NEWS THE VSL NEWS MAGAZINE • ISSUE ONE 2010

NUCLEAR CONTAINMENTS New generations’ challenges LNG tank Formwork System Moses Mabhida Stadium NUCLEAR 8

SUSTAINABLE 4 DEVELOPMENT Assessing sustainability 4 FACTS&TRENDS 6 EIT: Worldwide first 6

R&D: No voids 7 COVER STORY 8 BRIDGES Post-tensioning solutions for nuclear containments 16 Addressing the new generations’ challenges TANK SITE INSIGHTS 16 FORMWORK Australia: Six months ahead 16 27 New Zealand: Staged delivery 17

Abu Dhabi: Parisian prestige 20

Spain: Tight squeeze for a TBM 25 R&D 26 New LNG tank Formwork system: One system, one cycle highlights FOCUS 28 Fast track road construction with PPCP

TECHNICAL REPORT 31 Testing the SSI saddle STADIUM 32 TECH SHOW 32 We shelter the fun The Moses Mabhida Stadium in South Africa will soon be staging the Soccer World cup. VSL placed the arch above the stadium and lifted the cable net roof structure

NEWS, magazine published by VSL International Ltd. • Bern, Switzerland Director of Publication: Daniel Rigout• [email protected] Editor in chief: Jane Rousseau • [email protected] Editor : Elisabeth Lichter-Rodriguez • [email protected] Co-ordinators: Carlos Such, Emilie Parati, Doris Tong. Distribution: VSL Communications Design: Red Line Photos: Derek Allan, Philippe Guignard, Hervé Gouband, Christine Mueller-Sinz, David O’Donnell, others Copyright: VSL 2010 •

Cover photo: Shin Kori 1-2 nuclear plant, Korea ISSUE ONE • 2010 EDITORIAL

VSL, a name that is recognised and highly valued

For more than 50 years, VSL’s core strategies have been research and innovation, technical development and achieving high quality to serve our clients. Today more than ever, our key assets are our R&D department in Subingen, Switzerland, as well as our Technical Centres in Singapore and Saint Légier, Switzerland, which bring together over a hundred highly skilled engineers and technicians. They allow us take on the most ambitious technical challenges of building today’s infrastructures.

Our teams in 50 countries throughout the world focus on optimising each structure from its very start. Later, during construction, our sophisticated method statements help guarantee project schedules, quality and safety.

Clients can count on VSL to mobilise all its technical resources from the outset to optimise costs and other key factors for successful projects, and to minimise the risks involved in their investments.

This latest issue of our magazine is showing the daily efforts of our technical teams and R&D engineers to develop systems that serve the booming worldwide nuclear industry and meet a growing requirement for the construction of LNG tanks.

VSL endeavors to ensure that its name on a project is recognised and highly valued as a global guarantee of quality, technical performance and reliability both during construction and in terms of long-term durability, with minimised maintenance costs. At the same time, there is a focus on sustainability and achieving the lowest possible environmental impact. All members of VSL staff make this their priority.

Daniel Rigout, CEO SUSTAINABLE DEVELOPMENT Assessing sustainability

Initial efforts have been focused on raising awareness of sustainability issues through education, training and encouraging changes in behaviour through green initiatives. Even small individual improvements become major gains. How to measure these efforts?

ustainability covers a considered as ‘goal achieved’ complex and wide-ranging however continual improvement is Sset of issues, and VSL has a an integral part of this so the work clear concept of what sustainability never stops. means and does not treat it as a set of easy to manage tasks. Quantitative approach The other main tool is Enablon, a The Actitudes initiative focuses on software used to report the SD actions across seven different performance data online. The themes: content of the report evolves over - Foster a trusting relationship time as performance improves and with our clients, based on priorities change. Reporting is also 4 consideration, transparency and carried out annually, however only innovation the largest operating units report - Incorporate risk management representing 80% of the turnover into the day-to-day running of the of the group (which can broadly be company translated into ‘impact’). The - Lead our business sectors in report covers information such as terms of occupational health and energy use, waste generated, staff safety development, and injuries. The - Develop our employees' skills reporting is again completed by and promote equal opportunity one country) usually by the the Administration, Finance and - Establish balanced, long-term Administration, Finance and QSE QSE departments, and is approved relationships with our partners, Departments. Each of the 42 actions by a senior manager. suppliers and subcontractors is measured against a performance - Ensure that our businesses criteria to assess the current Applying a sustainable respect the environment (design of situation and set an improvement development approach to VSL’s works) objective for the coming year. activities will not only contribute to - Participate in the economic and These assessments are then reducing the environmental impact social life of the regions where we reviewed by the Regional of our activities but will also reflect operate. Management for consistency and the attitudes of an increasing accuracy before being number of VSL clients and However, straightforward consolidated, based on turnover, stakeholders. Self-assessment measurement is useful if it by the VSL Group. Following this a carried out at group level in 2008 describes real impacts and random sample of the self- was complemented by a number of improvement. Which is what VSL assessments are subject to an VSL subsidiaries carrying out their has done, with the two main tools external audit. Each Actitudes own self-assessment at the end of developed to measure the action is graded as 1 to 4 with 2009 to monitor progress and set performance. 1 being the minimum acceptable new objectives. The exercise standard (e.g. legal compliance) allows the whole company to Qualitative approach and 4 applying to a mature system, recognise and share best practices The first one is a self-assessment achieving excellent results and and to identify areas for carried out annually by each incorporating a comprehensive improvement on which future operating unit (typically covering feedback loop. Level 4 can be efforts can be focused.

