VSLNews2-2006 29/11/06 17:39 Page 1 NEWS THE VSL NEWS MAGAZINE • ISSUE TWO 2006

VSL & PARTNERSHIPS Attractive network for business ETA for VSL Casino in Macao highlights VSLNews2-2006 29/11/0617:39Page2 For VSL, it is a large scale precast beam precast scale large a is it VSL, For development to build another giant casino. giant another build to development 55 to 1 (from range comprehensive Cover photo: the Venetian Macao Resort Hotel Phase I Phase Hotel Resort Macao Venetian the photo: Cover project installation scale large a is I Phase Macao Venetian Playing megascale inMacao TECH SHOW market. the of approved ETA of strands) most the with VSL provides This for VSLpost-tensioning systems European Technical Approval (ETA) FOCUS :ShatinT3bridgenears completion Chile: 30,000m France: Landmark winfor VSoL Dubai: Record pace for world’s biggest mall Australia: Gateway toalliance SITE INSIGHTS signed… recently relevant for partnerships cards JV trump services: new VSL’s of Some Attractive network for business VSL andpartnerships: COVER STORY Tanks: Cryogenic success inFujian, China New tests for Ductal Protection ofcritical assets: FACTS&TRENDS to helpensure sustainable development Global issues atlocal level: VSLobjectives DEVELOPMENT SUSTAINABLE Trin • jean-philippe.trin • Trin Sandra Puel • sandra.puel • Puel Sandra by published magazine NEWS, 2 distribution centre inSantiago @ vsl-intl.com vsl-intl.com @ ® vsl-intl.com vsl-intl.com VSL International Ltd. • Bern, Switzerland Switzerland Bern, • Ltd. International VSL Editor in chief: chief: in Editor Design: ® Red Line Red Jane Rousseau • jrousseau • Rousseau Jane Photos: 27 24 14 17 23 23 18 14 D. Allan, F-X. de Larminat, J. Roussseau, others. others. Roussseau, J. Larminat, de F-X. Allan, D. 8 6 4 7 6 4 and and VSL • Challenger - Saint-Quentin-en-Yvelines, France. France. Saint-Quentin-en-Yvelines, - Challenger • VSL CORES 8 PARTNERSHIPS @ vsl-intl.com vsl-intl.com PRECAST DEVEL Co-ordinators: SU 6 Carlos Such, Renata Tamburrino, Doris Tong. Doris Tamburrino, Renata Such, Carlos Copyright: STAINABLE OPMENT VSL • • VSL 27 Director of Publication: Publication: of Director SLABS Jean-Philippe Distribution: 4 21 VSLNews2-2006 29/11/06 17:39 Page 3

ISSUE TWO • 2006 EDITORIAL

Sustainable development: our responsibility

For over 50 years, VSL has made valuable contributions towards innovative and highly-efficient construction solutions focusing on raw material consumption (concrete, steel, etc.). Our local facilities spanning more than 40 countries and our training policy are both aimed at long-term sustainability, by promoting integration and economic development across many nations.

The term sustainable development is in vogue today, but the prime focus needs to be placed on personal and collective responsibility.

We must adapt our mode of operations and make the most of our team spirit inside the company to expand the approach and convert our broad-based drive for environmental protection into decisive actions.

Sustainable development is more than a concept, it embodies a daily practice derived from a visionary objective and from the will to work for a future to preserve a high- quality planet for our children's sake.

Jean-Philippe Trin VSLNews2-2006 29/11/06 17:39 Page 4

SUSTAINABLE DEVELOPMENT

CONSTRUCTION AND SUSTAINABLE DEVELOPMENT Global issues at VSL is constantly reassessing its way of working and looking to best practice, quite simply to ‘be the best’. Sustainable development is already firmly on the agenda. During 2006 objectives have been developed.

round the world, from developed areas of the world, and governments and industry is not enough to control the A to the public, there is a problem, especially in developing growing realisation that current areas. As development continues methods of development are and grows in intensity, new and unsustainable. In 1987 the UN larger problems will emerge. For successfully promoted the most example there simply is not widely used definition of enough fuel in the world for sustainable development countries like China and India use “Development which meets the cars like North America does. 4 needs of the present without The effects on the world of Asia’s compromising the ability of future recent demands for natural generations to meet their own resources can clearly be seen needs”. Current levels of resource (e.g. steel shortages). It has risks. For example consumer usage and wastage are placing to recently been reported that China’s boycotts due to poor performance high a burden on the planet. greenhouse gas emissions will risk corporate reputation. Globally we are not meeting the exceed the USA’s 20 years earlier Companies that anticipate changes needs of the present let alone than predicted. in resource availability and considering the future. acceptability of working practice New ways are in a stronger position. A part to play of doing business Leaders in business, government, We are using up our natural Higher energy costs, a growing academia, and communities are resources quicker than we are demand from consumers and providing innovative new solutions replenishing them. We face a governments are putting greater to sustainability issues. Large future that will be less secure. pressure on businesses to change. corporations, as well as small We all need to However, these businesses are going beyond legal reduce our Development which challenges are also compliance to conserve resources. environmental meets the needs of the opportunities to Perhaps the single most influential impact, not just improve factor that has emerged is the because it is the present without performance realization that waste reduction, right thing to do, compromising the ability through reduced energy efficiency, and pollution but also because of future generations to input costs, better prevention make economic sense. it is in our own “ external relations Companies are starting to meet their own needs long-term best and greater understand that sustainability (Definition used by UN and many interests. other organizations). innovation. involves more than ethical The standard In tomorrow's considerations - it improves the approaches in the past to the world, sustainability will more bottom line and is good business. environmental problems visibly impact on business generated by business have been performance.” Increasingly, social How to survive? legal driven "end-of-the-pipe" and environmental issues are an Sustainable Development is not a clean-up efforts. This approach area of risk for businesses new thing to VSL though it has not has had limited success in alongside traditional economic been called this before. Few

NEWS N°2•2006 VSLNews2-2006 29/11/06 17:39 Page 5 t local level businesses survive for 50 years, as improving is even better. • Improving the capability of staff VSL has done, that have not As such during 2006 objectives to assist in designing already embraced aspects of have been developed to ensure and implementing sustainable sustainability. For example VSL that VSL is covering ‘the development initiatives; invests heavily in R&D and is fundamentals’, and targeting its • Auditing of suppliers on quality continually introducing new efforts. These include reducing and social issues; techniques (e.g. Pipeline impacts on the environment, • Initiating research projects Rehabilitation). employees and the wider focused on sustainable An important aspect of community. In particular the development; sustainability for VSL is being part following areas will be focused on • Encouraging reduction, reuse, of the local community. This has in 2007: recycling; been done by adopting a decentralized business model, which better meet the needs of local markets and allows greater flexibility in decision making. VSL 5 also produces high quality work, more safely and with less waste than its competitors, and of course VSL’s core activities reduce the resources used by clients and increase efficiency (e.g. prestressing, precasting). Additionally VSL also looks after its employees better than the norm especially in ‘terms and conditions’ (30 year service awards are not uncommon in VSL). They are also active in supporting charities (e.g. the Lighthouse Club Construction Charity in Hong Kong) and industry • Assessing customer • Providing educational support to development initiatives. satisfaction systematically employees and their families. and in relation to a wider Global issues range of business VSL operates in over 40 countries, at a local level concerns; employing 80 different Until now there has • Aiming to be a nationalities usually as a small or been no clear leader in health medium sized company. VSL is strategy in relation to & safety therefore in a position to some of the wider standards in all understand global issues at a local aspects of areas; level, and also local issues. This is sustainability such as • Improving the not something new, and is not a environmental impacts. ratio of women marketing slogan, it has been a The full power of the group in technical cornerstone of VSL’s success to network has not been used at and date. The new measures are the local level to address all operational simply expanding the scope of sustainability issues. Also roles; what is meant by ‘sustainable while VSL may be good, development’. ■

