NEWS THE VSL-INTRAFOR MAGAZINE• ISSUE TWO-2002

Strategies for packages Environmental friendly foundations Full span pre-casting in Taiwan FACTS&TRENDS 4 VSL Damping system is launched 4 VSL at fib 2002 Exhibition 5 DAMPERS 4 COVER STORY 6 COMPREHENSIVE SERVICES & PACKAGES High skills packed together 6 Interview: Jacky Mazars, an expert in natural risks and structural vulnerability. 11 SITE INSIGHTS 12 Hong Kong: Even deeper at Package 7 foundations 12 MONITORING 10 Australia: The tallest VSoL® for Mount Arthur 14

A two-bridge slide in Prague, CZ 16 Europa Bridge in Portugal: ® High-tech response 16 VSoL 14 Innovative analysis applied to tunneling plugs, France 18 ENVIRONMENTAL PRESERVATION 20 highlights Environmental protection concerns for the deep foundations for the Museum of Primitive Arts in Paris. 20 HSR TAIWAN 25 SPECIAL REPORT 22 HEAVY LIFTING - Power to the point: VSL's Heavy Lifting system enhances quality, compresses construction schedules and saves costs. 22 TECH SHOW 25 HSR TAIWAN: Full span pre-casting for high speed erection 25 An unusual alternative option, the“full span pre-casting” (FSPC) was mooted to build a 340km Rail Link of primarily Viaduct in Taiwan.

NEWS, magazine published by VSL International Ltd. • Scheibenstrasse 70 – Bern, Switzerland and VSL-INTRAFOR • Saint-Quentin-en-Yvelines, France. Director of Publication: Jean-Philippe Trin • [email protected] Editor in chief: Jane Rousseau • [email protected] Co-ordinators: Julie Arnoux, Ruth Boss, Anne Perez, Carlos Such, Doris Tong, Brian Callagher. Distribution: Cécile Parmentier • [email protected] Design: Red Line Photos: Y. Chanoît, A. Derek, C. Dumont, V. Paul, B. Strahm, L. Zylberman, other. Copyright: VSL • December 2002 Cover photo: HSRL project, Taiwan BY JEAN-PHILIPPE TRIN EDITORIAL Specialist and The projects that our customers are undertaking nowadays are partner increasingly complex in terms of technical content, scheduling and constraints, both environmental and legal.

VSL-Intrafor's engineering capabilities and many years of experience with challenging projects allow its engineers to imagine cost-saving solutions that minimise risks to the environment and cut down the interfaces that customers have to manage. Using its range of specialisations, VSL-Intrafor can offer integrated, full- service "packages" that reduce the number of companies involved in a project and offer greater assurance of meeting deadlines.

When large owners such as the KCRC (Rail) in Hong Kong award a contract, they take into account a technical rating as well as a 3 financial one. The principle of selecting the best technical and financial bid requires that specialised companies be involved in the tender preparation phase. This gives VSL-Intrafor the opportunity to demonstrate its technical creativity and draw attention to its references.

This approach is becoming very popular in many countries, either through "owner-contractor" partnerships or through a selection process that gives priority to risk management, meeting deadlines and environmental protection. The teams at VSL- Intrafor have a crucial role to play for their customers, and our "Packages" strategy is the key to doing it. FACTS&TRENDS Australia Marked out! > The facilities at Lyell McEwin Hospital in N. W. Adelaide required 16,000 m2 of suspended floor area with 10-m spans. Authorities were reluctant to accept post-tensioning out of fear over potential collisions with tendons in coring future penetrations. VSL offered the client a tendon-marking solution, whereby the tops of slabs are marked with a single continuous line while slab and beam soffits VSL Damping System are stenciled every 5-6 meters. ■ Contact: [email protected] Ready for action as needed > VSL has developed a friction exposed to strong winds, the damper to control stay cable friction force has been adjusted to vibrations on bridges. The VSL activate the damper only when the damper is set up to remain idle for vibration amplitude of the longest small and non-critical vibration cable exceeds 70 mm. amplitudes, thereby reducing both After some two years in operation, 4 wearing and maintenance costs. 30 friction dampers were checked VSL’s friction damper is currently during a maintenance operation of being used on two bridges: the stays; this operation confirmed 120 dampers installed on the stay the effective damper behavior, and cables of the Uddevalla Bridge demonstrated the ease with which (Sweden), and 4 dampers installed components may be dismantled in 2001 on the longest cables of and then reassembled in situ. ■ the Gdansk Bridge (Poland). For Contact: yves.bournand@vsl- the Uddevalla Bridge, which is intrafor.com Earthquake protection Chile Footbridges: Spider on its way > “Spider” is now well on its way stroke can accommodate the large strides to commercial application. VSL has displacement of each story. This taken an active part in the system offers a promising solution > VSL has built a total of development of this project in that no major additional 15 pedestrian bridges in Chile sponsored by EEC, aimed at strengthening is required and during 2000 and 2001 and is retrofitting buildings as an architectural constraints get currently working on another earthquake protection measure. satisfied all at the same time. 23 units in the vicinity of Santiago. The “Spider” method consists of Furthermore, it limits structural Use of the post-tensioning extending energy dissipation limits movement. ■ technique in building such bridges through an innovative system Contact: [email protected] has produced a major impact: based on the serial coupling of technically and for aesthetics. damping devices and prestressed The company's next step will be cables. The damper cable system to improve designs for urban is preloaded and transmits seismic concessionary projects. ■ energy from the building to the Contact: [email protected] damper via a cable. The damper

NEWS N°2•2002 Events NOTE PAD

The best - The Seonyu Ductal® VSL at fib 2002 footbridge constructed by VSL > The first fib Congress Innovative footbridge in Seoul- Korea was awarded by the "Concrete Structures in the 21st Seonyu Footbridge (Mouloud Korea Concrete Institute as “the Century" took place in Osaka, Behloul), Controlling vibration of best concrete structure”. Japan, in October 2002. Approx. stay cable, Enhancing the curability New tech award - VSL in Chile 80 exhibitors and 2000 visitors of stay cable (Yves Bournand), have been awarded the attended the event. VSL Enhancing the durability of post- "Technologic Development International held a booth tensioned structures by improving Award" by the Chilean Institute displaying the SSI 2000 stay cable the quality of grouting (Hans-Rudolf for Cement and Concrete. This system and CS 2000 anchorage, Ganz, Stéphanie Wildaert), Recent prize highlights features in high and presented several papers at developments in the protection of excellence cement or concrete the conferences: Design and prestressing steels (Hans-Rudolf activities. construction of precast concrete Ganz). Three awards attributed for Gallery job - At one of the segmental viaducts on KCRC West "Outstanding concrete structures" terminal platforms in Paris's Rail Project, Hong Kong (Neil went to projects to which VSL Roissy Airport, a site where Thorburn), Electrical isolation as contributed: Bras de la Plaine Intrafor has been working enhanced protection for post- Bridge in the Reunion Island, extensively over the past five tensioning tendons in concrete Vlatava River metro Tunnel in years, the company has now structures (Adrian Gnaegi, Juan Prague, and the TGV viaducts in been commissioned to build the Ayats), Fire resistance of Ductal® Avignon, France. ■ Contact: diaphragm walls for the 240-m ultra high performance concrete, [email protected] long future baggage-conveyance gallery at module 2E. 5 Australia Improved version of AMS – VSL's Automatic Monostrand Stressing System accurately A few years in hospitals? stresses each individual strand to the specified load and records the data. The lift-off mode now permits to execute automatic lift-off of individual strands of a stay cable to detect and record the actual strand force. Enhanced reinforcement cages - Development of the CADA software through a joint project between the Paris and Hong Kong foundation design offices now enables the computation and automatic generation of the drawings for diaphragm wall reinforcement cages on the basis of force computation results.