NEWS N°1-2010 KNOWLEDGE DISASTER RELIEF MANAGEMENT RISK MANAGEMENT Help for Haiti Tips & tricks Drawing mergency Architects provided help following to share E the devastating Haiti the line earthquake, sending a team to f a picture is worth a thousand assess damage to strategic words, then a 3D drawing must buildings and identify places that Ibe worth a million… were safe for shelter. VSL in Development of new cost-effective Australia supported the work via technologies now allows VSL and donations. Intrafor to use 3D tools for improved risk management. For example, applying the new AWARD approach to foundations enhances comprehension and planning of Recognized by complex projects, situations and details, resulting in better government preparation, understanding and explanation. Clients, consultants, ong Kong’s Labour contractors and sub-contractors Department awarded a all benefit from the very accurate H Bronze Prize to the Central representations of projects. Reclamation Phase III project in 5 the Construction Industry Safety Awards. Intrafor’s safety manager ISO 9001 Cesar Shum and safety supervisor emo-tech is Intrafor’s newly Jerry Chan received the award on implemented tool aimed at VSL Vietnam behalf of the joint venture team Mcollecting and sharing tips running the project. Next year they and tricks of the trade that are certified are “going for gold!”. developed on individual projects, but which disappear with the SL Vietnam has successfully project’s completion. It keeps track achieved ISO 9001:2008 of the knowledge and allows V certification, following audits ENVIRONMENT sharing throughout Intrafor (and carried out by Bureau Veritas VSL) of experience, solutions, ideas (BVQI) on its head office and Minimising and good practices, including safety projects both in north and south measures. Vietnam. impact ivil project staff members COMPANY SPIRIT from VSL United States are C part of a team designing VSL at Macau Grand Prix and building the Foothills Parkway Bridge No. 2 in the Great Smoky he Macau Grand Prix is Mountains National Park. a major annual event, One of the key reasons for T known for being the choosing the proposed design was only street circuit where both that it accommodated the unique car and motorcycle races are challenges of the site and the held. Race car No. 12, strict requirements to minimise supported by VSL Intrafor environmental impact. This was logos, successfully completed imperative given the bridge’s one of November’s events, sensitive location on a the Macau Road Sport mountainside in the densely Challenge. wooded national park.

NEWS N°1-2010 FACTS&TRENDS

EIT Bars Worldwide first Joining forces with electrical isolation of post- > Tysan Foundations awarded tensioned cables. The project VSL a contract for the supply uses a special EP sheath coupler and installation of 75 temporary developed for this type of work by ground anchors as part of an VSL’s R&D teams in the USA and extension to the Singapore Switzerland. Preliminary International School in Hong laboratory tests showed that the Kong. Intrafor carried out the system could provide a category C structure while allowing flexibility during installation. Construction confirmed the concept’s theoretical behaviour and that the bridge met EIT requirements. VSL’s construction of the viaduct is part of a five-year project to develop Geneva’s railway network. The 330m-long S-shaped structure includes pronounced curves at entry and exit. VSL has drilling works while VSL’s teams > Geneva’s Lect Viaduct marks installed about 85t of strands as were responsible for the the world premiere for the well as 4,600m of PT-Plus® ducts installation and stressing of the combined use of prefabricated and 1,200 duct couplers. Contact: anchors in a coordinated joint 6 segment construction together [email protected] effort that delivered the project three weeks ahead of schedule. The project involved Hong Kong’s first use of SAS Bars and Dampers Corrosion tight schedules meant that VSL’s work had to be carried out Staged by client Hong Kong first in parallel with excavations. Contact: alice.lin@vsl- > The Korean highway > VSL was recently awarded intrafor.com authority responsible for the its first corrosion protection Incheon Bridge decided to contract in Hong Kong for the display samples of VSL dampers redevelopment of Kai Tak, the at its showroom following site of the former international Coupler successful installation on the airport that closed in 1998. bridge. The cable-stayed bridge Three different types of corrosion Approval was the first project to combine protection systems will be used both VSL friction dampers and by VSL on the project. The in Florida Gensui dampers. This key impressed current cathodic > The Florida Department of project is expected to create protection method will protect Transportation has approved other opportunities for dampers the existing pile caps of the VSL’s new segmental coupler. Its on forthcoming cable-stayed taxiway bridge. A sacrificial first use will be on the new bridges in the country. anode cathodic protection I-4 Interchange in Tampa, where Contact: [email protected] system will be provided on a 18,000 of the couplers will be newly-installed sewerage installed. VSL will also supply pipeline to be laid along the the post-tensioning systems. former runway. Thirdly, a When complete, the structure complete corrosion monitoring will connect the Lee Roy Selmon system will be installed inside Expressway to Tampa the caissons of future seawalls. International Airport. The overall Contact: project value is US$450 million. [email protected] Contact: [email protected]

