck, 627 segments
Deep Bay Link - Hong Kong (2004-2005)108,000m2 of deck, 3,014 segments
Penny's Bay - Hong Kong (2003-2004)16,240m2 of deck, 627 segments
West Link - Australia (2004-2005)86,000m2 of deck, 3,013 segments
East Rail - Hong Kong (2000-2003)58,320m2 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.
SPAN BY SPAN LIFTING FRAME CRANE PRECAST BEAM FULL SPAN PRECAST FALSEWORK INCREMENTAL LAUNCHBALANCED CANTILEVER
Launching Nose
Casting Bed
Vertical Reaction Beams
Scaffolding for Access
Pulling Jack
Direction of Launch
Monolithic or Stressed Connectionto 1st Segment
Launching Bearings
Lateral Restraint
N N+1 N+2 N+3
INCREMENTAL LAUNCH
INSITU CONSTRUCTIONINCREMENTAL 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, 4,947.6m2 of surface
FEATURES & ADVANTAGES
FORM 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 attachedto 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
Rybny Potok - Czech Republic (2005)58m of span length, 10,858m2 of surface
Brides Glens Bridge - Ireland (2003-2004)45.9-65m of span length, 3,200m2 of surface
Caguanas River Bridge - Puerto Rico(1981) 385m of bridge length
Tampanies Sengkang Flyover - Singapore (2002-2003)24.5-63m of span length, 10,623.85m2 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 launchingnose, launching jacks,conventional jacks, launchingbearings and guides.
SPAN BY SPAN LIFTING FRAME CRANE PRECAST BEAM FULL SPAN PRECAST FALSEWORK INCREMENTAL LAUNCHBALANCED CANTILEVER
Front Transverse TrussAnchoring Jack
Rail Beam
Main Frame
Lower Rear Transverse Beam
Stitching Beam
Closure Stitch FormworkEnd Span Falsework
Form Traveller
Lower Front Transverse Beam
Outer Roller Beam
Form Traveller
N N+1
INSITU CONSTRUCTIONFORM 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.
20
Taiwan High Speed Rail - Taiwan (2002-2003)80-100m of span length, 22 cantilevers
FEATURES & ADVANTAGES
FORM TRAVELLER FORM SYSTEM STAY CABLEHEAVY LIFTING
Bridge Abutment
Temporary Support
End span constructed using Form Traveller
DescriptionTypical Construction Cycle
Removal of stop end form and form tiesInstallation of strandStressing of cantilever P.T.Stripping of outer, inner, bottom formLaunching and fixation of rail beamLaunching and fixation of main frameCleaning of form panelsRolling back of inner web formsAdjust / Close outer and bottom formsPlacing P.T. ducts / inserts for bottom slab / websLaunch inner web forms, adjust / close inner web forms
Final survey / check of level / alignmentPour concreteCuring - Traveller #1Curing - 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
FORM 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
Chenur Bridge - Malaysia (2002-2004)140m of main span length, 7 cantilevers
Angara River Bridge - Russia (2000-2005)105m of main span length, 5 cantilevers
Sinu Bridge - Columbia (2005)150m of main span length, 2 cantilevers
Deep Bay Link - Hong Kong (2004-2005)71.5m 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.
SPAN BY SPAN LIFTING FRAME CRANE PRECAST BEAM FULL SPAN PRECAST FALSEWORK INCREMENTAL LAUNCHBALANCED CANTILEVER
INSITU CONSTRUCTIONVSL FORM SYSTEMS
VSL has considerable experience in awide variety of insitu form system rangingfrom 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 ofprecast 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 reinforcementand 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
FORM TRAVELLER FORM SYSTEM STAY CABLEHEAVY LIFTINGFORM SYSTEM
casting of highly complex structures withvariable geometric properties, andproduce 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 perfour 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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Tsing Ma Bridge - Hong KongPier climbform
Tsing Ma Bridge - Hong KongPier climbform
Kisosansen Bridge - JapanMatch cast short line cells
Kisosansen Bridge - JapanMatch cast short line cells
Pakse Bridge - LaosMatch cast long line
Metro de Santiago - ChileMatch cast long line
Ahnpyung Bridge - KoreaMSS
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
SPAN BY SPAN LIFTING FRAME CRANE PRECAST BEAM FULL SPAN PRECAST FALSEWORK INCREMENTAL LAUNCHBALANCED 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.
