Breaking New Ground With Intrafor Stays: The Strand by Strand Method
Breaking New Ground With Intrafor Stays: The Strand by Strand Method
Breaking New Ground With Intrafor Stays: The Strand by Strand Method
V S L - I N T R A F O R
NEWS
M A G A Z I N E I S S U E
O N E - 2 0 0 1
Breaking new ground with Intrafor Stays: the strand by strand method
highlights
FACTS&TRENDS
Ductal, a rock-solid asset. VSL Bars, a promising beginning in Switzerland.
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BARS 2 INTRAFOR 4
COVER STORY
FOUNDATION WORKS IN THE NETWORK Breaking new ground with Intrafor! Interview: Christian Besson, Intrafor R&D Technical & Plant Officer. Foundation techniques in the field.
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SITE INSIGHTS
The challenge of the side span erection for Kisosansen Bridge in Japan. Chile: 30,000 m2 of joint-free slab! Thin slabs for big ambitions on the Austrack project, Australia. PT providing a new lease of life for ageing bridge in France. Mauritius : Intrafor cuts through the boulders.
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TECH SHOW
INSTALLATION OF STAYS Strand by strand, the way up! This method allows high speed of erection. See how the story went for the Sucharskiego Bridge in Poland, all in pictures.
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BOULDERS 19
STAYS 20
NEWS, magazine published by VSL International Ltd. Bernstrasse 9, 3421 Lyssach, Switzerland and VSL Management Saint-Quentin-en-Yvelines, France. Director of Publication: Jean-Philippe Trin jptrin@vsl-intrafor.com Senior Editor: Jane Rousseau jrousseau@vsl-intrafor.com Co-ordinators: Julie Arnoux, Ruth Boss, Brian Callagher, Valrie Foyart, Chng Hwee Bin, Anne Perez, Carlos Such, Doris Tong. Distribution: Ccile Parmentier cparmentier@vsl-intrafor.com Design: Red Line Photos: Bert, Y. Chanot, C. Dumont, V. Paul, J. Rousseau, L. Zylberman, other. Copyright: VSL August 2001 Cover photo: Antony Hospital, France.
BY JEAN-PHILIPPE TRIN
EDITORIAL
Our group has reached an important stage in its development. By pooling Intrafor and VSL resources, we have created a specialist platform that can offer its customers an extensive range of services in more than 40 countries. Our recognised expertise in high added value works, and our recent technological advances enable us to apply innovative and efficient solutions to our customers' complex projects. The Sucharskiego bridge in Gdansk, for example, demonstrates the efficiency of our new cablestay system. We are pursuing our R&D program with a view to developing new solutions that combine the use of diaphragm walls and post-tensioned floors. Car parks in urban zones are one of our main priorities. Backed by our network of engineers and technicians, we are able to successfully export a new technology across the world, giving main contractors a competitive edge to clinch new contracts. VSL-Intrafor, which holds a leading position on its specialist markets, is standing by to take up the challenges set by its customers in their design departments.
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FACTS&TRENDS
VSL Bars
Ductal
As well as being used for rock bolts, soil nails and micropiles, this high performance Threadbar technology is also applicable to underground and tunnel construction operations. In many cases, its characteristics allow the diameters of B 500 standard quality bars to be reduced by a unit, resulting in more economical solutions for projects with similar strength and deformation parameters. s Contact: bjoss@vsl-schweiz.ch
> VSL Intrafor is pleased to announce that since March, Marcel Cheyrezy and his assistants Mouloud Behloul and Mireille de Buzelet, have joined the VSL-Intrafor network. They are responsible for the development of Ductal, a product now entering into its operational use phase. While working for the Bouygues group scientific department, Marcel Cheyrezy carried out research on new concretes being developed, particularly ultra high performance concrete (UHPC) which is now being
Marcel Cheyrezy, Ductal Development Director
jointly developed with the French Lafarge and Rodhia companies under the name of Ductal. The advantages of this high added value concrete are its great strength, attractiveness, extreme durability and the fact that it can be used without passive reinforcement, thus spectacularly reducing the thickness of structural elements.
Superconcretes represent a major technological leap forward, allowing more daring, safe and attractive structures and buildings to be designed, while simultaneously cutting costs and construction time. Ductal is being made available to VSL-Intrafor clients in a number of selected territories (initially Japan, Korea and Australia) to provide technical solutions combining the use of Ductal and post-tensioning. s Contact: m.cheyrezy@bouyguesconstruction.com
Vibroflotation
VSoL
Breakthrough in Argentina
> VSL Argentina has been awarded a first VSoL contract as part of the Rosario Victoria road link. This 60 km link between Rosario and Entre Ros Province, across the Paran River, will greatly improve traffic movements between Brazil and Argentina. VSL is responsible for the engineering and supply of 750 m2 of VSoL walls for the abutments, using hexagonal panels. The main contractor is the Puentes del Litoral Joint Venture. The VSoL system was chosen for its technical performance and its competitive cost. A second project using 500 m2 of VSoL walls is also underway. s Contact: vsldt@house.com.ar
COVER STORY
Foundation works in the network
By joining forces, both companies benefit from the others expertise. Thanks to VSL, world posttensioning leader, Intrafor now forms part of one of the most
efficient networks in the construction market. Thanks to Intrafor, a major player in the special foundations sector both in France and Hong Kong, VSL has broaden its offering.