NEWS N°1-2010 Pot bearings & PT R&D SGK (Swiss Society of corrosion protection for VSL) the sensors Elegant solution No voids enable monitoring of the injection and control of grout properties at critical points along the tendon to reduce the risk of undetected defects such as poor grout quality, voids and the presence of any bleed water. Measures can then be taken to remedy any substandard areas of filling before the grout has set. > A successful test has been A sensor management unit will > VSL has provided post- carried out in Switzerland on a be developed to enable the tensioning and bearings for this full-scale mock-up of a post- technology to be applied on a 730m-long new crossing of the tensioning tendon equipped with pilot project. Contact: River Cacheu in Guinea-Bissau grout void sensors. Supplied by [email protected] that will replace the old ferry service. Contractor Soares da Costa has completed the concrete structure, an elegant Equipment solution designed by Armando Rito. The bridge includes six Multi-purpose rig 86m main spans and two 52m > Intrafor is renewing its fleet spans built by the free cantilever with a new Klemm KR805-2 7 method as a variable-section multi-purpose environmental- box girder. Only bonded post- friendly hydraulic drilling rig, which tensioning was installed in the is suitable for top-hammer and deck although provision has down-the-hole works as well as for been made for future installation jet grouting. In addition to the usual of external cables. The main horizontal and vertical movements, piers required temporary it can turn around the axle of the external cables to balance the slewing column to allow set-up and deck during construction. The alignment in difficult situations such pot bearings manufactured by as the corners of buildings. The CTT have capacities of up to KR805-2 is equipped with a newly 14,500kN and all have been developed computer system to equipped with load cells installed ensure quality and efficiency of jet inside the pot to monitor grouting operations. Contact: vertical loading. Contact: sebastien.frebourg@vsl- [email protected] intrafor.com

Ground investigation modified slightly to Wireline technique accommodate the wireline and survey systems. Preliminary > Development of a commercial testing using the wireline version of Intrafor’s own technique on Intrafor’s own directional coring system steerable core barrel system started in September 2009 has proved very successful and following the delivery of an larger scale testing will be Atlas Copco BQ wireline drilling performed to confirm the system and Reflex EZ-AQ EMS properties of Intrafor’s borehole survey instrument. commercial system. Contact: The steerable core barrel was [email protected]

NEWS N°1-2010 COVER STORY

POST-TENSIONING SOLUTIONS FOR NUCLEAR CONTAINMENTS Addressing the new generations’ challenge

8

Shin-Kori 1-2 nuclear plant in Korea, 2010. VSL is providing the post tensioning design and installation equipment.

NEWS N°1-2010 The worldwide nuclear market is booming with over 260 containments to be constructed in the next 20 years. Criteria for post-tensioning in this ges field are the most stringent to be met in civil works to date. The required performance, the difficulty of installation, the layout and the size of the tendons pose unique challenges that have for many of them never been pushed so far in the detail and in the performance. Demonstration of VSL’s post-tensioning for the new generation of nuclear plants... 9

Different tendon layouts allow for compression of the concrete in three directions within the walls.

ost-tensioning for nuclear them never been pushed so far in containments of the new the detail and in the performance. P generation is like what Nuclear structures demand special Formula One is to the automotive designs and methods to meet the industry, though requiring absolute extremely stringent requirements safe and full performance for the for installation and long term design life of the structure. The behaviour, together with the principles of post-tensioning for external controls that are imposed nuclear applications are similar to by the nuclear regulators. the ones for other large civil structures; however, the required The safest performance, the difficulty of ultimate barrier installation, and the layout and the Generally, nuclear reactors produce size of the tendons pose unique massive quantities of heat and challenges that have for many of require isolation from the

