www.bbrnetwork.com 2nd Edition – 2008

Treading on thin ice? BBR’s response to global warming and other topical themes Optimising with BBR technology and expertise Review of post-tensioned slab applications and advantages

Package deals in Poland Energised for the future How the package approach has Renaissance in the nuclear sector benefited clients in and BBR track record Eastern Europe Taking power to the people MRR delivers solutions for all types of structure

THE MAGAZINE OF THE GLOBAL BBR NETWORK OF EXPERTS BBR is recognised as the leading group of specialised engineering contractors in the field of post-tensioning, stay cable and related construction engineering. The innovation and technical excellence, brought together in 1944 by its three Swiss founders – Antonio Brandestini, Max Birkenmaier and Mirko Robin Ros – continues, more than 60 years later, in that same ethos and enterprising style. From technical headquarters in Switzerland, the BBR Network reaches out around the globe and has at its disposal some of the most talented engineers, technicians and the very latest internationally approved technology in the world.

The Global BBR Network Within the Global BBR Network, established traditions and strong local roots are combined with the latest thinking and leading edge technology. BBR grants each local BBR Network member access to the latest technical knowledge and resources – and facilitates the exchange of information on a broad scale and within international partnering alliances. Such global alliances and co-operations create local competitive advantages in dealing with, for example, efficient tendering, availability of specialists and specialised equipment or transfer of technical know-how.

Activities of the Network All BBR Network members have established and strong local connections in their N e t w l o respective regions. They are all structured differently to suit the local market and a r k b offer a variety of construction services, in addition to the traditional core o o l f business of post-tensioning. G

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e BBR technologies have been applied to a vast array of different structures –

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S t such as bridges, buildings, cryogenic LNG tanks, dams, marine structures,

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n - nuclear power stations, retaining walls, tanks/silos, towers, tunnels, wastewater c e 1 9 4 4 treatment plants, water reservoirs and wind farms. The BBR brands and trademarks – CONA, BBRV, HiAm, DINA, SWIF ... and CONNAECT – are recognised worldwide. The BBR Network has a track record of excellence and innovation – with thousands of structures built using BBR technologies. While BBR’s history goes back over 60 years, the BBR Network is focused on constructing the future – established traditions are blended with the latest thinking and leading technology.

BBR VT International Ltd is the Technical Headquarters and Business Development Centre of the BBR Network, located in Switzerland. The Shareholders of BBR VT International Ltd are: BBR Holding Ltd (Switzerland); BBR Polska Sp. z.o.o. (Poland); BBR Pretensados y Técnicas Especiales, S.L. (Spain), member of the FCC Group (Spain); KB Spennteknikk AS (Norway), member of the KB Group (Norway); VORSPANN- TECHNIK GmbH & Co. KG (Austria / Germany), member of the Porr Group (Austria). hrough the pages of this, the second edition of CONNAECT, you will see that Tover the past year, the Global BBR www.bbrnetwork.com 2nd Edition – 2008 Network of Experts has delivered leading edge solutions for some challenging projects. Very often, these have involved structures which affect the safety and well-being of the general population – we can all be confident and take pride in the knowledge that our people have provided the Treading on thin ice? very best of the latest technology and know-how BBR’s response to global warming in their completion. and other topical themes Without doubt, the commitment of our engineers to the Optimising with BBR technology and expertise development of new products has kept BBR ahead of the pack Review of post-tensioned – and produced highly satisfied clients around the world. We slab applications and advantages are fortunate indeed to have some of the best qualified and Package deals in Poland Energised for the future most dedicated construction professionals working within the How the package approach has Renaissance in the nuclear sector BBR Network. The glue that holds us all together and drives benefited clients in and BBR track record Eastern Europe our success is excellent communication – we are constantly Taking power to the people sharing information and knowledge. MRR delivers solutions for all types of structure The Global BBR Network is truly greater than the sum of its parts! THE MAGAZINE OF THE GLOBAL BBR NETWORK OF EXPERTS Bruno Valsangiacomo Marcel Poser Chairman CEO BBR VT International Ltd BBR VT International Ltd

Treading on thin ice? – An P1 exploration of BBR’s “green” product range, along with further news from within the BBR Network. contents Talking BBR 1 P13 Package deals in Poland BRIDGES & FLYOVERS, POLAND 13 BRIDGES Place for pilgrims JAMARAT BRIDGE ACCESS RAMPS, First use of BBR VT CONA CMI SAUDI ARABIA 15 KULMBACHTAL BRIDGE, NEAR NABBURG, GERMANY 6 Imaginative Alliance Double vision LAWRENCE HARGRAVE DRIVE MT HENRY BRIDGE, PERTH, WESTERN AUSTRALIA 8 BRIDGES, NSW, AUSTRALIA 16 Croatia’s largest construction project Bridge to the future MIDDLE BRIDGE ACROSS SUNGEI PONGGOL, THE RASCANE VIADUCT, CROATIA 8 SENGKANG NEW TOWN, SINGAPORE 18 Speedy construction VIADUCT OVER NALON RIVER, ASTURIAS, SPAIN 9 BUILDINGS P19 Taking flight Optimising with BBR technology BRIDGES K33A & K35A, P11 and expertise ROISSY, FRANCE 10 POST-TENSIONING FOR SLABS 19 Thinking ahead Gateway to new economic zone LAVANT BRIDGE, SUBIC BAY PORT DEVELOPMENT, LUZON ISLAND, A2 SOUTH MOTORWAY, AUSTRIA 11 PHILIPPINES 22 P41

As the nuclear energy industry gears up for a revival, contents we examine the marketplace, as well as the products and expertise within the BBR Network. continued P46 BUILDINGS continued STAY CABLES Review of the BBR CONA Alternative advantages The ultimate stay cable system HiAm system – including a PT CONDOMINIUM TRANSFER FLOOR, KUALA LUMPUR, BBR HIAM look at cable damping MALAYSIA 22 STAY CABLES 46 mitigation measures. Logistical goal Teamwork on the Drava CHANGI DISTRICENTRE, SINGAPORE 23 BRIDGE OVER DRAVA RIVER, PTUJ, SLOVENIA 48 Complex and challenging project Hungary’s first extradosed bridge THE LINKS SEASIDE, WOLLONGONG, NSW, AUSTRALIA 24 MOTORWAY BRIDGE, LETENYE, HUNGARY 49 P23 Embracing PT floors On track in Patna PT FLOOR PROJECTS, UK 25 CABLE STAYED BRIDGE, CHIRAIYATAND, PATNA, INDIA 50 Graceful & awe-inspiring Foothills of the Himalayas BRIDGEWATER PLACE, LEEDS, UK 26 PARVATI RIVER BRIDGE, HIMACHAL PRADESH, INDIA 52 New wave elegance QUEEN STREET, PORTSMOUTH, UK 27 MRR Optimised for speed Taking power to the people HAYES CENTRAL, MIDDLESEX, UK 28 TRANSMISSION TOWER FOUNDATION UPGRADE, UPPER SOUTH ISLAND, NEW ZEALAND 53 Great and timely efforts THE PRIME MINISTER’S OFFICE, CANBERRA, AUSTRALIA 29 P53 Breakdown recovery WAREHOUSE REPAIR, Modern marvel STARACHOWICE, POLAND 55 JUMEIRAH LAKE TERRACE, DUBAI, UAE 30 Concrete carbonation repairs Flooring successes AIRBASE HANGAR REPAIRS, PT FLOOR SOLUTIONS, NEW ZEALAND 31 WHENUAPAI, NEW ZEALAND 56 BBR Contech’s award- Winning hearts and minds winning project strengthened Collaborative challenge TUSKANAC PARKING GARAGE, ZAGREB, CROATIA 34 power transmission towers UNDERPINNING PIER 7, in challenging terrain on New MAKATOTE VIADUCT, Impressive solution Zealand’s South Island. WOOLWORTHS REGIONAL DISTRIBUTION CENTRES, NEW ZEALAND 57 AUSTRALIA 35 Timely solution in live traffic Creating a new town BATU KITANG BRIDGE, SARAWAK, MALAYSIA 59 ROUSE HILL PROJECT, AUSTRALIA 35 Upgrading dam safety ROSS RIVER DAM, TOWNSVILLE, AUSTRALIA 60 P38 TANKS & SILOS Keeping Fijian trade afloat Key role for grout 36 QUEEN’S WHARF MAINTENANCE REPAIRS, LAUTOKA, FIJI 62 Special grouting operation High performance concrete FOURTH LNG TANK, WASTEWATER REHABILITATION, HASTINGS, CARTAGENA, SPAIN 37 NEW ZEALAND 63 Shared experience Benchmark bridge ADRIATIC LNG TERMINAL, SPAIN-ITALY 38 BEARING REPLACEMENT, MORSHEAD OVERPASS, The Monaco challenge MELBOURNE, AUSTRALIA 64 FLOATING BREAKWATER, SPAIN-MONACO 38 LANDMARK STRUCTURES Towering success RETENUE LES BLANCHETS, LA PLAGNE, FRANCE 39 Jewel of the Austrian Alps BERGISEL SKI JUMP, INNSBRUCK, Purifying Queensland’s water AUSTRIA 65 P67 WATER TREATMENT TANKS, AUSTRALIA 40 Metamorphosis in Norway HOLMENKOLLEN SKI-JUMP, OSLO, NUCLEAR ENERGY NORWAY 67 Energised for the future RENAISSANCE IN THE NUCLEAR POWER INDUSTRY 41 BBR Worldwide Directory 2008 68 R

Treading on thin ice? B

hatever your personal beliefs about why global warming is B

happening – or whether indeed it is happening at all G

– there are some real benefits to be derived from adopting N W I an environmentally sensitive approach. BBR VT International Ltd’s K

CEO, Marcel Poser, outlines recent developments within the L

BBR Network which give the construction industry some A greener options. T

CONNÆCT 1 hat is absolutely clear is that there is no Wsingle means of halting climate change, so we need to explore all the options we have to reduce our environmental footprint, as we need to take care of our planet – because, so far, we only have one!

We have to change our attitude and abandon our fear that an environmentally sensitive approach means restrictions to our lifestyle. The fact is that taking a greener approach actually leads to innovation, business opportunities and continued growth. It is a challenge for our society and we need to work together. We need strong politicians, as well as sensitive and smart business leaders. Once clear and challenging targets have been set, mankind has always delivered. We flew to the moon, tore down the Iron Curtain … not because they were easy, but because they were hard and because there have been visionary leaders. Narrowing our focus to the construction sector, it’s simply not enough to rely only upon “sustainable technology” to fight the challenges of the future; we have to consider the entire lifecycle of a structure.

A good example in construction is the post- benefits of the “sustainable” post- footprint and environmental impact during tensioning of slabs in buildings. PT slab tendons tensioning slab technology, as well construction and have, in fact, also achieved a are the sustainable technology, but they only lead as early stage re-usage and higher quality end product at a lower cost – to a truly environmentally sensitive structure if ultimate disposal considerations. If thus, an environmentally sensitive structure we make smart choices from the beginning to we do all of this, we not only end which actually saves money! You can learn more the end - from the building placement, through up with a structure which uses less about the benefits of PT slabs in the Optimising integrated and customised building designs, to concrete and steel, but have with BBR technology and expertise feature on construction methods which fully exploit the significantly reduced the carbon Page 19. 2 CONNÆCT tendons are now grouped so that you only use what you actually need. All the size groups can be handled and stressed with just one piece of gear – the kit has been rationalised. In this way, we are helping to ensure that only the amount of anchoring material which is really needed goes

into the structure, whilst minimising additional R

transportation impacts for construction gear. B In 2008, we are offering 25 different sizes of B

multi-strand anchorages – ranging from 1 to 61 G N

strands. At the same time, our products will I

continue to promote faster construction K L programmes through early strength concrete A

stressing which reduces the construction cycle T time – the earlier you can stress, the earlier you can build. Alternatively, a lower quality, cheaper or possibly recycled concrete can be used. One year on, BBR VT CONA CMI remains unmatched in offering early stage stressing. BBR technologies also remain the benchmark for compactness in the anchor zone – even a year One size FITS ALL?! after introducing the new range of products. Our systems use the least amount of space in the The one-size-fits-all concept is no longer a viable working with multi-strand systems anchor zone – again reducing materials. one for construction products – optimisation is with four or five different sizes and European Testing of the BBR VT CONA CMI needed to achieve the most environmentally- you would have had to use a 31- range has enabled the BBR Network to win a friendly structure. Opting to use post-tensioning strand anchor when, for the most large number of jobs – in fact, the number of means that a wider product range is available. economical solution, you actually projects and product sales have exceeded our For example, in days of old, you might have been needed a 24-strand anchor. BBR expectations. Genuine Technology ecently there’s been much talk about counterfeit components – cheap copies of construction R products which ultimately risk lives. There are indeed many “local” post-tensioning systems on the market which, despite some of them carrying our trademarks, actually bear no relation to the original, genuine BBR technology. Genuine BBR products are extensively tested according to the latest provisions, are based on over 60 years of experience and are constantly under surveillance by an independent auditor to ensure they continue to fulfil all the requirements of our European Technical Approval. There are now documents in the public domain, thanks to European Technical Approvals, which provide a real comparison with these copycat, look-alike and half-hearted copies. However, if you are in any doubt about a product which is offered, seek advice from the BBR Network. MARKET RESPONSE Over the past 12 to 24 months, we have truly felt year, the response from the market underway in the Middle East, Asia and Australia. the benefits of the BBR Network, a confederation place has been tremendous – and This success can be attributed, in equal parts, to of individual companies with their own strong local we are already now tackling the the expertise and excellent track record of BBR roots – and being the only company within the markets outside of Europe with our Network members, as well as the superiority of post-tensioning market place to have brand new new product range. the products and their technical and and genuinely state-of-the-art products which are ETAG and CE have become environmental advantages. All of these qualities tested and approved to the European Technical international benchmarks which were well-publicised in 2007 - for example, Approval Guidelines (ETAG) and CE marked. have driven projects by BBR during a road show to officially launch the Since launching the BBR VT CONA CMX range last Network members that are now products in Australia. CONNÆCT 3 What’s in a slogan? Get plugged into the BBR Network! “Nothing in this world can take the place of persistence. Talent will not; nothing is more common than unsuccessful people with talent. If your credentials and Genius will not; unrewarded genius is almost a proverb. Education will aspirations match ours, we not; the world is full of educated derelicts. Persistence and would very much like to hear determination alone are omnipotent. The slogan 'press on' has solved – and always will solve – the problems of the human race.” from you – we are always looking for good, highly- CALVIN COOLIDGE, 30TH PRESIDENT OF THE USA (1923-1929) qualified people and market- Have you ever wondered why, at BBR, we call project, you have to try more than leading organisations to join our team a “Global Network of Experts”? It was once to find the right recipe – – and remains – important to us that any slogan optimising and changing things as the international BBR we use should reflect the qualities of our you go. Again, if you read the article Network. organisation – an international presence, our on Page 37 Special grouting interconnection and positive working relation- operation, you’ll understand exactly At BBR, we inspire our team ships and, above all, the attitude of our people. I what I mean. members to improve believe that the BBR Network embodies the Thirdly, we have “Pleasure” – the themselves, both personally “Three Ps” – professionalism, persistence and BBR Network can undoubtedly put pleasure – which go together to make a smiles on faces. A key secret of the and professionally. successful business. Professionalism is when BBR Network is that we are in fact For further information, please organisations and individuals go the extra distance a family who respect each other as to develop and launch products or produce individuals and as professionals, contact us at leading-edge project solutions. Have a look at the have a desire to learn and enjoy [email protected], we feature on Page 53 – Taking power to the people. working together – this is quite would be pleased to hear Next comes “Persistence” – this, for me, is about evident at all our meetings and not giving up. For example, when testing indeed at our Global BBR from you. something or finding the best solution for a Conferences. 4 CONNÆCT R B B G N I K L A T

2007 BBR PROJECT OF THE YEAR At the 2007 BBR Conference in Singapore, BBR PTE (Spain) won The Navia River Bridge project convinced the jury because of the the BBR Project of the Year Award for their excellent execution wide range of BBR post-tensioning systems that were used – stay and innovation in post-tensioning for the Navia River Bridge, in cables, internal and external prestressing (massive 42 strand Asturias, in northern Spain. tendons) and bars. In addition, the project team used BBR heavy The bridge’s most striking characteristics are the two 160m central lifting strand jacks and BBR auto-propelled robots to place the spans held up by two arches. jacks inside the deck.

Global BBR conference OUT LOOK ver the next 12 months, we expect to be Oharvesting the fruits of our labours – with some additional product launches within the 2008 BBR VT CONA CMX series. These products will be larger sizes – including world record- sized multi-strand tendons which will be used in the nuclear industry. We have new products for external post-tensioning and will be launching a proprietary product mainly geared for strengthening structures.

As far as the market place is concerned, we anticipate that the energy sector will continue to perform strongly in 2008 and beyond. We are also looking forward to exciting cable stayed his year, we are looking forward to seeing the whole BBR family together in bridge projects which typcially feature cross- Sydney. There will be a number of presentations and BBR technology continental BBR Network collaboration – more Tupdates, but it will not be all about work. We have planned a number of social of that in the next edition! events too – including a Charity Golf Tournament. The Conference will reach it’s climax with a formal dinner – during which the winner of the 2008 BBR Project of Finally, we have also grown as a Network and I’d the Year Award will be announced. Then, the BBR Network will return to their work like to welcome some new faces who have – revitalised and ready to deal with upcoming challenges. joined us – check out the penultimate pages to discover where! CONNÆCT 5 KULMBACHTAL BRIDGE, NEAR NABBURG, GERMANY First use of BBR VT CONA CMI

hanks to their use of the BBR VT CONA CMI and BBR VT CONA CMB prestressing systems, Dipl.-Ing. Thomas Weber of BBR Network member VORSPANN-TECHNIK GmbH reports Tthat, at the end of 2005, his company received a major order. Their commission is to carry out all the prestressing work for the largest of nine bridges on the A6 motorway widening project, between the Amberg-Ost junction and interchange at Oberpfälzer Wald, in Germany.

6 CONNÆCT he A6 motorway runs in an East-West direction S – from Waidhaus on the German-Czech border,

T E to Saarbrücken on the German-French border. It is part of the international East-West axis – the E50 G European Highway – which connects Paris with D

Prague. The construction of the Kulmbachtal Bridge I

took place as part of the project to close the gap in R the A6 between Amberg and the interchange at Oberpfälzer Wald. The bridge represents an B important milestone for Germany within the context of the expansion of this vital axis – which is becoming increasingly more important with the enlargement of the EU in an easterly direction.