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> Until now, VSLs geotechnical activity was based on reinforced earth walls and anchor ties. With Intrafor, a company No 2 on the French deep foundations market a sector that covers all construction fields: building, civil works, both in the public and private sectors and whether directly or subcontracted, VSLs product
range has now considerably increased. This foundation market involves many small size contracts (certain pile contracts represent less than 30,000 Euro). In Asia, Intrafor's business volume is mainly in Hong Kong. Its activities include diaphragm walls, which are the companys core business, barrettes, and soil improvement projects. Intrafor is also developing specific foundation techniques such as instrumentation monitoring and vibroflotation.
Shared technology
The very nature of these two companies means that they share common features, starting with their clients. VSL (approx. 160.7 m turnover in 2000) and Intrafor (approx. 118.7 m turnover in 2000) generally act as subcontractors to general contractors. They also have the same technological added value approach. The increasing level of shared research in the geotechnical and structure monitoring sectors will bring
Groene Hart in the Netherlands, a major foundations project: very deep foundations (20 m) without intermediate slabs, beneath the water table, anchored by 108 columns sealed into 52 metre deep barrettes.
The networks strength: shared experience, proactivity and communication. John Sindel, head of Australian operations, with Andrew Payne, responsible for Asia.
together engineers from both companies will contribute to developing new solutions. In operational terms, the first result of this alliance was the creation of a single Central Management in January 2001, run by Jean-Philippe Trin and Pierre Dussauze. The resources and
Intrafor
teams of VSL in France and Intrafor are now together in the same building in Saint-Quentin-enYvelines. The teams in Asia will be brought together in Autumn 2001, creating a springboard for VSL throughout Asia.
Cross-corporate strategies
The initial development paths of this shared future have now been defined. A top priority is to create synergies in Asia to take advantage of the great potential that exists in China and India for infrastructure packages involving embankments and walls (VSoL, Keystone), foundations and soil improvement works. Intrafor Branch S.A. works
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For the Caen water treatment plant foundations, Intrafor used a rheostatic concrete that permitted the installation of full height reinforcing cages for the 1,600 piles ranging in depth from 17 to 22 metres.
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COVER STORY
in Hong Kong on major projects, such as the Hang Hau Station (MTRC 601) and KCRC 300 now underway. In 2001, Singapore should account for approx. 10% of the turnover. The use of the VSL network will also make it possible to market in selected European and Asian countries. Intrafor's new
Interview
A down-to-earth app
VSL and Intrafor are now both connected to the same Local Area Network and share resources throughout the world.
marketing strategy is to implement cross-corporate flows between Intrafor and VSL profit centres, successfully manage large foundation projects in Europe, promote vibroflotation and soil improvement activities, and continue developing various foundation techniques such as continuous or secant piles, diaphragm walls, soldier pile retaining walls and soil-nailed walls. Major infrastructure tenders are also currently prepared. s
While the skills of its engineering departments mean that Intrafor can be very involved from the earliest stages of a project - allowing it to suggest alternative solutions - its abilities are essentially based on the experience of those who are in the field.
Interview with Christian Besson, Intrafor R&D Technical & Plant Officer.
Our techniques: deep foundations to transfer loads down to a solid base, supports to either temporarily or
roach
once youve eliminated a few unreasonable solutions, you generally have to make the difficult choice between three or four different options. And the choice has to be made fast. How do you make that kind of decision? This is where experience comes into play. The more difficulties youve come across, the better you can cope because youve already run into the same problem. For example, if a site caves in due to a geological accident and if theres a risk of another collapse: the new situation is then fairly stable but any move could either improve it or make things worse and endanger life. As you can see, risk analysis is not just a technical issue. This is why its vital to train young engineers. What does it take to be a foundations specialist? Generally speaking, you must be enterprising and sure of yourself, although this can occasionally lead to haste being mistaken for speed. You need to invest a great deal of time and be mobile given that operations are generally carried out over short time spans: between a week and six months, rarely more. And given the nature of the works, conditions are hard, so you need to be both levelheaded and keen. What are Intrafors favorite technical fields? Deep foundations to transfer loads down to a solid base, supports to either temporarily or permanently stabilise earth during excavations, anchorages, and the vast field of soil improvements used to modify mechanical and hydraulic characteristics.