NEWS N°1-2010 ADDRESSING THE NEW GENERATIONS’ CHALLENGES COVER STORY

environment through a dual circuit design. The primary circuit SYSTEMS FOR 3D GENERATION CONTAINMENTS transports the heat between the Testing on a slice reactor and the steam generators and is situated inside a nuclear VSL has anticipated the containment vessel. The secondary circuit transports the steam outside current boom in the the containment, steam that is used energy market by setting to activate the turbines to generate VSL’s experience in the nuclear civil up a full-scale mock-up electricity. Among the few reactor business includes 58 references in technologies available worldwide, nuclear containment structures, of of a slice of an EPR-like one of the most common is the which 34 use the complete VSL containment to Pressurised Water Reactor (PWR). anchorage system and installation. demonstrate new In this case, the containment is The highly specialised pool of VSL’s designed to withstand high internal technicians and engineers has the capabilites. It is the pressures that would result from a experience and the qualifications largest R&D investment leakage of steam or an accident. required to carry out all special ever undertaken by VSL. Such pressure applied to the inside operations of supplying and surface of the containment cause installing the post-tensioning on The testing program and results tensile forces inside the nuclear containments to the have demonstrated the efficiency of containment walls, that are often highest level of quality and safety. VSL’s range of post-tensioning offset in the design principles by the A proactive R&D policy, with an solutions for the latest nuclear use of post-tensioning. integrated R&D team, allows VSL containment designs to suit power to carry out independently stations ranging from 1,000MW to This post-tensioning is typically important projects such as the full- 10 1,600MW, for the latest generation made of a layout of horizontal loop scale mock-up in Gien (see box). of containments, including the tendons, vertical tendons, and dome European Pressurised Reactors or gamma tendons, depending on Anchorages are key elements for (EPR), the VVER, the Advanced the containment design. This post-tensioning systems. VSL pressurized water reactor (APWR) combination of tendons withstands provides various types to suit each for MHI and Obayashi, and the design pressures of typically client’s requests, such as CPR 1000. 0.4MPa. Unbonded or bonded post- replaceability of strand, friction The mock-up was designed as a tensioning tendons may be used: values, and containment geometry. 2.75m-high slice of a nuclear the choice depends on the VSL’s systems, all designed containment vessel, including specifications and on the according to ETAG 013 criteria, 6 different types of post-tensioning technology. provide excellent performance at tendons of various systems. The radius for the tendons matched the 24.46m outer tendon radius of Pressure gauge Displacement sensor directly on the jack on the piston an EPR. A high-grade C60/75MPa concrete was poured in the walls. Global Load cell The high density of reinforcement 1 500tons within the buttresses led to the anchorages being cast into 55 Individual prefabricated elements to load cells guarantee the accuracy of installation and the quality of concreting. Special installation and checking methods were developed Jack with long to meet the stringent criteria for stroke 520mm the post-tensioning installation. Construction of the mock-up VSL DAU: allowed demonstration of the duct • Continuous recording waterproofing, adjustment and of all parameters • Special user function placement of three different types to pick out records of ducts: PT-Plus®, low friction The ZPE1350 VSL Jack for for QA purpose nuclear applications

NEWS N°1-2010 Concerned about environment and sustainable development issues, VSL handed over the mock-up to the city of Gien after completion of the tests. The ring was transformed into a rainwater storage tank and surely it will have long years of water tightness duty in this new role.

Construction of the mock-up at Gien, France steel sheet ducting and steel tubes. - Stressing with the ZPE 1350 FJ Four tendon types were also long-stroke jack; installed, using different - Comparison of strand installation anchorages, different type and sizes method between prefabricated and of ducts and different strands. For push-through tendons, these tendons, three new designs of - Equalisation of the force in each casting were developed, all of them strand using the Low Force Jack; 11 meeting the nuclear requirements. - Measurements of friction The tendon sizes were 6-37 and coefficients for the overall tendon; 6-55, using a maximum of 37 or 55 - Measurements of the variation in strands of 15.2 or 15.7mm diameter. force between strands of the same tendon during stressing, and Successful stressing test at calculation of standard deviations; the Gien mock-up - Validation of various cement grout formulae with different rheology The tendon layout values and setting times. of the full scale test mock-up at Gien, 2009

Anchorages for every nuclear application

Possibility Possible Type of Post- Design friction Performance at of strand monitoring after tensioning coef value* ultimate state replacement installation

Bonded with Grout No 0.18  steel duct sensor Grout sensor Bonded with No 0.14  EIT (electrical plastic duct Load measurements isolation) of the 55 strands Force (global Unbonded with or individual force On completion of the civil works, bare strands Yes 0.14  measured during clients and system owners were and steel duct maintenance or invited to attend demonstrations permanently covering a variety of site tests: Unbonded with - Threading test of a tendon with a Grout sensor, greased and PE Yes 0.05  EIT or force high vertical deviation simulating sheathed strands the tendons at the vicinity of the containment hatch; * These friction values are generally lower on site and confirmed by a friction test.