CONSTRUCTION DATA AND METHOD The Kulmbachtal Bridge consists of a single prestressed concrete box girder via nine spans with a maximum span of 62m, for each carriage- way. The overall length between the north and Section joint with BBR VT CONA CMI 1506 fixed couplers and overlapping prestressing tendons. south abutments is 515m. The maximum height of the bridge above the valley floor is 32m. The The higher permissible prestressing CLEARING THE WAY two superstructures are being built using the forces, as set out in the new DIN In order to fulfil these requirements, VORSPANN- incremental launching method in weekly cycles 1045-1 national standard, were TECHNIK used the European Approved BBR VT of 17 sections each. The standard section length already envisaged during construc- CONA CMI post-tensioning system. In fact, the is 31m. tion planning (P 0,max = 0,9 x f p0,1,k ). first use worldwide of the BBR VT CONA CMI Due to the existing carriageway slab prestressing system – with its ground-breaking PRESTRESSING CONCEPT thickness of only 48cm, combined technological advantages. The superstructures are being constructed by the with the large number of tendons, it For the eccentric prestressing, the BBR VT CONA so-called “hybrid construction method” – using was of the utmost importance that CMB 1606 – 150 1770 band system is being BBR VT CONA CMI 1506 – 150 1770 post- the prestressing system selected used. The tendons are deviated with PE saddles tensioned prestressing tendons for the centric should have as small as possible at the support cross beams and the span prestressing. Up to 22 tendons are used in the centre spacings and edge distances pilaster strips. For each bar, three tendon strands carriageway slab, while in the bottom slab up to from the tendon anchorages. In run via the complete bridge length, with a 10 tendons are being placed – all run over two addition, the minimum concrete maximum tendon length of 220m. The tendons sections and 50% of the tendons are anchored at strength at the time of stressing had are each prestressed, on both sides, at the the section joints. In the spans with the largest to be as low as possible in order to anchorages fixed in the final cross beams and distance between supports, two additional achieve the weekly construction span pilaster strips. The installation and the tendons of the same type are arranged in the cycle. A minimum concrete prestressing of the external tendons is done after bottom slab – these are, however, shot in and strength of 30N/mm 2 was targeted the final launching of the corresponding stressed via pilaster strips after the final launching. and finally agreed. superstructure. G

TEAM & TECHNOLOGY OWNER Federal Republic of Germany, represented by Autobahndirektion Nordbayern (Motorway Administration Office of Northern Bavaria) CONTRACTOR DYWIDAG Bau GmbH DESIGNER Leonhardt, Andrä und Partner, Nuremberg TECHNOLOGY BBR VT CONA CMI internal BBR VT CONA CMB band system BBR NETWORK MEMBER External prestressing tendons – in the foreground, span pilaster strip with curvatures and VORSPANN-TECHNIK GmbH (Germany) anchorages and, in the background, cross support with curvatures. CONNÆCT 7 s part of the New Metro Rail Project connecting Perth Double Ato Mandurah, the existing Mt Henry Bridge across the Canning River on the Kwinana Freeway needed to be widened, or duplicated, to take the two new rail lines, reports Hudson Lun of STRUCTURAL SYSTEMS LIMITED , the vision Australian BBR Network member. The city of Perth in Western Australia boasted a world class light rail link from the City central business district northwards to the satellite city of Joondalup, situated within the centre corridor of the city’s Mitchell Freeway. However, Perth had no rail link in a southerly direction within the corresponding Kwinana Freeway. Out of this urban transport need was born the New Metro Rail Project which would eventually provide the missing rail link southwards from Perth to the satellite city of Mandurah some 100km to the south. BRIDGING THE GAP The existing Mt Henry Bridge was constructed in the 1970s and

he 36m high THE RASCANE VIADUCT, CROATIA Rascane Viaduct, Twhere BBR CONEX is supplying leading edge post- tensioning services, spans the most challenging terrain on the Zagvozd to Ravca section of the Zagreb motorway and cuts through the mountains, giving magnificent views of Biokovo Nature Park. Croatia’s largest construction project The difficult terrain and traffic. Launching is performed in TRANSFERRING FORCES The Zagvozd – Ravca section of considerable incline of the a downhill direction and the The casting yard bears a the motorway is expected to ground drove the decision to total weight of the structure to horizontal force of a total of open for traffic during 2008. G construct the viaduct using the be launched is 13,000t. 1200t – generated by the jacking incremental launching method. equipment during launching – and TEAM & The viaduct is a 633m long, 19- REPETITION REDUCES to transfer this massive force to TECHNOLOGY span, box girder road bridge – COSTS the ground BBR CONEX has also OWNER with a downhill slope of 4%. On the top of each pier, a provided geotechnical anchors. Hrvatske Autoceste (Croatian End spans are 26m long and 17 guiding system has been installed Motorways) of the middle spans are 33m which consists of two steel OPTIMISED METHOD CONTRACTOR long. structures positioned on both The use of relatively long 33m Osijek Koteks, Osijek / Palmir, sides and is helping to guide the segments is very economical Zagreb SEGMENT PRESTRESSING structure whilst allowing for because of the straight tendon Prestressing of segments is being small deviations. Formwork is layout and reduced number of DESIGNER carried out by BBR CONEX. A being reused many times – the joints in the structure. In Kresimir Ilic (IPZ, Zagreb) 2.8m high box girder cross- regular repetition of identical addition, the casting cycle is TECHNOLOGY section is prestressed with BBR tasks for the construction of optimised in a week-by-week BBR VT CONA CMI internal VT CONA CMI internal post- each of the segments rhythm which is a particular tensioning technology, in a single substantially reduces the ratio of benefit of using the incremental BBR NETWORK MEMBER BBR CONEX (Croatia) stage, for all the loads – including labour-to-material costs. launching method. 8 CONNÆCT carried six lanes of freeway traffic, with three lanes in each direction. It was a post-tensioned double box concrete girder type bridge, originally built using pre-cast segments assembled on a supported steel truss and then stressed together. Following extensive analysis, it was decided to construct a separate bridge alongside the existing bridge to carry northbound traffic – and to strengthen the existing structure to take both the southbound S traffic and the new rail lines. However, this new bridge would be of the incremental launching system, including temporary bearings and E G virtually touching the existing bridge and, to the casual observer, side guides. The existing bridge actually served as the main side guide D would appear to be simply a widening of the original bridge. for the launching process. I R

INCREMENTAL SOLUTION VITAL STATISTICS B The final design was a single box concrete girder with large underside The large 76m spans required the use of temporary piers during the flanges to carry pedestrian and service traffic. The method of launching process. The 660m long structure comprised 28 segments, construction chosen was an incrementally launched solution to provide each typically 25m to 28m long, and contained over 400t of 15.2mm the least disruption and the quickest possible construction period. strand. Tendon sizes varied from 5 strands to 31 strands. Structural Leighton Contractors employed Structural Systems to supply and Systems also supplied and installed stress bars for the external install the post-tensioning works in addition to the hire and operation strengthening works on the existing bridge. Speedy construction VIADUCT OVER NALON RIVER, ASTURIAS, SPAIN

tendon emerges from the hanging tool was designed to concrete, it is protected by the operate the jack. G corrosion-free HDPE duct. The concrete end spans were TEAM & post-tensioned with BBR CONA TECHNOLOGY internal 2406. The steel section was joined to the concrete ends OWNER by BBR CONA external 2406 Principado de Asturias tendons. CONTRACTOR Stressing of all the tendon pairs J.V. FCC CONSTRUCCION, S.A. uillermo Molins Roger of BBR Pretensados y (with cross symmetry) was + ALVARGONZALEZ carried out symmetrically and Técnicas Especiales describes the construction DESIGNER simultaneously using two jacks. IDEAM Gof this remarkable bridge which forms part of Some tendons were stressed the regional AS-17 highway running between Avilés and from inside of the concrete box. TECHNOLOGY Puerto de Tarna in the Principality of Asturias, Spain. The The anchor for these tendons BBR CONA internal + external was placed in the angle between road passes through a narrow corridor and, as a result, BBR NETWORK MEMBER the lateral walls and the upper BBR PTE (Spain) several structures are needed in a relatively short slab of the box. A special distance – the most important of these is the double viaduct over the Nalon River.

It is a composite bridge in two designed the structure using BBR directions – longitudinally and systems. The BBR CONA cross-wise – and has spans of external system was chosen to 27.5m, 110m and 27.5m. The provide a joint longitudinally end spans are of concrete box between the concrete end construction, while the central section and the central steel main span was constructed as a section. steel beam with a concrete slab The tendons which join the steel above. With this combination, a structure to the concrete boxes huge span and fast installation have a combination duct. It time were achieved. begins in the abutments with a BBR PTE was involved in this steel strip duct, then the material construction project right from changes from steel to HDPE the design stage – leading ducting whilst still inside the Spanish design practice, IDEAM, concrete, so that when the CONNÆCT 9 BRIDGES K33A & K35A, ROISSY, FRANCE Taking flight

Bridge K35A will serve the new terminal at Roissy Charles-de-Gaulle Airport.

BRIDGE K35A Bridge K35A has one 37.6m long span which is 1.3m thick. The cross-section consists of a section of concrete which is 7.10m wide in the middle of the span and 9.10m wide on the abutments. The width of the total cross-section, including the lateral cornices, is 15m. G

new Terminal – T2G – at Roissy Charles-de-Gaulle Airport is due to come into service during autumn A 2008 to handle flights operated by Air France’s three regional subsidiaries, Brit Air, City Jet and Régional. BBR Network member, ETIC, has provided post-tensioning technology and know-how for the construction of two bridges, one of which will be the principal vehicle access for passengers to the new terminal. Both bridges have been designed by the client organisation, ADP (Aéroport de Paris) and are well on target for completion.

BRIDGE K33A is anchored on the foundations by Bridge K35A is 48.2m long and 0.75m thick, with tensioned bars which are protected a total width of 16m. The two spans are by wax. supported from one central pier which has been The abutments consist of concrete designed with five special 310mm diameter pier caps with transversal post- metallic bars and a spherical bearing on the top tensioning and one additional short to assure the connection with the slab. The pier slab.

TEAM & TECHNOLOGY OWNER/DESIGNER ADP ( Aéroport de Paris) CONTRACTOR RAZEL Grands Chantiers CONSULTANT JV Prodétis and IOA TECHNOLOGY BBR VT CONA CMI internal BBR NETWORK MEMBER ETIC (France)

10 CONNÆCT he A2 South Motorway in the Austrian province of Carinthia was built in the early T1980s, since when the traffic on this route has quadrupled and, looking to the future, a further increase must be expected. The S motorway has now been widened to meet this E G

increased demand – the scheme includes the D I construction of additional bridges alongside R B existing ones. Rudolf Vierthaler of Salzburg-based VORSPANN-TECHNIK GmbH & Co. KG, the Austrian BBR Network member, presents details of the erection of the second structure at bridge

P19, focussing on the post-tensioning concept.

THINKING AHEAD LAVANT BRIDGE, A2 SOUTH MOTORWAY, AUSTRIA

CONNÆCT 11 he existing structure 45m and have been built as a “THANKS TO MODERN DESIGN, RELIABLE POST- of bridge P19 has main steel-concrete composite TENSIONING SYSTEMS – AND EXCELLENT Tspans of 74m, 146m, structure. CRAFTSMANSHIP – A VERY HIGHLY DURABLE 160m, 160m, 155m and 85m POST-TENSIONING STRUCTURE IS EXPECTED.” – making a total length of CONCEPT 780m. There are four side For the post-tensioning of the In this particular case, four with pouring and compacting of spans of 43.5m and one of main spans, a modern concept bands are stapled on top of the concrete. The external 38m, totalling 299m. The was implemented. each other, to form a tendon tendons can be inspected easily height of the box girder is The tendons for the negative with a permissible stressing and, in case of any defect, they

9.5m on top of the piers and moments of the free cantilever force of 2.974kN at 0.7f pK . can be replaced in live traffic – 3.8m in midspan. The ar e VT 12-150 internal bonded TENDON LAYOUT and additional tendons can be elevation of the bridge deck tendons, with plastic ducts to The internal tendons are added, if necessary. is about 160m above the meet the crack-width limitation located in the deck slab (up to Thanks to modern design, valley floor. regulations. For the final dead 54 units) and in the bottom reliable post-tensioning systems The main spans were erected slab (up to 6 units) only, which – and excellent craftsmanship – between 1981 and 1984, by allows easy concrete pouring a very highly durable structure Steiner Bau GmbH, as a for the webs and, thus, ensures is expected. G concrete structure cast in situ sound concrete quality. using the free cantilever The external post-tensioning is TEAM & TECHNOLOGY method, while the side spans achieved with 12 BBR VT CONA were constructed by CMB 1606-150 1770 tendons, OWNER incremental launching. Post- loads and for the live loads, BBR with an average length of 221m. Country of Carinthia Bridge Department, tensioning was provided by VT CONA CMB 1606-150 Facilities for the possible future on behalf of ASFINAG 540t of VT 16-100 internal 1770 external tendons have strengthening of the bridge CONTRACTOR bonded tendons. been used. have been incorporated now, by Steiner Bau GmbH, St. Paul / Lavanttal NEW SECOND The band tendons, originally making space for an additional STRUCTURE invented by VT Austria, consist eight external tendons. DESIGNER The second structure was of bands with four 0.62” The tendons are guided by Ertl, Horn & Partner, Klagenfurt / FCP, completed in 2007 by the same diameter strands. The strands deviator saddles in the middle Vienna / A. Pauser, Vienna contractor and the main spans are individually greased and of the spans and at the pier TECHNOLOGY follow the contours of the first covered with one extruded sections. The saddles are curved VT internal bridge – and were also built layer of 2mm HDPE and a polyethylene boxes, produced BBR VT CONA CMB band system using the free cantilever second HDPE layer 3mm thick by the CAD-CAM method. BBR NETWORK MEMBER method and cast in situ. in a rectangular shape. The ENDURING STRUCTURE VORSPANN-TECHNIK GmbH & Co. KG The side spans of the second ultimate strength of such a band The tendon layout concept has (Austria) structure are 58m, 52m and with four strands is 1.062kN. minimised the risk of problems 12 CONNÆCT BRIDGES & FLYOVERS, POLAND S E G D I R B

Package deals in Poland he extensive scope of works, for the construction of the Warta Bridge, with which BBR Polska has been entrusted is a great example of a “package deal” – that is, an arrangement convenient to all Tparties involved. Such a one-stop-shop approach offers single-point responsibility for a range of construction services and helps the client manage the overall project more effectively – as well as attracting cost and programme benefits.

Today, the arches of the Warta Bridge, near The five-gap modular joint is the Dunajec River in Brezna and forms part of the Gorzów Wielkopolski, project a thin line against largest one ever assembled and Stary Sàcz Bypass. the sky – a simple, elegant silhouette. One has installed by BBR Polska. It was The three-span bridge (77.92m, 143m and to realise the actual dimensions of the bridge – manufactured in BBR’s own 77.92m) is a continuous beam structure, with a length of 708m – to understand that this workshop. pylons placed on the intermediate supports. Six lightness is just a visual effect – in reality, we are FIRST IN POLAND pairs of diagonal stay cables are anchored at the looking at a robust structure which makes the The most recent package deal – a top of each of the pylons, which tower 18.47m hangers look like threads. project which is not yet completed over the deck. The beam consists of two BBR Polska’s work for this project included the – brings BBR Polska back to the concrete decks – upper and lower decks – supply of 32 pot bearings; supply and installation landscape where their activity which are connected by two steel pipe trusses. of expansion joints; incremental launching of the started, some thirteen years ago – This type of structure is being used for the first steel bridge superstructure; and the supply, the mountains! The road bridge time in Poland. installation and adjustment of the hangers under construction crosses the CONNÆCT 13 Launch process The launching process was undertaken in two phases: • Section 1, between piers 1 and 7 (starting from pier 1) - total weight of the structure shifted was 4,200t • Section 2, between piers 7 and 13 (starting from pier 13) - total weight of the structure shifted was 3,240t It took seven launching cycles to complete the whole operation. For Section 1, the structure was launched together with the steel arch. The hangers were fixed in the steel arch structure before the seventh launching cycle started. On completion of the launching process, the support of the main span – the bottom fork anchors of the hangers – were fixed in place. The final adjustment was made after the deck had been completed.

“THESE TWO FLYOVERS – WHICH INCLUDE POLAND’S LONGEST ONE AT 730M LONG – FORM THE LARGEST INTERCHANGE ON THE SIEKIERKOWSKA ROUTE.” consideration the changed one project, as it enables long- sequence of span execution and term planning and effective the characteristics of the BBR resource management – of prestressing system. personnel, materials and Both flyovers were built by the equipment. While for the owner “span-by-span” method on and the contractor, it is certainly scaffold – but, for the flyover easier to co-ordinate the curved on plan, construction various operations with just one took place from both sides. team providing a range of The construction is also being The works contracted to BBR The long and frosty winter of services – rather than with carried out by the incremental Polska included detail design; 2006/2007 did not significantly several different organisations, launching method. The bridge supply and installation of 54 affect the construction schedule each providing one element. G superstructure has 13 sections bearings; prestressing of the and the completed crossing was – not counting the pylons – to superstructure – one of the opened to traffic in June 2007. be launched, making a total flyovers is also transversely WELL-ROUNDED weight of 6070t, including the prestressed with 64 50mm PACKAGE 50t launching nose. diameter prestressing bars; Package deals are the goal we BBR Polska has been entrusted supply and installation of multi- aim for, as they benefit not only with prestressing of modular expansion joints. BBR everyone. For the the bridge structure, but also Polska also adapted the subcontractor, it is obviously with the supply and installation construction method, relating to convenient to carry out the pot bearings and expansion the cable layout, to take into whole range of activities within joints; supply of materials and execution of the bridge structure’s suspension; and the supply of equipment and services – and execution of the incremental launching operation. WARSAW FLYOVERS Another project, carried out by BBR Polska as a package arrangement, makes a dramatic statement on the city landscape of Warsaw – the two main flyovers of the three level Mars Junction. These two flyovers – which include Poland’s longest one at 730m long – form the largest interchange on the Siekierkowska Route. 14 CONNÆCT PLACE for pilgrims S E G D I R B

JAMARAT BRIDGE ACCESS RAMPS, SAUDI ARABIA he increasing number of pilgrims has dictated the continuous need to develop infrastructure to and around the Islamic holy places in the Kingdom of Saudi Arabia. One of these places is the TJamarat site, where at least three million worshippers have to be present, once a year, in a single daylight period.

In order to solve the difficulties associated with bridge – consists of four floors of excellent example of co-operation between two hosting such a large gathering of people, the approximately 600m long, 12m high BBR Network members – Huta Hegerfeld BBR Government of Saudi Arabia initiated a new and widths ranging between 60m to Prestressing Division, Saudi Arabia and Marwan design for a multi-story structure which creates 97m. In addition, there are access Al Kurdi & Partners Co. Ltd, Jordan – which has more space and additional areas that will more ramps – consisting of precast, resulted in a very successful performance. G easily facilitate the casting pebbles supplication prestressed T-beams – covering a and the movement of the pilgrims. total area of approximately The project also has many features which will 180,000m 2 – to the different levels TEAM & TECHNOLOGY significantly improve emergency access and of the main structure. evacuation, as well as providing much better Huta Hegerfeld Saudia Ltd was OWNER services, generally, in a comfortable environment. contracted to construct the access Ministry of Municipal and Rural Affairs The main structure – a precast segmental ramps in their entirety. This is an MAIN CONTRACTOR Saudi Binladin Group SIGNIFICANCE OF JAMARAT DESIGNER Worshippers come to the Jamarat site in Mina as part of the annual Hajj pilgrimage – to Dar Al-Handasah (Shair and partners) the Islamic holy city of Mecca – during which a number of rituals must be performed. TECHNOLOGY Once at the Jamarat site, they hurl pebbles at three stone walls. “Jamarat” literally means BBR CONA internal “stone pillars” in Arabic – however, the pillars at the Jamarat site were replaced with walls, BBR NETWORK MEMBERS following the 2004 Hajj during which over 500 pilgrims were either killed or injured. HUTA/BBR Prestressing Division (Saudi Arabia) The ritual act – where seven stones are thrown at the pillars in a prescribed sequence Marwan Al Kurdi & Partners Co. Ltd. (Jordan) over a three day period – represents the stoning of the devil by the Prophet Abraham.

CONNÆCT 15 Imaginative awrence Hargrave Drive is a spectacular section of coast road, just north of Wollongong in New South Wales. Between Clifton and Coalcliff, this road had a long history of geotechnical L instability, resulting in road closures, sometimes for months at a time. Many attempts were made to maintain the road in an open condition – none with long term success. Former principal engineer on the project, Mark Sinclair from BBR Network member Structural Systems Limited tells of the Alliance which was formed and the imaginative structure which emerged – to the east of the original alignment and, in places, in the Pacific Ocean. The new structure – now known formed between RTA, Barclay geometry. Although this is a evolution also occurred with the as Sea Cliff Bridge – consists of a Mowlem Construction Limited, rarely built type of structure in pile caps, which changed from a five span, 450m long balanced Maunsell Australia and Coffey Australia, the technology is well- hexagonal to rectangular shape cantilever bridge adjoining a Geosciences. Structural Systems’ established and was a suitable for the balanced cantilever seven span, 203m long role in the project was the solution to the site constraints. bridge, saving material and incrementally launched bridge, provision of the incremental FORMWORK TRAVELLERS enabling simpler construction. both sharing a common pier. The launching technology. In order to construct the PIER HEAD bridges incorporate two traffic DESIGN CONCEPT balanced cantilever bridge, CONSTRUCTION lanes of 3.5m to 3.8m wide, with The concept of a double “T” formwork travellers needed to Pier head construction for the 2m by 1m wide shoulders and a incrementally launched bridge, be procured. Two second hand balanced cantilever bridge 2.5m shared pathway on the was adopted from the outset for pairs were sourced which had involved the casting of a 6.2m eastern side. The goals of this the northern structure, while a just completed a bridge in long section centrally over each ambitious project were to balanced cantilever structure Slovenia, and which had a 6.0m pier. A large 15.4m by 12.5m provide a fully available road was chosen for the main wide main box. The initial bridge four module working platform with a design life of 100 years. southern structure – given the design was with a 6.5m box, but was attached to each pier to IMAGINATIVE ALLIANCE 108m central spans, which was changed to 6.0m to allow for construction. Three In a “first” for the Roads and enabled the foundations to fit on minimise the modifications to pours of 25m 3, 50m 3 and 25m 3, Traffic Authority (RTA) of NSW, the few available areas but could the travellers. were necessary to each pierhead, the LHD Link Alliance was still follow the road’s necessary Considerable refinement and for the base, walls and deck slab.