How do you give added-value to engineering projects? Unfortunately, new ideas dont constantly pop up and we arent able to develop technologies every day of the week! But we try to keep this frame of mind in our everyday activities, particularly in R&D. It is essential to begin by clearly understanding what the client wants and, while fully providing this, be able to come up with an idea that he has not considered. The best technical solution is the one that is the most profitable, both for him and for us! What are the technical links between Intrafor and VSl ? Intrafor has been using wedges around strands the VSL posttensioning process for ages. We are now working in areas such as post-tensioned slabs associated with the consolidation of support soils, and the protection of structures around excavation works. Thanks to the new network, we can provide a global solution, particularly for the repair and maintenance sector. What kind of changes can be expected in your profession? Our future lies in a better understanding of all aspects of the soil and we are working to improve our knowledge, particularly in automation technologies. We will also need to have highly qualified workers to operate sophisticated equipment. Our business is essentially based on those who are out there in the field, given that it is these people who analyse all the soil data collected during site works. It is not enough to simply know how to use a computer. If you dont pull on a pair of boots and go and look for yourself, you cant possibly know whats going on. s
It is not enough to simply know how to use a computer. If you dont pull on a pair of boots and go and look for yourself
What is the most appealing characteristic of your profession? Christian Besson: The fact that it is highly technical and requires considerable field experience. We have learnt to expect the unexpected. You never quite know what youre going to come across. This, along with the vital role played by the workforce, is what makes the profession so attractive. So how do you control the risks? By making sure that we understand them and by constantly being on the lookout to react rapidly to any type of situation. In our business,
permanently stabilise earth during excavations, anchorages, and soil improvements used to modify mechanical and hydraulic characteristics.
COVER STORY
Foundation techniques in
Specialized skills and equipment are used to control settlement, strengthen foundations, improve soil conditions and stabilise slopes.
DEEP FOUNDATIONS
Driven piles: Steel H-section beams or thick-walled tubes are hammered down as far as possible to provide foundations in soft soils. Barrettes: large rectangular section piles constructed using a grab bucket on kelly or cables, or 'hydromill' cutters. Barrette section is not dependent on the dimensions of the grab or cutter and can take many forms (e.g. a cross). Using a cutter, hard ground can be excavated to depths of 100m with very little vertical deviation. To complete the barrette a reinforcement cage is installed and the barrette concreted. Bored piles: concrete pile of varying depth and diameter, reinforced with a steel cage. The founding depth required to meet the bearing load specifications is calculated according to soil characteristics at different levels. A number of drilling methods can be used. Maybe required to construct down to or into rock. Micropiles: small diameter reinforced piles that are drilled and grouted to support structures in all ground conditions where only limited room is available for drilling rigs. These piles can accept working loads of up to 300 tons and be drilled to depths of around 60 metres. Used for structural support (underpinning existing and new structures, settlement prevention, seismic retrofit) or for in-situ reinforcement (settlement reduction, structural stability, slope stabilization, soil mass strengthening) CFA or PIP: A continuous boring auger is used to drill a pile (typically <1m diameter). Concrete is placed through the auger as it is withdrawn and finally a reinforcement cage is installed.
RETAINING WALLS
Diaphragm wall: retaining, supporting and/or water proofing wall e.g. a basement. A trench is constructed using a cable suspended grab or hydromill cutter. A reinforcement cage is then installed and the trench concreted. Precast Diaphragm wall: constructed using prefabricated elements to improve water tightness. Water-stop joints are filled with grout to give a good seal. Nailed wall: retaining wall utilising anchors for support. Berliner wall: non-continuous wall constructed from piles to retain excavations. Ground anchor (or tieback): drilled and grouted, post-tensioned (stressed) passive or active ground reinforcement system providing resistance to uplift and lateral forces, used for retaining walls, buildings, bridges, dams, unstable slopes and to prevent water table uplift. Taking the form of strands or bars, the system can be temporary (during the construction phase) or permanent. VSL has developed a complete electrical insulation system for permanent anchorages. VSoL system: Ranges from galvanised steel mesh or polymeric strips to reinforce the soil mass, to pre-cast concrete facing panels providing a variety of shapes, surface textures and colours.
SOIL INVESTIGATION
Investigation: to determine soil characteristics by seismic investigation, penetrometers, drilling, crossholes and in situ tests (pressuremeter, inspection, gamma density, permeability...).