ISO9001-2000 - VSL's manufacturing plant in Hefei, China had its quality management system certification renewed and > In Victoria, Australia, both the these projects and has already won upgraded to the ISO9001-2000, private and public sectors will be two: Epworth Hospital Centre including the recent bearings spending hundreds of millions of Redevelopment in Richmond, and and joints activity. Such a dollars in building new hospitals Stage 1 of the Austin & Repatriation distinction represents a first for and health facilities over the coming Medical Centre Redevelopment. ■ any VSL company. years. VSL in Australia is targeting Contact: [email protected]

NEWS N°2•2002 COVER STORY

Comprehensive services & packages High skills packed togeth

The packages — or over 10 years now, VSL the construction of very tall buildings has been offering customers or the pylons of suspension or cable- combined service F comprehensive solutions, or stayed bridges, will be a determining “packages”, structured around one factor in developing the methods, offers structured of its recognised specialities such defining the resources and setting up as post-tensioning, construction the scheduling. systems or methods. The potential around a recognised scope of these packages grew When it comes to deep even broader a year ago with the foundations, the erection of speciality such as addition of Intrafor’s exceptional diaphragm walls (Intrafor’s core know-how in the field of deep activity for over 30 years) will post-tensioning or foundations. These packages can affect, for example, how an be put together in many different underground parking facility is foundations — ways to provide customers with constructed. Managing the project-tailored services that will interfaces with the future floors are designed to optimise costs and scheduling. takes on major significance because it offers a way to save 6 optimise costs and This strategy of offering broader time and materials by dealing with combinations of services is a two issues - infrastructure and scheduling. The response to the complexity superstructure - at the same time. and inter-related aspects of a success of this project such as post-tensioning/ At the customer’s reinforcement, segment erection request strategy is becoming and concrete works in operations involving ever-shorter deadlines. The idea of “extended services” or broader. Here are By giving specialists the central “packages” was inspired by the role in dealing with technical demands of customers - demands issues, efforts can be focused on that arise in the continual dialogue some examples. devising effective solutions to the maintained with them concerning most complex problems and possible technical solutions and implementing them as efficiently the analysis of possible risks. The as possible. purpose of this relationship with customers is to limit from the At the heart of the action beginning the interactions that may complicate or slow down the Whether post-tensioning is used in successful completion of a project. the construction of a cantilever It also allows the responsibility for bridge, a girder bridge, a meeting the stipulated quality segmental bridge erected with a standards and deadlines to be launching gantry, ground slabs or placed on a single service provider. some other project, it is always on In such a relationship, VSL-Intrafor the critical path of the work is able, if appropriate, to work as a because it affects the organisation partner with the customer, and not of the construction cycles and thus only as a sub-contractor. This was the overall progress of the project. the case, for example, in the Puente de la Unidad Bridge project, Likewise, the use of climb forms or a turnkey undertaking in Mexico slip forms, two other VSL-Intrafor executed in partnership with one of specialities that are well adapted to the main companies in Monterrey.

NEWS N°2•2002 er

Optimising costs construction of the towers of the Singapore (the Telok Blangah Tsing-Ma suspension bridge in Hong bridge). In the Gateway project at There are many examples of VSL- Kong. Numerous segmental bridge Hong Kong, VSL was called on to Intrafor packages in projects in Asia, decks have been built in places like provide a particularly broad range of Central America, South America and Hong Kong (Hung-Hom bypass, services in the building construction Europe. In Asia, for example, VSL West Rail C201/211, East Rail), Laos field, including climb forms, post- supplied a package of slip form and (Pakse), Malaysia (2nd crossing), tensioning, table forms and concrete heavy lifting services for the Thailand (NS4, NS7) and recently in works. In every case, VSL’s extensive ▲

PUENTE DE LA UNIDAD: A PACKAGE FOR DESIGN & BUILD Complete bridge supply

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The Grupo Garza Ponce - VSL Mexico joint venture has fastened onto a massive 8,000-m3 concrete slab been awarded, as main contractor, the “Puente de la footing up to 5 m thick. The entire structure reaches Unidad” construction project, a 300-m long cable- 160 meters in height; 13 pairs of stays on the stayed bridge crossing the Santa Catarina River in northern side have been installed to support the main Monterrey Nuevo Leon (north of Mexico City). As deck and its four-lane traffic. The pylon is being partner to this 50/50 joint venture, VSL Mexico has erected along the alignment of a major highway, been assigned a scope of works that includes project which has been temporarily diverted while awaiting management, complete technical and methods project completion and opening of the ensuing support, and a portion of production management. VSL highway crossing. The deck is composed of a Mexico will also supply and install both the 220 tons of 100-m long concrete transitional span, designed to post-tensioning and 440 tons of stays using the SSI accommodate two access ramps, along with a 2000 system. Structural design has been performed 150-m long composite (structural steel and concrete) by the joint venture set up between SOCSA, a local element connecting to the northern viaduct. company, and International Bridge Technologies Inc., This US$ 17-million project, contracted for the a US company based in San Diego, California. Nuevo Leon government, commenced in June 2002 The bridge is composed of a single 60-degree inclined and is scheduled for opening by August 2003. ■ post-stressed pylon on the south side of the crossing, Contact: [email protected]

NEWS N°2•2002 COMPREHENSIVE SERVICES COVER STORY

EAST RAIL KCRC: A PACKAGE FOR CONSTRUCTION METHODS 14 fronts simultaneously The East Rail KCRC project represents a true construction of 286 spans, built span-by-span, challenge for the VSL Hong Kong site team in terms and 20 FCM spans erected with cranes. of organising an around-the-clock schedule of works. Overall, 4,449 segments are to be erected, stressed This meant accommodating erection of the segments together with 3,210 tons of post-tensioning. The over highways during night shifts and a constantly- project reached a critical production peak in August: changing sequencing of the works program (heavily 12 erections fronts, featuring 6 under-slung gantry influenced by pier availability and local traffic units, 1 overhead gantry unit and 3 sets of scaffolding constraints). In January 2001, VSL HK, in partnership, systems, plus 2 erection fronts for the FCM signed a contract with the Necso-China State-Hip construction were mobilized and simultaneously Hing Joint Venture for the construction of East Rail operating; 46 staff members and a crew of some KCRC extensions in Hong Kong (Contracts TCC200 210 workers were involved. Completion of the and 300). With an overall bridge deck length erection works is scheduled for February 2003. ■ of 10,800 meters, the project includes the Contact: [email protected]

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involvement benefits the prime Our business is service Rail project in Hong Kong with five contractor by improving its ability to launching girders, constructed the meet deadlines. In addition, having In 2002, VSL-Intrafor has done the Bayan Barn segmental bridge in VSL supply several services means precasting and erection of 700- Penang, Malaysia and completed that supervision costs of a value- tonne beams on a 20-km section of the precasting of beams for Collins added business are spread out, the high-speed train line between Street, in Melbourne, Australia. thereby reducing their impact on Taipei and Kaoshung in Taiwan. It Packages like these are attracting unit costs. also continued work on the East the attention of companies

HSRL PROJECT IN TAIWAN: A PACKAGE FOR FULL SPAN PRE-CASTING AND ERECTION Over 600 bridge spans

Whereas in-situ options such as cast-in-place and pre- cast segmental structures are well known in Taiwan, with multiple standard and advanced shoring systems common throughout the island, a technique such full span pre-casting promised the structural advantages of a single monolithic box girder for the double track (14m wide) plus a speed of erection faster than one bridge span per day. See page 25. ■

NEWS N°2•2002 CHATEAUDUN STORMWATER BASIN: A PACKAGE FOR INFRASTRUCTURE / SUPERSTRUCTURE INTERFACE Foundation — post-tensioning synergy

EE EE Diaphragm wall Diaphragm wall

EB EB Supporting corbel Reinforced Prestressed concrete slab slab

Micropiles

W.S

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CONFORMING SOLUTION VSL-INTRAFOR SOLUTION

Intrafor-VSL signed a contract for the construction of beam. The post-tensioned slab, designed as a 22-m a retention basin measuring 22 m in internal diameter post-tensioned plate with a 3-m borehole diameter and approximately 7.5 meters in depth. reserved at the center to account for potential heavy The peripheral wall consists of a diaphragm wall, cracking damage, responds in order to withstand uplift whereas the basin bottom has been designed in post- exerted on the coping beam attached to the diaphragm tensioned concrete, owing to the fact that the slab will wall, with a water-stop system installed to ensure be required to withstand considerable loading/ watertightness between apron and beam. unloading stresses. Post-tensioning was applied using six 6”-strand cables The conforming solution is a circular diaphragm wall with a 22-meter variable length divided into two levels. along with a conventional reinforced concrete slab This set of cables is anchored by means of passive 1.10 m thick able to resist uplift by virtue of an anchorages of type “H” at both extremities and of type extensive system of micropiles. As a project variant, “Z” over the central zone. Intrafor-VSL proposed building a diaphragm wall to The value inherent in this innovative variant is suit a 0.90-m thick prestressed slab (with the load fourfold: increased steel and excavation quantities, transfer modification serving to up the thickness from reduction in slab thickness, improvement in slab 0.60 m to 0.90 m). This slab design relies on a corbel watertightness (thanks to post-tensioning), connected to the diaphragm wall. and time savings due to elimination of the micropile To perform these works, the diaphragm 0.52 m-thick operation… ■ wall has been surmounted by a peripheral coping Contact: [email protected]

undertaking projects in Europe construction of industrial ground Paris and Switzerland and of the and across the Atlantic, such as slabs in Australia, Chile and France. Special Project teams headed by the Brides Glen incrementally experienced professionals. Its launched bridge in Ireland, the This “package” strategy, which success is reflected in the efficient cable-stayed bridge at Monterrey, currently represents over 15% of technical solutions generated for Mexico and turnkey pedestrian VSL-Intrafor’s revenues, is being clients through relations of bridges in Chile. Expertise in soil developed thanks to the outstanding mutual confidence, where the stabilization and post-tensioning is technical capabilities of the word “service” takes on its full also being combined today in the engineering offices in Singapore, meaning. ■