A large 15.4m by 12.5m four module working Closure pours utilised a series of additional systems For incremental launching, a kinked 30t launch nose platform was attached to each pier to allow for – including a small travelling system and special was fitted to reduce the bending moments and construction. formwork. deflections.

16 CONNÆCT S E

The travellers were assembled in a back-to-back pair arrangement on each After completion of cantilevering, the travellers were “back launched” to the pier G D

completed pierhead for the first north and south segment pours. for disassembly and relocation to the next piers. I R B with the subsequent 13 being recognised by the Concrete 15m long each. Institute of Australia who The entire structure is on a selected the project as the ALLIANCE constant 150m plan radius, 3% overall winner of the Kevin crossfall and 2.531% longitudinal Cavanagh Medal. Awarded just The travellers were assembled in precambered to accommodate gradient. As a double “T” once every two years, this medal a back-to-back pair arrangement deflections within the traveller structure, strengthening is the premier award and is on each completed pierhead for and the cantilever loading. The diaphragms were added at each made on the basis of Excellence the first north and south closure pours on the balanced pier location and the abutment. in Concrete – the winner is segment pours. Each pier cantilever bridge were generally An hydraulically operated casting chosen from all projects required 10 segments of 4.95m 2.8m internally and up to 9.4m mould formed each segment, nominated Australia-wide. – cast both on the north and at the south abutment and 8.6m which had substantial piled This project demonstrates south sides. The deliberate at the pier 7 interface. These foundations to limit deflection. admirably that the Alliance sequencing was that the north were built by a series of systems, The mould was raised and approach can be the right segment was cast then stressed a small travelling system for the lowered to suit the production solution, given certain prior to the casting of the southern and northern closures, and stripping. The external circumstances. To design and opposing segment. special formwork for the span 2 sideforms were hydraulically construct this project by more Each of the four travellers, once closure and the traveller for the stripped to provide sufficient conventional mechanisms would fully operational, could complete closures to spans 3 and 4. clearance to launch, as webs have added perhaps 12 months a 4.95m segment per week. As INCREMENTAL were near vertical. and millions of dollars to the there was no 50% segment LAUNCHING At the abutment, Structural cost – as well as adding still offset in the pier head, a maxi- The incrementally launched Systems’ launching equipment further to community mum of one segment was out of bridge was constructed at the was used to progressively launch dislocation. The main balance during cantilevering. In northern abutment and launched the 50,000kN structure. A construction contractor was order to offset the moment south over piers 1 though to 7. calculated thrust of 3,200kN was able to provide key support effects, the deck had kentledge A kinked 30t launch nose was required for the final launching. and leadership in this project, applied at critical times on the fitted to reduce the bending AWARD WINNING which has delivered a highly southern side of the pier. moments and deflections. PROJECT challenging and spectacular The road geometry dictated The spans were six by 30m, plus This successful and innovative structure to the Wollongong varying horizontal radii – straight, an abutment span of 22.8m. The project has received many district – and indeed to 350m and 500m. Segments were first segment was 8.255m long, awards and was recently Australia’s road network. G

Rock falls and embankment failure had been very regular over the lifespan of the road, with over 50 rock falls reported between 1996 and 2003. The road was finally closed in 2003 The incrementally launched bridge was constructed at the northern abutment after major cracks up to 1m wide developed. and launched south over piers 1 though to 7.

CONNÆCT 17 Bridge TO THE FUTURE MIDDLE BRIDGE ACROSS SUNGEI PONGGOL, SENGKANG NEW TOWN, SINGAPORE

he latest technology for monitoring the post- from the riverbanks to the piers. Sheet piles were driven in as temporary earth retaining structures. A construction behaviour of structures is being embedded second layer of sheet piling was used together with into Middle Bridge, currently under construction across two layers of strutting, as a temporary cofferdam T for the construction of the four main pile caps and the Sungei Ponggol in Singapore. BBR Construction Systems piers. The excavated depth to the pile cut-off level Pte is providing technological support and services to the is about 10m and the soil movement monitoring, project which is due for completion by April 2008. which is a requirement for deep excavation works, was carried out throughout for each pile cap As part of the infrastructure development works fabrication and operation of two construction with geotechnical instruments, i.e. for Sengkang New Town, the Singapore Housing pairs of form travellers. inclinometer, piezometer and water standpipe. and Development Board (HDB) decided to SEGMENT CONSTRUCTION POST-TENSIONING construct a vehicular bridge across Sungei Punggol Each bridge consists of 64 segments The post-tensioning tendons consist mainly of 22 to serve the future development in that area. of cast in situ balanced cantilever 15.7mm diameter strands utilising BBR CONA Together with their designer, Surbana prestressed box girder. Segment internal anchorage systems. Hydraulic jacks of 480t International, they designed a pair of three span length varies from 3m to 4m. Cycle capacity are used for the stressing of these tendons. balanced cantilever bridges, with mid-spans of time per segment is targeted at FIBRE OPTIC MONITORING 105m and end-spans of 75m. The width of each seven days on average, with the In collaboration with a local specialist, we have bridge is about 17m. designed and implemented an in situ Structural Singapore Piling And Civil Engineering (SPACE) – Health Monitoring System (SHM) for the Middle a wholly-owned subsidiary of BBR Holdings Bridge. Singapore – in collaboration with BBR Eight types of devices are used to monitor static Construction Systems, tendered for and was behaviours of bridge components and corrosion of awarded this project in September 2006. foundations. Upon completion of construction and WORK SCOPE when the bridge is open to the traffic, dynamic As main contractor for the project, the scope of measurements are required for vibration mode works includes bored piling, earthworks, analysis. The same sensors are used for both static reinforcement and concreting works, box culvert deeper segments at the and dynamic measurements. drains, bearings, expansion joints and, of course, all hammerhead taking slightly more Fibre optic sensing (FOS), the latest technology for the post-tensioning works, including the design, time compared to the smaller SHM, was used in this bridge. For concrete segments towards the mid-span. structures, FOS is embedded into the steel TEAM & TECHNOLOGY FAST-TRACKING reinforcement cage at the concreting stage or, for OWNER The original intention was to existing structures, mounted on the surface of the Housing and Development Board construct one of the bridges first concrete with coating protection. The sensors are and use this newly-constructed accurate, free of calibration, not prone to signal loss MAIN CONTRACTOR bridge as an access for construction over long distances and suitable for long-term Singapore Piling and Civil Engineering of the other one. However, due to usage. G SPECIALIST SUB-CONTRACTOR the time constraints, we decided to BBR Construction Systems Pte Ltd fast-track the works programme by using the form travellers for the mid- DESIGNER span concurrently for the two Surbana International Pte Ltd bridges, using a conventional scaffold TECHNOLOGY system for the end-span. BBR CONA internal WATER WORKS As the four main piers are located in BBR NETWORK MEMBER the river, the method being used for BBR Construction Systems Pte. Ltd. (Singapore) their construction involves backfilling 18 CONNÆCT S G N I D L I U B POST-TENSIONING FOR SLABS Optimising with BBR technology and expertise

esigners, builders, owners and Dusers of buildings require more efficiencies today than ever before. BBR slab post-tensioning systems offer all the stakeholders in a building project many benefits, as well as reducing environmental impacts.

CONNÆCT 19 hether for ground slabs or suspended floors, the advantages to be gained from using post- tensioned solutions are immense. Used for decades in Australia and the United States, Wpost-tensioned slabs are now becoming popular throughout the world, as the enhanced value they deliver is being recognised by clients, developers and construction professionals.

The post-tensioning of slabs is a highly efficient special design challenges necessary multi-storey buildings, a reduction of the floor method that offers many benefits in a wide range to meet all the needs of modern height often permits the addition of one or more of structures, such as residential and commercial architecture. floors – with no increase in total building height. In buildings, industrial floor slabs on the ground, the case of underground structures or slabs on parking structures, water tank bases and MATERIAL SAVINGS ground, PT can lead to reduction in the cost of transverse stressing of bridge decks. A post- Post-tensioned slabs are normally excavation, soil retention systems and dewatering tensioned slab is the perfect balance of concrete about 30% shallower and – due to in areas with high water tables. and steel. Concrete is strong in compression and the fact that prestressing steel has a weak in tension and steel is best used in tension. very high tensile strength which is CONSTRUCTABILITY about four times that of common Post-tensioning can enhance the speed of ARCHITECTURAL FREEDOM reinforcing steel bars – also require construction and overall constructability. High-rise For the same depth, longer spans are possible significantly less steel. With the rising buildings can be constructed very quickly using with post-tensioning. In buildings, this can mean cost of concrete and steel, this can post-tensioned concrete and earlier stripping of larger column-free space as spans up to 15 be a major factor! The reduction of formwork can significantly reduce the floor-to- metres are common in standard post-tensioned slab thickness reduces the building floor cycle time, the need for formwork and the slabs. Post-tensioned concrete can easily be height and consequently the costs of construction time. adapted to accommodate complex geometry and all related building components. In SERVICEABILITY “POST-TENSIONED STRUCTURES DESIGNED AND CONSTRUCTED PT structures are durable and require little maintenance because the compressive forces that WITH A LIFECYCLE APPROACH ARE ENVIRONMENTALLY SENSITIVE are applied to the structure during prestressing AND ACTUALLY SAVE MONEY FROM THE FIRST DAY ONWARDS.” result in better crack and deflection/vibration

Metuljcek, the “little butterfly”, nears completion in the Slovenian ski resort of Kamnik – a commercial and residential development with underground parking which has benefited from a BBR CONA post-tensioned floor solution.

20 CONNÆCT S G N I D L I U B

This distribution centre, approaching 32,000m 2, was constructed for a large superstore retailer in New Zealand. Using BBR-developed special design application software, BBR Contech was able to ensure maximum floor size and a minimum number of joints. The level of post-tensioning varies depending on the rack and vehicle loadings, but tendons are typically configured using BBR CONA flat 405 bonded cables at 1.5-2m centres.

“ ..... BY ADDING EXTERNAL PT TENDONS, THE LIFE ventilation and air conditioning. In that develops with experience OF A STRUCTURE CAN BE EXTENDED WITH parking structures, the openness and sound understanding of post- of post-tensioned designs allows tensioned structures – but it is MINIMAL ENVIRONMENTAL IMPACT.” for improved lighting and more the essential part of a cost- control. Monolithic connections as formwork. The cement man- efficient energy usage and safety. effective and reliable structure. between slabs, beams and ufacturing process is one of the Structures can be easily adapted The BBR Network can offer columns can eliminate main- largest producers of greenhouse for re-use through post- design and construction input tenance-intensive joints between gases and, by increasing the tensioning – by adding external from initial advice to fully elements. slenderness of the structures tendons, the life of a structure detailed design for construction using PT, less concrete, less can be extended with minimal drawings to ensure that the ENVIRONMENTAL IMPACT cement and therefore less CO2 environmental impact. design and floor configuration BBR VT International Ltd’s CEO, is emitted. The reduced floor-to- meets the specified Marcel Poser, states that by floor height results in a smaller WORLD CLASS BBR performance requirements. The carefully considering the entire building envelope that saves KNOW-HOW Network has worked closely lifecycle of a building at the exterior finishing material and Structural detailing and sound over many years with builders outset – from the building place- reduces energy usage for heating, construction practices are an art and construction personnel ment, through the design and resulting in a well understood construction, onto early Benefits of post-tensioned slabs system which enhances the considerations on re-usage and construction process. BBR offers ultimate disposal – post- N Reduced structure depth two specific post-tensioning tensioned structures are systems for slab post-tensioning. N Larger clear spans environmentally sensitive and The unbonded CONA CMM actually save money from the first N Design flexibility post-tensioning system, day onwards. N Formwork versatility consisting of 1, 2 or 4 seven- The correct use of post- wire prestressing mono-strands, tensioning helps lower the N Reduced construction costs where each strand is environmental impact of a N Enhanced construction speed manufactured with a flexible building by reducing the quan- corrosion inhibitor and an tities of steel and concrete used N Improved durability individual HDPE sheathing, and – whilst, at the same time, it N Reduced environmental impact the bonded CONA CMF post- increases construction speed and tensioning system with 1 to 6 reduces the need for N Minimised maintenance costs strands inside a post-grouted construction gear and items such flat steel or flat plastic duct. CONNÆCT 21 hen Subic Naval WBase – the largest American Naval Base outside of the United States of America – was closed in 1991, it was converted into a Free Port. With its natural deep water harbour, international airport and skilled work force, the Subic Bay Freeport Zone has become a major economic hub. To maximise the economic potential of the Subic Bay SUBIC BAY PORT DEVELOPMENT, LUZON ISLAND, PHILIPPINES Freeport Zone and the Clark International Airport Zone – a

PT CONDOMINIUM TRANSFER FLOOR, KUALA LUMPUR, MALAYSIA Alternative advantages

All beam tendons installed before Slab tendons and wall starter bars Stage 1 tendons stressed and forces Heavy duty scaffolds to support half first stage casting installed before second stage casting in props released before Stage 2 of total concrete weight casting

BBR MALAYSIA proposed an alternative design for this PT OPERATIONS backpropping was necessary for project which now uses BBR post-tensioning as The solution was provided by the sixth floor. After stressing of construction formwork and as part of the permanent casting the concrete in two the second stage tendons, all structure – saving costs and creating more space. stages with partial post- falsework was removed and The 12-storey condominium to be carried by many floors tensioning for the first stage. For construction of reinforced walls tower comprises reinforced below as they were only the first stage, concrete was began. concrete walls supporting designed for car park loading of poured up to 0.6m of the beam TOP SCORE reinforced concrete slabs at each 3.0kN/m 2 imposed load – which depth. When concrete strength The moments, stresses and floor. The loads from the walls is relatively light. reached 30N/mm 2, the first deflection of the two stage are transferred at seventh floor ALTERNATIVE DESIGN group of tendons embedded casting were analysed using a level to the car park structure BBR Malaysia proposed an within the 0.6m concrete were prestressed finite element below. The car parking floors alternative design using post- stressed. Next, the screw jacks programme. We also checked were post-tensioned with tensioned beams and slabs. Live of the heavy duty scaffolds were the long term stresses in the grouted tendons. loads from the reinforced loosened. At this point, the structure to carry the service THE CHALLENGE concrete walls sat on the slabs weight of the first cast was loads of the tower. By The original transfer floor or beams. Maximum depth was carried by the tendons back to combining powerful modern consisted of 1.5m deep 1m for beams and 0.5m for the columns – the structure was computer analysis techniques, reinforced concrete beams. As slabs. Post-tensioned flat plates then self-supporting. Next, the along with the strong and well as the disadvantage of were not possible due to the screw jacks were retightened to trusted BBR tendons, we solved reduced headroom below, it irregular layout of columns and receive the impending loads the problem of dealing with the would have been costly to long cantilevers. The post- from the second cast. Thus, the massive concrete loads on provide falsework to support tensioning technology used was scaffolds supported about half of scaffolds and floors below – and, the concrete loads. A third BBR CONA internal 705 tendons the total concrete floor load at at the same time, gave the client problem was the heavy for the beams and BBR CONA each stage of the casting. the added benefit of improved construction loads that needed flat 5x5 tendons for the slabs. Consequently, only one level of headroom. G 22 CONNÆCT Gateway to new economic zone former American Air Base which would be inadequate for the container stacking foundations in and lengths ranging from 6.29m was devastated by the eruption increasing volume of commercial the new container terminals. to 9.10m. The post-tensioned of Mount Pinatubo in 1990, the traffic. To remedy the situation, The total area of the slabs is slabs have widths ranging from 2 Philippine Government is the Philippine Government approximately 47,000m and the 1.5m to 2m and lengths ranging S building the Subic-Clark-Tarlac decided to undertake the Subic total volume of concrete is from 10.5m to 40.8m. G

3 N Expressway Project to link vital Bay Port Development Project. approximately 14,000m . BBR With the successful completion I economic nodes in the central PT SLABS Philippines Corporation of the Subic Bay Port D L part of Luzon Island. Part of the project involved the utilised BBR CONA flat 205 and Development Project, another I DEVELOPMENT PROJECT fabrication of 1416mm to 405 tendons for the post- vital piece of infrastructure has U As shipments for the Clark 350mm thick pre-cast, pre- tensioned slabs. The total weight been put in place that will help B International Airport Zone enter tensioned slabs and the of prestressing steel for the propel the Philippines’ drive the Philippines through the Subic construction of 512 250mm project is more than 500t. towards greater economic Bay Freeport Zone, it became thick cast in situ post-tensioned The pre-tensioned slabs have success. clear that the old port facilities slabs. They form part of the widths ranging from 1m to 2m Mabuhay!

whole of the construction project. HEIGHT RESTRICTIONS The close proximity of the project site to Changi Airport meant that the building would be subject to a maximum height restriction. The major challenge during the design stage was to reduce beam depths and slab thicknesses, so that the overall building height would not exceed the height limits set by the Urban Re-Development Authority – and, at the same time, ensure that the required headroom usage would not be compromised. The adoption of post-tensioning for this project not only achieved the client’s objectives, but the PT solution also meant CHANGI DISTRICENTRE, SINGAPORE that the resultant smaller structural member size and thinner slabs reduced both foundation load and overall LOGISTICAL GOAL building cost. G TEAM & &P Changi Districentre is a massive six-storey building – the tallest TECHNOLOGY warehouse in Changi South Road, located in the eastern part of CLIENT CSingapore. BBR Construction Systems Pte Ltd reports that it was C&P Holding Group completed and successfully handed over to the client early in 2007. CONTRACTOR JH Builders Pte Ltd The client was C&P Holding hub for life sciences materials systems in all the horizontal Group – the largest logistics, and medicine to the Asia-Pacific elements for the entire TECHNOLOGY transportation and warehousing Region. warehouse. The 50,000m 2 BBR CONA internal development company in TEAM & PROJECT warehouse scheme consisted of BBR CONA flat Singapore. The anchor tenant is BBR Construction Systems Pte four zones – warehouse, BBR NETWORK MEMBER an established US logistics Ltd was engaged by JH Builders driveway, ramp and ancillary BBR Construction Systems company, TNT, who uses this Pte Ltd to design, supply and office – and there was a 12 Pte Ltd (Singapore) warehouse as a transshipment install the post-tensioning month programme for the CONNÆCT 23 Complex and

challenging project

THE LINKS SEASIDE, WOLLONGONG, NSW, AUSTRALIA he Links Seaside, is a new residential development located the head consulting engineers, architect and the services consultants. in Southern New South Wales on Wollongong Golf These revisions led to significant changes in the Course and overlooking City Beach. The Links Seaside will concrete outlines which were approved by all T relevant parties. The podium level consists of 14 offer residents spacious, luxurious surroundings combined with a pours which have been separated by construction wide array of services and first class recreational facilities. Sam joints and expansion joints. Fassaie of BBR Network member Structural Systems Limited EXPANSION JOINTS Though corbels are generally the most common (Australia) gives an overview of the project. option for expansion joints, because of Structural Systems was awarded the design and accommodate shearheads, two architectural considerations, corbels could not be construction for the post-tensioning of the layers of mesh (top and bottom), designed for all expansion joints in this slab. project by Wideform Constructions. This top and bottom reinforcement in Therefore, the application of shear connectors included the basement raft slab (12,850 m 2), 400mm and 550mm thick slabs, with high shear capacity in some expansion joints ground floor podium (12,560 m 2) and Building C and the post-tensioning tendons was essential, given free horizontal movement in – Level 1 (3,560 m 2). running both directions required both directions had to be achieved. SOIL CHALLENGES days of discussion, planning and co- Building C, Level 1 consisted of seven pours As the site soil conditions were not quite suitable ordination. Thanks to the expertise which were designed and constructed for such a large scale development, detailed of those involved on the project, simultaneously with the ground floor slab. design co-ordination was required between there were minimal problems on Similarly, shear connectors were applied in the Structural Systems and the geotechnical and head site during construction. expansion joints in this level. The construction of consulting engineers. To avoid excavation in the COMPLEX PODIUM Level 1 slabs was completed in June 2007. G existing loose ground, it was decided that the The ground floor (podium) slab optimum solution would be a 400mm to 550mm posed very complex concrete thick post-tensioned raft slab. The magnitude of profiles due to the combination of TEAM & TECHNOLOGY the transfer loads dictated that Structural down-turn and up-turn beams, OWNER Systems’ design team should select strands with rebates, folds, steps, varying slab Wideform Constructions higher tensile strength in order to avoid tendon thicknesses, diagonal beams – and congestion. the multitude of transfer columns CONTRACTOR DESIGN SHEAR on the slab. Similar to the Wideform Constructions There were serious punching shear problems in basement slab, strands with higher DESIGNER the basement slab which did not allow the tensile strength were used. Structural Systems Limited (Australia) conventional use of closed ties or stud-rails. The slab thicknesses and the beam TECHNOLOGY Instead, shearheads made of steel profiles were sizes were reviewed by the BBR CONA flat devised to resist the punching shear forces. This, Structural Systems’ design team to however, made the design, detailing and, in create the optimum design for the BBR NETWORK MEMBER particular, the installation of post-tensioning ground flood slab. This had to be Structural Systems Limited (Australia) tendons on site very complicated. In order to carried out in co-ordination with 24 CONNÆCT RESIDENTIAL & COMMERCIAL PROJECTS, UK Embracing S

PT floors G N I D L I U B

Bridgewater Place in Leeds, pictured here, is one of three major residential schemes undertaken in recent months as the UK construction market starts to embrace the advantages of post-tensioned floors. On the following pages, the team from BBR Network member Structural Systems (UK) Ltd takes up the story.