Dam
Preloading Investigation
Stone columns
Dewatering Drainage Cut off wall Bored pile Anchors Diaphragm wall Water-proof grouting
Compaction grouting
Jet grouting
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the field
SOIL IMPROVEMENT
Drainage and preloading: to consolidate compressive soils, before building construction, using vertical drains (to eliminate water and gas) and a certain height of fill acting as a preload, to be removed after consolidation. Atmospheric consolidation is when the fill load is replaced by applying a vacuum between a membrane and the soil to create the necessary pressure. Soil mixing: mixing in-situ existing soil with additives (cement-lime) to obtain semi-rigid inclusions. Dynamic compaction: Lift and drop a steel weight. Simple! For granular soils under uniform loaded areas. Vibroflotation: soil compaction by vibration. A vibrator penetrates to the maximum soil depth and is then withdrawn step by step (typically 0.5m intervals) to allow gravel to flow into higher density positions at each step. Additional material is often required to compensate for loss of volume due to the increased density. Stone columns: columns made of compacted gravel to reinforce and drain a cohesive soil. Compaction in not the primary goal. Wet stone columns: flushing a hole with a vibroprobe and then creating a column by pouring gravel from the top. A widely used, fast and low-cost soil improvement method. Dry stone columns: introduction of gravel at the bottom of the hole through a separate gravel duct alongside the vibroprobe. Grouting: controlled injection of a self hardening mix (grout mixes can include clay-cement, bentonite cement, mineral gels, organic resins) through drilling rods into the soil. This system is used to fill cavities and cracks, as well as strengthen and/or waterproof the soil. The spacing of injections is determined by local conditions. Compaction grouting: Stiff, low mobility grout is slowly injected into loose soils, displacing and compacting the surrounding materials. Rather than being absorbed by the adjacent soil, the grout forms a bulb that compacts and increases the surrounding soil density by forcing it to occupy less space. This technique is used to control the settlement of existing foundations, improve soil conditions prior to new foundation construction, lift or align structures, increase soil bearing capacity and eliminate voids. Jet grouting: using a high pressure jet, this system restructures the soil by introducing a cement grout that forms a hardened mix with the existing materials. Soil freezing: to improve soil strength and tightness when excavating beneath the water table, using brine or liquid nitrogen.
OTHERS
Cut off wall: watertight grout curtain wall in alluvial deposits beneath an earth dam. Directional drilling: For pipe or cable laying. A hole is bored along the required alignment. The hole is enlarged by drilling backward (reaming') and the pipe or cable laid by pulling back towards the drilling machine. Dewatering: ground water lowering to guarantee either a maximum water flow inside a deep excavation (and/or to allow construction of a basement) or a maximum draw down outside a deep excavation to control settlement. This means also controlling permeability of the grouted raft. Bentonite slurry: the secret weapon! Used for drilling, piling and diaphragm walls to 1) support excavations by exerting hydrostatic pressure, 2) retrieve spoil earth, 3) guarantee grout mix stability.
VSoL
Barrettes
Grouting
Soil freezing
SITE INSIGHTS
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Japan
> The K1 Kisosansen Bridge Project is now completed and VSL has successfully met the challenge presented by the side span erection. This critical final phase of the construction was the most important part of VSLs contract with the P.T.Y. (PS-TaiseiYokogawa) Joint Venture.
Taiwan
Gigantic!
extra dosed bridge, length of main span: 275 m 450 t precast segments precast cell and rebar gauges weighting 900 tons 1st use of heavy lifting hydraulic jacks on a lifting frame in Japan VSL awarded a special licence Side span girder with twin stay cable beams weighing 3,000 tons Between Singapore (TCAA) and Paris (TPMP), 30,000 hours of design work 2,000 fabrication drawings 3,200 tons of steel manufactured in China 280 containers shipped to Japan
Taiwan
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> VSL Taiwan was awarded the subcontract work for the construction engineering and segment erection works of this project (C310) designed by Sinotech Engineering Consultants Ltd. with Jon Engineering Corporation as Main Contractor. VSLs scope of works includes the design of the segment casting yard layout,
SITE INSIGHTS
Argentina Philippines
> In order to reduce serious flooding in an area affecting over 3,000,000 people, works are being undertaken to channel and increase the width of the Reconquista River north of Buenos Aires. IECSA awarded VSL a first subcontract for four railway bridges. VSLs scope of works includes the supply and installation of PT components. This project is the first time in Argentina that corrugated ducts have been used to improve the fatigue resistance of bridge tendons. VSL was also awarded a second subcontract by CIMARG to supply PT components for 840 permanent ground anchors. This project will represent the largest concentration of ground anchors ever installed in Argentina. s Contact: VSL Sistemas Especiales de Construccion Argentina S.A
Philippines
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Post-tensioned works at Manila's Abu Dhabi new airport VSoL walls add camel
> The new Ninoy Aquino International Airport (NAIA) Terminal III project (US$ 500 million), being built using a B.O.T. scheme, was awarded to Takenaka Corporation. VSL was awarded the design and post-tensioning works for levels 4 and 5 of the main terminal building. The structure is typically a flat slab (200-300 mm) spanning 9 m using S5-4 tendons. Over 53,300 m2 of floor area will be constructed using 290 tonnes of post-tensioning. s Contact: mphillips@pacific.net.ph
> VSL Middle East has recently completed the design and supply of VSoL polymeric walls for contracts 1 and 2 of the new Abu Dhabi to Dubai Trunk Road. During the project design phase, it was realised that the new road alignment would cut across traditional camel routes in the desert areas. The VSL solution to this unusual problem was to construct two camel-crossing underpasses using the cost effective VSoL polymeric wall
System. Final design of the camel crossings comprised a reinforced concrete box structure to form the underpass with VSoL walls supporting approach ramps up to 9.0 m high and designed to take full containment crash barrier loading. Working closely with main contractor Copri Construction Enterprises,VSL Middle East supplied 8000 m2 of VSoL wall on the project undertaken for the Abu Dhabi works department. s Contact: Stephen Burke.