NEWS N°2•2002 COMPREHENSIVE SERVICES COVER STORY

PACKAGES FOR STRUCTURAL MONITORING Full-service package against ageing

Structures are undergoing permanent change These “monitoring packages” are offered as an throughout their life cycles: service requirements, additional VSL-Intrafor service to provide the client loading conditions and physical properties of with value-added benefit and long-term cost savings component elements. This is why VSL is developing by generating solutions that match specific needs. new systems that enable monitoring the “health” As an example, when sensors are intalled in order and the aging of structures. VSL’s monitoring to measure critical parameters (such as loading strategy focuses on structures such as configurations, stress, strain, temperature, cable-stayed bridges, LNG tanks, displacement, inclination, vibration and fatigue deep foundations and other types of loading), checking the sensor installation strategy buildings. Packages include: risk can prove to be useful by optimising the use and analysis, functional analysis (both the type of sensors needed. for determining parameters to be monitored, relevant alarm In-house R&D have placed emphasis on durability thresholds and possible issues, new methods, chain measurement and sensor corrective action). The next configurations. Development analysis, testing and steps in the VSL proposal are application tools are now provided and adapted to VSL inspection and systems. Promising results have already been instrumentation (for achieved on various R&D projects and additional obtaining quantitative tools have been derived, thus allowing VSL to both information on identified assess the actual condition of stay cable system parameters), evaluation components and predict subsequent evolution… and interpretation of making a truly full-service “package against aging” 10 results, prognosis of available on the market. subsequent evolution, and action proposals. VSL-Intrafor is also in the process of joining Together with this forces with experienced partners specialized in “health analysis”, diagonostic tools and in predictive analysis, maintenance activities signal processing and management of are offered to provide existing structures. ■ Contact: a full service [email protected] package.

VSL entered the instrumentation market in the 1980’s with a wide range of sensors and has been offering technical assistance as well as sensor installation services. Today’s challenges lie in the field of structural durability.

NEWS N°2•2002 Interview Jacky Mazars, formerly deputy director of the Ecole Normale Supérieure de Cachan, is a member of the board of directors of natural phenomena, explosions and Oxand, a company of EDF Group, devoted to Risk Management of so on. Risk is a field of knowledge structure ageing. He is also director of the research platform that needs to be developed. “Natural Risks and Structural Vulnerabilities” (Université Joseph Fourier & Institut National Polytechnique de Grenoble, Cemagref - How can the additional cost of this LCPC). He is an internationally recognised expert in structural mechanics and durability in the field of civil engineering. monitoring be recovered? In an area where seismic risk is moderate, protection for building What do you mean by “structural How does monitoring improve amounts to only 5% of the total monitoring”? structural durability? building cost, if it is taken into It is something that is not done It systematically tracks normal account at the time of the widely enough. For many years we phenomena like the ageing of the construction. It is nearly marginal. put all our energy into building, materials - for example, the As for existing structures, for with the principal aim of developing corrosion of steel or degradation of example, the University of the country’s infrastructures, but concrete. Take pure water: it can California, Berkeley, has started a without considering how these represent a danger because it programme to strengthen all its structures would age. “Risk” was a absorbs minerals. By dissolving the buildings to make them term that was not used very much constituents of concrete, water earthquake-resistant. Cost is about 30 years ago. Attitudes have makes it less resistant. If, in one quarter or one-third of the changed today. Safety is at stake, addition to these normal value of the property! Another and more thought is given to what phenomena, your structure is example is the highway tunnels. will happen to these assets over subjected to excessive loads or Improving air circulation keeps the time. It is the capacity to diagnose a even slightly shifting ground, air fresh, but also slows down structure’s condition at a given damage can occur and accelerate structural ageing due to the 11 moment. It is a bit like a medical ageing process. combined attacks of exhaust fumes check-up. Visual inspections are and humidity. Monitoring in this not always adequate. More case can substantially increase the sophisticated systems of “Every functional life span of the structure, perhaps measurement must be put in place. as much as doubling it! Dealing aspect of with this sort of problem calls What kind of structures does specialists, who stay abreast of this science of structural a bridge should engineering requirements and health apply to? research. Sophisticated forecasting First, all structures that be monitored!” tools call for interpretation and the have a long life span, such integration of probability brackets. as bridges, tunnels and dams. It also concerns What is the market for this type of What makes VSL well qualified in “sensitive” structures: that analysis? monitoring services? is, ones whose sudden Contracting authorities benefit if VSL has a strong background and shut-down would their structures last as long as long-standing reputation in post- interfere with the possible. Maintenance and tensioning, reflecting extensive normal functioning of monitoring are crucial to making knowledge in a high-tech area of society, such as power sure that everything goes well. the construction industry. Post- plants or health Ideally, the monitoring devices tensioning is a very special and public safety should be incorporated in the business. By analysing feedback facilities. structure when it is built. We are data from past projects, it can take coming around to systems similar into account the future evolution of to those installed in recent structures as of the design phase. automobiles that allow garage A construction company that mechanics to get data on a vehicle’s naturally gives serious vital functions simply by connecting consideration to the way structures it to a monitor. will change over time definitely has However, besides the risk a “culture of monitoring”. That is associated with “classic” durability, why it is well positioned to be a there is the whole area of accidental leader in the trend toward risk related to violent shocks, monitoring durability and risk. ■

NEWS N°2•2002 SITE INSIGHTS

Hong Kong Ever deeper and higher! 12 > Foundations are now well on composed of a 76-m circular site. Among the extensive equipment their way in Package 7 of Hong diaphragm wall shaft, 297 barrettes involved in this project is Intrafor's Kong's Kowloon Station development up to 100 m deep and a composite brand-new BC40 cutter. Daily project, whose foundations system bentonite-cement / sheet-pile excavation has reached an average design and construction was perimeter wall. The diaphragm wall of about 450 m3. A fully- awarded to Intrafor in a joint venture is now standing and 2/3 of the computerized grouting container is in January 2002. This 102-storey barrettes have already been cast. also being used by Intrafor to office-hotel tower, developed by Sun In order to complete construction perform shaft grouting, one of the Hung Kai Properties Limited, will be within the tight contractual period key elements to the development one of the tallest buildings in the (20 months), seven cranes and three plan.■ Contact: [email protected] world. The foundations are hydromills have been deployed on intrafor.com

Spain PT silo in Almeria silo with a steel roof solution. 230 t foce, by that fully optimizing The post-tensioning has consisted all anchorage components. of 70 horizontal rings with 12/0.6"- Silo walls are supported on strand cables alternating over 90º, 188 BS-type guided Stronghold 132º and 180º within the first bearings and include a 4x4 m door 6 meters and then over 180º for maintenance purposes; the > In order to increase the storage throughout the remainder. walls were slipformed (by CTT- capacity of a silo 30 m in diameter This configuration thus gives rise Stronghold together with GBG) over and 40 m high while complying with to 4 buttresses 75 cm thick. The a 20-day period. The steel roof was environmental regulations in effect centre to centre spacing of the lifted in conjunction with the at the Carboneras cement plant in horizontal cables in the wall slipforming operation, thereby Almería (southeastern Spain), increases with height to enable reducing overall construction time. Holcim opted for a post-tensioned stressing all cables to the same ■ Contact: [email protected]

NEWS N°2•2002 NOTE PAD

Calling on VSL - VSL in South Australia was nominated as a subcontractor for the JP Morgan Australasian Call Centre construction project. This structure utilizes composite beams. Steel shear studs were welded onto steel beams for integration with the concrete slab.