NEWS N°2•2006 VSLNews2-2006 29/11/06 17:39 Page 6

FACTS&TRENDS Geotechnics Long cores > Intrafor’s steerable long hole coring method is attracting considerable interest among tunnel designers in Hong Kong. It will be used to gather information about the complex geology of fault zones at the ends of a 5.5km-long drainage tunnel to be built from to Ting Kau. The advanced technology of horizontal directional coring will enable coreholes of 935m and 660m to be drilled from the portals across the fault zones. ■ Contact: [email protected] Ground engineering intrafor.com First project in the UAE Network

> VSL is carrying out its first to 1,200mm. A BC40 cutter and five New Turkish 6 ground engineering project in the cranes were mobilised from Hong UAE, with Intrafor’s installation Kong and Perth. They will shortly of diaphragm walls for Burjuman be joined by a second cutter, an licensee station and a cut and cover tunnel MBC30. The project team has a as part of the new Dubai Metro. challenging task in installing Japan Turkey Metro JV has been 73,000m2 of diaphragm wall by

building the metro since late 2005. mid-2007. Work takes place around Bener Yildirim Gokhan Kutlu Excavations vary from 20m the clock and temperatures to 60m deep and require a range approach 50ºC in summer. > VSL has welcomed Mega Yapi as of tools as there are four different ■ Contact: [email protected] its newly-appointed licensee in wall widths, ranging from 600mm intrafor.com Turkey to cover this growth market. Ankara-based Mega Yapi works throughout the country. The range of services will include post- Formtravelers tensioning, supply and installation of bearings and joints and as well as bridge deck erection. Mega Yapi Record in and VSL are already working together: a recent success has been the award of a project for the sight for seismic retrofit of major bridges in Istanbul where VSL will be Climbform responsible for the post-tensioning. basement and the system will be Other projects include a 90m-span > Gammon Construction is using built up to the 308m-high roof. The footbridge in Konya where Mega VSL’s Climbform system for the client plans to accelerate work to a Yapi and VSL are supplying the rapid construction of the core wall three-day cycle which would be a stays and carrying out the erection. of Hong Kong’s 70-storey One new Climbform record, This is only the second bridge in Island East tower. A key factor in considering the restricted working Turkey with stays made of parallel choosing Climbform was its ability hours. strands inside an HDPE pipe using to incorporate the projecting lintel ■ Contact: [email protected] the VSL SSI 2000 system. ■ Contact: beams. Installation started at the intrafor.com [email protected]

NEWS N°2•2006 VSLNews2-2006 29/11/06 17:39 Page 7

Tanks Offices Cryogenic Year of the slab

success > This is proving to be the “year of the slab” in Chile, with the NOTE PAD completion of more than 400,000m2 of post-tensioned slabs, especially Double win. VSL has recently offices, together with projects such received two awards from the as Territoria (91,000m2), Parque Post-Tensioning Institute, USA. Araucano (56,000m2) and Plaza The first was for efficient use Oeste (39,000m2). Almost all have of light-weight concrete and post- been won by proposing bonded tensioning the Union Station parking garage expansion in post-tensioning using the Washington, DC which called > VSL’s involvement in the rapid Bondtech monostrand system with for wide areas uninterrupted expansion of LNG tank development polypropylene ducting. Clients have by columns. The other was for in China continues with a contract recognised its economic LeJeune Road Flyover in Miami to supply all the post-tensioning advantages in rebar reduction. For for repair, rehabilitation and material for a major new facility in instance, VSL provided the most strengthening with post- Fujian. The contract also includes competitive solution for Plaza tensioning as an economical way. design and supervision work and Oeste, where more parking was there was a special requirement for needed in time for Christmas. General industry. Coca-Cola’s VSL to complete cryogenic tests at ■ Contact: [email protected] largest Latin American bottling temperatures of -170°C. China plant has been inaugurated in 7 National Offshore Oil Company has Mexico by Grupo Tampico. The invested in the project. Engineering, VSoL® plant was built using cutting-edge procurement, and construction of technology, including 25,000m2 of the facility’s two LNG tanks and slab on grade by VSL Mexico. receiving terminal are being carried Wall firsts out by Chicago Bridge & Iron VSL officer as fib president. Company, in collaboration with > VSoL® is enjoying significant designer Chengda Engineering market growth in Australia, the Corporation. The tanks are each Middle East and Spain. Recent designed with a storage capacity of highlights include: 1st Keystone 160,000m3. They have VSL’s GC6-27 wall project in Hong Kong (full horizontal prestressing while the installation of a 13m-high vertical prestressing is made up of Keystone® segmental block wall U-looped tendons of size GC6-12. for main contractor China State ■ Contact: [email protected] Construction); 1st VSoL® Polymeric wall project in Thailand (16,000m2); The General Assembly of fib has elected Hans Rudolf Ganz, 1st Geogrid reinforced steep slope currently Chief Technical Officer Bridges project in Hong Kong; (24,000m2 of at VSL International Ltd, as fib noise barrier panels supplied with President for 2007 – 2008. H.R. VSoL® walls on Albury Wodonga Ganz was appointed Chairman of PT in Riga st ® by-pass in Australia); 1 VSoL the FIP Editorial Board in 1997, > Post-tensioning supplied by VSL Projects in Egypt and Morocco. and served as member of the fib is being installed on the concrete News contracts also include: presidium since 2002. Further 2 ® approaches of a new bridge over 125,000m of VSoL Polymeric affiliations include membership in 2 the Daugava River in the Latvian walls in Oman (92,000m on the ACI, ASCE, IABSE and other capital, Riga. Major construction Southern Expressway project); national organisations in France, 2 ® company BMGS is contractor for 47,000m of VSoL Polymeric wall Switzerland and USA. Since 1996 the bridge and VSL is providing on NH28 at Lucknow, India; he has served as Chairman of FIP supervision and equipment as well 88,000m2 of VSoL® Steel system then fib Commission 9 as the post-tensioning system. walls on 17 No. projects in Spain. “Reinforcing and Prestressing Work is due for completion in 2008. ■ Contact: [email protected] Materials and Systems”. ■ Contact: [email protected] intrafor.com

NEWS N°2•2006 VSLNews2-2006 29/11/06 17:39 Page 8

COVER STORY

VSL & PARTNERHIPS Attractive network for

In line with VSL’s successful corporate strategy Whether as a springboard from existing activities or by offering the to integrate new business venture synergies, VSL network as a ready-made tool for distribution of products and several JV partnerships have recently been services, VSL strongly believes in developing through business launched. Here are some of VSL’s new trump partnerships. Bars in the booming Midlle-East, pipeline rehabilitation in cards for relevant services. Hong Kong and Australia, a new slab lifting system in New Zealand and Australia, FRP in post-tensioning systems, vibration control of cable structures are some of the new paths. Whatever field, the quality of the partners selected is a must, 8 as is the resulting benefit to clients. Threaded bars to address Gulf boom Commencing from the beginning of this year, VSL Middle East launched a partnership with Stahlwerk Annahuette (SAH) of Germany –the oldest existing steelworks in Europe with a history of more than 460 years. This partnership combines SAH’s technical expertise & quality of their products (threadbars in reinforcing and prestressing quality for large construction rprojects ) combined with VSL Middle East’s active presence in the region & their market leadership in the field of post- tensioning and specialized construction systems. More than $1 trillion worth of construction projects are planned or underway in the Gulf region. JV operations are planning to supply SAS Threaded Bars to activities such as tunneling, reinforcement, marine, form ties, post-tensioning, soil nails, ground anchors & micro piles. SAS Thread bars are produced in various

NEWS N°2•2006 VSLNews2-2006 29/11/06 17:39 Page 9

r business

For VSL this strategic merger will Admiralty pipeline rehabilitation increase its already determined project in Hong Kong. involvement in the repair and strengthening sector. For Insituform®’ VSL provides a platform in the Asia Pacific region. This platform will allow them to quickly establish new business ventures backed by the support and establishment of a contractor with considerable expertise delivering specialist services to the civil engineering sector.