Australia
Deep excavations
> With a 22 metre deep footprint covering an area of 5,000 m2, the MacArthur Centre development is a major excavation and shoring project in Brisbanes central business area. L & D Contracting Pty Ltd, earthmoving contractors, sub-contracted VSL to carry out the installation of 900 temporary ground anchors (up to 2,200 kN working load), and 2,400 m2 of sprayed concrete panels for retention of the upper levels of weathered rock and clays. The 22 metre deep excavation is predominantly through fresh phyllite (shale) rock with weathered clays in the top 3-5 metres.
Anchoring and sprayed concrete wall construction to the upper levels was carried out using an alternate excavation slot and rock buttress technique to maintain the excavation's stability. The project required anchors to be drilled to clear existing services below the road and adjacent structures. The load transfer of the large anchoring forces is operated by sprayed concrete panels in the weathered rock areas, and by isolated sprayed concrete pads in the fresh rock faces. One of the major design requirements was the preservation and protection of two Queensland Government Heritage listed buildings around the site. Extensive anchoring through temporary structural concrete underpinning walls was required and restraint beams were fully anchored to the bed rock. s Contact: bcavill@vslsyd.aust.com
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Chile
to work simultaneously, one on each side, without interruption. The work was completed in 1.5 months with daily pours of
approximately 600 m2. The main contractor for this job was Constructora Inarco S.A. s Contact: aavend@vslchile.cl
SITE INSIGHTS
N O T E P A D
Malaysia
Seven launchers! To erect the 8,500 segments over 10.9 kilometres on the new railway line from Hong Kong to the New Territories, the KCRC project (sections 201 and 211) is using no less than 7 launching systems and 2 form travellers. More from KCRC. Working with the Necso-China State-Hip Hing JV, a VSL-Freyssinet Joint Venture has been awarded a HK $150 m contract on the KCRC East Rail network (TCC200 & 300). The works are scheduled for completion in September 2002. Accurate loading. AUSPAC is researching a method to measure the anchorhead load of an unbonded tendon using an accurate electronic micrometer.
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Recycled launch girder. To erect the segmental balanced cantilever bridge for the impressive 2nd Freeway Extension project in Taiwan (C310), VSL is using the launching girder assembled in Hong Kong for the Hung Hom bypass. This girder, launched in 1978, was also used for Rambler MRT 510, Chung Ching Viaduct, Rambler Channel and Kwun Tong bypass projects in Hong Kong, and the St Maurice Viaduct in France. Pollution-free injection. Intrafor is consolidating an aqueduct in Frances most famous forest, Fontainebleau. The works involve filling the external voids in the structure, waterproofing and injecting the interior cracks. The injection plants are directly linked to a water pollution detection system (turbidimeter). Hola! VSL IPSALA has moved its offices to a new address in the heart of Barcelona: VSL IPSALA, CTT-Stronghold, S.A. c / o Casanova, 2-4 3 plant 08011 Barcelona Spain. Tel. +34 932 892 330. Fax.+34 932 892 331. cttbcn@vslsp.com
USA
USA
Germany
Customized slide
Australia
> One of the main links between Germany and Poland is the Oder bridge in Frankfurt-Oder. Given the steadily increasing traffic levels, the decision was taken to replace the old bridge. The new bridge was built in a temporary position alongside the old one, just in front of the existing customs building. This required the moving of the customs building to a new location to provide access to the construction site and permit a subsequent temporary traffic diversion onto the new bridge. VSL Heavy Lifting was awarded the sliding contract by the German contractor Porr. The 300 tonne customs building, a steel structure with large glass windows, was initially lifted by 0.2 m. It was then slid by 0.5 m to the east in order to separate it from an annexe building. This was followed a 21 m slide to the south and then a 35 m slide to the west. The operation was successfully carried out in the first week of March 2001. The building will be returned to its initial position at the end of 2002. s Contact: ftrenkler@vsl-schweiz.ch
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> VSL has proven its capacities in Australia with the completion of the Austrack project. This is an intermodal rail freight station set on a series of ground slabs able to accept the repeated passage of forklift trucks with axle loadings of up to 80 t. VSL designed the entire structural slab system and installed 160 tonnes of post-tensioning last April. Ground slabs provide an alternative to reinforced concrete solutions and VSL tendons axially
SITE INSIGHTS
USA
Korea
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the tensioning of the roof structure required the installation of an additional 48 SLU-120 units. During this phase, the pulling forces were rapidly increased until the lower radial roof cables could be connected. The total quantity of 96 lifting units represents a new record for a single project. s Contact: psiegfried@vsl-schweiz.ch
Australia
One advantage of this configuration is the elimination of stressing pilasters typically required for walls where tendons are placed orthogonally. Access for placing the strands, stressing, and grouting was provided from the top slab decking. VSL provided the installation of mild reinforcements in addition to supplying and installing the post-tensioning systems. The project was an overall success due largely to the combined pre-planning efforts by VSL, Jennison Construction, and Plains Engineering. s Contact: bgallagher@structural.net
France
France
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represents a promising market in France for ageing bridges built in the 1970s. s Contact: jf.cubille@intrafor.fr
SITE INSIGHTS
France
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Station 1
Angle boreholes equipped with sleeved tubes are placed in haloes comprising 3 to 4 boreholes at a distance of 0.75 m from one another.