Former quarries - As part of the new “Olympiades” station for the metro line in Paris, Intrafor is consolidating former underground limestone quarry sites and backfilled former surface quarries via 13 gravitational injection and treatment injection, hence a Australia total of 13,300 meters of perforation and 2,660 m3 of From brickpit injections. Full encapsulation - On the Inner City Bypass project in Brisbane, to suspended floors VSL is drilling, supplying and installing 47 fully-encapsulated > Sydney Park Village is a large two layers and two directions. A permanent anchors to act as a low-rise residential project of total of 101 tons of post-tensioning buoyancy restraint at the middle 229 units located immediately was required over a 6,600-m2 of the ground slab. south of Sydney. The site served surface area. VSL was also Large VSoL® - On the Port of previously as a brickpit, then as a awarded the project’s suspended Brisbane Motorway project, VSL landfill, required an innovative floors component (26,300 m2). has been contracted to install foundation solution. This was a Following the contract award, VSL 1,680 m2 of VSoL® walls varying 600-mm thick post-tensioned was requested to produce final in height from 6 to 11 m. The basement raft slab partially drawings for initial pours and panels used are 2.4-m square. supported on steel piles at variable mobilized on site within 2 weeks. ■ spacings; tendon units were 6-5 in Contact: [email protected] Safe and sound - VSL Dubai has been subcontracted to supply and provide technical assistance for post-tensioning works on the Tareeq Sarie Highway Project bridge structures in Jubail, Saudi Arabia. As a result of VSL's sound performance on the project thus far, Phase 2 of the Tareeq Sarie contract has also been awarded to VSL Dubai.

NEWS N°2•2002 SITE INSIGHTS

Vietnam Poland Wagons lined up New profile to reline a tunnel for 400

> Repairs on the Hai Van Pass into several units working Railway Tunnel renovation project simultaneously in diffrent areas. beam ends have now entered the construction Operations are conducted over a phase. These works entail short possession time span lasting > For the car park underneath demolishing the existing tunnel 6 hours. VSL France, in the Auchan shopping center in lining, composed of both concrete partnership, concluded this Warsaw, the existing support (vault) and masonry (walls), and contract late last year with Vietnam structure of the beams does not then securing the excavation left National Railways (VNR) for the allow for sufficient dilatation. open with rockbolts and shotcrete. renovation of 4 railway tunnels A complementary shotcrete layer within the Hai Van Pass region, for filling voids is to be applied and a close to the city of Danang in the waterproofing membrane installed, middle section of the country. using 3 layers of shotcrete covering These tunnels, part of the strategic reinforced with either wire mesh or north-south railway link between fibers. The repair works include Hanoi and Ho Chi Minh City, had construction of this new structure suffered from aggressive water over a total length of 670 meters as penetration, exposure to climatic well as renovation of the four tunnel conditions and aging. The project is 14 entrances. Two working trains scheduled for completion by the comprise 11 special-purpose end of 2004. ■ wagons to be sequenced depending Contact: [email protected] on the production cycle and split intrafor.com

The solution designed by VSL's Technical Center Europe allows Australia the horizontal slab movement by ® means of creating a gap between The tallest VSoL beams and columns and installing bearing pads under the newly corbel-supported beams. The load for Mount Arthur gets transferred from existing corbels to temporary supports equipped with jacking units. The existing corbels are then sawed and removed so as to provide a 10-mm gap between beams and columns. Beam-ends are subsequently strengthened and re-profiled. The new corbels, made of two precast "C"-shaped concrete elements, are fitted to the column > As part of a major BHP-Billiton and 220 tons of reinforcing mesh with post-tensioning bars, followed coal development, VSL-Intrafor and components. These VSoL® by installation of the bearing pads. completed a large-scale dump walls represent the tallest ever The load is then re-transferred hopper structure in March 2002 installed by VSL-Intrafor in the from temporary supports to the for John Holland Pty Ltd. Australasian region: 22.6 m. columns. These works, which The scope of works included the VSL also offered the full range of encompass repairs to 57 columns design of two VSoL® hopper architectural facing elements for and 400 beams, will be completed structures and the supply of this job. ■ by the end of November 2002. ■ both 3,300 m3 of facing panels Contact: [email protected] Contact: [email protected]

NEWS N°2•2002 Hong Kong Heavy duty compaction for Disneyland > A large-scale land reclamation the sand fill (40 million m3). finished level, with vibroflotation project (200 hectares) is being Dredging and placement of sand works being carried out from the conducted by the government of fill are being undertaken by top of the load to depths reaching Hong Kong SAR at Penny's Bay on Hollandsche Aanneming 38 m. The quantities of sand to be Lantau Island for the construction Maatschappij BV (HAM), while sand compacted, along with the 15 of the new Disneyland amusement compaction and testing lie within extremely heavy equipment park. Stage 1 started up towards Intrafor's scope of works. The involved (up to 16 rigs working the beginning of 2001 and is vibroflotation technique (heavy-duty 24 hours a day), make this project scheduled for completion by the vibrating pokers for in situ sand one of the largest vibrocompaction end of 2002. This large reclamation compaction) is used by Intrafor in jobs ever taken on. In october, a undertaking involves: the removal order to meet requirements in new contract to carry out 10 000 of soft soils from the seabed by terms of strength and settlement. stone columns has been awarded dredging (42 million m3), placement The sand fill is placed 15 meters to the JV. ■ of sand fill on the dredged seabed above water level to provide a Contact: jean-christophe.gillard (67 million m3) and compaction of temporary load of 4 m above the @hk.vsl-intrafor.com

Philippines Cebu project nearing completion

> After a 6-month delay in 2001 working relationship and due to local political hurdles, the coordination between VSL and final precast girder on Segment Taisei Marubeni Joint Venture. No. 3 of the Cebu South Coastal The project, a 1.4-km long x 16-m Road Project was cast in July and wide bridge over water with a concrete, 2,725 tons of reinforcing erected in August. The parapet typical span length of 35 m, had steel and 470 tons of post- railings are due to be completed by begun in September 2000. VSL's tensioning. The project also December 2002, some 3 months assigned contribution was divided provided VSL with the opportunity ahead of the contractually- into 5 subcontracts that incorporated to introduce Honel expansion joint stipulated target date. This the structure from the coping technology in the Philippines. ■ program compression was beam level upwards. Overall, this Contact: [email protected] achieved thanks to the close scope represents some 8,700 m3 of intrafor.com

NEWS N°2•2002 SITE INSIGHTS

track in Prague. ILM technology Czech Republic had not been used in this region Germany for several years. Bridge construction by means of this Two-bridge method is basd on segmental deck For stiffness production in a casting yard > The fixed Rostock crossing slide located in front of the bridge project through the mouth of the abutment. The deck is pulled out Warnow River is drawing to a of the casting yard after particular close. VSL Germany provides the in Prague segment tensioning. The bridge is supply and installation job for incrementally launched on 150 tons of bonded post-tensioning supports, that are equiped with in the tunnel structure and 50 tons lateral guides and sliding of post-tensioning installed at three bearings. A steel nose is fixed at bridges crossing the tunnel the front of the deck to reduce the approach roads. This submerged bending moment o the first tunnel consists of six elements and segments.VSL Systemy (CZ) s.r.o. two portals. Each element is participating in both designing the casting yard and detailing the launching method to be used. The system relies on braking as well as pulling units. VSL's responsibilities > VSL Systemy (CZ) s.r.o. is include overseeing deck-sliding providing incrementally-launched operations (two bridges launched technology (ILM) in the simultaneously) and performing construction of two bridges on the the post-tensioning works. ■ 16 Hlubocepy-Barrandov tramway Contact: [email protected] comprises eight sections 15 m in length. In order to provide the Portugal necessary stiffness while the 120-m long elements are being floated into position, the eight sections are High-tech response longitudinally stressed against one another. Once an element has been correctly located, the tendons are for the Europa Bridge cut at the seven construction joints, allowing for small rotations of the > For the Europa Bridge project tightly-extruded HDPE coating sections. As a chain, the entire in Coimbra, which includes pipe with helical ribs, and element can then settle smoothly 13 distinct bridges and viaducts, vandalism protection on both deck onto the riverbed. ■ VSL is supplying 750 tons of post- anchorages and retention blocks. Contact: [email protected] tensioning and 400 tons of stay ■ Contact: Carlos Correia cables. The main bridge extends (ccorreia@vslsistemas) 329.4 meters in length, with one Morocco 186.5-m span and a total of 67 precast segments. The stay cables have been categorized into First beam 19 principal pairs and 9 retention > In August 2002, VSL lowered pairs, ranging from 6-55 to the first beam of the Laayoune 6-31 tendons and then from Wharf restoration project. 6-91 to 6-37 tendons (for rear This project represents 2 M2 and stays). All active anchorages are to 2 years worth of business to provide be installed on the pylon. On this technical assistance and heavy lifting job, VSL is using individual services for some thirty prestressed galvanized and greased strands concrete beams, each measuring (protected by means of HDPE stay 45 m in length and weighing pipes), individual tensioning, 110 tonnes. ■ Contact: jean- replaceable strands, an external [email protected]