The initial business targets are 9 Hong Kong, Macao, Australia and Taiwan. The Hong Kong and Macao locations have been in operation since October 2005 and have completed work for the Water grades such as SAS 500 (grade 75), in Fujairah, UAE. Moreover, orders Supplies Department and the SAS 670 (grade 97), SAS 950/1050 for form ties, stress bars & Hong Kong Mass Transit (grade 150), SAS 900/1100 (grade accessories, have been received. Corporation. A steady stream of 160) and Cold rolled SAS 850 rehabilitation contracts is also (grade 120). These threaded bars Trench-less pipeline being tendered by Hong Kong’s are available in diameters 12mm to rehabilitation Water Supplies Department. 75mm. These threaded bars and all In August 2006, Insituform Opportunities are being explored in the accessories are complying to Technologies®, Inc.and VSL Australia, particularly in the the relevant standards as well as formally agreed to start Insituform heavily populated areas of South with the project requirements. In Asia Ltd. as a 50:50 joint venture. and East Australia addition, any specific request / Established in the United Kingdom requirement to the construction in 1971, Insituform® has grown to In addition to operating as a industry are being developed and become an international pipeline contractor, IAL has exclusive tested by SAH’s Research and rehabilitation company with annual rights for sale of the MTube® brand Development Department. revenues of 2500m. While its core Cured-in-Place Pipe (CIPP) tubing business focuses on sewer pipe for Hong Kong, Macao, Australia For VSL Middle East who is in the rehabilitation, Insituform® also forefront with its activities as a restores steel, iron, concrete, PVC “Solutions Provider” in the region, and asbestos cement (AC) pipes this partnership will definitely conveying a variety of fluids. contribute and provide value added Because Insituform®’s techniques services to their ever expanding avoid digging up existing pipelines, list of satisfied customers. The JV disruption to the public is operations have recently received minimized. Disposal problems with an order for the supply of rock AC pipes are also eliminated since bolts for the Portal works for the pipes remain safely in the ???????????? Daftah-Shis Road & Tunnel Project ground following rehabilitation.

NEWS N°2•2006 VSLNews2-2006 29/11/06 17:39 Page 10

VSL & PARTNERSHIPS COVER STORY

and Taiwan. IAL has non-exclusive The synergy of quality materials for difficult access sites or rights for a wide range of Asia from Sika and innovative structures; easy and fast Pacific countries (with the engineering from VSL provide installation without special exceptions of Japan, Singapore significant advantages and equipment; strengthening at low and Malaysia) and sales have benefits for clients. For the temperatures (down to -10°C non- already begun in both Korea and designer, advantages are: high bonded) without additional curing Hong Kong. The IAL Taiwan flexibility in anchorage design to equipment; minimal breakout on operation is in the initial stages of suit specific structural situations; site. Easy and economic to bond development and should be fully standard solutions for bridges, to the structure; can also be used incorporated early in 2007. roofs, floors and walls; thin CFRP non-bonded; short load transfer plates make tendon cross overs of external PT force into sound CFRP laminate post- possible. For the contractor, concrete; increased ductility for tensioning system advantages are: very light weight non-prestressed structures. Since the development of CFRP (a10m-tendon weighs only 3,5kg; Last but not least, for the owner, (Carbon Fibre Reinforced Polymer) can be rolled easily; good solution advantages are longer life in the late sixties these materials have been used increasingly for structural strengthening. During the last ten years, they have also been used as post-tensioned strengthening tendons for applications on bridges and other structures. Sika and VSL are co- operating in the worldwide market with their newly developed composite CFRP laminate post- 10 tensioning system. By combining their respective know-how, expertise, products and networks in this field, the parties have decided to create this year and market a “quality controlled pre- stressed CFRP system” under the trademark CarboStress®, with local expertise and site support from the global network of both CFRP laminate post-tensioning companies. for buildings expectancy and low maintenance due to non-corrosive CFRP tendons, CFRP laminate post-tensioning good fatigue characteristics, for bridges pre-assembly in quality controlled factory conditions, active PT force (reduction of passive steel stress, crack widths and stress amplitude), and cost effective and safe strengthening solutions for external prestressing. Multi-point synchronised slab lifting system VSL and Jacking Systems Ltd NZ have come together to combine modern computerized jacking techniques and slab post-tensioning to deliver an innovative flooring construction system: VSL Climbfloor.

NEWS N°2•2006 VSLNews2-2006 29/11/06 17:39 Page 11

VSL Climbfloor is used for the The key advantages are: protection being automatically construction of cast in-situ post- • Substantial cost savings over carried up. tensioned slabs without the use of timber formwork and pre-cast • Environmentally friendly through conventional formwork. In a typical concrete systems. reduced formwork materials and Climbfloor application, each slab is • Larger spans and thinner slabs waste. cast on top of the previous slab inherent in PT slabs, whilst The 121 Strand in Auckland New then lifted into place by a retaining the benefits of pre-cast Zealand is a 4 level car park with computer-controlled multi-point systems. 3 floors being lifted with a total synchronised jacking system. • Significant reduction in cranage. area of 3,300m2: 36 synchronised The system can combine void All formwork, screens and edge screw jacks elevated each of the formers, edge formwork, self- platforms are self-climbing. slabs within a relative accuracy of climbing perimeter access • Allows the continuation of the 0.1mm. The entire slab could be platforms with edge protection and next floor cycle as soon as the lifted the 2.1m in only 20 minutes. safety screens. VSL Climbfloor concrete starts setting on the In the case of the three-storey provides a comprehensive self- previous slab. There is no need Middlemore Hospital car park, climbing and self-contained slab to wait for the erection of the next 40 jacks were set-up to lift the slab forming system allowing infinite levels formwork to commence the in two parts; each slab measured combinations of flat slab and band installation of the reinforcement 1,300m2 and weighed 700t, creating beam configurations. & PT for the next level. one half of a 2,600m2 level. • Superior surface finishes, This system provides a safe and especially in flat plate slabs. Vibration control a very cost competitive alternative • Slabs can be lifted to 5.2 metres of cable structures to labour intensive conventional eliminating costly high propping. VSL has signed an exclusive formwork and crane intensive • Improved safety with safety purchase and distributorship pre-cast concrete operations. screens, edge boards and edge agreement with SRI Hybrid for special damping devices. This 11 proprietary rubber mix named Gensui gives the material unique Middlemore Carpark, properties both for monotonic and Auckland, New Zealand for cyclic loading. Presently, two 40 jacks lifted the slab types of Gensui rubber are in two parts; each slab available, standard and high measured 1,300m2 and weighed 700t. damping types with loss-factors of ≥ 0.50 and ≥ 0.63, respectively. The Gensui rubber has other quite exceptional properties which result in a loss-factor which is very little dependent on actual shear displacement/strain, temperature, frequency of cyclic displacements, and age of the rubber. These properties make Gensui rubber an excellent material of choice for damping devices to control vibrations of stay cables and other components or entire structures.

The Gensui rubber damper has been installed first in 1994 on the Odawara Blueway cable-stayed bridge in Japan. Since then more than 36 cable-stayed and extradosed bridges have been equipped with Gensui dampers in Japan. Span lengths of these bridges ranged from less than 80m to more than 400m. Typically, the Gensui dampers

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VSL & PARTNERSHIPS COVER STORY

Gensui damper being able to offer two excellent damping systems for stay cables to clients: the VSL Friction damper and the Gensui damper. The Gensui damper will be the preferred choice for cables where the required installation position for the specified damping ratio is within the practical limitations of the guide pipe length and/or for cases where damping at small amplitudes is desired. The VSL Friction damper and/or a combination with the Gensui damper will be preferred for cases where high damping ratios have to be provided with dampers installed close to the deck as it is often the case for long stay cables anchored above the bridge deck.