Re l iab i l i t y, based upon soundengineer 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 fi rst pr ior i ty. Special isedhydraulic 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 ofreliable 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 flexibiltyto 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 Lift ing servicesprovided throughout the world include:
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Bridge at Miraflores - Spain (2005)Two lowering operations of main arch (1,360t each)
FEATURES & ADVANTAGES
FORM TRAVELLER FORM SYSTEM STAY CABLEHEAVY LIFTINGHEAVY LIFTING
E CONSTRUCTION
Feasibility studies and preliminaryconsultation for lifting, horizontaljacking and lowering operations.
Project design and planning,equipment specification, schedulingand budgeting.
Design, manufacture and supply ofspecial equipment and temporarystructures, if required.
Leasing 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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Infiernillo II Bridge - Mexico (2000)Lifting of 3 arched steel trusses (600t each)
Industrial Ring Road - Thailand (2005-2006) Lifting of 500t bridge deck segment
Lanjaron Viaduct - Spain (2001)Launching over deep valley with fishing line principle
Weser Bridge Hehlen - GermanyCrane assisted launching over the river
Dreirosen Bridge - Basel SwitzerlandLifting and floating in of 4 steel trusses (540t each)
VSL Heavy Lifting Equipment (from left)Hydraulic pump, lifting unit, strand coiler
Loire River Bridge - FranceLifting 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.
SPAN BY SPAN LIFTING FRAME CRANE PRECAST BEAM FULL SPAN PRECAST FALSEWORK INCREMENTAL LAUNCHBALANCED CANTILEVER
STAY CABLE BRIDGE CONSTRUCTIONVSL SSI 2000 STAY CABLE SYSTEM
The VSL SSI 2000 Stay Cable System isacknowledged 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 corrosionprotection, easy monitoring andmaintenance. Instal lat ion 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 systemincorporates greased and sheathedmonostrands contained within acontinuous external HDPE stay pipe, withno grouting in the cable. Addit ionalenhancements can be offered including;metal isation (galvanising) of the
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La Unidad Bridge - Mexico (2002-2003)Main span length: 240m
Industrial 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
FEATURES & ADVANTAGES
FORM TRAVELLER FORM SYSTEM STAY CABLEHEAVY LIFTING STAY CABLE
monostrands for additional corrosionprotection, 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 andinstallation 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 worksand construction equipment.
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Wadi Leban Bridge - Saudi Arabia(1997) Main span length: 405m
Neva Bridge - Russia (2002)Main span length: 382m
Peldar Bridge - Colombia (2003)Main span length: 120m
US Grant Bridge - USA (2003)Main span length: 267m
Yichong Yiling Bridge - Hubei, China(2001) Main Span Length: 348m
Safti Bridge - Singapore (1995)Main span length: 99m
Taney Bridge - Ireland (2002)Main 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.
HEADQUARTERSVSL International Ltd.
Scheibenstrasse 70 - Bern - CH-3014 - SwitzerlandPhone: +41 32 613 30 30 Fax: +41 32 613 30 55
www.vsl.com
AMERICASARGENTINAVSL Sistemas Especiales deConstrucción Argentina S.A.BUENOS AIRESPhone: + 54-11-4326-06 09Fax: + 54-11-4326-26 50
CHILEVSL Sistemas Especiales deConstrucción S.A.SANTIAGOPhone: + 56-2-233 10 81Fax: + 56-2-233 67 39