NEWS N°2•2002 NOTE PAD

Technical lineup - For the execution of 276 piles on the A4 motorway near Paris, Intrafor has simultaneously implemented: dry boring, cased boring by vibratory driver and dry boring with permanent casing; cased boring by Ireland vibratory driver and dry boring with temporary casing extracted upon completion of concreting; Dublin port project and dry-cased boring using oscillator with casing removal upon completion of concreting. delivered A cutter was activated on a section where the intrusion of stronger Bayan Baru - For this viaduct > This underground highway for limestone (Rc > 100 MPa) had project, VSL Malaysia will erect the Port of Dublin tunnel project, reached 8 meters. This exceptional 37 precast spans for the main the Mowlem-Piling - Intrafor project - comprising a 52-m viaduct and 18 for the ramps. consortium (in partnership with diameter shaft excavated over Completion planned for mid 2003. Mowlem and Irish Co.) installed 32 meters and two hatches 400 and between June 2001 and August 350 m in length - was executed Over the Neva - VSL has been 2002 more than 50,000 m2 of without interruption over a 15-month awarded the technical assistance diaphragm walls (1,200-1,500 mm period and mobilized up to and supply/ installation of the 17 in thickness). Given the very poor 25 Intrafor staff members. It is the stay cables system on the Neva quality backfill, black clays and first large european infrastructure River Bridge in Saint Petersburg a limestone substratum with project for VSL-Intrafor to be for Mostootriad 19, a new VSL inconsistent strength, adaptations delivered, the next one beeing the client in Russia. Installation of to both tools and methods were huge Groene Hart project. Both the stays (600 tons of strands) required: most diaphragm wall show the group’s capacity to work will start in April 2003. sections had to be excavated using in all types of ground, from very cable-driven buckets with 4 stations hard to very soft. ■ operating during peak shifts. Contact: [email protected]

Chile Slabs for Specially for gas - On the Dahej LNG tank in the Western State El Golf of India, one of the first projects under the ownership of > The El Golf 2001 project offers Petronet LNG in India, VSL is a total surface area of 58,000 m2, supplying PT materials, split into 7 underground levels and end of last year, VSL Chile began horizontal and vertical tendons, 22 upper levels, and represents promoting the VSL-bonded post- all PT equipment and technical one of the year's largest in Chile. tensioning slabs using the system assistance plus site supervision. It is located in one of the most developed in VSL Argentina, which A first in Vietnam - VSL was upscale areas of Santiago adjacent is basically the monostrand anchor awarded by Sumitomo to two other VSL post-tensioning S5N, with a single polyethylene Construction the installation of projects: Banmedica (1995) and duct. An excellent track record 234 tons of SSI 2000 stay cables Isidora 2000 (1999). All three of from past projects convinced the for the Kien Bridge, the first these projects have involved the client to approve the new bonded precast segmental stay cables ■ same teams (client, architects system. bridge in Vietnam. & engineers, contractor). At the Contact: [email protected]

NEWS N°2•2002 SITE INSIGHTS

France Innovative analysis applied to tunneling plugs USA > Within the scope of the Paris 1.50-m thick cement grout western bypass project (A86 pavement, were designed by VSL- highway), VSL-Intrafor acts as Intrafor using a truly innovative VSL buoys up authorized representative of a computation method. consortium contracted to build a While the technical sizing diaphragm wall box (155 m x 23 m specifications (e.g. 3-MPa Fallingwater x 23 m). This structure is to serve minimum simple compressive both as a breakout shaft for the strength) were imposed by the 11-m diameter tunnel boring client, the computation method > In October 2001, VSL was machine (TBM) operating north-to- was left entirely up to VSL-Intrafor. selected by the Western south then south-to-north and as Since the plug turns out to be a Pennsylvania Conservancy to ventilation shafts for tunnel solid element, conventional perform the restoration work of sections already placed into service. software applications for sizing both the master bedroom and Two ground treatment breakouts structural supports could not be living room cantilevered terraces (“plugs”) have thus become adapted. A simplified approach of Frank Lloyd Wright’s historic necessary to support the ground based on material strength Fallingwater. Designed in 1935 and mass and withstand the pressure as formulae (which consider the plug completed in 1939, Fallingwater is the TBM rises to the surface inside as a rectangular plate resting on its recognized as one of the most 18 the structure. These plugs, made of circumference) was also feasible, unique houses ever built in yet this approach would have led to America. The Fallingwater excessive plug thickness. renovation plan recognized the The VSL-Intrafor foundation design need for strengthening as well as office proposed a sizing procedure concrete repair. Special attention that entails a finite element was required during construction computation program for modeling to prevent damage to the the ground with a multitude of architectural features and small-sized (mesh) elements in landscaping. At the main terrace order to study each element’s level, strengthening involved individual behavior. bonded post-tension tendons This computation procedure parallel to the cantilever girders thereby enabled: validating the and unbonded tendons in the compressive and shear stresses in transverse direction. The all possible cross-sections; strengthening plan also called for Model mesh and normal stresses: estimating the displacements and steel members to be bolted to stress concentration in the vicinity settlements at any point; and each side of the master-level of the diaphragm wall opening and formation incorporating successive project concrete joist directly above the of a compression arch in the plug. stages throughout the entire four ‘T’-shaped mullions. In service life of the plug. The addition, VSL repaired and thickness was determined so as to strengthened the master-level ensure that the plug remains fully parapet walls. In respect of compressed when exposed to Fallingwater’s pristine setting, various applicable loads (i.e. thrust restoration and repair activities of earthen material, TBM thrust were conducted with great care to upon arrival, deadweight). The minimize environmental impacts solution proved to be elegant, on the stream, the falls and the reliable and a more economical site’s landscaping. The VSL means for solving a rather technology solutions employed complex problem. ■ herein included both monostrand Contact: [email protected] and multistrand cables. ■ intrafor.com Contact: [email protected]

NEWS N°2•2002 The Netherlands Challenges piling up!

> Initiated in 2000, the 8-km long Groene Hart tunnel project on the Dutch high-speed rail line has provided Intrafor with the opportunity to undertake some exceptional structures in a new national market and under most challenging soil conditions (peat, called “Soil Mixing” process. Intrafor used the “Jet Grouting” loosely-compacted sand, etc.) The installation of slurry trench technique on several structures within a heavily-protected zone. piles with prefabricated low- (over 1 500 linear meters in all). The overall works program levelled piers represents another Intrafor has also earned the VCA contains both diaphragm walls VSL-Intrafor company innovation certification for site safety. (53,900 m2) and slurry trench piles (see News Magazine issue 1, Work on the final ventilation shaft (38,100 m2) and calls for creating 2001). Designed by the Intrafor (Bent) is underway and the long two tunnel access hatches and methods office, this tremie and deep Southern hatch is three ventilation shafts. The concrete technique can be applied scheduled for completion next northern hatch and two of the on sites where more conventional spring. ■ ventilation shafts have already pile-driving solutions, are Contact: [email protected] 19 been completed using the so- impossible due to depths involved. intrafor.com Ireland Australia Dublin’s Terragong Swamp Golden Gate Bridge > The ongoing Terragong Swamp Bridge project, located approximately 150 km south of Sydney and extending 942 meters in length, is part of a bypass to redirect coastal highway traffic. Constructed over swampland, the 23.1-m wide, 30-span bridge essentially consists of a low-level viaduct with short spans to > For the Taney Bridge in Dublin, minimize foundation loads. an alternative design for the main VSL’s scope of works encompassed deck is based on units to be cast post-tensioning of 3 spans. like shells, leaving the center In order to provide for enhanced devoid of any reinforcement or continuity/cost savings, the concrete and keeping the weight 41 m-long main span has been of the deck during construction to supported on “V” piers. a minimum. VSL, which provided The two legs of the “V” were input to develop this alternative, temporarily tied together with is also supplying and installing 40-mm diameter VSL HR 52 SSI-2000 stay cables. ■ stressbars. ■ Contact: [email protected] Contact: [email protected]

NEWS N°1•2002 ENVIRONMENTAL PRESERVATION SPECIAL REPORT

Foundations for the Museum Wall excavation of Primitive Arts in Paris

Noise-free, Excavation along the abutting vibration-free structures

excavation A typical audiometer Environmental protection concerns raised during building projects, as regards neighbors, the subsoil and the structure itself, have been taking on increasing 20 importance for project owners. The deeply-embedded

An exceptional site foundations for the Museum of Primitive Arts in Paris have asked for special measures to limit both noise and vibrations.