VSL has secured the contract for were installed at a distance 10-20% larger than the the first bridge in Canada to use equivalent to about 2.5-6.0% of the theoretically determined damping. the Gensui damper system. The cable length from the deck cable In mid 2006, VSL tests with the precast segmental extra-dosed anchorage and typically contained Korean Highway Corporation cable-stayed bridge is part of 12 between two and six pads. confirmed again the excellent Vancouver’s Canada Line light rail behaviour of the Gensui damper. system. Installation of the Significant number of projects in VSL is right now supplying Gensui 24 Gensui high damping rubber Japan have shown that the actual dampers for the Richmond- dampers is expected to take place damping is equal or typically Vancouver Airport North Fraser in the first quarter of 2007. VSL River Crossing cable-stayed has also been awarded the project in Vancouver/ Canada, the contract to supply 400 Gensui first application outside of Japan. high-damping rubber dampers for the John James Audubon Bridge, However, the one additional very Louisiana, USA, set to become appealing characteristics of the North America’s longest cable- Gensui damper is maintenance: stayed bridge. apart from the steel components, VSL and SRI started with the the rubber pad in fact needs no bridge damper but such a maintenance at all. VSL is now in partnership could expand to the very comfortable position of another area in near future. ■

The damper is made of supporting elements attached to cable and guide/structure between which a number of Gensui rubber pads are installed which provide damping when the cable moves relative to the structure

Gensui dampers on record bridge in the US The John James Audubon Bridge to be built in south central Louisiana, USA is set to become North America’s longest cable-stayed bridge with a main span of 482.5m over the Mississippi River and back spans of 195.5m. The bridge will be supported by 900t of stays up to 256m long. VSL has recently been awarded the contract to supply 400 Gensui high- damping rubber dampers The project is being constructed by Audubon Bridge Constructors and is due for completion in 2010.

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Gensui flagship

Interview with Mr Toji, general manager market; we think that VSL and its various activities can offer other of Sumitomo Rubber Industries, and director applications to Gensui dampers.

of SRI Hybrid, Mr. Shimizu, marketing manager Since our agreement in 2005, and Dr. Matsumoto, technical manager. how about the first steps? Mr Shimizu: We hope VSL will install Gensui damper at least over What is Gensui? the industry and in the university 1600 pieces annually. Judging from Mr. Toji: The Gensui damper is –as for example the research Japanese market, we thought it a rubber damping system centre of Kyoto University– was a reasonable estimate. developed for, but not limited to, recognize the quality of the Dr. Matsumoto: Among this stay cable bridges. It is used to Gensui damper. quantity, we also expect VSL to mitigate stay cable vibrations that install Gensui damper to the could be induced for example by Why did you choose VSL existing small medium size rain and wind. This system stems as a partner? bridges having vibration problem from our core technology, rubber, Mr. Toji: We have been quite and not only newly built large which made Sumitomo Rubber successful in Japan, so I believe bridges because the Gensui Industries the number one in the that the world market should be damper is quite easy to install and world. As a rubber manufacturer bigger than Japan. We were we think the cost is interesting we concentrate on Gensui’s looking for an international considering other dampers. development. In Japan, in the last partner able to open up the world Mr. Toji : We always believed that twelve years, we installed Gensui market for our product. VSL will meet our expectation. We damper on 38 bridges and we Mr Shimizu: Particularly for stay realized that exporting our Gensui 13 have been keeping the top share cable bridges, we thought we solution could take time, but now (about 90%) for the last few years. should tie to a stay cable supplier. with a project coming in In Japan, general contractors Vancouver, an extradosed stay How do you explain such a have cables supplied from cable cable bridge, and another successful development? suppliers and have dampers potential project in the USA in Mr. Toji: First of all, technical supplied from a damper Saint-Francisville, longest span reasons. manufacturer such as us. But in stay cabled bridge in the US, we Dr. Matsumoto: Indeed, our Europe it is often the cable feel very confident. damper is easy to install due to its suppliers who decide what kind small size. Besides, it is basically of dampers should be installed on What does “Gensui” mean? maintenance free. It is designed the bridge. We learned a damper Mr. Toji: The direct meaning is to last around 60 years on bridges supplier should have the cable high damping. But as we use applications. In comparison with supplier as a partner. Chinese characters, depending on other damping systems, it offers Dr. Matsumoto: We recognized the pronunciation it can be less temperature dependency and VSL is a reliable partner through understood as “admiral”, a top less frequency dependency, and discussion particularly with ranking officer. My wish is that our also our damper has the same Dr. Ganz and Mr. Bournand. In Gensui system will be the flagship damping performance whatever addition, we think VSL could be the of VSL range of dampers! ■ the frequency, from very low best damper supplier by having mode to very high mode. two options: VSL Mr Shimizu: And, its cost is very original friction competitive. damper and Gensui Dr. Matsumoto: Aesthetics is damper which could be very important too. Our damper is applied up to 250m or small and compact and matches 300m cable length. well with the structure it is Mr. Toji: installed on. Moreover, while Mr. Toji: Our product also meets the other two the bridge industry needs in cable suppliers Japan, where as you know, we only concentrate have many bridges. Key people in on the bridges Dr Matsumoto, Mr Toji, Mr Shimizu.

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SITE INSIGHTS

Australia 14 New tests Australia for Ductal® Gateway to alliance > Successful tests were conducted this year for resistance of Ductal® against rife and fragment projectiles, the effects of close- charge threats and large-scale blast effects. A prototype modular Ductal® Protective Solution building constructed from 100mm thick panels connected with steel plates, was subjected to the effects of 500kg > VSL Australia, in alliance with cantilever techniques. VSL's scope of industrial grade Ammonium Abigroup Contractors and as main bridge alliance partner Nitrate Fuel Oil (ANFO) at a distance Leighton Contractors, has been includes assisting in the of only 12m. In a separate test, 2m awarded the contract for the construction engineering, long and 1m high Ductal® Protective construction of the Gateway provision of key personnel and Panels were subjected to the effects Upgrade Project in Queensland, specialist plant & services for the of a 5,000kg packed TNT charge at Australia. This project worth entire bridge structure from its distances of 20 and 30m. The tests 1.35 billion USD comprises 10km foundations (piles caps, piers, demonstrated the superior of new freeway, 10km of existing abutments) up to and including the protective performance of Ductal® freeway to be upgraded and one superstructure. The main bridge in direct comparison to ordinary major bridge to be duplicated. The alliance is 15% of the total project reinforced concrete panels. Similar duplicate bridge is a post budget, the construction of which panels are currently in use as roof tensioned concrete structure will be shared collectively between protection against mortar threats comprising 260m-long main spans the three partners and represents for a government building in a high- and 70 to 80m long approach approximately 4 years of activity threat zone. ramps. The main deck will be for VSL Australia. ■ Contact: mrebentrost@vsl- constructed using formtravellers ■ Contact: sgrogan@vsl- australia.com.au utilising cast in-situ balanced australia.com.au

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NOTE PAD

Neva again. Stay installation for Australia the second Neva River cable- stayed bridge on the St Petersburg Ring Road is due to start in High-speed cycle December 2006. The contract for the 382m-span bridge follows VSL’s successful completion in at Windsor 2004 of work on the first crossing, using VSL SSI 2000 stay cable > Achievement of fast deck erection times means that the system in extreme temperatures superstructure for a new bridge near Sydney is now on track to finish two of below –30°C. months early. VSL-Abigroup Alliance is building the bridge as part of the Windsor flood evacuation route. Twenty two of the bridge’s 800t spans have Centenary upgrade. VSL in been erected since the work started in June, with cycle times as little as Australia has won a contract for 24 working hours. The 1,500m-long bridge is being constructed using the the supply and installation of soil segmental match-cast method with an under-slung erection system. It is nails as part of the Centenary made up of 34 simply-supported spans, each 44.3m long and consisting of Link Alliance project for the 15 segments with 18t of external prestressing. upgrade of an intersection in ■ Contact: [email protected] Queensland. The work involves more than 680 fully-encapsulated soil nails up to 12m long as well Taiwan as almost 2.5km of slotted PVC drains.