CONNÆCT 25 Bridgewater Place is a BRIDGEWATER PLACE, LEEDS, UK RESTRAINT SOLUTION The office levels comprise two graceful yet awe- floor plates which measure inspiring 32-storey 120m by 17m and 76m by 17m. tower development in Graceful & Both blocks contain two reinforced concrete cores and, in the business quarter of order to solve the restraint Leeds, one of the UK’s awe-inspiring issue, Structural Systems intro- duced a temporary movement principal northern cities, joint across both floor plates. reports Kevin Bennett, This comprised sleeved dowels Technical Manager of crossing the construction joint between two pours. Once Structural Systems sufficient slab shortening had (UK) Ltd. Located just occurred – 28 days after stressing the second pour – the minutes from the rail sleeves were grouted to lock the and motorway joint and restore structural connections, it has integrity to the floor plates. FAST BUILD already attracted a It was important to construct major firm of solicitors the building quickly and the reduced quantities used in PT as main tenants. construction helped P.C. The nine lower storeys house Harrington (Contractors) 23,000m 2 of high quality office Limited, the concrete frame space in two buildings separated contractor, achieve floor-to-floor by the largest feature atrium in cycles of just three days. Leeds – 1,500m 2 of retail and The project is now completed leisure facilities are also and the majority is let ... but, if contained in these lower levels. you’re really quick, you may just Rising majestically and offering be lucky enough to catch one of superb panoramic views, the the panoramic penthouses on residential tower provides 200 the 32nd floor! G luxury apartments within its additional 23 levels. The basement offers 400 car parking spaces. It is estimated that Bridgewater Place will accommodate 3,000 people per day in its iconic 110m tall structure. MAXIMISED FLOOR SPACE Consulting engineer Mott Macdonald selected post- tensioning for the slabs in order to maximise the floor space TEAM & TECHNOLOGY available within the building Technical details envelope – the thinner slabs Typical loading for the offices is 4.0kN/m 2 (live) and 1.5kN/m 2 OWNER St James Securities/Landmark allowing more storeys to be (dead superimposed) and this requires 225mm thick PT slabs to Development Projects accommodated in a given height. span the 9m by 7.5m grid, a span-to-depth ratio of 40. Plant A second significant benefit was loading (7.5 plus 2kN/m 2) necessitated slab depths of 270mm on CONTRACTOR the vast reduction in steel levels 9 and 10. Tendon spacings vary between 800-1000mm for Bovis Lend Lease content that post-tensioning column strips and 1500-1700mm for middle strips, leading to a DESIGNER brings, with the project being P/A of 1.7MPa in the longer span direction and 1.5MPa the Connell Mott MacDonald started when world steel prices other way. were very volatile. The The residential floors are 17m wide and range in length between TECHNOLOGY reduction in financial risk by 46m and 40m. Slab depth stayed at 225mm for the residential BBR CONA flat selecting post-tensioning was a loading (1.5 plus 1.5kN/m 2) in order to control deflections for BBR NETWORK MEMBER factor in deciding to proceed the cladding. Structural Systems (UK) Ltd with the project. 26 CONNÆCT QUEEN STREET, PORTSMOUTH, UK NEW WAVE elegance leek, stylish and with award-winning Sarchitecture, the vision for Queen Street is to make a positive contribution to the S skyline of Portsmouth. At the same time, the G N scheme is focused on providing unsurpassed I value-for-money homes which complement D L the surrounding area and are sympathetic to I historic landmarks, whilst being central to U the regeneration of the city and harbour. B Kevin Bennett,Technical Manager and Alina Wiaz, Project Design Engineer – both from STRUCTURAL SYSTEMS UK LTD – tell how this major project is shaping up. The Queen Street scheme is part of a new wave of very large projects currently being constructed by Ardmore Construction. This superb develop- ment, being constructed in two phases, is Ardmore’s first using post-tensioning. They were persuaded to go with PT by structural engineers Cameron Taylor who had used it on the earlier Montrose Place project in London – another Structural Systems UK job. PROJECT DETAILS The project comprises the construction of 569 apartments in 17 buildings up to seven storeys CONA flat 505 bonded tendon “POST-TENSIONING WAS high – arranged around the perimeter of the site – system, Comprising up to five INTRODUCED TO THIS PROJECT plus a landmark tower 22 storeys high. A two level 12.9mm diameter high yield strands BECAUSE OF TWO OF ITS CLASSIC car park covers most of the site area with upper inside a flat galvanized steel duct. ATTRIBUTES – THIN SLABS FOR floor private gardens within the centre of the After stressing, the ducts are development. Retail units occupy the ground floor injected with cement grout to LONG SPANS, PLUS VERY LITTLE of some of the buildings. provide bond and corrosion CONVENTIONAL REINFORCEMENT.” The two storey car park is formed from 225mm protection. thick post-tensioned concrete slabs with an MEETING CRITERIA movement joints, back to supports. entrance at ground level. The roof of the car park, The uplift forces generated from the Structural Systems UK’s in house design team in in the centre of the development, is used to parabolic tendon profiles balance Southall has designed all of the post-tensioned support landscaped gardens and these PT slabs are much of the dead loadings. This slabs and, as the project nears completion on site, 350mm thick. means long-term creep deflections the tall ships in the adjacent historic dockyard will CLASSIC ATTRIBUTES are virtually eliminated allowing the soon be complemented by this elegant and Post-tensioning was introduced to this project stringent deflection criteria of the modern addition to the Portsmouth Skyline. G because of two of its classic attributes – thin slabs curtain walling to be achieved for long spans, plus very little conventional without edge beams. Eliminating reinforcement. This permits fast construction times. edge beams is important to allow TEAM & TECHNOLOGY The site is in the centre of Portsmouth and the the table forms to be used at their OWNER reduced quantities of concrete and steel in a PT optimum efficiency. Crest Nicholson job also have a direct benefit on traffic volumes in The post-tensioned flat slab such city centre locations. thicknesses are typically 225mm for CONTRACTOR The post-tensioning system adopted is the BBR a 7.5m by 7.8m grid. Occasional Ardmore Construction Ltd spans of up to 10.2m are handled ARCHITECT by locally thickening the slabs to David Richmond & Partners 275mm. The strength of concrete DESIGNER used in the design of post-tensioned Cameron Taylor floor slabs is 40 N/mm 2. The vast 200m by 100m develop- TECHNOLOGY ment is divided into 17 separate BBR CONA flat buildings by movement joints. Shear BBR NETWORK MEMBER connectors are being used to Structural Systems (UK) Ltd transfer shear across many of these CONNÆCT 27 HAYES CENTRAL, MIDDLESEX, UK OPTIMISED for speed

tuart Crole, General Manager of Structural Systems (UK) Ltd reveals the story of how a different type of Ssteel has started to sprout from the ground of the old scrap yard at Hayes, in Middlesex.

As an up-and-coming area, the site the UK and SDS in Poland. The slab represented prime development land – depths vary depending upon loadings and, being located adjacent to the and include a 210mm slab, 225mm for Grand Union Canal and Hayes and the internal podium and the Harlington Station, the location residential/hotel slabs, and a 300mm provides easy access into London. for the podium slab where this is SCHEME OVERVIEW externally located. TEAM & TECHNOLOGY The 72,100m 2 Hayes Central scheme The average pour size of the scheme is OWNER comprises seven blocks of mainly 520m 2 – with around 13 pours per Ballymore Properties residential units – with one block floor for the residential areas, 12 pours providing a hotel on the complex. The for the mezzanine and 18 pours for CONTRACTOR majority of the blocks spring nine level 1. The scheme features some Ballymore Properties (main) floors from a podium deck at level 1, 72,100m 2 of post-tensioning. P.C. Harrington Contractors Ltd (frame) with one rising to ten floors. The FAST & SIMPLE DESIGNER mezzanine level provides parking for Discussions with the frame contractor, Walsh Associates (Structural Engineer) the residents and the hotel. P.C. Harrington (Contractors) Limited, Structural Systems (UK) Ltd & SDS PT DESIGN resulted in minor changes to provide a (Poland) (slab design) The initial scheme was designed by faster and simpler construction TECHNOLOGY Walsh Associates as a post-tensioned process, which delivered programme BBR CONA flat solution, typically utilising an 8.35m by benefits. 6m column grid. The final post- Post-tensioning, which uses the BBR BBR NETWORK MEMBER tensioned slab design is being CONA flat fully bonded system, is due Structural Systems (UK) Ltd constructed by a combination of SSL in to be completed in July 2008. G 28 CONNÆCT S S G E N G I D D I L I R U B B

Stringent deflection requirements from the clients were achieved for all slabs and bands, the inter-floor differential deflection was especially strictly controlled to suit the high standard of glass and stone façade. Great and timely efforts were made by Structural Systems to ensure all special details – such as security, fire, temporary and permanent joints etc – were well-incorporated by the post-tensioned floor systems, ultimately ensuring that the building THE PRIME MINISTER’S OFFICE, CANBERRA, AUSTRALIA was finished to the highest possible quality. G Great and timely efforts onstruction of the offices, at 1 National Circuit in Canberra, for the Prime Minister of Australia and his CCabinets has been completed. Carl Xu of Structural TEAM & TECHNOLOGY Systems, the BBR Network member in Australia, explains the OWNER Industry Superannuation Property Trust challenges of this prestigious project. CONTRACTOR The building consisted of five levels of offices economic and structural benefits, Bovis Lend Lease and two car park basement levels – with a total but also ensured construction DESIGNER of 28,300m 2 of post-tensioned slabs. speed and high quality of Peckvonhartel In view of the regular column grids and large construction work. The bonded TECHNOLOGY span arrangement design, a one way post- BBR CONA flat anchorage post- BBR CONA flat tensioned banded slab floor system was tensioning system was used suggested by Structural Systems and approved throughout the project. Around BBR NETWORK MEMBER by the builder Bovis Lend Lease. The one way 200t of PT strands were used in Structural Systems Limited (Australia) banded floor systems not only provided the project. CONNÆCT 29 he post-tensioning works on NASA Structural Systems LLC was Tthe 44-storey high-rise tower contracted to undertake the design, of the Lake Terrace project in supply and installation of 205t of post- Dubai has been completed, tensioning – covering a total area of reports Warwick Ironmonger of approximately 46,500m 2. NASA Structural Systems LLC. Situated in the 730,000m 2 Jumeirah TECHNICAL REQUIREMENTS Lakes district of Dubai, the high-rise The typical residential levels consisted tower will overlook the 116,000m 2 of 500mm deep by 1800mm wide man-made lake and the project will be post-tensioned band beams, spanning surrounded by extensive lawns and 13m between supporting shear walls, recreational parks. whilst supporting the 180mm post- tensioned slabs. However, plant floor OPTIMUM SOLUTION WITH PT requirements necessitated the Lake Terrace is a marvel of contemporary implementation of a 400mm thick – architecture. Due to the unusually long essentially one-way – post-tensioned spans, post-tensioning was the optimum flat slab, spanning the 13m between solution. In addition, it provided a the supporting shear walls. manageable and economical structure The 206 and 506 slab anchorage tendons, whilst maintaining sufficient facilitating a reduction in floor-to-floor systems were combined effectively to concentration of the tendons within construction cycle times. permit significant spacing of the slab the beams. G Modern marvel LAKE TERRACE, DUBAI, UAE

TEAM & TECHNOLOGY OWNER DAMAC Properties CONTRACTOR Al Hamed Development & Construction Co. China State Engineering & Construction Co. DESIGNER WS Atkins & Partners Overseas TECHNOLOGY BBR CONA flat BBR NETWORK MEMBER NASA Structural Systems LLC (United Arab Emirates)

30 CONNÆCT S G N I D L I U B

FLOORING successes

ver the past few years, BBR Contech has worked with a number of New Zealand’s best known businesses to design and install post-tensioned floors. These Ohigh-performing systems are ideally suited to large commercial and industrial environments, offering a total absence of joints – the single largest contributor to failures in traditional floors – a smooth appearance, high resistance to applied loading, easy care and long-term durability.

CONNÆCT 31 BBR Contech has designed “YOU (AND THE BBR MEGAFLOORS FOR MEGASTORES and installed post- CONTECH TEAM) WERE, BBR Contech’s association with DIY giant Mitre 10 tensioned building solutions AS ALWAYS, ABLE TO continues with three new projects in Upper Hutt, New for all types of businesses, Plymouth and Ferrymead – bringing the tally to 12 including those in the DO BETTER THAN PRO- stores nationwide. The floors are ideally suited to the logistics, distribution and GRAMME WITH A MIND- company’s megastores, offering a smooth surface for retail sectors – they all SET AND KNOWLEDGE retailing, storing and moving goods and materials. share market-leading BASE TO MATCH.” Averaging 6,500m 2 in area – and requiring pours of reputations – and a need 500-600m 3 of concrete – other post-tensioned floors for high quality floors. located at the entrance of the can be found in megastores in Hastings, Napier, PREMIUM SOLUTIONS business park and is a prime Petone, Wanganui, Nelson, Hornby, Dunedin and East The direct motorway access to example of the quality of tenant Tamaki and Papakura. Highbrook is now operational, that clients can expect in this The latest three stores are being built by Armstrong giving direct and fast access to development. Downes (Upper Hutt) and Calder Stewart (New this world class business park The facility has been rapidly Plymouth and Ferrymead). comprising some 150 hectares expanded and two warehouse of premium commercial extensions have been added in property. Located alongside recent times, bringing the total water and green open spaces – post-tensioned floor area to and just 15 minutes from the some 30,000m 2. Auckland Central Business These impressive modern District (CBD) and airport, commercial facilities were Highbrook has attracted some designed by MSC Consulting and of New Zealand’s leading constructed by Haydn & Rollett. companies such as DHL, NZ The floors were installed by full Post and BMW. delivery contractor Conslab, The award-winning layout has with BBR Contech providing the been developed by Goodman post-tensioning services. Ltd – one of Australasia’s GROCERY PACKAGE premier developers. The site has Foodstuffs’ is New Zealand’s a commercial land area of 107 largest grocery distributor and hectares with an additional 40 its newest warehouse, com- hectares of public park space, pleted early in 2007, is located in esplanades, sports fields and Hornby, Christchurch. 14km of walkways. Working as a subcontractor to With a strong commitment to full delivery floor specialist, quality and innovation, Goodman Conslab, BBR Contech’s job was has selected post-tensioned to install post-tensioning for a floors for many of the 10,700m 2 floor slab designed by Highbrook development sites. consultant Evans Douglas. The DHL was one of the founding 180mm slab was poured in tenants and its first warehouse three stages and used five-strand boasted a 14,000m 2 post- tendons as well as conventional tensioned floor. DHL is proudly reinforced steel. 32 CONNÆCT S G N I D L I U B

“Further to completion of the above project, we write to express our house and construction company appreciation for the way in which Conslab carried out their Naylor Love. A smooth, durable subcontract for this project. The client set a challenge to our and joint-free surface is just what company to deliver completion in a very short time frame. We is required to cope with the achieved the completion date with the help and commitment of many customers visiting the store Conslab. The quality of the finish achieved was excellent and we each day. have received compliments from our client for the high standards of Soon after completion, BBR workmanship delivered. We are proud of the result achieved on this Contech’s Northern Regional project as you should be, and we look forward to working with your Manager, Keith Snow was de- company on future projects. Please pass on our appreciation to all lighted to receive a letter from your staff involved.” Steve Walker, Naylor Love’s The main building contractor, Paul Blackle, General Manager Construction Contracts Manager: “Keith, a big Armitage Williams Construction & Mark Blyth, Director thank you for Contech’s involve- was very pleased with the Armitage Williams Construction ment in The Warehouse Sylvia performance of the flooring team Park. You (and the BBR Contech and praised those involved in the team) were, as always, able to do project. in the new flagship store, The maintenance but also a rein- better than programme with a BBR Contech has worked in Warehouse Extra. forcement of The Warehouse mindset and knowledge base to close partnership with Conslab The 10,000m 2 joint-free expanse brand – a result BBR Contech match. A pleasure to deal with on a large number of post- offers not only great aesthetics has already achieved in a number you and a successful outcome. A tensioned slabs throughout New and minimal requirements for of other projects with The Ware- job well done.” G Zealand and is pleased to be associated with another successful project. Following on from this, another Foodstuffs’ project is currently under construction and the latest building is a very large scale distribution centre. With a total floor area in the vicinity of 40,000m 2, this will be one of the largest post-tensioned slabs on grade installed in New Zealand to date. Completion is scheduled for 2008. SMOOTH SHOPPING Auckland’s latest shopping destination, the magnificent Sylvia Park, is proving a huge attraction for shoppers throughout the city – and BBR Contech is delighted to have made the “trolley experience” a little smoother for many, with a post-tensioned floor CONNÆCT 33 Winning hearts and minds

TEAM & TECHNOLOGY DEVELOPER Zagrebparking, Croatia CONTRACTOR Tehnika, Zagreb DESIGNER APZ-inzenjering, with Dreibau Ingenieurs Conseils (Switzerland) TECHNOLOGY BBR CONA unbonded BBR NETWORK MEMBER BBR CONEX (Croatia)

100cm deep one-directional ribbed slab with V- shaped ribs at 120 cm. Just think of all the TUSKANAC PARKING GARAGE, ZAGREB, CROATIA formwork that would have been engaged for three whole weeks at a time – enough time to complete he Tuskanac parking garage five or six formwork cycles with BBR’s PT solution! in Zagreb provides parking MULTIFUNCTIONAL PT SAVINGS SOLUTIONS Post-tensioning was, once again, chosen for its T for 475 vehicles on five BBR CONEX and Dreibau structural and economical benefits. After the initial levels and incorporates a green offered a cast in situ solution adjustments, in terms of execution and with a one-way 14cm slab – technology, the contractor started “stacking” the roof with a promenade, pedestrian giving a 60cm deep slab and slabs in three weeks each, along with adjacent walkways and a basketball pitch. It beam section – 40cm or structures – walls, columns, stairs and ramps. Post- 50cm wide beams spanning tensioning also permitted increased floor-to-floor includes all parking, auxiliary areas, 16m and spaced at 4.8m. The heights and delivered savings in building weight. In plant installations and a car wash. beams are thicker over the addition, the 1.0MPa precompression in the Damir Paviãiç of BBR CONEX supports allowing the system garage slabs helps to control cracking and creates to provide increased shear a more durable driving surface. describes his company’s fifth project capacity which is needed to Much effort was spent on detailing for the release with unbonded post-tensioned produce flexibility of use. of the slab edges and beam ends, in order to The complicated car park minimise deflection – from the rigid walls and slabs. design meant that the massive basement mat – on the slender slabs. The 18.5m high structure consists of a basement majority of the beams would Each slab had a pour strip on one side, to allow mat, four floor slabs and a roof slab – with a 35m cover just one 16m span. simpler side stressing and to allow releasing. Pour by 78m footprint. Enclosed areas account for Beams were stressed from strips were left open for 14 days. 13,330m 2 and there is a further 2900m 2 of roof the top stressing pocket, as NEW ERA DAWNS and ramps. Structural features include sloped there was no room for side Just as on our earlier projects, the slabs were put slabs with circular traffic access to the various stressing. Deflections of the to the test. They were tested twice with water levels – this is a patented car parking solution by structure were minimised by and, once the tendon stressing had been applied, Hill Cannon of London. pre-cambering the formwork they were monitored in detail. The slabs behaved The Tuskanac structure started to grow in April for 80mm in the midspan of in a fully elastic manner, with deformations being 2007 and was completed in the autumn – a six the beams – which, at the fully returnable in two to three days. month programme involving some 7,500m 3 of same time, solved the Over the last few years at BBR CONEX, we had concrete and 800t of reinforcement, together drainage problem! been wondering how many projects we would with a reinforced concrete basement mat. have to do for the scepticism about post- FITTING DESIGN included narrow streets, restricted tensioning to fade away. However, by the end of Slab design was carried out in conjunction with site access, a high water table, this project, public and professional opinion in Swiss-based Dreibau Ingenieurs Conseils. Five minimum total building height – to fit Croatia started to change and it can be said – floor slabs were post-tensioned, each in with the nearby historic part of without any modesty – that 2008 will see BBR approximately 2,500m 2 in ground plan – and Zagreb – low maintenance and CONEX as the prime mover in changing the face which consumed 40t of BBR CONA unbonded moderate final cost of the structure. of modern civil engineering within the former tendons. Design and construction challenges The original design included a 70 to Yugoslavian territories! G 34 CONNÆCT WOOLWORTHS REGIONAL DISTRIBUTION CENTRES internal warehouse slabs as 160mm thick. These slabs were designed for racking post loads Impressive of up to 6.6t plus 6t axle loads from pallet forklifts. The external pavements were designed as