Point de vise
St-Etienne Square
Collge St Etienne
Cathdrale St Etienne
Ground slab
0.52 0.23
Station 2
Chalky loam
A support control system on the west facade of the cathedral using four detection cells automatically stops the injection process as soon as the 1 mm tolerance level is exceeded.
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Micropiles
Mauritius
> In Mauritius, upstream from the Midlands dam now under construction (Bouygues for the civil works, DTP for the handling of materials and Intrafor for the cut off wall), Intrafor is constructing a 30,000 m2 diaphragm wall anchored to the rock. Taken down to an average depth of 14 metres, this 0.65 m plastic concrete flexible screen is intended to pick up soil deformations during the
construction phase and prevent water from passing under the dam works. The nature of the soil, comprising rocky banks of basalt and large isolated boulders (from 2 to 8 m across) with a resistance of up to 2,000 bars, made the digging operations particularly difficult and the cutter had to be specially equipped to cut through them. The operation lasted six months. s Contact: p.congiu@intrafor.fr
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The centre of the island receives 4,000 mm of rainfall a year and cyclones from November to May.
TECH SHOW
I N S TA L L AT I O N O F S TAY S
Instead of fully prefabricated cables, VSL in Poland used the strand by strand method to install the stays for the Sucharskiego Bridge. Step by step, here's how the story went.
the pipes to the site in 12 m lengths and welding them with an automatic fusion mirror welding machine to the required length to meet geometric and thermal conditions.
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Several advantages. The strand by strand
method allows perfect parallelism of the strands, high erection speed, simple and repetitive operations for local labour, reduced construction loads thanks to light equipment, and the flexibility to adapt to the main contractors schedule.
I N S TA L L AT I O N O F S TAY S
TECH SHOW
pipe is erected with the first strand installed. This strand is connected at both ends to the anchorages and then stressed to raise the stay pipe. The strands are then pulled one by one through the stay pipe, connected to the anchorages and individually stressed.
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No crane required. The stay pipe is lifted from the deck to the pylon with winches
supplied by VSL. Anchorages are pre-fabricated on site in a protected area under well controlled conditions. There is no anchorage assembly on the bridge on the critical path of stay erection.
Pull up & pull in from the top. The winch installed on the pylon enables the strand, fixed to
the lifting cable, to be lifted inside the stay pipe. The stay pipe is temporarily fixed to the pylon during the strand installation.
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I N S TA L L AT I O N O F S TAY S
TECH SHOW
begins with strand end preparation on a workbench. They are then fed and going through a guide wheel to the stay pipes.
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wire strands, manufactured according to VSL specifications, are supplied to the site on wooden reels and protected against damage.
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Follow the shuttle ! The strand is fixed to the lifting cable inside the stay pipe using a special coupling
device before being passed through the pylon anchorage via the strand's anchorage hole. The lifting cable then pulls the strand up into the stay pipe. A hoisting shuttle connected to both the lifting cable and strand is used to return the lifting cable to the bottom of the stay after strand installation. Once the strand and shuttle reach the pylon, the hoisting shuttle is disconnected, the strand pulled completely into the anchorage and the pylon anchor wedges installed. The lifting cable is then disconnected from the strand, and the bottom end of the strand cut and threaded through the deck anchorage before being stressed. The lifting cable is then threaded through the next pylon anchor block hole, the hoisting shuttle connected to the lifting cable and both then returned through the stay pipe to the bottom of the stay for the next strand installation cycle.