® Dual success. Two VSoL 15 Concrete contracts have been won by VSL in Queensland. Work at the Russia savings for Wesfield North Lakes shopping centre builds on VSL’s relationship developed on the Ring road HannStar Westfield Chermside project. The second project involves panels for > An alternative design by VSL is abutments and wing walls for the return achieving a substantial cost saving RG Tanna Dozer Overbridge, > VSL’s July completion of its in construction of the three-storey which is part of a coal terminal work on a bridge over the Okhta HannStar TFT-LCD CUB factory in upgrade. River marked its second major Taiwan’s Tainan Science Park. structure for the St Petersburg The building was originally Flying success. A joint venture of Ring Road. The bridge follows on designed to use structural steel Kajima, Taisei, Obayashi and Maeda has awarded VSL Vietnam from a first cable-stayed bridge but the dramatic rise in steel a sub-contract to supply and over the Neva River and VSL’s prices led VSL to suggest the use install 280t of post-tensioning on involvement continues with a of post-tensioned reinforced the new terminal at Tan Son Nhat second Neva bridge (see note pad). concrete. More than 44,000m of International Airport. VSL Site constraints had led to the post-tensioning is needed for the anchorages and couplers are design of a steel arch with project, using tendons up to 71m being used on slabs beams and an composite deck. The arch reaches long. Floor-to-floor height is 9m access viaduct. a maximum height of 28m, with a as the factory will house the span of 160m. VSL was awarded equipment to manufacture very Reinforced tee-off. VSL Hong the supply and installation contract large LCD monitors and TV screens. Kong is undertaking a geogrid- for cables from its SSI 2000 stay ■ Contact: [email protected] reinforced steep slope project for cable system, based on the quality, Hong Kong Jockey Club’s third performance and experience of golf course on Kau Sai Chau earlier Russian schemes. Fifteen Island. Soil reinforcing geogrids pairs of SSI 2000 suspension and erosion protection matting hangers were used, ranging from will be installed on 10 steep 16 to 19 strands. ■ Contact: slopes up to 8m high. [email protected]

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SITE INSIGHTS

Singapore Diverse approach to bridge upgrades > Singapore’s Land Transport Authority has embarked on a series of projects to repair and strengthen vehicular bridges to take increased loadings. VSL has been involved as a specialist main sub-contractor for the upgrade of 11 bridges. The scope of work included concrete repair, protective coatings, bearing rehabilitation, expansion joint replacement, external post- tensioning and the application of 16 carbon fibre reinforced polymers Hong Kong (CFRP). Bridge soffit protection took the form of a three-coat anti- Alliance overcomes carbonation system comprising a layer of siloxane-silane and two project challenges acrylic-based coats. Deck parapet walls were given a two-coat > The final segment of the Lai ground on either side of the protective system made up of an Chi Kok Viaduct has been erected parallel bridge decks. A lifting epoxy undercoat and a and the closure pour completed. frame was used at piers with polyurethane resin sealer. External VSL Hong Kong formed an alliance single box girders where access at post-tensioning was used to with Acciona (formerly known as the pier was possible but where strengthen five of the bridges. The NECSO) for the project which is on the ground below the cantilever new concrete anchorage blocks Route 8, connecting Island was inaccessible. A sliding support incorporated lateral CTA 40 stress to Shatin. The scope of the system was used to take precast bars and main external post- alliance includes the erection of segments to inaccessible tensioning systems. 1,766 precast segments and the locations. The segments were Calculations had shown that the installation of post-tensioning, lifted by crane onto one end of the strengthening work would bearings and movement joints. sliding system and then moved up increase the structural capacity by The project is situated in a highly- to 80m. This method faced several at least 20% and up to 60%. populated area of . The challenges, such as the fact that ■ Contact: [email protected] deck is supported on piers up to the bridge was curved, had a 45m high, with the majority being longitudinal gradient of up to 4% about 25m. The 172m-long and that the piers were obstructing launching gantry, weighing about the slide. A tie-down system was 1,000t, had the capability to move also designed to counter sideways across a 45m range and movement and hold the box could be used to erect four parallel girders in the correct position box girders simultaneously. VSL’s during construction. strand lifting system allowed ■ Contact: [email protected] segments to be lifted from the intrafor.com

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NOTE PAD

Team building. Leading contractor Dragados picked VSL’s Hong Kong post-tensioned slabs for its new headquarters building in Madrid. VSL’s contract involved 27,500m2 Shatin T3 bridge of PT slabs, using the VSL Bondtech. Three PT slab designs were developed. All buildings nears completion have an 8m cantilever transferred by just two beams at first floor > Segment erection on the T3 erection project for this gantry, level, hidden in the façade. road project in Shatin, Hong Kong which had worked previously in is due to be completed in February Korea and Singapore. The T3 team Police drill. Intrafor is installing 2007. The scope of VSL’s work is to is made up of people from 15 64 horizontal ties by the erect 1,807 segments, which vary countries. Their greatest challenge Horizontal Directional Drilling from 30t to 90t, and to install to date has been the erection of a method at a project to turn the 1,240t of internal and external PT. 65m-span cantilever where the former Marine Police The segments are erected by the supporting lower cross beams Headquarters in Tsimshatsui into balanced cantilever method, using were launched onto the cantilever a hotel. The building stands on top a 450t, 108m-long overhead gantry while it was being erected. ■ of a small hill and needs retaining and various sizes of hydraulic Contact: [email protected] works. Precise drilling is needed cranes. This is the third segment intrafor.com and the Eclipse walkover surveying system is being used.

Sound performance. 17 VSL Australia’s successful installation of 4,000m2 of VSoL® on the first section of the Albury Wodonga Bypass Project has led to a further order for 6,000m2 and the subsequent supply of 24,000m2 of architectural sound barrier panels. At peak production, VSL Australia was casting 24 panels every day.

Singapore Bridge to luxury

> VSL is playing a major role in a a wide-ranging scope of work bridge to link Singapore and the including casting the 77 segments luxury apartment developments of and erection using a 400t barge Mexican silo. VSL in Mexico was Keppel Bay Island. Seven stay crane and a custom-made erection the main contractor earlier this cables support the 90m-long main frame. VSL Singapore led a key year for the rapid construction of span, with four more supporting design change that was needed 39.6m-high cement storage silo the back span. The cables are from because of height restrictions on for Holcim-Apasco. Some 14t of the VSL SSI 2000 Stay Cable the use of floating cranes imposed vertical 36mm-diameter PT bars System and range in size from by a nearby cable car. The design were used to join the foundation 22 to 85 strands. The inclined for the anchorage at the top of the to the superstructure, while the concrete pylon reaches almost pylon was therefore changed from superstructure contains 22t of 50m above deck level. VSL is in the original steel box to reinforced vertical and horizontal ring charge of superstructure concrete. tendons. construction above the piers, with ■ Contact: [email protected]

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SITE INSIGHTS

Dubai Complex cells for new LRT > The first mould has been delivered from China for the cantilever sections of the Dubai Metro Light Rapid Transit system and site installation and commissioning is under way. Five cells, made from approximately 450t of steel, will be delivered by January 2007, including all the mechanical, electrical and hydraulic systems. VSL Switzerland was appointed by the VSL-Freyssinet-Rizzani Joint Venture to design and fabricate the cell formwork. Cell design was complex because of the shape and variable geometry of the segments. Design has been closely managed by the VSL Technical Centre in Switzerland, with the manufacture in China supervised by VSL. ■ Contact: [email protected] 18 Dubai Record pace for world’s biggest mall > The world’s largest shopping mall -a million square metres- is under construction in Dubai and VSL is working around the clock to maintain the exceptionally fast pace of construction. In several occasions, more than 200t of strand have been installed within a single month. It would normally take nine months to install this quantity in a typical building with post-tensioned slabs in Dubai. The structure has been designed with post-tensioned beams and slabs. VSL’s scope of work covers approximately 30% of the total floor area –some 300,000m2. The mall stands next to the world’s tallest building, the Burj Dubai tower. VSL has also recently won the post- tensioning for an adjacent project, involving some 3km of bridge deck on one of the major vehicular accesses to the new district. ■ Contact: Y S Li [email protected]

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NOTE PAD

Dual role. VSL Thailand has erected more that 109 spans of the elevated Suvarnabhumi Airport Rail Link. VSL Thailand was awarded a subcontract for superstructure erection and 5,600t of post-tensioning works. The work involves the erection of 612 of the project’s 900 spans and PT works for the remainder.