150mm thick post-tensioned S

solution G slabs, allowing for standard T44 N

Truck Loading. Joints in these I

slabs were typically spaced at D L 50m centres. I REPEAT BUSINESS U Our first Woolworths project B was at Warnervale, New South Wales. The client was suitably impressed with our post- oolworths is Australia’s largest grocery retailer. As part of its expansion tensioned solution and chose to program, reports Ian Gibbon of BBR Network member Structural use the Structural Systems post- W tensioned solution on their next Systems, Woolworths embarked on a plan to establish Regional Distribution two distribution centres at Centres throughout Australia to streamline their logistics operations. Woodonga in Victoria and Minchinbury in New South The Regional Distribution engineered subgrade. Structural number of joints in the slabs Wales. Centres are large storage ware- Systems offered an alternative would also save them money on Structural Systems has designed houses surrounded by external post-tensioned design for these future joint maintenance. over 140,000m 2 of slab on heavy duty truck pavements. The slabs using the BBR CONA flat Woolworths spend over $3.00 ground for these three projects. warehouses have sophisticated system. Our post-tensioned slabs per square metre per annum on Woolworths were pleased with pallet racking systems, enabling were thinner with less joints and joint maintenance for con- the substantial cost savings and the fast turnaround of goods to with a reduced volume of engi- ventionally reinforced slabs. Our the performance of the slabs Woolworths’ retail stores. neered subgrade. Our alternative post-tensioned slabs typically and recently decided to construct ECONOMIC ALTERNATIVE design resulted in significant cost reduce the number of joints in their most recent distribution Both the internal warehouse savings for the client. these slabs by around 90%. This centre at Laverton in Victoria slabs and the external truck LONG TERM SAVINGS leads to significant future main- with our post-tensioned solution. pavements were originally Woolworths acknowledged that tenance savings for the client. This is another 42,000m 2 of designed as reinforced slabs over the major reduction in the Structural Systems designed the warehouse slab on ground. G CREATING a new town major project, bonded, slab which revolve around a Town system post-tensioned cast-in- Centre. situ concrete is by far the most The Rouse Hill Town Centre will common method of con- evolve over a number of stages. struction of suspended shopping Stage 2 will include a residential centre floors in Australia. and commercial sleeve around The concrete outlines are mostly the perimeter of the Town continuous, one-way spanning Centre, to serve as a screen and slab and band beam structures. add to the level of diversity. G The entire post-tensioning scope was entrusted to Structural Systems under the Strategic Facts & Figures Procurement Alliance between Bovis Lend Lease and Structural N 65,000m 3 of concrete Systems. N 1,000t BBR CONA flat ROUSE HILL PROJECT The site of the Rouse Hill Chris Harris of BBR Network Almost 1,000t of BBR CONA Regional Centre consists of N 5,300t conventional member, STRUCTURAL flat bonded post-tensioning was approximately 100ha of green- reinforcement SYSTEMS, describes his shop drawn, procured, supplied, field land and involves the N 270,000m 3 earthmoving company’s work on Stage 1 of installed, stressed and grouted by development of a new planned N 1,700 reinforced cast-in- the Rouse Hill Project, located Structural Systems within seven community, including situ concrete piles. northwest of Sydney, Australia. months. Used exclusively on this approximately 1,500 homes CONNÆCT 35 Key role FOR GROUT ince the introduction of post-tensioning technology in the construction market about 60 years ago, its evolution has been continuous in terms of performance and durability. In this context, it must be acknowledged that the efforts over so many years have heralded Smajor improvements in the materials, products, specifications and working procedures. Local standards and regulations was not a concern – in the sealed ducts and good quality KEY ELEMENT were being adapted, at the same sense that it was considered an grouts. The erstwhile design When looking at corrosion time as the technological intrinsic feature of the principles have been refocused protection for bonded tendons advances were being made in technology itself – just as with to improve durability – and items as a whole, grout is a key post-tensioning systems. There is reinforced concrete. such as waterproofing, drainage, element. This is the last absolutely no question about the Practical experience in the last concrete cover and concrete protection layer in the fight to economic and technical efficiency few decades has demonstrated quality are taking a higher profile. prevent corrosion and to of post-tensioning technology – this belief to have been ill- In the case of PT, this has been improve durability. For unbonded and this is the reason that the founded and has forced a more provided with a first protective systems, soft filling materials such time, cost and energy which holistic consideration of barrier against corrosion – as grease and wax or plastic have been poured into develop- durability – as a problem relating namely, grout. The second sheathing fulfil this function. ing the technology further are not only to the PT system in protective barrier is provided by Grout has two main tasks in a totally justified. A further advan- isolation, but also to the the duct. Commonly used metal bonded tendon: tage of technological develop- concrete structure as a whole. corrugated or smooth ducts do N To protect the prestressing ment has been the ability to deal MULTILAYER not necessary constitute steel from corrosion. with issues surrounding durability PROTECTION permanent corrosion protection. N To provide the necessary concerns in particular. With the introduction of the So, to mitigate the risks, the bond between the strands HOLISTIC multilayer protection strategy, sealing of the ducts – and the and the structure member, in CONSIDERATIONS protection against corrosion is entire tendon – has been accordance with the design. In the early projects carried out provided by waterproofing, improved, and the use of plastic Cementitious grout provides using PT technology, durability dense impermeable concrete, ducts has been introduced. excellent protection for

Top of page: Full scale testing of new grouting procedures. Bottom: Examples of tests for extended performance and height.

36 CONNÆCT prestressing steel, thanks to the were found to prompt a review grout and grouting process to Whilst no single protection S highly alkaline environment of the quality of the grout be fully compliant with all of the layer will guarantee durability, which passivates it against specified for use – but most of demanding requirements a good quality grout and O corrosion. All the analysis all, of the grouting practice itself. contained within the new good grouting practice are of L I demonstrates that the vast QUALITY BBR GROUT standards – even long before prime importance for the majority of PT structures have Throughout the years, the BBR they came into force. The BBR robustness of any post- S behaved satisfactorily – experts have been working to Network was so conscious of tensioning installation. Grout demonstrating excellent produce a truly remarkable the importance of this aspect, can provide excellent & durability of the post-tensioning grout in terms of quality – using that most grout tests – which protection for post-tensioned tendons with, at the very least, prime products in the market, nowadays are compulsory – had, structures – even more than S good design principles and best leading equipment and grouting for some years, already been any other protection layer – K practice installation techniques. technology. conducted on most projects as and this vital tool is in our N However, enough deficiencies This has made it possible for our a BBR internal requirement. hands! G A

FOURTH LNG TANK, CARTAGENA, SPAIN out in sequence with T construction because of the forces applied to the structure. Special grouting operation The agreed sequence began with the stressing of some horizontal tendons and the next stage was to stress the first half of the vertical loops. Afterwards, half of the horizontal tendons were stressed before the second half of the vertical tendons. Finally, the lowest horizontal cables, beside the access doors, were stressed. GROUTING OPERATION When considering corrosion protection of the cables, our main concern was the grouting of the 40m high vertical loop tendons. We decided to use a special grout – specified in ETAG - 013 clause c.4.3 – combined with a specific method for the grouting of vertical tendons. The chosen grout was made he fourth tank in Cartagena is a 40m high, 78m diameter cylindrical with Portland cement I-42.5, Tconcrete tank constructed to store Liquefied Natural Gas (LNG). thixotropic admixture and water (w/c=0.44). In addition to the David Olivares Latorre of BBR PTE – the BBR Network member in Spain – standard tests for grout, we reports that, in total, more than 600,000kg of post-tensioning steel, for both constructed a battery of inclined tube tests and wick-induced vertical and horizontal tendons, was used for the project. tests to demonstrate the The prestressing system used PT DESIGN by hanging the strand pushing suitability of the grout – and was 0.6” diameter BBR CONA Foundation slab rings consist of machine from a crane while the obtained excellent results in for cables with 15, 19 and 24 horizontal tendons made with operators were on an elevated terms of bleeding, change of strands. galvanized duct. Meanwhile, the platform. The pushing machine volume and workability. The interior prestressing vertical loops have an inferior was tied onto the tank to keep The specific method designed consisted of: curve also made of galvanized it stable. Meanwhile, the vertical for vertical tendons was the N three foundation slab rings – duct – and the remainder of the cable loops were pushed by wringing method which involves 24 M2406 anchorages in vertical straight design consists means of a flexible duct situated forced bleeding of the grout to 135m tendons of 8m of 104mm diameter rigid between the M1906 anchorage force water out of the tendon N cylinder horizontal wall – 288 ducts connected to each other and the pushing machine. and through the wires of the M1506 anchorages in 130m by male-female ends. In addition, SEQUENCED STRESSING strands at the upper anchor tendons each joint is covered with a The foundation slab rings were head. The result is the complete N cylinder vertical wall – 144 thermo-shrinking sleeve. stressed before construction of elimination of any possible water loops with over 90m in each STRAND PUSHING the tank. Stressing of the seepage at the top of the and 272 M1906 anchorages. Horizontal cables were pushed remaining tendons was carried tendons. G CONNÆCT 37 “SHARING THE BBR PTE TEAM’S EXPERIENCE ... HAS BEEN THE MOST IMPORTANT CONTRIBUTION WE HAVE MADE ON THIS CURRENT CONTRACT.”

This 180m long gravity-based structure will be towed, when complete, to its intended offshore location – in 30m deep Adriatic waters, 17km from the Italian mainland, between Venice and Punta della Maestra in Rovigo. BBR PTE has been working on this project as part of a joint venture – PT Adriático UTE – which is tasked with post- ADRIATIC LNG TERMINAL SPAIN-ITALY tensioning works for the scheme. INNOVATIVE TECHNOLOGY Construction of this unique gravity-based Shared experience structure has employed innovative technology – and approaching 4,000t of prestressing steel! s reported in the last edition of CONNAECT, the world’s BBR CONA anchorages were installed in a number of horizontal tendons. In all vertical loop first offshore LNG terminal – the Isola di Porto Levante tendons BBR rigid ducting was used. terminal – has been under construction in a dry dock The threading of the cables was carried out A strand-by-strand, even for the vertical loops. near Algeçiras, Spain. Andrés Soriano of BBR PTE now brings us a Special grout, as specified in ETAG 013, was used further report about the project as it nears completion and how – and full-scale tests (horizontal and vertical) his company’s earlier experiences combined with best-in-class were carried out prior to starting field grouting. Thixotropic grout was used for the horizontal and BBR technology to steer the best solution for the challenge. vertical tendons.

THE MONACO Challenge

he huge floating breakwater, made in Spain for the Government of Monaco, was designed to expand the Tprincipality into the sea and double the size of its La Condamine Port, making it possible for large cruise liners to dock. The completed wharf has four levels, a storage area for boats and a multi-storey car park as well as several shops and restaurants.This innovative construction project which had a 100-year lifetime requirement was carried out as two separate contracts – one for the fixed structure and another for the floating breakwater. The latter contract was secured by a consortium including FCC Construccion – and for which BBR PTE carried out the challenging post-tensioning work. In 2006, the project was recognised as an “Outstanding Concrete Structure” through a prestigious award from fib (The International Federation for Structural Concrete).

38 CONNÆCT The Adriatic LNG Terminal contains two Facts & Figures nickel-steel LNG storage tanks with a total 3 Horizontal tendons working capacity of 250.000m , TYPE 19, 0.6” DIAMETER approximately twice the capacity of a N Galvanized sheath ...... 147,370m typical LNG carrying ship. N Slabs ...... 1,706t important contribution we have N Walls ...... 1,183t S made on this current contract. S N Beams ...... 192t O NETWORK STRENGTH E Vertical tendons L G The long experience and expertise I

TYPE 19, 0.6” DIAMETER S D

& TYPE 12 0.6” DIAMETER of Norwegian BBR Network I & Rigid tubes ...... 44,183m member, KB Spennteknikk, in TEAM & TECHNOLOGY R S Loops ...... 769t providing bearings to enable B

OWNER K Prestressing steel flexible nodes for international

ExxonMobil (45%), Qatar Petroleum (45%) and N Total quantity ...... 3,850t offshore applications was harnessed

Edison (10%) A

for the Adriatic LNG project. A T For the grouting of vertical cables, the wringing total of 53 special marine TOBE CONTRACTOR Aker Kvaerner method was used – in combination with the pot bearings were designed and sucking out and flushing method. However, for produced in Norway and DESIGNER the horizontal cables the vacuum method was transported to Algeçiras for Aker Kvaerner chosen. This obviated the need to use installation. The fixed bearings are GBS CONTRACTOR intermediate vents – which would have been a manufactured from the highest Acciona Infraestructuras, S.A. major challenge, as access was very difficult. This quality steel and designed to method was proposed by BBR PTE, based on our endure the harsh marine environ- PT SUBCONTRACTOR experience on the award-winning Monaco Float- ment, as well as being capable of BBR PTE, within PT Adriatico UTE Joint Venture ing Breakwater project – built some years ago, in withstanding loads from earth- TECHNOLOGY the same dock (see adjacent story). Sharing the quakes and blast events.The main BBR CONA internal BBR PTE team’s experience on the latter project construction work has now been BBR NETWORK MEMBER and also the post-tensioning of a number of LNG completed and the terminal is ex- BBR Pretensados y Técnicas Especiales (Spain) tanks throughout Spain has been the most pected to be floated in July 2008. G Towering success

RETENUE DES BLANCHETS, LA PLAGNE, FRANCE TEAM & TECHNOLOGY his tower was built within the scope of a water reservoir OWNER construction project – high in the mountains, at an altitude of SIGP – Syndicat Intercommunal de la Grande Plagne 2,400m. The project was completed between May and August T CONTRACTOR 2007. The structure was erected using 15 prefabricated concrete elements ISL – Company : SOCCO and OSC – each was 1350mm high and had a 2350mm diameter. The segments were TECHNOLOGY installed with the help of a crane and using special mortar. After the erection BBR VT CONA CMI internal of the tower, 16 vertical BBR VT CONA CMI 0.406 cables were tensioned BBR NETWORK MEMBER ETIC (France) and injected with high performance grout. G CONNÆCT 39 WATER TREATMENT TANKS, AUSTRALIA Purifying Queensland’s Water he Queensland Government has invested heavily in upgrades to various waste water treatment plants within the Brisbane, Mackay and Gold Coast areas. Work includes upgrades to the T existing plants with the construction of new cast in-situ feed tanks and precast bioreactor and clarifier tanks. BBR Network member Structural Systems was contracted to provide installation and stressing to all associated post-tensioned works – Justin Hampton talks us through the project. IN SITU TANK CONSTRUCTION SYSTEM SELECTION Large rectangular base slabs were designed with One of the keys to this successful project was post-tensioning to minimise the requirement for deciding on a construction system that was econ- joints in the large raw feed tanks. This ensured omical, quick to construct and ensured that impact that the structure could be adequately water- on the local environment was minimised. The proofed and reduced the amount of flexible water- project demanded a solution that would enhance stops at joint locations. Post-tensioning of the the long term durability of the structure, as well base slab also reduced the likelihood of cracking, as minimise long term maintenance issues. Post- minimising any environmental damage caused by conventionally. Tendon ducting was tensioned construction was the obvious choice. the leaking of dangerous raw sewage into the coupled within the stitches to A total of nine pre-cast tanks and six in-situ ground water system. Larger pour sizes also all- ensure continuity of the tendons. concrete tanks have been constructed throughout owed for an acceleration of the works programme. Once all the stitches were poured, Queensland using the bonded BBR CONA flat PRE-CAST TANKS strand was pushed into each and BBR CONA internal anchorage systems. Circular precast tanks were chosen for their ducting void. BENEFITS speed of construction and reduced quantities of The tank panels sat on rubber Structural Systems was contracted to supply and falsework required. This resulted in minimal pads, which allowed movement at install the post-tensioning systems for all tank struc- disruption to the plant work areas – which was the base, to reduce any likelihood tures. Post-tensioning was chosen for both eco- paramount, as each plant was fully operational of restraint from drying and nomic and structural benefits, allowing for reduced during the construction phase. compression effects. slab thicknesses in the base slabs and thinner walls Two types of precast tanks were constructed. Precast tank construction allows for in the circular pre-cast tanks than would exist with The bioreactor tanks were 85m in diameter and quick site construction – and is a conventional reinforced solution. G 6.5m in height and required ten 706 tendons. particularly effective in remote The clarifier tanks were 50m in diameter and areas where equipment and TEAM & TECHNOLOGY 5.4m high and required seven 705 tendons. Each material supply is difficult. This also OWNER precast element was formed and poured off site, reduces complications which arise Queensland Government with an average panel width of 3.42m. from remote concrete batching Between the precast panels, a 600mm stitch joint requirements for single tank ALLIANCE CONTRACTORS was left which was formed and poured construction. BWEA Alliance – Oxley, Sandgate and Wynnum WWTP Waterfuture – Merrimac WWTP Tenix John Holland Alliance - Mackay North and South WRP Gibson Island Alliance – Gibson Island WRP DESIGNER Bonacci Group (Qld) Pty Ltd TECHNOLOGY BBR CONA flat BBR CONA internal BBR NETWORK MEMBER Structural Systems Limited (Australia)

40 CONNÆCT Y G R E N E R A E L C U N

RENAISSANCE IN THE NUCLEAR POWER INDUSTRY Energised FOR THE FUTURE

ince the epic failure, in 1979, at the nuclear plant on Three Mile Island (TMI), Pennsylvania – and indeed the Chernobyl disaster in 1986 – many lessons have been learned. One of these is Sabout the importance of strong nuclear containment vessels, as the strength of the structure at TMI potentially prevented a greater disaster. With increasing pressures to slow climate change, governments around the globe are now showing interest in commissioning new nuclear plants. We examine the shape of the current market, contemporary nuclear vessel design and practice – as well as the BBR Network’s range of nuclear products and capabilities. CONNÆCT 41 The global picture Nuclear technology was first produces as much electricity from nuclear energy developed in the 1940s and uses as it did from all sources combined in 1960. the energy released by splitting the Civil nuclear power now supplies 16% of global atoms of certain elements. needs, in 30 countries – which together have Research initially focused, during some 439 commercial nuclear power reactors. the Second World War, on Over 30 further power reactors are under producing bombs by splitting either construction, equivalent to 7.5% of existing uranium or plutonium atoms. It was capacity, while over 80 are firmly planned, only in the 1950s that attention equivalent to 24% of present capacity. turned to the peaceful purposes of Sixteen countries depend on nuclear power for at nuclear fission, notably for power least a quarter of their electricity. France and generation. Today, the world Lithuania obtain around three quarters of their power from nuclear energy, while Belgium, COUNTRY NUMBER OF NUCLEAR REACTORS Bulgaria, Hungary, Slovakia, South Korea, Sweden, Switzerland, Slovenia and Ukraine get one third or OPERABLE UNDER PLANNED PROPOSED more. Japan, Germany and Finland get more than CONSTRUCTION a quarter of their power from nuclear energy, Argentina 2111while the USA gets almost one fifth. Armenia 1001 Bangladesh 0002WORLD ENERGY DEMAND Belarus 0020From 1980 to 2004, total world primary energy Belgium 7000 demand grew by 54% – and to 2030, it is Brazil 2014 projected to grow at much the same rate. Bulgaria 2020 Canada 18 242Electricity growth is even stronger, and is China 11 5 30 86 projected to almost double from 2004 to 2030. Czech Republic 6002Increased demand is most dramatic in developing Egypt 0001countries – and that is projected to increase. Finland 4101Currently some two billion people have no access France 59 101to electricity and remedying this lack is a high Germany 17 000priority. Hungary 4002With the United Nations predicting world India 17 6 10 9 population growth from 6.4 billion in 2004 to 8.1 Indonesia 0020 billion by 2030, demand for energy must increase Iran 0121 substantially over that period. Both population Israel 0001 Japan 55 2 11 1 growth and increasing standards of living for many Kazakhstan 0001people in developing countries will cause strong Korea DPR (North) 0010growth in energy demand. Korea RO (South) 20 260 Lithuania 1002MEETING FUTURE NEEDS Mexico 2002Nuclear power generation is an established part Netherlands 1000of the world's electricity mix and is especially Pakistan 2122suitable for large-scale, base-load electricity Romania 2021demand. Russia 31 7820 The World Energy Outlook 2006 from the Slovakia 5200 OECD's International Energy Agency (IEA) Slovenia 1001 South Africa 20124 highlights the increasing importance of nuclear Spain 8000power in meeting energy needs while achieving Sweden 10 000security of supply and minimising carbon dioxide Switzerland 5001emissions. The report demonstrates that nuclear Thailand 0004power could make a major contribution to Turkey 0003reducing dependence on imported gas and Ukraine 15 0220 curbing CO2 emissions in a cost-effective way, United Kingdom 19 000since uranium fuel is abundant. USA 104 0725 Vietnam 0002 CURBING GREENHOUSE GASES WORLD 439 33 94 222 On a global scale, nuclear power currently reduces carbon dioxide emissions by some 2.5 Source: World Nuclear Organisation, October 2007 billion tonnes per year. Carbon dioxide accounts 42 CONNÆCT burning of fossil fuel to generate electricity. Nuclear power plants do not emit these gases. In 2007, the UN Intergovernment Panel on Climate Change (IPPC) produced a report on mitigation of climate change which says that the most cost-effective option for restricting the

temperature rise to under 3°C will require an Y increase in non-carbon electricity generation from G R

34% (nuclear plus hydro) now to 48 – 53% by E

2030, along with other measures. With a doubling N

of overall electricity demand by then, and a carbon E

emission cost of US$ 50 per tonne of CO2, R nuclear's share of electricity generation is pro- A E

jected by IPCC to grow from 16% now to 18% L

of the increased demand, representing more than C

Hydro Natural U a doubling of the current nuclear output by 2030.

and other gas N 19% 15% These projected figures are estimates, and it is evident that if the renewable energy sector – Nuclear such as solar, wind and water power – fails to 16% for half of the human-contributed grow as much as hoped, it means that other non- Coal portion of the global warming carbon sources will need to play a larger role. 40% Oil effect of the atmosphere – over Thus nuclear power's contribution could triple or 10% one-third of human-induced perhaps quadruple to more than 30% of the greenhouse gases come from the global generation mix in 2030.