Paris’s Museum of Primitive Arts, 800-mm diameter auger; pumping Fact sheet represents France’s first major shafts for both draining the State-sponsored project under the enclosure and monitoring the Project owner: nation’s new five-year presidency. plastic wall; definitive pressure- Etablissement Public du Musée The structure is to be located near relief drains to protect against du Quai Branly, Paris (Quai the Seine River in the vicinity of the excess water table pressure in the Branly Museum Authority) President’s Office annex and of a deepest zone; and a shoring Project Architects/Engineers: number of the city’s most system to hold the walls (weighing A.J.N. - Jean Nouvel Architect prestigious avenues. Last but not approx. 150 tons) in place. (Representative), INGEROP, O.T.H. least, near the Eiffel Tower. Within This building program also Diaphragm wall: 18,409 m2, such a setting, the various encompasses a portion (18,000 m3) consisting of 116 panels from basement levels of this building of the earthwork required to install 500 to 1000 mm in thickness require undertaking specific works the corresponding infrastructure. Grout wall: 990 m2, to ensure the utmost in minimum thickness: 0.52 m environmental protection. A prestigious address

Piles: 32nos 800-Ø units, This deep foundations contract The key difficulty in performing 22nos 1,000-Ø units includes: a peripheral diaphragm these works pertains to both the wall 735 meters long and up to buildings along the famous avenue 32 meters high; a watertight, de la Bourdonnais and the definitive plastic wall 520 mm President’s Office annex next to thick; a series of 1,000-mm the museum structure. diameter bored-molded foundation Consequently, diaphragm wall piles, “protective” piles driven deformation thresholds were using a continuously-operating established.

NEWS N°2•2002 After adapting the supporting wall for preservation of all neighboring stiffness (thickness-reinforcement) buildings during excavation. For and connection and then phasing the this particular operation, the works program, a 30 to 50-kN/linear project owner urged paying special meter prestressing force is to be attention to vibratory aspects applied on selected floor supports, (protection of buildings as well as which vary from one cross-section their occupants and activities) and to the next. In addition, the noise-related aspects (protection diaphragm wall layout has been of neighbors), thereby making it offset with respect to the plain of necessary to establish warning and the buildings, as the inclined part emergency shutdown thresholds. of the museum will be supported by 700-Ø piles driven prior to The critical threshold for noise has diaphragm wall excavation using been set at 5 dB(A) above a a continuously-operating auger. reference background level derived Driving supporting piles A flat coping beam serves to join at during regular daytime periods the head the diaphragm wall and the over several zones. axis) was introduced in the aim of piles, whose embedment overlaps. mitigating nuisances for neighbors. Orange limit A “red” limit serves to protect the Mandatory warning built structures, through invoking the thresholds As for vibrations, an “orange” limit rules applicable to mechanical based on the ISO standard (i.e. a vibration emissions for landmarked Due to the project’s abutment on perception threshold of 0.1 mm/sec facilities, i.e.: frequencies of between a number of structures, once the measured in 1/3 octaves (RMS) with 4 and 8 Hz = 4 mm/sec; frequencies works got underway regular a multiplier of 4 along the vertical between 8 and 3 Hz = 6 mm/sec; 21 deformation measurements and frequencies between 30 and were employed to ensure 100 Hz = 9 mm/sec. Partititon wall This 7-month project involved 3 to Wall 2d phase Heightened wall 4 cable-driven bucket excavation g + q assemblies, 1 sludge mixing plant, Neighbors g2 + q2 2 tooling stations for sludge-based avenue de la g1 + q1 Bourdonnais 30.20 pile-driving and 1 continuously- 29.00 operating auger, all being run over Section view a 13-hour workday. On average, a Flat beam aligned with the Recent alluvions crew of 45 (reaching 75 during peak 25.50 abutting buildings periods), including management 24.50 on the avenue de la Bourdonnais and skilled operators, participated Existing piles in this project. 21.15 20.50 Including execution Ancient alluvions 18.50 This building operation has provided 16.50 Slope wash the opportunity not only to raise awareness among project actors as regards environmental protection problems, but also to highlight the Future piles Base of diaphragm wall = 10.00 difficulties involved in terms of both Clay noise and vibration, application of appropriate thresholds, position of measurement stations and 6.00 implementation on a work site. It has also enabled making great Sand clay strides towards incorporating 3.70 Pile base = 2.50 Base of extended wall = 2.50 environmental considerations

Sand during the execution phase of a major project. ■

NEWS N°2•2002 HEAVY LIFTING SPECIAL REPORT

HEAVY LIFTING Power to the point More than 30 years ago, Da Chi Bridge Pylon Lifting, TAIWAN VSL came up with the Working at height - VSL visionary idea to use a Taiwan was selected for this job in combination of proven order to reduce the tremendous components from its crane costs, hazards to personnel working high above ground for an strand post-tensioning estimated 150 days and concerns system along with over on-site welding hydraulic jacks and pumps workmanship, project quality, windy site conditions and for lifting heavy loads. construction accuracy. The As an initial application in company’s mission consisted of Sardinia, three 490-ton the design, supply and operations concrete dome shells for Palexpo Congress and Exhibition of a heavy lifting system to erect Hall 6, SWITZERLAND this steel pylon (1,280 t) quickly, a series of circular Record roof lift - To save accurately and safely. 22 aluminum silos were lifted costs and improve quality, the A temporary stay tower behind the 5,300-ton structure (20,000 m2) pylon provided anchor for both the a height of 28 m. Lifting was assembled and then lifted on lifting cables and backstay cables. and stressing of the steel ground by 24 VSL strand units The whole operation required just cable net system for the mounted on 4 temporary support three working days. towers. The main lift (12-m), Contact: [email protected] acrylic tent-shaped roofs at Munich’s Olympic took place in mid-February 2002. Following the installation Stadium in 1971 served as of 4 column systems, the lifting another milestone in this cables were released, thus new erection technique. transferring roof load to the Strong growth in the permanent supports. Contact: [email protected] market for alternative

Bhairab Bridge, Bangladesh, INDIA Innovative construction method - For deep submersion of some pile caps for the Bhairab Bridge project, pile caps with a dry weight of 3,300 tons were cast on a suspended above-water platform around 6 steel piles. For each pile, 2 VSL strand units provided concentric pile loading. After removal of the casting platform and an initial 9-m lowering, 6 casing tubes were placed around the piles and then sealed to the pile cap. Together with “donut” seals at the pile cap soffit, these tubes allowed for dry concreting in order to seal the steel piles into the concrete cap, after lowering a further 7m fo final level. Contact: [email protected]

NEWS N°2•2002 Afsin Elbistan B Power Plant, Maureen Alpha platform, NORWAY TURKEY Innovative deconstruction method - The Maureen Alpha All-round services - VSL Platform is presently being deconstructed in a Norwegian fjord. As an initial was contracted to provide strand step, the 10,000-ton Hi-Deck, was separated from its floating substructure, jack-lifting services for erecting transported to the shore and then jacked onto shore for subsequent boiler suspension grillages dismantling. This 85-m sliding (530 tons), together with less bulky operation was carried out in mid- items like flue gas ducts and an May 2002 using the VSL strand- impressive number of other heavy jacking technique. VSL will be components. VSL services started involved in the lifting and lowering up in autumn 2001 and will extend work for deconstruction of the 3 steel tanks and connecting support structures. Contact: [email protected]

heavy lifting (lifting by means other than cranes) reveals that the strand-lifting technique has more than ever become state-of-the-art and that VSL continues to be a major player in this market. Both the equipment and its controls have been improved and new fields of Tucuman Power station- application opened up for ARGENTINA 23 this technique. VSL’s Accurate to within 10 mm - Heavy Lifting system has For the lifting of two boilers (850 tons each) at a height of 18 m, through mid-2003. On-site hydraulic contributed to enhancing VSL used a synchronized lifting lifting equipment includes around quality, compressing system between the jacks. The 70 strand units with capacities construction schedules maximum allowable difference ranging between 100 and 3,300 kN. between two points needed to be Upon completion of this contract, and saving costs. VSL less than 10 mm after each stroke. the total weight of components continues to stand for Contact: [email protected] lifted by VSL will have reached innovative engineering, 10,000 tonnes. Contact: [email protected] high safety standards and reliable performance.