VSoL® record for ME. VSL Middle East, in JV with VSL Hong Kong, Kuwait has secured its largest ever VSoL® win with the award by Galfar Engineering & Contracting Hot season at Stadium of a sub-contract for the Oman > VSL has been working as the skeleton made up of 52 wall piers Southern Expressway: design, specialist contractor for lifting and with inclined cantilever beams.The supply and supervision of more 2 ® tensioning the cable net structure cable net is made up of 52 radial than 92,000m of the VSoL supporting the roof membrane of a cables and a central tension ring. polymeric wall system. Panels will be installed at a peak rate stunning new stadium under VSL supported the contractor with 2 construction in Kuwait. The project an innovative scheme to optimise exceeding 120m a day. follows on from the company’s the installation and tensioning. Imported gantries. VSL India is 19 involvement in many sports The construction schedule set to start gantry erection for a stadiums worldwide. Local timber- required the work to be carried out scheme to build an 8km viaduct to built merchant ships have inspired in the hottest season, when carry four lanes of traffic above the architecture of the Jaber Al- temperatures in the stadium an existing six-lane highway Ahmad International Stadium. The reached 60°C. Crews worked near Bangalore. A total of circular structure has a diameter seven-day weeks and the stadium 2,860 segments are to be erected. of 250m and rises at opposite ends is on track for completion in 2007. The three launching gantries have to 65m. The elegant wave-shaped ■ Contact: wschroeppel@vsl- been fabricated in China and roof is carried on a structural schweiz.ch shipped in 90 containers. This was two months quicker than making them locally. USA Noiseless. VSL Hong Kong has recently completed a full scope supply and installation package Supporting Utah’s Capitol for VSoL® retaining walls on Hong Kong’s T3 project. Working on a congested site, the VSL site team seismic isolation of the dome of 2 ® installed 1,725m of VSoL wall Utah’s Capitol building. VSL’s together with associated parapet responsibility includes supply and barriers and noise barrier installation of a bonded post- support walls. tensioning system as part of the seismic isolation of the dome. Spanish showcase. Post-tensioning was chosen CTT Stronghold has completed because it allowed for the transfer the installation of stay cables for of dome loads from existing the new exhibition centre in footings to new seismic isolators La Coruña in northern Spain. The and deep foundations. Large post- VSL SSI 2000 Stay Cable System > VSL has been working with tensioned tendons have had to be was used for the 18 stays that Jacobsen Hunt Joint Venture to placed under difficult access support the 160m by 50m roof supply and install a bonded post- conditions. from three steel pylons. tensioning system as part of the ■ Contact: [email protected]

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SITE INSIGHTS

UK Flower for savings

> VSL UK’s method of post- tensioning two LNG tanks in Wales has saved time on the critical path for the main contractor, Whessoe- Volker Stevin Joint Venture. Owner Dragon LNG commissioned the tanks at Milford Haven. One of the key aspects of VSL’s proposal was to use the new AF flower anchorage system for the vertical tendons instead of the original design with stressing at both ends, or the U-shaped system that is commonly used for this kind of structure. The vertical tendons are anchored in the bottom with the type AF dead anchorages. The proposal saved time by avoiding 20 excavation and subsequent back filling below the tank slab. More than 52km and 6,500 couplers of the PT-PLUS® system have been installed. The 700mm-thick wall is reinforced with 144 vertical and 158 horizontal tendons. High- performance Ductal® G2 grout has been used. ■ Contact: [email protected]

Czech Republic Team success at Rybny Potok

> Excellent coordination between temporary bearings with all participants has led to permanent ones. The maximum successful completion of work on a lift on a single pier was 3,500t, bridge over Rybny Potok on the D8 provided by eight 500t jacks. A highway. VSL installed secondary consortium of Strabag and external cables on the bridge, Skanska was the general following the launch of the 20,000t contractor for this section of superstructure. The cables, which highway, with Metrostav as bridge are up to 360m long, consist of contractor. Bridge design was 31-strand replaceable CS 2000 carried out by SHP with assistance tendons. VSL also carried out all from VSL. the lifting works needed to replace ■ Contact: [email protected]

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UK NOTE PAD

Towers Out or rain. VSL Argentina has been appointed to build two PT water tanks to prevent flooding reaching for inside the Repsol-YPF Refinery in La Plata. Each water tank is approximately 70m by 70m with the skies 3.5m-high walls. VSL is using the > VSL is carrying out post- Bondtech system with 0.5” tensioning on the tallest tower in strands. Liverpool. A construction boom is under way in this World Heritage Carbon plate. VSL France has City and future European Capital of installed a 15m-wide, 100m-long Culture, with new sports, cultural suspended floor underneath the and shopping facilities as well as deck of a motorway viaduct over an impressive skyline of towers. the River Yonne as part of a Tallest is the 120m-high Beetham project to repair the structure. West Tower, for which VSL CFK 150/2000 carbon plates are designed the post-tensioned slabs being bonded to the beams as and is carrying out the installation strengthening. using the SO 6-4 system. ■ Contact: [email protected]

Tunisia 21 Works start

> VSL Switzerland has recently started building the deck of the main bridge of the Rades–La Goulette project in Tunis for Taisei Corporation. The extradosed bridge is 260m long, with a main Switzerland span of 120m and end spans of 70m. VSL is supplying two pier Flexible build table formwork units, two pairs of form-travellers, PT components > Post-tensioning has recently doubled as lost formwork. The and all the necessary construction been completed by VSL on floor fourth level, the roof slab, has to supervision. Components and slabs for the extension of a car support heavier loads and so is supervision are also being park in Lausanne. The lower three 600mm thick and post-tensioned supplied for another part of the levels were made up of 350mm- with VSL EC-H 6-12 cables. The project, which involves four post- thick prestressed slabs with VSL flexibility and adaptability of the tensioned ramps constructed on SO-H 6-4 post-tensioning cables. VSL system also facilitated an easy scaffolding. Completion is due in Cycle times were reduced to less transition between the new November 2007. than a week, thanks to VSL’s post- extension and the existing car ■ Contact: k.doghri@bouygues- tensioning method and the use of park. construction.com thin prefabricated slabs, which ■ Contact: [email protected]