Pioneering BBR spirit

internationally. The BBR team has now completed close to 100 nuclear energy projects in 15 countries.

BBR engineers were pioneers in the truest sense of the word when it came to developing high capacity tendons for nuclear applications. As early as the 1960s, they tested the first generation of large tendons for nuclear power plants – BBR wire tendons with button heads simulated the environment of a and BBR strand tendons with wedges. reactor vessel. This early BBR testing of tendons involved the Although in the sixties, at the construction of a special facility at the tendon beginning of this new application, assembly plant in Switzerland, in order that large some pressure vessels had been tendons could be tested in conditions which realised with tendons which are ABOVE: Construction of bottom cap with buttresses for today considered quite small, the anchorages of the UK’s Dungeness B pressure vessel. use of large capacity tendons soon BELOW: Testing of BBR anchor head. Stressing became common practice. device consists of three 500t jacks, hydraulic pumps Since 1965, prestressing by and load cells. post–tensioning has become a clearly established technique for pressure confinement in the nuclear power industry. Today, the recognised adaptability and reliability of BBR Prestressing Full-scale grouting and replacement test with Systems for the post-tensioning of tendons consisting of 7mm diameter wires in tightly nuclear power plant pressure and twisted groups of three wires each, as well as with containment vessels has made tendons composed of strands. them some of the best known CONNÆCT 43 Contemporary PT SOLUTIONS NUCLEAR VESSEL DESIGN n nearly all projects, the basic structural design is a cylindrical A vessel with flat end slabs or a I Cane shaped A convex dome. Practically all recent tendons nuclear structures consist typically B of two shells, the inner and the Vertical tendons outer containment. B Today, the post-tensioned nuclear structures have reached an outside diameter of 50m and a height of 70m of the inner shell with a capacity of 1600MW. Horizontally BBR PT TENDONS looped cables Three types of BBR post-tensioning tendons are typically used the inner containment, as follows: N Vertical tendons for wall post-tensioning The lower anchorage is situated in the roof of mechanically tested or inhibiting compounds or wax. The tendons can the tendon gallery and the higher anchorage is retensioned in the event of be mechanically tested in-situ and the actual placed on the ring in the base level of the greater than expected loss of prestressing force can be monitored by lift-off dome. prestress. tests or through permanently installed N Horizontally looped tendons (hoop tendons) N Grease or wax grouted tendons equipment. They can be retensioned and they These can accommodate a varying number of For these unbonded tendons, can also be removed for visual inspection and vertical buttresses (ribs) – for example, four the prestressing force is eventually replaced. buttresses with 180° tendon hoops or three transmitted to the concrete N Tendons protected with circulating dry air buttresses with 240° tendon hoops. The primarily at the location of the For these unbonded tendons, the same tendons are anchored alternately in one of the anchorages. Corrosion is properties and advantages apply as for the vertical ribs and both anchorages are situated prevented by grease, corrosion- grease grouted tendons. on opposite sides of the same rib. The current trend is to reduce the number of buttresses. N Horizontal end slab post-tensioning “cane shaped” tendons These are placed in two right angled planes in the dome, which have a varying length. The lower anchorage is situated in the roof of the PT gallery and the upper anchorage is placed under the retaining ring of the dome.

BBR PROTECTION During the entire lifetime of the pressure vessels, the greatest attention must be paid to the protection of the prestressing steel from corrosion. The BBR Network uses three different types of corrosion protection for nuclear tendons: N Cement grouted tendons The cementitious grout surrounds the prestressing steel in an alkaline environment that inhibits corrosion. If there is a local fracture of a tendon, part of the prestressing force remains transmitted to the concrete due to the bond with the grout. However, grouted tendons cannot be visually inspected, Spanish BBR Network member BBR PTE’s grouting plant. 44 CONNÆCT Our periodical surveillance procedure is as follows: N Lift-off of the anchor head with the BBR SA 500 automatic stressing device to determine the actual prestressing force – this is digitally recorded by an x-y-writer. N The tendon is subsequently released and a single tensile element is extracted for corrosion examination and further testing in the

technical laboratory. Y N A new single tensile element is installed and the tendon is stressed G R

again to its original prestressing force. E

Utilising the latest technology for monitoring prestressing force, all N

types of BBR VT CONA CMI anchorages can be equipped with the E

BBR WIGAring ELASTO force measuring system. It allows for long- R Periodical technical inspection of the tendons with lift-off tests at the term tensile force measurements with digital control, memory, A E

Forsmark nuclear power plant in Sweden. WINDOWS compatible data files and printing facilities. L

In addition, Spenntekknik has been assisting with the replacement of C steam generators at one of the plants. This work requires a large U

Inspection and N hole to be cut in the one metre thick secondary containment wall. improvement work The BBR team removes both horizontal and vertical tendons before the cutting process – and destresses the wall on the opposite side to or the continuous safety of service of large tendons, accurate avoid unexpected forces developing in the wall – keeping it in balance measurement of the stressing force and regular controls are of – during the replacement work. Fgreat importance. For many years now, BBR Network As well as preparing Risk Assessment and Health & Safety statements members have been carrying out lift-off tests and the experience of for each job, our staff have to undergo a three day training course Norwegian BBR Network member, Spenntekknik, is typical – which covers behaviour inside the special facility. They are carefully managing director, Tommy Lindstrand describes the work at a number screened and personal radiation logs are maintained and provided by of nuclear energy installations in Scandinavia. the owner.

NUCLEAR TESTING With flying colours

he BBR VT CONA CMI system has passed all prescribed European Organisation for Technical T Approvals (EOTA) tests with flying colours – and has even withstood more stringent voluntary testing commissioned by the dedicated BBR engineers. From the very beginning, ever since the foundation of the BBR partnership in 1944, many hundreds of tests have been executed in different technical laboratories for the approval of various anchorage types in many countries. However, since 2002, BBR VT CONA CMI bonded post-tensioning anchorage types have been developed and tested extensively in accordance with standards set by EOTA – and have secured European Technical Approval. Static load, resistance to fatigue and load transfer tests were completed successfully according to ETAG guidelines. Although well in excess of the ETAG requirements, the team decided to go above eight million load cycles – already over four times more than required – in one additional voluntary test run. It was amazing that, even under these extremely hard conditions, the tendon endured this gruelling fatigue testing without any strands breaking. It is worthy of note that these tests were carried out as part of the certification of the largest post-tensioning tendon ever to be tested to these guidelines – anywhere in the World. In addition, a full scale installation, replacement and grouting test was undertaken for the 6106, similar to the trials carried out on smaller tendons by BBR forefathers (see Pioneering spirit, page 42). G

Top: Arrangement of the displacement transducers on wedges and strands for the BBR VT CMI 6106 tendon. Bottom: Control unit in static load test for the BBR VT CMI 6106 tendon. CONNÆCT 45 THE ULTIMATE stay cable system

n the last edition of CONNÆCT, we delved into the history of BBR’s stay cable products and experience – extending over almost 60 years and over 300 projects. In 1968, BBR completed the world’s first strand stay cable application for the Olympic Stadium in Munich and, in this edition, we focus Ion the benefits and technical superiority of the BBR HiAm CONA parallel strand stay cable system. In terms of whole life cost, this is simply the best BBR HiAm CONA socket, where and to withstand the ultimate breaking load of product on the market, especially when combined each strand is individually guided, the strand bundle with adequate safety. with the expertise of the BBR Network. Its sealed and locked. Ring nuts superior fatigue resistance – “HiAm” stands for screwed onto the anchor heads STRESSING & MAINTENANCE high amplitude fatigue resistance – makes it transfer the cable loads, by contact The BBR HiAm CONA system has been attractive for the most challenging of projects and pressure, to the supporting bearing designed for single strand stressing or restressing, thus it appeals to engineers and clients alike. plates. All anchorage components at any time during or after the installation, which Designers and architects have welcomed, in have been designed for a stress means the system is easy to handle and requires particular, the compactness of the anchorage range greater than 300N/mm 2 – significantly less equipment for stressing system, as it allows them greater scope to produce a structure which has sleeker lines and which appeals to the visual senses of all who use and gaze upon it.

STAY CABLE CONFIGURATION BBR HiAm CONA cables are made up of a compacted bundle of parallel seven-wire strands, enclosed in a ultraviolet-resistant high density polyethylene (HDPE) sheath of circular cross- section. The individual strands generally have a diameter of 0.62’’ and are of low relaxation grade, with a nominal cross-sectional area of 150mm 2 and a minimum guaranteed ultimate tensile stress of 1770N/mm 2 or 1860N/mm 2. The strands are galvanised, greased or waxed and individually sheathed with a continuous and wear- resistant HDPE coating, providing each strand with an individual multilayer protection system. Alternatively, epoxy coated strands with a corresponding corrosion protection system, compacted strands with a cross-section of 165mm 2, or 0.6” diameter strands with 140mm 2 cross-section may also be used.

ANCHORAGE CONFIGURATION In the anchorage zone, the strand bundle passes a deviator and spreads out towards the compact 46 CONNÆCT operations. By the same token, maintenance is example, the use of a helical rib on CERTIFICATION S also easier as each individual strand can be the outside of the cable surface is The BBR HiAm CONA stay cable system inspected or replaced and additional strands can particularly effective against wind- complies with the fib recommendation E be added – saving time, costs and waste rain induced vibration. This “Acceptance of stay cable systems using L materials. prevents the formation of the prestressing steels” as well as the corresponding B A unique feature of this system is that each coherent water rivulets which are PTI and SETRA recommendations. A strand is sealed off individually – and not only can responsible for the cable vibration the strand be inspected or replaced individually, and therefore mitigates the INSTALLATION C but the sealing system can be inspected and excitation at its source. Other The installation of the BBR HiAm CONA Y replaced on an individual strand basis too. cable surface treatments include system is typically performed on site using the dimples and longitudinal grooves. strand-by-strand installation method which A T BENDING DAMPER Cross-ties can be used to shift the comprises four basic steps: In the anchorage socket, each strand is natural frequencies of the cable N Installation of the upper (pylon) and lower S individually protected with a proprietary bending stays and to avoid any possible (deck) anchorages. damper. Bending effects in cables may be interaction of deck and pylon with N The preassembled stay cable sheath is hung introduced by excessive construction tolerances the stay cables. The use of cross- between the two anchorages using two master and cable vibrations. ties can also be an effective strands. The stay cable sheath is now used as a method for suppressing other guide and passage from anchorage-to- COUNTERING CABLE VIBRATIONS types of cable vibration. anchorage. The short-term consequence of cable vibration is Supplemental devices can be used N The strand is positioned at deck level, pulled up complaints from bridge users – the long-term to add damping to the cable – through the stay pipe and the upper consequence may be reduced safety factors or hence achieving sufficient total anchorage, then inserted into the lower even failures of complete cables due to a rapid damping as an efficient measure anchorage. accumulation of bending fatigue stress cycles at against cable vibration. N Each strand is tensioned immediately after the anchorages. Common phenomena which can A proprietary and advanced cable installation, using the BBR ISOSTRESS tensioning cause cable vibration include: damping solution is the BBR method, ensuring an equal stress distribution N vortex shedding Square Damper which can be used among the strands of an individual cable. N galloping internally or externally. The BBR As an alternative to the single-strand installation N parametric excitation – deck/pylon and cable Square Damper requires minimal method, fully or partially prefabricated cables can interaction maintenance and operates be installed and tensioned. The BBR HiAm CONA N wind and rain-induced vibration. essentially in the same way as car stay cable system is exclusively installed by teams Various countermeasures are available – for brakes. of certified BBR PT Specialist Companies. G

CONNÆCT 47 BRIDGE OVER DRAVA RIVER IN PTUJ, SLOVENIA What is an extradosed bridge? The structure of an extradosed bridge is often described as a cross between a box-girder bridge and a cable stayed bridge. However, unlike a cable stayed bridge, an extradosed bridge has a self-supporting deck. Benefits that extradosed bridges might offer include: N longer spans – in navigable watercourses, for example N reduced tower height – in proximity to airports, for example N reduced girder depth – enabling a longer span without impacting bridge deck profile

With a typical cable stayed bridge, most of the load – bridge deck, girders and traffic – is carried, through the cables, to the top of the towers and then down through the towers to the foundations. In an extradosed bridge, both TEAMWORK the girders and the cables bear the load. In an extradosed bridge, the deck is directly on the Drava supported by resting on part of the tower – so that, in close proximity to the tower, the deck can act as a continuous beam. he Ptuj bypass road project required the construction of a bridge over The tension exerted by the cables acts more to Tthe Drava River. The design concept was for a so-called “extradosed” compress the bridge deck horizontally than to bridge, as described by Rudolf Vierthaler of Austrian BBR Network support it vertically, because of the lower angles member VORSPANN-TECHNIK GmbH & Co. KG (VT), who executed of intersection with the tower and deck involved. The cable stays thus act as prestressing the project with BBR CONEX of Croatia. cables for the concrete deck. The end result is a highly efficient load-bearing At some 720km long, the River Drava is one of BRIDGE STRUCTURE bridge, with striking visual qualities offered by the longest rivers in Europe. On the journey from The bridge structure is a the exposed cables and concrete towers above its source in the Italian Alps to Croatia, where it continuous, 2.6m deep box-girder the road surface. joins the River Danube, the Drava flows for with three central spans – 100m around 102km through Slovenia and through the centre span and two side spans of country’s oldest city – Ptuj. 65m, making a total length of The tendons comprise a bundle of 31 galvanised Until recently, motorists in the Ptuj area faced the 430m. The overall width of the strands 150mm 2 1570/1770, greased and PE- daily frustration of traffic jams as they travelled bridge deck is 18.7m. In plan view, coated, inside HDPE co-extruded duct. Co- across the city’s only road bridge over the River the bridge has a 460m radius extruded HDPE duct for stay cables combines the Drava. It is, therefore, no surprise that local curve. well-proven durability of black HDPE with the people were eagerly awaiting the opening of this CONSTRUCTION METHOD desire for architectural colouration and with new river bridge which forms part of the The deck structure was erected by improved thermal behaviour. Hajdina-Ormoz expressway. the free cantilever method and 5m Assembly, installation, stressing and grouting works long segments were cast in situ – associated with the external tendons, were the operation ran in parallel on carried out with technical support from VT. TEAM & TECHNOLOGY both sides of the piers. The bridge The external tendons were prefabricated on land, is post-tensioned with both internal then installed and stressed as deck construction OWNER and external tendons. progressed. After stressing, the ducts were filled Dars d.d., Celje POST-TENSIONING WORK with cement grout. G CONTRACTOR The BBR VT CONA CMI system PORR d.o.o. was adopted for the internal tendons and the anchorages were DESIGNER installed and stressed by BBR Ponting d.o.o. CONEX. TECHNOLOGY The external tendons are VT 31- BBR VT CONA CMI internal 150 SK strand tendons and these were guided through deviator BBR NETWORK MEMBERS VORSPANN-TECHNIK GmbH & Co. KG, (Austria) saddles on the 9m high pylons, then BBR CONEX (Croatia) anchored underneath the deck slab outside the box-girder. 48 CONNÆCT S S E E L G B D A I C R Y B A T S

MOTORWAY BRIDGE, LETENYE, HUNGARY HUNGARY’S first extradosed bridge

eometrical conditions dictated the design of an extradosed Gbridge for the junction of the M7 and M70 highways on the Becsehely-Letenye section, in south-western Hungary. Rudolf Vierthaler of VORSPANN-TECHNIK, the Austrian member of the BBR Network, gives details of this elegant solution.

The bridge structure is a continuous, 1.6m deep geometric shape – were installed in three-cell concrete box-girder with spans of position before concreting. The 52.26m and 61.98m. The overall width of the deviators are designed to allow bridge deck is 15.85m. The abutments are skewed movement of the tendons by to the bridge-axis at an angle of 60°, while the means of low friction sliding agents, then they were installed and stressed after pier axis between is skewed at an angle of 40°. such as Teflon and non-corrosive erection of the deck structure. steel strips. The architectural design The engineers, whilst resolving the challenge of POST-TENSIONING CONCEPT of the deviation points shows the designing a bridge to suit the special geometrical Post-tensioning was undertaken using a statical system to best advantage. conditions, devised a truly aesthetic solution combination of internal and external tendons. The external tendons were which permits the function of the structural The internal tendons are strand tendons with 19 prefabricated in VT’s factory in elements to be appreciated – and admired. G 150mm 2 strands – four in each of the two inner multiples of the required lengths, longitudinal beams and six in each edge beam. TEAM & TECHNOLOGY The 125m long BBR VT CONA CMB external OWNER tendons run from abutment-to-abutment and are National Highway Directorate, Budapest, Hungary guided over deviators on the pylon and at transversal beams outside of the edge beams. The CONTRACTOR design of the abutment chamber allows easy Hídépitö Rt. control of the tendons and, if necessary, the DESIGNER adjustment of their force – or even their Technical Department of Hídépitö Rt. replacement. Load cells are installed for TECHNOLOGY monitoring of the tendon forces. BBR VT CONA CMB band system EXTERNAL TENDON DEVIATORS BBR NETWORK MEMBER For the deviation of the external tendons, hollow VORSPANN-TECHNIK GmbH & Co. KG (Austria) steel profiles – bent to match the radius of the CONNÆCT 49 CABLE STAYED BRIDGE, “AS A PART OF THE STAY CABLE TESTING, A CHIRAIYATAND, FULL-SCALE TEST FOR TENSILE FATIGUE PATNA FOR THE LARGEST CABLE ASSEMBLY WITH 189 WIRES, WAS CONDUCTED AT THE SWISS FEDERAL LABORATORIES FOR MATERIALS TESTING AND RESEARCH ...”

his four lane cable stayed road overbridge has been constructed to replace an existing two lane bridge which connects the junctions at the southern end of Kankarbagh and northern end of Exhibition Road in Chiraiyatand, Patna, Gopinath Jonnadula, General T Manager (Projects & Products) for BBR (India) Pvt Ltd reports that a cable stayed bridge solution was recommended for some very practical reasons.