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strand installation method ensures that all strands are parallel. Each strand is first stressed to a level that satisfies the required stay force specified by the engineer, and ensures that the same force is applied to all individual strands. In the subsequent stressing operations, each strand is stressed to a specified stay elongation.
I N S TA L L AT I O N O F S TAY S
TECH SHOW
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6 to 8 strands were installed per hour. By using prefabricated anchorages, VSLs system is optimised and simplifies cable installation on site, avoiding delicate anchorage assembly on the critical bridge erection path.
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Lonely jack. Once installed, the strand is stressed from the stressing anchorage.
All tensioning operations can be carried out using a monostrand jack weighing less than 20 kg.
Pick a colour! The High Density Polyethelene (HDPE) pipes can be black or coloured. External helical ribs reduce cable vibration caused by rain and wind.
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bridges are longer and more slender. As a result they have higher flexibility and require additional stay stressing operations. VSL's specific lightweight Automatic Stressing System controls each operation during construction and logs a record.
I N S TA L L AT I O N O F S TAY S
TECH SHOW
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The Sucharskiego project. Construction works for this project over the Martwa Wisla River near Gdansk (Poland) began in 1999 and will be completed in 2002. The
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overall deck comprises one 25 m long span, one 230 m long main span and four 26 to 39 m long back spans. The main span is supported by cable stays from a single pylon, and equilibrium is provided by stays to the back span. Total length is 372 m, pylon height is 100 m and the quantity of strand for stay cables is 425 t. Sixty stay cables are to be installed. The units vary between
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31 and 55 strands, and are 60 to 215 m long. The client is the Polish Road Administration and the main contractor is a joint venture between Demathieu & Bard (France) and Mosty-Lodz S.A. (Poland). VSL Polska is the subcontractor for the installation of the stay cables. The VSLs scope of works comprises design and installation of the stay cables including materials, supervision, labour and equipment.
s Contact: rk@vsl-pl.it.pl
All stays are individually stressed a second time and the anchorages are secured by power-seating of the wedges. This final tuning and the installation of the antivandalism protection for this bridge should be completed by the end of September 2001.
HEADQUARTERS
VSL International Ltd. Bernstrasse 9 - LYSSACH CH 3421 - Switzerland Phone: +41 - 34 - 447 99 11 Fax: +41 - 34 - 445 43 22
http:\\www.vsl-intl.com http:\\www.intrafor.com
J O I N I N G FO R C E S FO R YO U R P R OJ E CT S
Americas
ARGENTINA
VSL Sistemas Especiales de Construccin Argentina SA BUENOS AIRES Phone: +54 - 11 - 4326 - 06 09 Fax: +54 - 11 - 4326 - 26 50
Europe
AUSTRIA
Universale GSB VIENNA Phone: +43 - 1 - 878 170 Fax: +43 - 1 - 878 17 782
Asia
NORWAY
VSL Norge A/S STAVANGER Phone: +47 - 51 - 56 37 01 Fax: +47 - 51 - 56 27 21
BRUNEI
VSL Systems (B) Sdn. Bhd. BRUNEI DARUSSALAM Phone: +673 - 2 - 380 153 / 381 827 Fax: +673 - 2 - 381 954
THAILAND
VSL (Thailand) Co. Ltd. BANGKOK Phone: +66 - 2 - 237 32 88 / 89 / 90 Fax: +66 - 2 - 238 24 48 Intrafor Pacific (Thailand) Co. Ltd. BANGKOK Phone: +66 - 2 - 643 17 35 Fax: +66 - 2 - 643 17 45