Airbus Assembly Hall - FRANCE Aéroconstellation- Airbus, Toulouse - As part of the "Aéroconstellation-Airbus" project in Toulouse, VSL- FRANCE was called on to perform the roof-lifting job (4,500 t, 120 m x 250 m) for a hangar using 28 lifting points spread among 16 poles. Following two partial operations conducted in October and November 2002, final lifting of the entire structure will take place in January 2003. Contact: [email protected]

NEWS N°2•2002 HEAVY LIFTING SPECIAL REPORT

Deepwater sewage system, Aquitaine Bridge, FRANCE SINGAPORE Four-point Handling a tunnel suspension - boring machine - For modifications to the In February suspension cable anchorages 2001, VSL of the Aquitaine Bridge over lowered a the Garonne River, the 420-ton anchorage modification tunnel imposed on the left abutment boring machine (TBM). VSL’s a new concrete structure services included design and measuring 10 x 4 x 30 m and supply of a heavy-duty sliding weighing 3,500 tons. The track system and a gantry main contractor needed to cast this anchorage at a lower level and then lift it equipped with strand units to lift through 30 m to reach its final position. After a first liftoff stage over 30 mm, the TBM, slide it over the shaft the main lift with full load was carried out in March 2002 by VSL France using opening, lower it by 40 m and 12 SLU-330 strand units, arranged so as to provide 4-point hydraulic ultimately rotate it by 16° for suspension of the load. Contact: [email protected]

Power production plant, AZERBAÏJAN Moves of heavy 24 machinery - For placing a gas turbine and generator, VSL began by lifting 12 heat-recovery boiler modules weighing a total of 1,700 tons. Subsequently, the MHI gas turbine along with an ABB generator, each weighing some 350 tons, were lifted off their alignment with the tunnel axis, transport vehicles outside the machine hall, moved into the building and then before placing it on a launching placed onto their foundations by means of VSL’s steel gantry and strand-lifting cradle. units. Site work was carried out during October and November 2001. Contact: [email protected] Contact: [email protected]

Lanjarón Viaduct - SPAIN An innovative solution for a single- span bridge - The structure to be launched consisted of a bowstring formed by two parallel trusses, with a single span of 114 m and a weight of 504 tons. It had to span a 90-m deep valley without any intermediate support. CTT Stronghold (VSL Spain) first loaded the structure with a counterweight and moved it using two VSL SLU-70 units. From this advanced position, the cables for the second phase were installed from the extremity of the bridge to the towers and concrete structures installed on the other side of the valley. The bridge was then pulled across. Contact: [email protected]

NEWS N°2•2002 TECH SHOW

THSR PROJECT IN TAIWAN Full span pre-casting for high speed erection 25

When the Taiwan High Speed Rail Project was conceived, the question was how to build a 340 km Rail Link of primarily Viaduct, interspersed with Tunnels, in a hurry. An unusual alternative option, that of “full span pre-casting” (FSPC) was mooted for the C215 works in Taiwan.

NEWS N°2•2002 THSR PROJECT IN TAIWAN TECH SHOW

Whereas in-situ options such as single monolithic box girder for the cast-in-place and pre-cast double track (13m wide) plus a segmental structures, are well speed of erection faster than one known in Taiwan, with multiple bridge span per day. standard and advanced shoring systems common throughout the Over 600 pre-casted island, FSPC has been rarely used. spans In fact, there are only a handful of equivalent structures throughout The Taiwan High Speed Rail the world as structures of this size corridor runs on the western side have, in recent years, tendered to of Taiwan from Taipei in the north be pre-cast segmental. A to Kaohsiung in the south. The technique such as FSPC promised track has a 350 km/hr design Truss launching beam. This 40m long beam is the structural advantages of a speed and maximum operating 5 supporting the 30m long inner formwork. On speed of 300 km/hr. For civil both sides of the beam can be seen the bottom part works, tenders were initially called of the inner formwork. In the foreground, steel in late 1998 with the subsequent bulkhead and coupling strands. award of 12 no. major packages in early 2000. Successful tenderers Cleaning of external and bottom formwork. were generally joint ventures of 3 Formoil is applied already. In the front left and major local and international right side, connected to the bottom form panel is a contractors. In the north, the first recess plate with 4 corrugated steel ducts which will form a recess for the dowels of the bridge bearing. two sections (contracts C210 and On the left side, rebar concrete spacers have already been C215) were awarded to a joint placed on top of the bearing recess plate and some spacers venture of Obayashi and Fu Tsu are now going to be place on the right side. 26 Preparation of the mould. Formwork 2 (square frame with a few transverse bars) with the potential of some 20km of for a permanent access opening in the bottom FSPC contained within the C215 slab of the formwork. contract.

Three casting lines. Each of them consists 6 of two reinforcement jigs for the end diaphragms, one full length rebar jig for the primary steel cage, one casting mould, a post-tensioning storage place and an outside storage area for completed spans.

NEWS N°1•2002 Subsequent to this, Obayashi- Fu Tsu JV let a major sub-contract, encompassing all pre-casting and erection of some 602 no FSPC bridge spans, as well as 7 in-situ free cantilever bridges to a joint venture of specialist European contractors VSL and Rizzani de Eccher. Work commenced on site in 2001 with the first pre-casting achieved in June 2002 and the first span’s erection one month later. 2 days per 30m-beam

Both the design of the spans and Coupling strands. Bulkheads design of the casting yard have 4 and pre-tensioning strands are installed centred around a target peak cycle and will be prepared for stressing. of 2 days per 30m beam per For a 30m box girder there are 98nos. of 0.6'' pre-tensioned strands and casting bed. The pre-cast yard is 88nos of 0.6'' post-tensioned strands. mostly covered by a purpose built factory and consists of three casting lines, each with the ability Fabrication of rebar cage. The diaphragm to operate independently. The 1 rebar cage is prefabricated inside a diaphragm cycle is such that the diaphragm jig. During lifting in, the team has to make sure that the rebar is located properly. 27

NEWS N°1•2002 THSR PROJECT IN TAIWAN TECH SHOW

rebar cages are lifted into the The carrier is an overhead beam primary reinforcement jig where supported by two rotating 8 tyred the main cage, weighing in excess trailers over a 45m span which of 50 tonnes, is completed. moves crab-like over the stored Bulkheads and pre-tensioning box girders, lifts them and strands are installed and stressed transports them. The support and the concrete is poured. The beam is a 72m-long steel box addition of steam curing and girder which rests on the release of the pre-tension jacks completed span at the rear and on completes the 2 day casting cycle steel legs and carries a service for the 740 tonne, 30m long box trolley on its top chord.

girders. The transport and erection Strand preparation. Cleaning of the strand of such huge box girders, up to Drive–in erection 7 coupler attached to the coupling strands. 20kms from the point of casting, is After cleaning the strands, the rebar cage will pivotal to the success of the FSPC On arrival at the new span’s be lifted into the mould and the couplers method. VSL and its partner have erection location, the carrier drives connected to the strands in the cage. adopted an approach where the into the support beam with the device for transport forms an front trailer straddling the beam integral part of the device for the and its service trolley. Jacks on the launching of the box girders. The service trolley raise the front of the system contains one “carrier” and carrier and the assembly of carrier one “support beam” (see pictures). and box girder is pulled out onto

Pre-tensioning work. 28 8 Coupling strands for the pre-tensioning work are going through the steel stressing bulkhead. Inner formwork (upper part right) is launched towards the mould.

Crab-like transport. The carrier 13 is an overhead beam supported by two rotating 8 tyred trailers over a 44m span. It moves crab-like over the stored box girders in the casting yard, lifts the unit to be erected and reverses from the casting yard where the trailers are rotated 90°.

NEWS N°2•2002 Storage. The heavy lifting 10 gantry transfers the box girder to the storage yard.

Long distance travelling. The girders travel 12 up to 20 kms from the point of casting.

29

Huge beams. Each 11 of the 602 box girders weigh up to 740 tonnes!

Self-launching mould. The inner 9 formwork mould, a 30m long collapsible, self launching system is propelled from the inside the just-cast span to inside the completed reinforcement cage.

NEWS N°2•2002 THSR PROJECT IN TAIWAN TECH SHOW

the support beam. At the stage where the box girder is suspended above its final position, the support beam is launched from underneath so that the box girder can be placed. The support beam is retracted slightly, the carrier reversed onto the newly place deck and returns for the next cycle.

With the commissioning period underway in July and August, and allowing for subsequent learning periods, full production was achieved in late 2002 with works carrying on through 2003 and completed in 2004. ■

30

Delivery at 4km/hr. The carrier travels 14 to the support beam, at a loaded speed of 4km/hr, along the previously erected viaduct. The transport and erection of such huge box girders, up to 20kms from the point of casting, is pivotal to the success of the FSPC method.