50 CONNÆCT ON TRACK in Patna

The choice of a cable stayed STAY CABLES bridge meant that no pier Since prefabricated, factory- S E

supports would need to be assembled stay cables with three L

constructed within the existing nested layers of corrosion B railway lines below – and, in protection were proposed for A addition, any future extensions to the construction, the BBR DINA C the railway tracks could be more stay cable system was adopted Y A easily accommodated. for the bridge. Various sizes of T

anchorages have been used, S BRIDGE OVERVIEW starting from DINA Type 42 to The 110m long bridge has a span Type 102 for both outer pylons configuration of 65m for the and Type 102 to Type 192 have main span and side spans of 45m, been used for the inner pylons each with two individual decks which are jointly supporting the and carrying two lanes. The stay two decks. The stay cables have cables are arranged in three been assembled with parallel parallel planes, with the central galvanized wires to passive and plane common to both carriage- stressing end anchorages and ways. The pylon is a three legged encased in HDPE pipe. The H-frame with straight 40m high annular space between the wires concrete pylons. and HDPE pipe is also protected The 7.5m wide carriageway has with grease. a reinforced concrete deck with edge beams and diaphragms at INSTALLATION AND 2m intervals. Steel outriggers are STRESSING provided on either side of the The grease-filled, assembled stay the service of the structure. The The test specimen was installed deck to anchor the stay cables cables were coiled in steel embedment-type strain gauges, in a cable testing machine and bobbins and transported on with range of 3000micf, are load was applied to a maximum CONSTRUCTION trailers from BBR India’s bonded to the inner surface of of 5177kN and minimum of METHOD workshop in Bangalore to the the deck, as well as to the pylons 3799kN with force range of As the bridge site is located construction site at Patna – at various specified points. These 1378kN, at a testing frequency of within a heavily congested area approximately 2000km away. also measure the stresses in the 4.2Hz. After completion of two and there was no possibility of The cables were installed with concrete during construction, as million cycles, the test specimen traffic diversions, construction the help of a tower crane to well as during the operational satisfied the test recommen- was programmed over two anchor the stressing ends located lifetime of the structure. The dations of the PTI. This same phases. The first phase consisted in the pylon anchor zone. instruments are connected by specimen was subjected to static of constructing the first Deviators guided the stay cables armoured cables to a control load testing as per PTI recom- carriageway, with a two lane though the deck level steel panel, where the readings are mendations – again, the cable deck, which was commissioned riggers and they were then shown and then stored on was successful. G for traffic and was then followed anchored with locknuts. A special computer. by the demolition of the existing pulling mechanism was bridge. connected to the stressing end STAY CABLE TESTING TEAM & TECHNOLOGY In the second phase, the second anchorage to stress the stay As a part of the stay cable testing, OWNER carriageway deck was cables in a sequence prescribed a full-scale test for tensile fatigue Indian Railways constructed and integrated with the project engineer. for the largest cable assembly bridge already commissioned. with 189 wires, was conducted at CONTRACTOR Pylon and deck construction has BRIDGE the Swiss Federal Laboratories for M/S Ircon International Ltd been executed simultaneously INSTRUMENTATION Materials Testing and Research, DESIGNER and the complete deck was Strain gauge-type load cells – Empa, Switzerland – according to M/S L&T Ramboll Consulting concreted on continuous with capacities varying from recommendations of the Post Engineers Ltd scaffold, staging and shuttering, 200MT to 500MT – have been Tensioning Institute (PTI). TECHNOLOGY supported from the ground over installed at the dead end anchor The DINA stay cable specimen BBR DINA stay the full span. The entire deck heads of the stay cables. These was fabricated at BBR India’s scaffold remained in position measure forces in the cables Bangalore workshop and BBR NETWORK MEMBER until stay cable stressing had during stressing and monitor the transported to Empa by air BBR (India) Pvt Ltd been completed. forces in the stay cables during freight as a preassembled unit. CONNÆCT 51 PARVATI RIVER BRIDGE, HIMACHAL PRADESH, INDIA FOOTHILLS OF the Himalayas

he Parvati River Bridge has been constructed in the engineering and construction services, along with associated construction stage support – for Tpicturesque location of India’s Himachal Pradesh state, example, design of temporary stays, steel tower, reports Mr B. Appa Rao, Deputy General Manager (Projects) for form traveller etc. We were responsible for the supply, erection and stressing of temporary stays BBR (India) Pvt Ltd. This bridge connects Chandigarh with and backstays – and indeed of the BBR DINA Manali tourist resort in the foothills of the great Himalayas. hangers. G

The bridge consists of a 120m span and a 30m supporting the form travellers TEAM & TECHNOLOGY high two-rib arch for two-lane road traffic. The consist of 42 BBRV 7mm cables concrete arch was constructed with the help of a and 82 BBRV 7mm diameter cables. OWNER 35m high steel tower and BBRV temporary stays. Supporting the bridge main deck M/S. PWD, Himchal Pradesh, India The arch is divided into ten sections, including the are 13 reinforced concrete CONTRACTOR starting stub. The remaining nine parts are cast, transverse beams which are, in M/S. V.K. Sood Engineers & Contractors, Haryana, using steel form travellers, in nine stages. Each turn, supported by 13 pairs of BBR India stage of casting is supported by one temporary DINA hangers spaced at 7.6m DESIGNER stay cable from the temporary steel tower intervals. Each BBR DINA hanger M/S. Tandon Consultants PVT Ltd balanced with two pairs of BBRV temporary consists of 75 high tensile 7mm Construction Engineers, BBR (India) PVT Ltd backstays located at the top and middle. The steel wires in HDPE pipe. At the bottom backstays consist of 57 BBRV 7mm bridge deck level, DINA hangers TECHNOLOGY BBR DINA stay diameter cables and the top backstays consist of are encased in steel trumpets for 80 BBRV 7mm diameter cables. These backstays protection. BBR NETWORK MEMBER are anchored to a heavy deadman at the For this bridge, BBR India’s BBR (India) Pvt Ltd adjoining pier. Similarly, the front temporary stays challenge involved construction 52 CONNÆCT Supreme Winner of the prestigious New Zealand Engineering Excellence Awards 2007 R R M

Taking power to the people

TRANSMISSION TOWER FOUNDATION UPGRADE, UPPER SOUTH ISLAND, NEW ZEALAND

s the debate continues over the future and sustainability of New Zealand’s energy supply, BBR Contech has been helping national grid operator Transpower, to ensure electricity continues to Areach businesses and households throughout the country. CONNÆCT 53 he company has been working on UPGRADE LOADING strengthen those foundations which would be Tstrengthening the foundations of towers The lines were originally installed in overloaded following the upgrades. In total, 160 on the Transpower transmission line which the late 1970s with a single towers were identified as requiring strengthening runs from the Islington substation, near conductor circuit on one side of – 88 between Hanmer Springs and St Arnaud, 11 Christchurch, to the Kikiwa substation, near the towers. This new work between Ashley and Waipara in North St Arnaud – the ISL-KIK “B” 220kV line – and involved stringing the second circuit Canterbury and 61 between Blenheim and Stoke. the line running between the Blenheim and and earth wire which increased the All up, a workface extending some 300km! Stoke substations in the upper South Island loads on the existing foundations. – the BLN-STK “A” 110kV line. BBR Contech was engaged to LANDSCAPE CHALLENGES As you can imagine, this was no easy project! The towers were located in a vast landscape with a huge diversity of topography, climatic conditions and underlying ground quality. Access was also limited and often extremely difficult, demanding an innovative construction approach which minimised the size of construction equipment and the quantity of materials while maximising the towers’ lateral stability and earthquake resistance.

LIVE ENVIRONMENT Added complications included the issues of working in a live transmission environment, dealing with a wide range of landowners – private owners, the Department of Conservation and commercial businesses – working around natural and man-made features, and complying with environment requirements.

Supreme winner EXPERIENCE TRIUMPHS BBR Contech has been presented with the 2007 New Zealand Engineering Fortunately, BBR Contech’s previous experience Excellence Awards Supreme Winner Award – the combined Transpower and BBR of similar projects on the North Island provided Contech team is pictured above, with Peter Higgins, BBR Contech Southern Regional Manager holding the award. On the same evening, they were also presented with a second award for their work, in the category Utilities, Networks TEAM & TECHNOLOGY and Amenities. OWNER The grid upgrade project scored highly on all judging criteria, and the judges Transpower NZ Ltd unanimously agreed it was a truly excellent example of engineering at its best. “The CONTRACTOR integrity of the power grid is vital to New Zealand’s economy, and the project was BBR Contech clearly of significant national importance,” said David Elms DistFIPENZ, Convenor of the Category Awards judging panel. He said the judges were particularly DESIGNER impressed by the calibre of both the technical and logistical management over an Transpower NZ Ltd extended site. Powlesland Consulting Ltd (structural expert) The New Zealand Engineering Excellence Awards are hosted by a consortium of Pacific Geotech Ltd (geotechnical expert) five partners and ten contributing organisations. The partners are: Centre for TECHNOLOGY Advanced Engineering (CAE); Association of Local Government Engineering New MRR range Zealand Incorporated (INGENIUM); Electricity Engineers Association of New BBR NETWORK MEMBER Zealand (EEA); Association of Consulting Engineers New Zealand (ACENZ); and BBR Contech (New Zealand) the Institution of Professional Engineers New Zealand Inc (IPENZ).

54 CONNÆCT WAREHOUSE REPAIR, STARACHOWICE, POLAND BREAKDOWN R

recovery R M

Concrete Technology Award BBR Contech has scooped the Technology Award at the annual New Zealand Concrete Society Conference for their work for national grid operator Transpower to strengthen the foundations of electricity transmission pylons enabling them to take additional loads. Pictured here is (right) Paul Wymer, Managing Director of BBR Contech accepting the award from Chris Munn, President of the New Zealand Concrete Society. The Technology Award is given to a project in recognition of outstanding innovation in the advancement of concrete practice in design, construction, rehabilitation or research. epair works to the workshop roof girders Rand frame supporting structures were carried “THE KEY TO SUCCESS WAS, OF COURSE, EFFECTIVE out by BBR Polska, during the modernisation and CO-ORDINATION AND COMMUNICATION – development of the MAN STAR Trucks & Buses ALONG WITH SPECIALIST EXPERTISE, Ltd production plant in Starachowice. PROFESSIONALISM, GOODWILL AND TRUST AMONG ALL THE PARTIES.” The poor workmanship of the original construction and the overload carried during the past 30 years meant that the reinforced concrete us with a useful starting point, N for towers requiring moderate girders in Workshop No. 9 were in bad shape structurally – they helping us to shape an approach uplift resistance – installing were even close to break down in some places. The dreadful that ensured cost-effective self-drilling ground anchors condition was quite evident – there were visible scratches and cracks methods, proven strength with grout encapsulation, and with displacement which were temporarily supported. However, the enhancements to the towers, passive low-capacity soil state of the concrete had to be thoroughly tested. This was done in minimal interruption and anchors situ by BBR Polska and using highly specialised methods – the tests disruption for landowners and N for towers requiring low-to- were repeated throughout the repair process. the environment – and a project moderate uplift resistance – The strengthening works involved various repair techniques and that we delivered on time. pressure grout enhancement materials – injection, composite bands with carbon fibre and to existing piles using tube-a- resin, carbon fibre sheets, post-tensioning locally with BBR WAY FORWARD manchette techniques. CONA external 106 tendons and bars. Appointed as head contractor The key to success was, of A technical paper on the operation was presented by Tomasz and providing most of the course, effective co-ordination Borsz – BBR Polska, site manager for the Starachowice project personnel for the physical works, and communication – along – during the Conference in Miedzyzdroje in May 2007. G BBR Contech worked closely with specialist expertise, with Transpower and its expert professionalism, goodwill and technical advisers, along with trust among all the parties. structural, geotechnical, design, Despite numerous changes to drilling, concreting and conser- the original programme and vation experts to help configure many unexpected issues, the a design and construction metho- team delivered the project on dology that could be tested and time. completed in a relatively short This achievement was timeframe. This involved: recognised by both the N for towers requiring maximum Department of Conservation uplift resistance – installing (DOC) and Transpower, with high-capacity post-tensioned DOC applauding “the Contech ground anchors with double guys” for their great attitudes corrosion protection and good systems. G CONNÆCT 55 uilt almost 70 years ago, two aircraft hangars at AIRBASE HANGAR Bthe Whenuapai Airbase form the maintenance REPAIRS, and repair hub for the Royal New Zealand Air WHENUAPAI, Force’s Hercules and Orion fleet. Used NEW ZEALAND daily, these spectacular structures – Beca Consultants discovered rising to a height of 20m and that carbonation of the spanning 67m in width – can concrete had advanced accommodate at least throughout the front façade of both hangars, causing corrosion two Hercules each. of the steel reinforcing bars and eventually spalling the concrete surrounding them. BBR Contech was called in to repair the damage, while ensuring 24- hour access for the aircraft. This access requirement and the sheer scale of the work required a lateral approach to scaffolding. The answer was found in the mobile “scissor” platform that had been used in Auckland’s Vector Arena project. The largest of its kind in Australasia, the scaffold offers reach – it has a working height of 22m – and mobility, allowing it to be moved out of the way of incoming and outgoing aircraft. The project involved the application of about 15m 3 of concrete to the hangar beams, struts and arches, once the reinforcing bars were prepared using ultra-high pressure, low- volume water-blasting. Once the repairs were complete, more than 800m 2 of a three-coat, elastomeric, anti-carbonation coating was applied – with the aim of protecting the hangars from atmospheric damage well into the future. G

TEAM & TECHNOLOGY OWNER Royal New Zealand Air Force CONTRACTOR BBR Contech DESIGNER Beca Consultants Concrete TECHNOLOGY MRR range BBR NETWORK MEMBER CARBONATION REPAIRS BBR Contech (New Zealand)

56 CONNÆCT Completed on 10 July 1908 and now close to 100 years old, the Makatote Viaduct has a total height of 78.6m. As part of the North Island Main Trunk Line (NIMT) the viaduct serves as a

vital link between Wellington and R Auckland. Regular rainfalls and R

seasonal melting water from the M adjacent volcanically active alpine region eroded the river banks and exposed the toe of the upstream mass concrete footing of Pier 7. SHAPING THE PROJECT A project was put together by ONTRACK to underpin the vulnerable foundations. The project team faced demanding constraints and difficulties that had to be overcome to ensure a successful outcome for the pro- ject. The construction was, effectively, being undertaken inside a National Park with numerous environmental challenges – including undertaking construction in a rare blue duck habitat and in a pristine trout spawning stream. Most critically, there was a possibility that the construction activities might, in themselves, destabilise the viaduct. EXTREME CONDITIONS ONTRACK, Fulton Hogan Civil Ltd and specialist engineering consultants worked collaboratively based on a no- blame and best-for-project approach to successfully complete the $4.2m scheme between May 2006 and February 2007. This extremely challenging project to underpin the eroded pier foundation was undertaken in difficult topography and during extreme UNDERPINNING PIER 7, MAKATOTE VIADUCT, NEW ZEALAND weather conditions. PREFERRED SOLUTION The preferred solution was Collaborative challenge underpinning of the two front footings by installing a large pile at each footing and spanning a ocated between Ohakune and National Park, the Makatote Viaduct is large cross beam between piles the third highest railway viaduct in New Zealand. Land instability and to support the lattice tower legs and relieve load on the existing L erosion resulted in Pier 7 of the Makatote Viaduct being vulnerable to footings. foundation failure and was identified as the greatest risk to any of the The proposed underpinning structure consisted of two 2m structures on the New Zealand Railway Network by its owner ONTRACK. diameter bored concrete CONNÆCT 57 Stop press ..... Railway network owner ONTRACK has won two category awards in the New Zealand Engineering Excellence Awards 2007 – Building & Construction and Roads & Transport

commenced once the down stream pile and pier were completed. The cross beam was post-tensioned with eight BBR CONA tendons with 19 12.7mm strands to a point slightly above load-balanced conditions. This is the biggest piles, constructed to a depth of transfer beam ever constructed 38m below beam soffit level. The in New Zealand. piles were spanned by a post- GROUND ANCHORS tensioned, cast-in-situ, bone- Six 12m long 40mm diameter shaped concrete beam 38m bar ground anchors were long, 1.5m wide and 3m deep. required to provide the lateral The horizontal loads are restraint to the new concrete transferred through three steel cross beam. The anchors were struts from the concrete cross drilled with temporary casing, beam to six ground anchors, using a down-the-hole hammer which were installed in pairs and drill. Drilling through the connected with a pre-cast andesite boulder material was concrete tie beam. team on the project The overall project was very experienced these challenges challenging for Fulton Hogan first-hand using today’s Civil Ltd and involved a technology, but can only marvel significant amount of temporary at what our pioneering works to deal with access, piling engineers and construction and falsework. BBR Contech teams achieved! The Makatote was associated with two Viaduct project has taught the subcontract elements of the team involved that the most contract – the post–tensioned important ingredients for a cross beam and ground successful project are the anchoring. identification of risk and PT CROSS BEAM difficult but all six anchors were walls and tie beams which were opportunity within the project, Work on the 38m long post- installed within a tolerance of fabricated off site. the determination of the people, tensioned cross beam – which less than 50mm. This allowed for The double corrosion-protected open communication at all levels transfers the load from the a smooth installation of the pre- ground anchors were grouted and a common goal. G tower legs to the piles – fabricated concrete anchor head and tested after curing to 75% UTS and locked off at 500kN. The tie back struts, consisting of TEAM & TECHNOLOGY 400mm diameter steel tubes, OWNER were then lifted into place to ONTRACK connect the main cross beam to the ground anchors. CONTRACTOR PIONEERING SPIRIT Fulton Hogan Civil Ltd The construction of the DESIGNER Makatote Viaduct, a century ago, Novare Design Ltd was a milestone in New Zealand railway construction and only TECHNOLOGY BBR CONA internal written reports can provide us Bar ground anchors today with an insight of the challenges the construction BBR NETWORK MEMBER pioneers encountered in this BBR Contech (New Zealand) rugged alpine environment. Our 58 CONNÆCT R S R E G M D I R B Timely solution IN LIVE TRAFFIC

BATU KITANG BRIDGE, SARAWAK, MALAYSIA

he bridge over the Batu Kitang River was built 40 years locking rings of the jacks were turned to hold ago using welded steel plate girders and a composite up the bridge. A greased 15mm thick HDPE sheet was placed between the soffit of the Tdeck slab. The retrofit and bridge widening project girders and top of the jacks to allow horizontal involved the widening of the piers and abutments, as well as the expansion and contraction movements of the existing bridge while bearings were being deck on either side of the existing structure, to provide two replaced. lanes of traffic in each direction. Before widening, the 40-year As the height between the soffit of the steel old bearings needed replacing – which is where BBR Malaysia girder to the top of the concrete was approximately 250mm and the laminated was able to help. elastomeric bearings only had a thickness The bridge has three spans – two 27m side spans LIFTING OPERATIONS 83.5mm and 99mm, the difference in height was and one central 40m span and fixed bearings are The lifting operation utilised four of made up by installing galvanised steel plates. on one of the river piers. BBR Malaysia was 250t “pancake” flat jacks, placed In spite of the tight schedule for sourcing of engaged to replace the existing 16 steel rock underneath each of the steel material and the huge amount of actual physical bearings with laminated elastomeric bearings, as girders and rested on steel bearing work to be carried out, the replacement works well as replacing the existing steel expansion plates on the concrete tops of the were successfully completed within the agreed joints. As the bridge was in constant daily use – respective pier columns and three month programme. G mainly by heavily-laden vehicles carrying loads abutments. These flat jacks lifted up from the nearby quarry – the replacement works the four girders at each support TEAM & TECHNOLOGY were both challenging and dangerous. location simultaneously using OWNER EXPERIENCED VIEW hydraulic jacks. A single pump was Public Works Department of Malaysia The sequence of the replacement works used to distribute the hydraulic commenced with Abutment A and then followed pressure to four separate jacks. A CONTRACTOR by Pier 1, next to Abutment B and finally moved needle valve was installed before Hart Builders Sdn Bhd onto Pier 2. At each pier or abutment, the the jack, to control and fine tune DESIGNER adjacent bridge girders were not lifted up at the the pressure going into each jack – TCS Consulting Engineers bearing locations – being a steel composite because the forces on all four bridge, the girders are not very rigid. girders varied. TECHNOLOGY Heavy Jacking System BBR put forward the proposal based on experience REPLACING BEARINGS of previous bearing replacement projects and lever- Steel plates were placed to cover BBR NETWORK MEMBER aging on our experience of hydraulics and heavy the joint being lifted. After the BBR Construction Systems (M) Sdn Bhd (Malaysia) lifting and our hydraulic jacks, pumps and accessories. girders were jacked up 25mm, the CONNÆCT 59 ROSS RIVER DAM, TOWNSVILLE, AUSTRALIA ith many dams now requiring upgrading to meet revised safety standards, Mark Sinclair of BBR WNetwork member Structural Systems, describes how they have recently completed permanent anchoring and trunnion restraint tendons to make the Ross River Dam secure for the local community.