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SITE INSIGHTS

Russia High and dry > VSL has been playing a key role in major scheme under way in St Petersburg. A new protective dam will guard against the danger of flooding and an elevated highway is also being built. The elevated structure is largely made of precast beams but also includes a 122m-long, 1,500t section of steel deck, which was assembled at ground level and raised 22m to its final level. VSL’s computer- controlled laser levelling system proved ideal for this as the structure was very flexible transversely. The lift was successfully carried out in a single, Iran smooth operation. ■ Tough tanks Contact: [email protected] 22 > The fast-growing list of the semi-circumferential liquefied natural gas storage horizontal tendons and U-shaped tanks built with VSL post- vertical loops. The system’s tensioning now includes the South superior friction coefficients Pars Gas Field project in allowed a significant reduction Assaluyeh, Iran. VSL is providing from the strand quantities initially the post-tensioning for two estimated. Further benefits came propane and two butane storage from the robustness and ease of tanks for the ninth and tenth installation. VSL’s CS 2000 phases of the huge project. PT- anchorage is used throughout. PLUS® duct is being used for all ■ Contact: [email protected]

Ecuador Achievements in deep forest

> Installation of 128 stays for a of the steel bridge with its 183m-span bridge over the concrete slab is being supported Pastaza River in the Amazonian by SSI 2000 stays, sized between forest has been completed three 6-12 and 6-31. A total of 81t of months ahead of schedule, despite replaceable stays were used. difficult site conditions. The stays Galvanised and waxed for the new bridge on the Baños- monostrands were placed in an Puyo road were installed in just external polyethylene pipe. five months. The composite deck ■ Contact: [email protected]

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France Seaside repairs

> Major renovation has now been Chile completed of the Grau Saint-Ange coastal bridge alongside the Mediterranean. VSL France was Superflat and smooth awarded the project which was financed by the local council of > A “superflat” slab surface has centre’s specialised fork-lift Pyrénées-Orientales. The 15-month been achieved at a major Chilean trucks. VSL’s ability to produce a project restored damaged areas distribution centre, far exceeding joint-free finish provided additional and brought safety features up to the project’s already demanding benefits. The high specification standard. Proximity to the sea had requirements. Expansion of was achieved through the use of led to chloride contamination in Falabella, one of Chile’s top three special formwork and narrow the double-deck structure’s retail companies, prompted the 4m-wide pouring strips. VSL’s concrete. Hydrodemolition construction of a new 30,000m2 scope of work also included removed some 800m2 of distribution centre in Santiago. engineering advice, supervision contaminated concrete, which was The slab needed to be very flat for and liaison. replaced using shotcrete. efficient performance of the ■ Contact: [email protected] ■ Contact: [email protected] 23

France Landmark win for VSoL®

> An exceptional VSoL® project Geneva as part of the Thonon-les- of more than 3,000 concrete facing has recently been undertaken Bains bypass. The scheme used panels measuring 1.68m wide by along the French banks of Lake almost 9,000m2 of VSoL®, made up up to 2.80m in height. All panels feature complex architectural finishes with patterns measuring up to 200mm. VSL’s role ranged from design through to construction and included securing the architect’s approval. The project specification also called for nearly 22,000m2 of VSoL® Steel with a mineral facing. The VSoL® Steel Mesh system was applied over straight and curved wall segments, for structural bridge abutments and for reinforced fill approach ramps. The first VSoL® Steel panels were installed during June 2006 and the team began setting up the concrete panels in mid- September. ■ Contact: jp.vernier@bouygues- construction.com

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FOCUS

European Organisation for Technical Approvals (EOTA) ETA for VSL post-tensioning systems

On 31st July 2006, French Approval Body SETRA has issued the European Technical Approval (ETA) for VSL post-tensioning systems for a period of five years. This provides VSL with the most comprehensive range (from 1 to 55 strands) of ETA approved of the market. VSL’s ETA is valid in all EU and EFTA countries.

The introduction of Construction tensile, fatigue and load transfer The tendons assembled as part of Products Directive (CPD) (see box) tests, as well as many other tests the VSL Post-Tensioning System 24 represents a giant step in the aim required to check the performance may have the following basic use of harmonisation and setting of of our post-tensioning system. categories: higher standards in post- • internal bonded tendon tensioning systems. Structures Full range approval for concrete and composite will be safer and also more structures, reliable thanks to the ETA process. The ETA has been granted for VSL • internal unbonded tendon To have certified systems that can full range of systems: for concrete and composite be used in all EU/EFTA countries • The VSL Multistrand System structure, without need of further country by (anchorages from 1 to 55 • external tendon for concrete country approvals certainly is the strands), intended more for structures with a tendon path main objective of the CPD. massive civil engineering situated outside the cross structures with either metallic section of the structure or Upon mandate from EU/EFTA and ducts or VSL PT-PLUS®. member but inside its envelope. in order to guarantee that all • The VSL Slab System (from 1 regulated characteristics were to 4 strands), intended for The following optional use taken into consideration, VSL thinner construction elements categories are added: assisted EOTA in the drafting of the such as building slabs or bridge • restressable tendon ETAG 013 which is the one decks, is used along with either (internal or external), referring to post-tensioning bare strands inside metallic • exchangeable tendon systems. VSL’s ETA has been ducts or VSL PT-PLUS® as well (internal or external), issued on 31-07-2006 by the as individually greased and • internal bonded tendon with prestigious French Approval Body sheathed strands. plastic duct, SETRA and is valid for a period of • encapsulated tendon, five years. VSL had to submit an The VSL Post-Tensioning System • electrically isolated tendon, application including full details of may be used for new structural •tendon for use in composite our systems and their intended works or repair and strengthening construction as external tendon, use as well as test reports and a works for existing structures. It • tendon for use in structural comprehensive description of our may also be employed in masonry construction as internal VSL manufacturing centres.Tests structures made of other and/or external tendon, were carried out at the prestigious materials than concrete as • tendon for use in structural Swiss laboratory EMPA and masonry, steel, wood or timber as internal and/or comprise mainly static load, combinations of several materials. external tendon.

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EU/EFTA countries

Austria

Belgium Cyprus Czech Republic Denmark

Estonia Finland France Germany

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Greece Hungary Iceland Ireland

Italy Latvia Liechtenstein Lithuania

Luxembourg Malta Netherland Norway

Poland Portugal Slovak Republic Slovenia

Spain Sweden Switzerland United Kingdom

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VSL differenciation

Other post-tensioning systems with ETA approvals had only up to EOTA, now anchorages ranging from 1 to 27 or 31 strands, whereas VSL how it works goes up to 55 strands, allowing EOTA (European Organisation for Technical Approvals) was born out of customers and consultants a much the Construction Products Directive (CPD) 89/106/EC of the European wider variety of choices. VSL’s ETA Union. The goal of the CPD is the removal of technical barriers in the is valid in all EU/EFTA countries construction products sector through: (today, 29 countries, in the future, • compliance of works with the six Essential Requirements (6ERs) maybe more than 40). This could • transformation of the 6ERs to product requirements by means of also affect many countries in the Interpretative Documents world that have national codes and • determination of performance oriented regulations for products used practices inspired from British in the works by technical specifications Standard, German or French • attestation of conformity of the product codes. Conferences will be carried • CE marking of the product by VSL during the next months in all subsidiaries affected by the EOTA comprises the Approval Bodies (AB) nominated to issue European implementation of ETA in order to Technical Approvals (ETA) by EU Member States and EFTA States who fully disclose the importance for have contracted to the European Economic Area Agreement. the post-tensioning industry of An ETA for a construction product is a favourable technical assessment these matters. of its fitness for an intended use, based on the contribution made by this product to the fulfilment of the six Essential Requirements, as stated in VSL will also continue to include new the CPD for the construction works in which the product is installed. An anchorage as well as developments ETA can be granted when any of the following conditions apply: 26 of the existing systems in future ETA • no relevant Harmonised Standards for the product exist so that customers and consultants • no mandate for such a Standard has been given by the European could have access to an even Commission greater choice of anchorages and • the European Commission considers that a Standard cannot be applications. developed (yet) • a product deviates significantly from the relevant Harmonised Standards The Attestation of Conformity (AC) procedure with a technical specification like the ETA, is intended to ensure that the product specification set out in an ETA is maintained by the manufacturer. The AC system is decided by the EU for each individual product or product family and given in the mandate for an ETAG.