The support beam. 16 This 72m-long steel box girder is launched into each new erection position such that it rests on the pier with the fixed rear leg and on the following 2 piers with its mobile supports. On its top chord, the service trolley traverses the full length of the beam.

Follow up works on the piers. 15 Pot bearings are grouted and the load is then transferred from the temporary jacks to the pot bearings.

NEWS N°2•2002 HEADQUARTERS www.vsl-intrafor.com VSL International Ltd. Scheibenstrasse 70 – Bern JOINING FORCES FOR YOUR PROJECTS CH-3014 – Switzerland Phone: +41 32 613 30 30 Fax: +41 32 613 30 55 VSL–INTRAFOR LOCATIONS

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ARGENTINA AUSTRIA NORWAY BRUNEI THAILAND VSL Sistemas Especiales de Grund-Pfahl- und Sonderbau GmbH VSL Norge A/S VSL Systems (B) Sdn. Bhd. VSL (Thailand) Co. Ltd. Construcción Argentina SA Industriestrasse 27a STAVANGER BRUNEI DARUSSALAM BANGKOK BUENOS AIRES AT-2325 Himberg bei Wien Phone :+47 - 51 52 50 20 Phone: +673 - 2 - 380 153 / 381 827 Phone: +66 - 2 - 237 32 88 / 89 / 90 Phone: +54 - 11 - 4393 - 28 07 Phone: +43 - 2235 87 777 Fax : +47 - 51 56 27 21 Fax: +673 - 2 - 381 954 Fax: +66 - 2 - 238 24 48 Fax: +54 - 11 - 4326 - 26 50 Fax: +43 - 2235 86 561 POLAND HONG KONG VIETNAM CHILE BELGIUM VSL Polska Sp. z o.o. VSL Hong Kong Ltd. VSL Vietnam Ltd. VSL Sistemas Especiales de N.V. Procedes VSL SA WARSAW WANCHAI HANOI Construcción S.A. BERCHEM Phone: +48 - 22 817 84 22 Phone: +852 - 2590 22 88 Phone: +84 - 4 - 8245 488 SANTIAGO Phone: +32 3 230 36 34 Fax: +48 - 22 817 83 59 Fax: +852 - 2590 95 93 Fax: +84 - 4 - 8245 717 Phone: +56 - 2 - 233 10 81 Fax: +32 3 230 89 65 Fax: +56 - 2 - 233 67 39 PORTUGAL Intrafor (Hong Kong branch) Ho Chi Minh City CZECH REPUBLIC VSL Sistemas Portugal Pre-Esforço, WANCHAI Phone: +84 - 8 - 8258 144 MEXICO VSL Systemy (CZ), s. r. o. Equipamento e Montages S.A. Phone: +852 - 2836 31 12 Fax: +84 - 8 - 9102 596 VSL Corporation Mexico S.A de C.V PRAGUE S. DOMINGO DE RANA Fax: +852 - 2591 61 39 MEXICO Phone: +420 - 2 - 67 07 24 20 Phone: +351 - 21 - 445 83 10 Phone: +52 - 55 - 5 - 396 86 21 Fax: +420 - 2 - 67 07 24 06 Fax: +351 - 21 - 444 63 77 INDIA Fax: +52 - 55 - 5 - 396 84 88 VSL India Private Ltd. FRANCE SPAIN CHENNAI Australia/Pacific UNITED STATES VSL FRANCE S.A. CTT Stronghold Phone: +91 - 44 859 2538 / 39 VStructural LLC ST-QUENTIN-EN-YVELINES BARCELONA Fax: +91 - 44 859 2537 AUSTRALIA - Queensland BALTIMORE, MD Phone: +33 - 1 - 39 44 85 85 Phone: +34 - 93 - 289 23 30 INDONESIA VSL Prestressing (Aust.) Pty. Ltd. Phone: +1 - 410 - 850 - 7000 Fax: +33 - 1 - 39 44 85 87 Fax: +34 - 93 - 289 23 31 GEEBUNG Fax: +1 - 410 - 850 - 4111 PT VSL Indonesia Intrafor S.A. VSL-SPAM, S.A. JAKARTA Phone: +61 - 7 - 326 564 00 ST-QUENTIN-EN-YVELINES BARCELONA Phone: +62 - 21 - 570 07 86 Fax: +61 - 7 - 326 575 34 Phone: +33 - 1 - 39 44 85 85 Phone: +34 - 93 - 289 23 30 Fax: +62 - 21 - 573 12 17 AUSTRALIA - New South Wales Fax: +33 - 1 - 39 44 85 86 Fax: +34 - 93 - 289 23 31 JAPAN VSL Prestressing (Aust.) Pty. Ltd. Middle East GERMANY SWEDEN VSL Japan Corporation THORNLEIGH VSL Systems GmbH Internordisk Spännarmering AB TOKYO Phone: +61 - 2 - 948 459 44 Fax: +61 - 2 - 987 538 94 UNITED ARAB EMIRATES BERLIN SOLNA Phone: +81 - 3 - 3346 - 8913 VSL Middle East Office Phone: +49 30 53 01 35 32 Phone: +46 - 8 - 504 37 200 Fax: +81 - 3 - 3345 - 9153 AUSTRALIA - Southern Division Fax: +49 30 53 01 35 34 Fax: +46 - 8 - 753 49 73 DUBAI KOREA VSL Prestressing (Aust.) Pty. Ltd. Phone: +971 - 4 - 282 08 03 GREAT BRITAIN SWITZERLAND VSL Korea Co. Ltd. NOBLE PARK Fax: +971 - 4 - 282 94 41 VSL Systems (UK) Ltd. VSL (Switzerland) Ltd. SEOUL Phone: +61 - 3 - 979 503 66 CAMBRIDGESHIRE SUBINGEN Phone: +82 - 2 - 553 8200 Fax: +61 - 3 - 979 505 47 Phone: +44 (0) 1480 404 401 Phone: +41 - 32 613 30 30 Fax: +82 - 2 - 553 8255 GUAM Fax: +44 (0) 1480 404 402 Fax: +41 - 32 613 30 15 MAINLAND CHINA Structural Technologies Inc. Africa Intrafor (UK) VSL (Suisse) SA VSL Engineering Corp., Ltd. TUMON BRACKNELL PENTHAZ HEFEI Phone: +1 - 671 - 646 8010 Phone: +44 - 1 - 344 742 115 Phone: +41 21 862 80 00 Phone: +86 - 551 - 557 6008 Fax: +1 - 671 - 646 8060 SOUTH AFRICA Fax: +44 - 1 - 344 742 146 Fax: +41 21 862 80 02 Fax: +86 - 551 - 557 6018 VSL Systems (South Africa) Pty. Ltd. Kya Sand, RANDBURG GREECE VSL Engineering Corporation Ltd. Phone: +27 - 11 - 708 21 00 VSL Systems A/E Shanghai Branch Co. Fax: +27 - 11 - 708 21 20 ATHENS SHANGHAI Phone: +30 - 1 - 0363 84 53 Phone: +86 - 21 - 6475 4206 Fax: +30 - 1 - 0360 95 43 Fax: +86 - 21 - 6475 4255 NETHERLANDS MALAYSIA VSL Benelux B.V. VSL Engineers (M) Sdn. Bhd. AT LEIDEN KUALA LUMPUR Phone: +31 - 71 - 576 89 00 Phone: +603 - 7981 47 42 Fax: +31 - 71 - 572 08 86 Fax: +603 - 7981 84 22 Intrafor (Netherlands) PHILIPPINES AC LEIDERDORP VSL Philippines Inc. Phone: +31 - 71 - 581 70 22 MANDALUYONG CITY Fax: +31 - 71 - 581 70 21 Phone: +632 638 76 86 Fax: +632 638 76 91 SINGAPORE VSL Singapore Pte. Ltd. SINGAPORE Phone: +65 - 6559 12 22 Fax: +65 - 6257 77 51 TAIWAN VSL Taiwan Ltd. TAIPEI Phone: +886 - 2 - 2759 6819 Fax: +886 - 2 - 2759 6821 Lanjaron Viaduct, Spain Jacking power to the point

Maureen Platform, Norway

Palexpo Congress Hall 6, Switzerland

Tunnel Boring Machine, Singapore

VSL HEAVY LIFTING

• Feasibility studies

• Design and planning

• Execution of lifting work

• Special equipment

for

- Bridge projects

- Roof structures

- Energy projects

- Industrial projects

- Building projects

Bairab Bridge, India

Airbus Assembly Hall, France

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