The Ross River Dam is located 20km southwest SPILLWAY UPGRADE permanent anchors ever undertaken in Australia of Townsville, Queensland and is not only the Upgrading the spillway involved (91 x ø15.2 x 142.2m) at Canning Dam – and major water supply for Townsville and Thuringowa, lowering the crest some 3.8m and were the preferred choice of the client, JHMJV to but also protects these cities from flooding. The providing a new curved “ogee” undertake this critical work at the Ross River dam was built in 1971, with a catchment area of crest to the original height. In Dam. The company was engaged to complete 750km 2 and a capacity of 219,000 mega litres. addition, two new piers and three nine permanent ground anchors – three in the Beside the 30m high, 40m wide concrete spillway radial gates were fitted. Structural structure, the dam has an earth embankment of Systems has undertaken a TEAM & TECHNOLOGY some 8km and averages a height of 27m. significant share of Australian dam OWNER stabilisation projects – including the SAFETY & CAPACITY NQ Water As a result of detailed investigation, with longest and largest capacity reference to local and international dam CONTRACTOR standards, the entire dam was deemed to need John Holland & Macmahon Joint Venture upgrading to achieve compliance at a cost of DESIGNER approximately US$70m. The improvements to GHD / MWH the concrete spillway and installation of radial TECHNOLOGY gates have increased capacity by 9% (+21,000 BBR CONA permanent anchor mega litres) providing an additional four months’ BBR CONA internal water supply, as well as allowing better flood control. Significant embankment works, including BBR NETWORK MEMBER 1,900,000m 3 of earthworks, have upgraded its Structural Systems Limited (Australia) safety to an acceptable level. 60 CONNÆCT “ON CLOSE INSPECTION THE ANCHORAGE ZONES WERE 100% DRY, EVEN AFTER BEING Project statistics SUBMERGED FOR A SIGNIFICANT TIME, CON- Permanent Anchors 9 – 50 x ø15.2mm strands N FIRMING THEIR RELIABILITY, THE QUALITY OF THE Vertical anchors ...... 48 or 54m long each N Bond length ...... 11m each SYSTEM AND THE WORKMANSHIP OF THE TEAM.” N Drill hole size ...... ø310 N top of each of the three ogee crests – and around 13m spillway bays, Minimum breaking load ...... 12,500kN R plus additional post-tensioning work to tie back the radial gates, at N Test force ...... 9,750kN (78% MBL) R the trunnion mounting, to two piers and two abutments. N Lock off load ...... 8,750kN (70% MBL) M ANCHORING WORKS N Design working load ...... 7,500kN (60% MBL) Anchoring works included the fabrication, transportation, installation, N Strands ...... 25t grouting, stressing and monitoring of the permanent ground anchors. N Class G Oilwell cement ...... 50t The anchors were up to 54m long, each providing a force of 875t. Trunnion Tendons 12 – 26 x ø15.2mm strands An anchor consisted of 50 15.2mm strands, individually greased and 2 – 31 x ø15.2mm strands sheathed over the free length allowing the strand to extend without N Inclined tendons ...... 16.4m long each restraint, while the remaining 11m of bare strand, in the bond length, N Minimum breaking load ...... 6,500kN / 7,750kN provides fixity via grout to the surrounding rock. N Maximum design load ...... 4,550kN / 5,425kN (70% MBL) Heavy duty corrugated polyethylene sheathing in the bond zone and N Capacity after losses ...... 4,160kN / 4,960kN (64% MBL) smooth sheathing over the free length form a flexible, but N Strands ...... 7t impermeable membrane to protect the strand tendon against N Class G Oilwell cement ...... 4t corrosion over its 100+ year design life. N Multi anchorages each end of the tendon ANCHOR FABRICATION N Drill hole size ...... ø165 / ø175 The anchors were fabricated at site on a specialist bed, using a N HDPE sheath size ...... ø160 purpose-built strand pusher and greasing machine. This machine UPGRADING dam safety opens each strand, separating the individual seven wires, fully greases each wire, then reforms the strand and pushes it into the 20mm HDPE sleeve. After fabrication, the anchors were transferred into a storage rack. Sheath for the main tendon, was prefabricated as a complete unit with spacers and grout tubes, prior to installation into the dam by crane. INSTALLATION & TESTING The anchors were individually loaded and transported on a specially designed trolley system and installed into pre-drilled holes in the dam crest, through into the underlying bedrock. This was followed by a meticulous grouting process with 0.36w/c ratio Oilwell cement grout. After the grout had achieved strength and an age of 21 days, anchors were stressed to their test and lock-off loads using a 1,250t capacity hydraulic jack. Each anchor’s residual load was checked a minimum of 48 hours after stressing to verify the residual load. Upon confirmation of the correct loading, the tendons were trimmed, corrosion protected and fully capped. TRUNNION TENDONS Initially the trunnion tendons were detailed in 75mm bar but, due to installation difficulties, an alternative was proposed to convert the tendons from bar to strand. The works were spread over two piers, MAJOR FLOOD each with 4-26 15.2mm diameter tendons, and two abutments with Works commenced in December 2006 – and were two days from 2-26 15.2mm diameter and 1-31 15.2mm diameter tendons. completion, when a 4m high major flood engulfed the site. It was six At the piers which were newly constructed, heavy duty HDPE pipes weeks before we could gain access to the work area again and were cast in during forming. A small window was left at the base to unfortunately the stressed, but ungrouted abutment tendons were allow fitting of the four dead end anchorages and, at the top, the damaged by corrosion and required replacement which we trunnion mounting incorporated provision for the stressing tendon completed in May 2007. anchorages. The existing abutments required careful drilling from the The flood event loaded and submerged the permanent anchors, top to intersect the lower anchorage location, which was excavated demonstrating their effectiveness in providing additional stability to into the side of the abutment. HDPE pipe was then installed and the dam. On close inspection the anchorage zones were 100% dry, later grouted. Thorough detailing was necessary in order to maintain even after being submerged for a significant time, confirming their the corrosion protection systems. reliability, the quality of the system and the workmanship of the team. G CONNÆCT 61 QUEEN’S WHARF MAINTENANCE REPAIRS, LAUTOKA, FIJI Constructed in 1981 and extended in 1994, the Hastings District Council wastewater facility screens and discharges wastewater from domestic and trade flows for the Keeping greater Hastings District. A 2004 report by Opus International Consultants found Fijian trade that the acid producing aerobic bacteria – which thrive in high concentrations of hydrogen afloat sulphide gas – had caused severe biological attack of the concrete (biogenic corrosion). Up to 50mm of concrete loss was observed in some locations and BBR CONTECH’ s experience and cap- SUITABLE SOLUTION the reinforcing bars were under abilities in concrete repair have recently To remedy the situation, in July 2006 BBR threat from corrosion caused by been applied to a year-long project in Fiji Contech and joint venture partner Downer EDI acid attack. in joint venture with Downer EDI Works – Works launched a project to cut out the at Queen’s Wharf in Lautoka. defective concrete, clean and repair corroding The Wharf is the hub of western Viti Levu’s reinforcing steel and reinstate with new shipping trade, an entry point for naval ships, concrete. With a requirement to ensure the yachts, cruise ships and cargo vessels – and an port remained operational throughout, the exit point for Fiji’s export trade. project was conducted in stages, with only small HISTORY areas being worked on at any one time. The Wharf was built in the 1960s and remained A unique combination of BBR Contech in full use until the 1980s, when the underside expertise and local hands-on experience from reinforced concrete elements began to show Downer led to a solution that matched the Fiji signs of severe deterioration. In 1990, a joint environment, as well as the Wharf’s operating venture between BBR Contech and McConnell conditions. Extensive analysis, development and Opus evaluated the potential Dowell undertook a two-year project to testing – in both New Zealand and Fiji – product options for remedial rehabilitate the substructure and topside resulted in a marine-grade mix of self- works to the facility and con- elements – and three years ago, the Wharf was compacting and dry-spray (gunite) concrete cluded that the special mortar, a extended and upgraded to allow for increased made from local aggregate that was well-suited 100% calcium aluminate import and export trade. to the tropical conditions and tidal environment. concrete, was the most suitable While the 1990 repairs are still in very good In addition, it was easy to use and apply using product given the various condition, project consultant Sinclair Knight Merz dry-spray techniques. limitations for this application. identified increasing signs of deterioration in the HYDRO-DEMOLITION SAVINGS The product meets the primary concrete beams and deck elements of the original With the help of a workforce of 50 local objectives of the project: wharf. tradespeople, the defective concrete was N It provided the replacement demolished and the corroded steel cleaned concrete that had been using “hydro-demolition” – a new, ultra-high eroded away. pressure (40,000psi) water-blasting system N It has a level of protection mounted on huge truck rigs that saved not only against biogenic corrosion at time and jack-hammer equipment, but also the least eight times that of OPC cost of employing an additional 30-40 people to mortar. do the work. The concrete mix (about 700m 3) N It can tolerate both moisture was then sprayed onto the new surface. on the substrate – and In total, the team completed 750m 2 of beam sewage flows – a short time repairs and 2000m 2 of deck soffit repairs, broke after application. out and rebuilt 114 shear walls and replaced N The material is machine- 650m 2 of deck. Given the heat and the gruelling applied by the dry “gunite” working conditions, it’s an impressive technique, ideally suited to achievement! G easy delivery to the work 62 CONNÆCT R High R performance M concrete

WASTEWATER REHABILITATION, HASTINGS, NEW ZEALAND

face. In addition, it is quick to the only really effective method mortar to the prepared the most difficult and challenging apply and the technique to remove this contaminated substrate demonstrated that conditions that a fully provides high levels of concrete – and prepare the bond strengths exceeding 1MPa operational wastewater facility compaction at a low water-to- surface to a suitable profile for were consistently achieved. can present. The skills, cement ratio. application of the special mortar Over a period of eight weeks, perseverance and teamwork of N Compared to any of the two – is to use ultra-high pressure, some 570m 2 of concrete was the contractor, sub-contractors, coat systems requiring both low volume (UHPLV) water- prepared and 14m 3 of the special plant operators and consultants concrete filler and an jetting. The added bonus of this mortar was applied to the all contributed to bring about a overcoat, it was a very method of preparation is that it various str uctures in the plant. successful result for Hastings effective and economical very effectively cleans and This contract was carried out in District Council. G solution. prepares for coating any BBR Contech was awarded a exposed reinforcing bars within FACTORS & CONSTRAINTS contract to supply and install the affected areas of the concrete. The Opus report identified the following factors and constraints special mortar for the remedi- With the limited access points which would need to be considered for a remedial solution in ation project and commenced and requirement to place the order to satisfy the Council’s objective of extending the useful life work on site in mid-January 2007 materials quickly before the of the structures in the plant: for what is thought to be the flows rose again the next day, N With very little opportunity available to isolate the various largest rehabilitation of a live the dry-spray application structures through by-pass pumping, the plant would need to wastewater treatment plant ever technique (guniting) proved remain fully operational during the remedial works. Repairs carried out in New Zealand. invaluable. On occasions when would have to be able to be completed in a live sewer. As with any concrete remedial the flows in the structures rose N The system used to remediate the corroded concrete would works, the secret of successful rapidly, the special mortar need to provide both a rebuild of the already corroded application is dependent on the remained fully bonded to the concrete and provide superior resistance to future further quality of the surface substrate, despite the breakdown than was exhibited by the Ordinary Portland preparation and the removal of submersion only hours after Cement (OPC) concrete that was used in the original the contaminated concrete from application. Random pull-off construction. the surface. With experience, tests conducted to check the N For the majority of structures associated with the treatment the contractor has found that bond characteristics of the new plant, the repairs would need to be carried out in a six week window of opportunity prior to some peak flows of trade waste produced by the local food canning industry. N Many of the structures had repairs extending right down to the level of the sewage and, in some cases, the repairs would be covered with sewage only hours after application of the repair materials. N Relatively large quantities of repairs would be required for some structures and this called for an application method which could provide ease of delivery and effective application of the materials onto the structure.

CONNÆCT 63 BEARING REPLACEMENT, MORSHEAD OVERPASS, Benchmark MELBOURNE, AUSTRALIA bridge

orshead Overpass located in Melbourne, Australia was built in 1963 and widened in 1999. Since its construction, the overpass has been exposed to steadily increasing traffic numbers Mand far heavier vehicle loads than its designers could have anticipated. The bearings beneath the bridge had not only reached the end of their operational life, reports Jason Xerri of Structural Systems Limited, but they had experienced loads well in excess of their initial design. Structural Systems Limited was awarded the replacement activities as this system bearing replacement project, which involved was unbonded. replacing 20 elastomeric bearings and 14 mechan- MECHANICAL BEARINGS ical bearings over four piers. These new bearings The mechanical bearings assist in have been designed for T44/L44 loading, in order supporting the main steel girders of to satisfy the Austroads bridge design code. the overpass which are, in turn, In order to replace all of the elastomeric and supported by concrete crossheads. mechanical bearings successfully, a replacement The replacement method here was procedure for each type of bearing was much simpler, in terms of jacking, as specifically designed. Each individual bearing and there was enough space on the its location presented its own special design crosshead to seat the jack behind execution of the project and all parties were challenges for the contractor. the existing bearing. extremely satisfied with the outcome. This project ELASTOMERIC CHALLENGE The bearings were fixed by weld to has also provided the benchmark for bridge The elastomeric bearings which support the main both a bottom and a top plate. The bearing replacement projects – featuring concrete girders of the overpass are, in turn, bottom plate was fixed to the innovative solutions and a professional approach supported by a corbel attached to the main crosshead and the top plate was to ensure the works were carried out safely and crosshead. The difficulty here was that the girders welded to the steel girder above. in a timely manner. G could not be jacked up from the crosshead as All of the welding was done once there was minimal space in which to work. The the bearing was in position during TEAM & TECHNOLOGY corbel could not be used either, as it was unable the jacking procedure, as the exact OWNER to support the loads imposed by the jacks. alignment of the crosshead exit Citylink Melbourne Limited Structural Systems, in conjunction with Maunsell holes could not be accurately Australia, provided road operator CityLink with located until the existing bearing CONTRACTOR an innovative solution. The lifting jacks were was removed. Structural Systems (Southern) Pty Ltd seated on prefabricated steel angle brackets UNIQUE PROJECT DESIGNER which were fixed to the edge of the corbel using This project was unique for Maunsell Australia 40mm stress bars. The bars were cored through Structural Systems in the sense that TECHNOLOGY both the pier corbel and crosshead. This method we worked directly for the Bearings created a sturdy, spacious and fully adjustable Principal and undertook the project lifting platform and not only provided permanent as the main contractor. Structural BBR NETWORK MEMBER strengthening to the corbel, but the stress bars System’s expertise and experience Structural Systems Limited (Australia) can also be utilised for future bearing in this field provided an efficient 64 CONNÆCT S E R U T C U R T S K R A M D N A L

Photographs courtesy of Roland Halbe, Stuttgart BERGISEL SKI JUMP, INNSBRUCK, AUSTRIA Jewel of the Austrian Alps he ski jump on Bergisel – one of the mountains which surround Innsbruck – is the third station of the annual Four Hills Ski-Jumping competition. This iconic structure – the jewel in the Tyrolean T capital’s crown – owes its reality, not only to a visionary architect, but also to excellence in construction engineering. CONNÆCT 65 or the 1976 Olympic Games, a post-tensioned structure was built for concrete. Dependent upon the the in-run of the jump, utilising VT tendons recalls Rudolf Vierthaler forces that had to be introduced, these tendons were of Austrian BBR Network member, VORSPANN-TECHNIK (VT). F of 6, 12 or 16 strands. With the constant evolution of section of steel frames and a concrete tower. These consoles the techniques involved in the concrete slab – with external – the heaviest of which weighed- IN-RUN EXTERNAL sport of ski-jumping, the tendons below, supported in the in at 550kg – had to be TENDONS configuration of the Bergisel form of a “fish belly”, by integrated into the climbing form In the early detail design phase, structure no longer met the triangular shaped distance for the tower to an accuracy of five closed ropes were international standards required members. 1cm. After finishing the concrete considered for the external by the sport’s governing body – Post-tensioning was applied for works for the shaft, the consoles tendons. Following an alternative the Fédération Internationale du fastening of the tower head steel were stressed against the tower proposal by VT, strand tendons Ski (FIS) – and was replaced by structure to the concrete shaft and grouted. The steel frames of were selected for the task. The a new structure in 2002 and, and for the external tendons to the tower head were plugged tendons are composed of again, a post-tensioned solution the in-run bridge. onto the consoles and fixed in 150mm 2 galvanised strand inside has helped to create a masterpiece of design. World famous architect, Zaha Hadid won the international competition, in 1999, with a design that reflects the dynamics of this sport in a truly breath- taking way.

STRUCTURAL CONCEPT The structure consists of the foundation platform, the tower, the tower head and the in-run. The 16m by 20m foundations contain floors which accommodate technical equipment, storage facilities and offices, as well as the entrance level to the elevator. The 48.5m high elevator tower is a hollow- box with 40cm thick concrete walls. The tower head is a three floor steel frame structure, weighing 90t, which cantilevers up to 12m from the tower shaft. The basic concept for the in-run was a four-span continuous beam with three piers. Finally, FIXING THE TOWER position by welding. a wax-filled HDPE-duct. The the in-run was completed with a HEAD Transversal bonded tendons tendons were prefabricated in single span of 70m in length and A system of steel consoles was through the walls between the VT’s factory, then transported to an inclination of 35 degrees. The developed for the connection of consoles managed the the site in reelless coils and structure is a composite trough the steel structure to the introduction of the forces to the installed using winches.

66 CONNÆCT Metamorphosis The stressing forces were applied in two stages – the first stage after assembling the steel in Norway structure and the second stage after concreting the slab for the in-run track.

Post-tensioning was an S E appropriate technology for the R U

realisation of the architect’s T vision. The first competition on C U the new jump took place in R T

January 2003 and, ever since S then, the building has been a K R

major landmark of Innsbruck. G A M D N A L

HOLMENKOLLEN SKI-JUMP, OSLO, NORWAY olmenkollbakken, the ski-jump at Holmenkollen – located on the hill of the same name in Oslo – is the venue for one of the world’s oldest Hski-jumping competitions and, over the years, the jump has been rebuilt or altered 18 times. Now, as Norway prepares to host the 2011 FIS TEAM & Nordic World Ski Championships, the ski-jump is about to be reborn yet again. TECHNOLOGY It all started in 1892, when were carried out for the 1952 using vertical BBRV tendons OWNER Bergisel Betriebs GmbH 10,000 people came to watch Winter Olympics. The opening installed by BBR Network the first competition at of a restaurant in the tower – member Spennteanikk. Sub- CONTRACTOR Holmenkollen – since then, making Holmenkollbakken a sequent alterations have included JV Alpine-Mayreder / Ast- crowds have grown to over meeting place for the summer modifications to the outrun, but Holzmann (concrete) 100,000 spectators. Ski-ing has months too – followed shortly soon Holmenkollen is to have a Stahlbau Pichler GmbH (steel) truly been the “sport of kings” in afterwards. completely new ski-jump. Given ARCHITECT Norway, with Crown Prince Olav However, for the 1966 World the importance placed upon Zaha Hadid, Jan Huebener taking part in competitions in Championships, an extension was skiing in the Norwegian culture, Structural Engineers 1922 and 1923 and the current needed to the actual ski-jump the process of choosing a Christian Aste, Andreas Glatzl, royal family always present for structure – the plan was to replacement structure has caused Gerald Huber the Holmenkolldagen – the extend its height by adding a much debate and, indeed, BBR NETWORK MEMBER national ski-jumping day. concrete lip. This was to be built controversy. A stunning design by VORSPANN-TECHNIK GmbH & Although the current ski-jump using the free cantilever method a Danish architect has been Co. KG (Austria) was constructed in 1939, it has and, in order to handle the chosen – the “Tower of Light” is seen many modifications since stresses and forces, a post- set to make a dramatic entrance then – most of the upgrades tensioned solution was chosen to the Norwegian landscape. G CONNÆCT 67 BBR W orldwide Directory

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