COLOMBIASistemas Especiales deConstrucción Ltda.BOGOTAPhone: + 57-1-633 21 09Fax: + 57-1-633 21 09
MEXICOVSL Corporation Mexico S.A de C.VMEXICOPhone: + 52-5-396 86 21Fax: + 52-5-396 84 88
UNITED STATESVStructural LLCBALTIMORE, MDPhone: + 1-410-850-7000Fax: + 1-410-850-4111
VENEZUELAGestión de Obras y Construcciones C.A.CARACASPhone: + 58-212 941 86 75Fax: + 58-212 941 86 75
MIDDLE EASTUNITED ARAB EMIRATESVSL Middle East LLCDUBAI, UAEPhone: + 9714-296-6399Fax: + 9714-296-6552
AFRICAEGYPTMatrix Engineering CompanyCAIROPhone: + 20-2-344 19 00Fax: + 20-2-346 04 57
SOUTH AFRICATsala-RMS Construction Solutions (Pty) Ltd.JohannesburgPhone: + 27 11 878-6820Fax: + 27 11 878-6821
EUROPEAUSTRIAGrund-Pfahl- und Sonderbau GmbHHIMBERGPhone: + 43-2235 87 777Fax: + 43-2235 86 561
BELGIUMN.V. Procedes VSL S.A.BERCHEMPhone: + 32 3 230 36 34Fax: + 32 3 230 89 65
CZECH REPUBLICVSL Systemy (CZ), s.r.o.PRAGUEPhone: + 420-2-67 07 24 20Fax: + 420-2-67 07 24 06
FRANCEVSL France S.A.TOULOUSEPhone: + 33 (0)5 61 00 96 25Fax: + 33 (0)5 61 00 96 51
GERMANYVSL Systems GmbHBERLINPhone: + 49 30 53 01 35 32Fax: + 49 30 53 01 35 34
GREAT BRITAINVSL Systems (UK) Ltd.BEDFORDSHIREPhone: + 44 (0) 1480 404 401Fax: + 44 (0) 1480 404 402
NETHERLANDSVSL Benelux B.V.OEGSTGEESTPhone: + 31-71-576 89 00Fax: + 31-71-572 08 86
NORWAYVSL Norge A/SSTAVANGERPhone: + 47-51 58 81 25Fax: + 47-51 58 81 26
PORTUGALVSL Sistemas PortugalPre-Esforço, Equipamentoe Montagens S.A.S. DOMINGOS DE RANAPhone: + 351-21-445 83 10Fax: + 351-21-444 63 77
VSL GEOSistemas de Aplicação em Geotecnia SAS. DOMINGOS DE RANAPhone: + 351-21-445 83 10Fax: + 351-21-445 83 28
SPAINCTT StrongholdBARCELONAPhone: + 34-93-289 23 30Fax: + 34-93-289 23 31
VSL-SPAM, S.A.BARCELONAPhone: + 34 93 846 70 07Fax: + 34 93 846 51 97
SWEDENInternordisk Spännarmering ABVÄSTERHANINGEPhone: + 46-8-5007 3820Fax: + 46-8-753 49 73
SWITZERLANDVSL (Switzerland) Ltd.SUBINGENPhone: + 41-32 613 30 30Fax: + 41-32 613 30 15
VSL (Suisse) SAVOUVRYPhone: + 41 24 48157 71Fax: + 41 24 48157 72
ASIABRUNEIVSL Systems (B) Sdn. Bhd.BRUNEI DARUSSALAMPhone: + 673-2-380 153 / 381 827Fax: + 673-2-381 954
HONG KONGVSL Hong Kong Ltd.WANCHAIPhone: + 852-2590 22 88Fax: + 852-2590 02 90
Intrafor Hong Kong Ltd.WANCHAIPhone: + 852-2836 31 12Fax: + 852-2591 61 39
INDIAVSL India PVT Ltd.CHENNAIPhone: + 91-44 4225 11 11Fax: + 91-44 4225 10 10
INDONESIAPT VSL IndonesiaJAKARTAPhone: + 62-21 570 07 86Fax: + 62-21 573 12 17
JAPANVSL Japan CorporationTOKYOPhone: + 81-3-3346-8913Fax: + 81-3-3345-9153
KOREAVSL Korea Co. Ltd.SEOULPhone: + 82-2-553 8200Fax: + 82-2-553 8255
MAINLAND CHINAVSL Engineering Corp. Ltd.HEFEIPhone: + 86-551-3822918Fax: + 86-551-3822878
MALAYSIAVSL Engineers (M) Sdn. Bhd.KUALA LUMPURPhone: + 603-7981-47 42Fax: + 603-7981-84 22
PHILIPPINESVSL Philippines Inc.PASIG CITYPhone: + 632 672 17 03Fax: + 632 672 13 95
SINGAPOREVSL Singapore Pte. Ltd.SINGAPOREPhone: + 65-6559 12 22Fax: + 65-6257 77 51
TAIWANVSL Taiwan Ltd.TAIPEIPhone: + 886-2-2759 6819Fax: + 886-2-2759 6821
THAILANDVSL (Thailand) Co. Ltd.BANGKOKPhone: + 66-2-237 32 88 / 89 / 90Fax: + 66-2-238 24 48
VIETNAMVSL Vietnam Ltd.HANOIPhone: + 84-4-8245 488Fax: + 84-4-8245 717
HO CHI MINH CITYPhone: + 84-8-8106 817Fax: + 84-8-9102 596
AUSTRALIA / PACIFICVSL Australia Pty. Ltd.SYDNEYPhone: + 61 2 9 484 59 44Fax: + 61 2 9 875 38 94
BRISBANEPhone: + 61 7 3265 64 00Fax: + 61 7 3265 75 34
MELBOURNE & SOUTHERNPhone: + 61 3 979 503 66Fax: + 61 3 979 505 47
NEW ZEALANDPhone: + 61 2 9 484 59 44Fax: + 61 2 9 875 38 94
YOUR BRIDGE PARTNER