BELGIUM
N.V. Procedes VSL SA BERCHEM Phone: +32 3 230 36 34 Fax: +32 3 230 89 65
POLAND
VSL Polska Sp. z o.o. WARSAW Phone: +48 - 22 817 84 22 Fax: +48 - 22 817 83 59
HONG KONG
VSL Hong Kong Ltd. San Po Kong / Kowloon Phone: +852 - 2590 22 22 Fax: +852 - 2590 95 93 Intrafor (Hong Kong branch) WANCHAI Phone: +852 - 2836 31 12 Fax: +852 - 2591 61 39
CHILE
VSL Sistemas Especiales de Construccin S.A. SANTIAGO Phone: +56 - 2 - 233 10 81 Fax: +56 - 2 - 233 67 39
VIETNAM
VSL Representative Office HANOI Phone: +84 - 4 - 8245 488 Fax: +84 - 4 - 8245 717
CZECH REPUBLIC
VSL Systemy (CZ), s. r. o. PRAGUE Phone: +420 - 2 - 67 07 24 20 Fax: +420 - 2 - 67 07 24 06
PORTUGAL
VSL Sistemas Portugal Pre-Esforo, Equipamento e Montages S.A. S. DOMINGO DE RANA Phone: +351 - 21 - 445 83 10 Fax: +351 - 21 - 444 63 77
MEXICO
VSL Corporation Mexico S.A de C.V MEXICO Phone: +52 - 5 - 396 86 21 Fax: +52 - 5 - 396 84 88
INDIA
VSL India Private Ltd. CHENNAI Phone: +91 - 44 859 2538 / 39 Fax: +91 - 44 859 2537
FRANCE
VSL France S.A. ST-QUENTIN-EN-YVELINES Phone: +33 - 1 - 39 44 85 85 Fax: +33 - 1 - 39 44 85 87 Intrafor S.A. ST-QUENTIN-EN-YVELINES Phone: +33 - 1 - 39 44 85 85 Fax: +33 - 1 - 39 44 85 86
SPAIN
CTT Stronghold BARCELONA Phone: +34 - 93 - 289 23 30 Fax: +34 - 93 - 289 23 31 VSL-SPAM, S.A. BARCELONA Phone: +34 - 93 - 289 23 30 Fax: +34 - 93 - 289 23 31
UNITED STATES
VStructural Llc. BALTIMORE, MD Phone: +1 - 410 - 850 - 7000 Fax: +1 - 410 - 850 - 4111
Australia/Pacific
AUSTRALIA - Queensland
VSL Prestressing (Aust.) Pty. Ltd. GEEBUNG Phone: +61 - 7 - 326 564 00 Fax: +61 - 7 - 326 575 34
INDONESIA
PT VSL Indonesia JAKARTA Phone: +62 - 21 - 570 07 86 Fax: +62 - 21 - 573 12 17
Middle East
UNITED ARAB EMIRATES
VSL Middle East Office DUBAI Phone: +971 - 4 - 282 08 03 Fax: +971 - 4 - 282 94 41
GERMANY
VSL Systems GmbH BERLIN Phone: +49 30 53 01 35 32 Fax: +49 30 53 01 35 34
JAPAN
VSL Japan Corporation TOKYO Phone: +81 - 3 - 3346 - 8913 Fax: +81 - 3 - 3345 - 9153
SWEDEN
Internordisk Spnnarmering AB SOLNA Phone: +46 - 8 - 504 37 200 Fax: +46 - 8 - 753 49 73
GREAT BRITAIN
VSL Systems (UK) Ltd. CAMBRIDGESHIRE Phone: +44 (0) 1480 404 401 Fax: +44 (0) 1480 404 402 Intrafor (UK) BRACKNELL Phone: +44 - 1 - 344 742 115 Fax: +44 - 1 - 344 742 146
KOREA
VSL Korea Co. Ltd. SEOUL Phone: +82 - 2 - 553 8200 Fax: +82 - 2 - 553 8255
SWITZERLAND
VSL (Switzerland) Ltd. LYSSACH Phone: +41 - 34 - 447 99 11 Fax: +41 - 34 - 445 43 22
MAINLAND CHINA
VSL Engineering Corp., Ltd. Anhui Province, HEIFE Phone: +86 - 551 - 557 6008 Fax: +86 - 551 - 557 6018
Africa
SOUTH AFRICA
VSL Systems (South Africa) Pty. Ltd. Kya Sand, RANDBURG Phone: +27 - 11 - 708 21 00 Fax: +27 - 11 - 708 21 20
GREECE
VSL Systems A/E ATHENS Phone: +30 - 1 - 363 84 53 Fax: +30 - 1 - 360 95 43
MALAYSIA
VSL Engineers (M) Sdn. Bhd. KUALA LUMPUR Phone: +603 - 7981 47 42 Fax: +603 - 7981 84 22
GUAM
Structural Technologies Inc. TUMON Phone: +1 - 671 - 646 8010 Fax: +1 - 671 - 646 8060
NETHERLANDS
VSL Benelux B.V. AT LEIDEN Phone: +31 - 71 - 576 89 00 Fax: +31 - 71 - 572 08 86 Intrafor (Netherlands) AC LEIDERDORP Phone: +31 - 71 - 581 70 22 Fax: +31 - 71 - 581 70 21
PHILIPPINES
VSL Philippines Inc. MANDALUYONG CITY Phone: +632 638 76 90 Fax: +632 638 76 91
SINGAPORE
VSL Singapore Pte. Ltd. SINGAPORE Phone: +65 - 559 12 22 Fax: +65 - 257 77 51 Intrafor (Singapore) SINGAPORE Phone: +65 - 334 00 36 Fax: +65 - 334 00 59
TAIWAN
VSL Taiwan Ltd. TAIPEI Phone: +886 - 2 - 2759 6819 Fax: +886 - 2 - 2759 6821
Post Tensioning Deep foundations Stay cables Soil improvement Heavy lifting Climb form and formworks Retained earth Superstructure erection Diaphragm walls
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