Although in certain circumstances it may be possible for an ETA to be issued on the basis of a common assessment procedure agreed among EOTA members, in most cases an ETA for a product will be granted to a Extralong CS 2000 trumpets manufacturer based on the assessment principles set out in an ETA on medway bridge deck Guideline (ETAG) for the relevant product sector.

After contributing to ETAG 13, VSL An ETAG describes how to assess, in an harmonised way, products of a is pursuing its efforts to guarantee particular product family, so that the result products, if the AC provisions that customers and consultants are satisfied, can carry CE marking and can be placed on the market in benefit from state of the art post- any of the EU/EFTA countries without further regulatory requirements. tensioning systems as well as safe ETAGs are binding for all Approval Bodies, grouped in EOTA. and reliable methods and installation personnel. The aim is that after a certain period, the a European Standard on Agreement, CWA 14646 which is expertise gained with issuing ETAs installation and qualification of already specified in many could be used for making a post-tensioning personnel adopted European countries and could European Standard for installation in EU/EFTA countries A first step eventually lead towards an prENV of post-tensioning. VSL is has already been done with the and thus become a European presently working in order to have preparation of the CEN Workshop Standard in the future. ■

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TECH SHOW

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Venetian Macao phase I Precast for mega casino

The Venetian Macao Resort Hotel Phase I is the major development of another giant casino by Las Vegas Sands Group in Macao. For VSL, the project involves large scale precast beam installation.

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VENETIAN MACAO PHASE I – EAST PODIUM TECH SHOW

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Giant footprint . 1 The East Podium is on a footprint of 250 x 310m. The main structure consists of level 1 at +7m above ground level, on a column grid of 10 x 10m, followed by level 3 at +18m and level 6 at + 33.0m above ground level, both on a column grid of 20 x 20m and 20 x 30m. Level 3 is carrying 2 canal structures and a retail level above and is partially supporting a hanging floor below, both composite structures. Level 3 and 6 are highly loaded, designed as wind and earth quake resisting frames supporting up to 20kPa live load.

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From left to right: K.F. Au, Erection Foreman; C.W. Chan, Erection Supervisor and Gary Hackett, Senior Superintendent

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VENETIAN MACAO PHASE I – EAST PODIUM TECH SHOW

Precast wind - and main beams at level 1. 2 Level 1 is the Casino level on a 10 x 10m grid. The main- and wind (framing) beams are full span precast beams supported on column heads and made continuous over the columns with cast in-situ stitches. The mainbeams with continuous nips on either side are carrying the precast double T beams.

Precast double T beams 3 at Level 1. The precast double T beams have proven to be the most efficient in terms of design as well as for erection: 3 numbers of double T beams are placed in a 10 x 10m bay, before a topping of 75mm thickness is cast in place. 30 Scaffolding System’s (MSS).

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Semi-precast pre-tensioned 4 mainbeams and precast pre-tensioned phi shaped beams at level 3 & 6. Level 3 and Level 6 have typical bay layouts of 20m x 20m and 20 x 30m. The structure consists of continuous post-tensioned framing beams, made up of semi-precast pre-tensioned mainbeams and precast pre-tensioned phi shaped beams supported on column heads. Simply supported precast and pre-tensioned T or I shaped secondary beams are supported on the continuous corbels on either side of the main beams. Precast planks are placed in between the secondary beams to receive a cast in-situ topping. The precast beams and planks are cast in China, transported by road to the construction site and installed by custom made high capacity traveling cranes, which allow placing 25 ton beams at a 50m radius.

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4-in-1 semi-precast main beams in the sequence of works. 5 The details of the 4-in-1 semi-precast main beams play a vital role to the success of VSL’s alternative design. The sequence of works is as follows: - Installation of 4 nos. of semi-precast main beams by heavy duty tower crane on column heads. - Stitching of flanges of precast beams to ensure the structural integrity. - Fixing of steel reinforcement cages and PT ducts in between precast beams. - In-situ concrete in-fill of main beam. - Span by span stressing of continuity tendons across columns. - Installation of precast secondary beams supported by corbels on main beams. - Erection of precast planking supported by secondary beams. - Fix top reinforcement and cast topping. Typical weights of precast beams are 20 to 28 tons

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VENETIAN MACAO PHASE I – EAST PODIUM TECH SHOW

Overlapping post-tensioning 6 tendons. The post-tensioning tendons of a 32 respective span typically overlap by High capacity tower cranes. 1/4 with the previous and next span. 7 The large footprint of about 250 x 310m and the heavy The detailing is done such as the precast beams of up to 28 ton required 4 custom made high tendons can be stressed at either capacity tower cranes made in Denmark, 2 of them rail mounted, end from stressing pockets, bringing capable of traveling under full load. The rail tracks consist of the stressing operation out of the steel or concrete beams spanning 20m from pile cap to pile cap critical path. above the lower ground floor. The beam installation started near to the hotel and moved progressively away. The access corridor for the tower crane was in-filled as the crane retreated. Upon completion, the tower cranes are dismantled by crawler cranes placed on top of level 6, which also fill in the last openings.

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Erection of precast secondary beams 8 and precast planking. The precast secondary beams are installed on top of the corbels of precast main beams after stressing the continuity tendons. The beams are T- or I-shaped to minimize the weight to 28t for erection. Half joints at either end of the beams are detailed by using strut-and-tie models to ensure the load transfer at the critical zones. In between the typically 4m spaced secondary beams, 75mm thick precast planks with cast in lattice griders are installed. Top slab reinforcement is fixed directly on top of the lattice girder to receive the in-situ cast topping. VSL’s services included as well the coordination with the architect and building services engineer for detailing of the planking layout.

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VENETIAN MACAO PHASE I – EAST PODIUM TECH SHOW

Venetian Macao project at a glance

Designed as a luxurious resort and convention destination with Venice’s landmarks, this pro- 34 ject includes a podium with casino and retail space, with an integrated canal structure to sail gondolas, a 40 storey hotel, a theatre and an exhibition centre. All are built on the newly re- claimed land in the Cotai Strip of Macao SAR, China. VSL, in a JV with Dragages and China Civil, were awarded the construction of the 5 level podium structure.

VSL Hong Kong successfully converted the cast-in situ structure into a partially precast scheme, which allowed fast track construction and minimized the need of large falsework and formwork. This enabled a quick handover of the completed bays to the next trade contractor. The precast unit weights were limited to maximum 28 ton and 19m length and required custom made high capacity travelling tower cranes for installation. VSL’s erection team un- der Henry Chan successfully demonstrated the effective- ness of the scheme and in- stalled over 9,300 precast units in less than 13 months.

The pre-tensioned beams and planks of level 3 and 5 have been cast by China Railway in Zuhai (Guangdong Province), about 30km away from the site, under close supervision of VSL.

NEWS N°2•2006 VSLNews2-2006 29/11/06 17:47 Page 35

HEADQUARTERS www.vsl.com VSL International Ltd. CREATING SOLUTIONS TOGETHER Scheibenstrasse 70 – Bern CH-3014 – Switzerland Phone: +41 32 613 30 30 Fax: +41 32 613 30 55 VSL LOCATIONS

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50 YEARS OF PARTNERSHIP

VSL operates through 35 subsidiaries as a world-wide network. The company has adapted post-tensioning principles to civil structures such as LNG tanks, plants, tunnels, off-shore platforms, dams -and stay cables. In addition, the group's scope of works covers rock and soil anchors, stabilized walls, precasting, formwork systems, launching gantries, heavy lifting, bearings, repair works, monitoring, deep foundation and soil engineering activities. VSL offers skilled and trained specialists; an experienced technical center able to benchmark new methods, new equipment and new materials; specialist equipment designed as modular as possible; innovative contracting approach to focus with the Main Contractor on what is “best for project”. www.vsl.com