NEWS N°1-2010 ADDRESSING THE NEW GENERATIONS’ CHALLENGES COVER STORY

ultimate state and, depending on VSL’s R&D team reproduced the the force between the strands prior the type of anchorage and project situation on a mock-up (see box) to the full stressing. requirements, can be monitored in and demonstrated that these different ways, either by means of differences in length could even To pre-tension each individual grout sensors, through electrical lead to strand breakage well before strand, VSL R&D team developed a isolation, or by force measurement the end of the stressing operation if Low Force Jack capable of (see table). no precautionary measure is taken. simultaneously stressing all strands Problems were identified and individually and independently at a Mixing in long quantified; specific measures were very same force. This jack achieves and short lengths then developed to guarantee the a force of up to 10% of the breaking The strands in a nuclear structure fulfilment of the nuclear load (28kN per strand). are subjected to significant requirements, including the Consequently, at the start of the deviations due to size and complex implementation of adequate stressing operation, all strands are pipe penetrations in such structure. threading methods to mitigate the loaded with the same force A major challenge encountered for “mixing” of strands, the use of the whatever the initial differences in the installation of post-tensioning in force, lengths, arrangements, and nuclear containments relates to the slack between the strands. arrangement of the strands inside the ducting during their threading. For the final stressing, VSL has When a LNG structure generally then developed two types of high- requires only 19 strands, on a capacity jacks. The ZPE 1350’s 180° layout, a nuclear containment long stroke allows stressing of the needs up to 55 strands, threaded on tendon in a single stroke without a 360° layout. Consequently, once any need for regripping. The other threaded, strands may vary lighter ZPE 1450 has a shorter 12 significantly in length –in a ZPE1350 VSL Jack between inner and outer stroke and is used where tendon magnitude of half the stressing containment access is difficult. Specific extension– depending on their final platforms for the stressing position inside the duct whether on appropriate lubricant to assist in operations are provided in case of the inner or outer edge. When reducing the friction between the difficult access and reduced space applying post- tensioning, this strands, and the development of on site. variation in length may lead to large methods (specific pre-tensioning of variations in force from one strand each individual strand prior to Real time black box to another. stressing to full force) to equalise More than anywhere else, contractors and clients in the nuclear field not only require safe systems in place but also ask for tangible proofs that procurement and installation of these systems were provided to the highest level without defect. To provide real time control to the operator, the owner and the designer, VSL has integrated a specific monitoring system in its nuclear special equipment, including stressing jacks and grout pumps. For the jacks, this control system is made of individual magnetic load cells installed on each of the tendon strands monitoring the force in real time during stressing operations individually in each strand. These load cells small enough to fit on each and all strands of the same Vertical inverted U tendon after stressing on tendon do not require a mechanical Shin-Kori 3-4 nuclear plant in Korea, 2010 connection to the strand and can be

NEWS N°1-2010 TENDONS Timely design for complex layout

The main difference between radius and the compatibility with nuclear containment the design specifications and, if structures and other need be, to modify the containment structures design for a successful such as LNG and LPG tendon installation on tanks resides in the site. Finally, the specific shape and specifications impose function of the stringent installation nuclear tolerances that require containment and the use of pre-cut and the stringent supply pre-bended steel tubes and installation installed on pre- requirements. In defined supports fixed order to allow for a to the liner or to the perfect sealing and previous cast layer. the displacement Should the layout of required for the the tendon cross the operation of the concreting level, containment, specific provisions are several pass- taken to avoid duct 13 through tubes with damages while specific design are preparing the needed. In some concreting of the next cases, the tubes layer. Close cooperation may interfere with between the or be too close to containment designer, the post-tensioning the VSL design team layout. VSL’s and the client’s experienced teams production and design provide their teams are required at services to validate all time, since these the detailed position provisions generate a on 3D or 2D models, significant quantity of as well as the tendon collaborative work.

seamlessly integrated into the the operation. It uses a personal Heavy duty grouting normal stressing operation. digital assistant to process the The quality of the grouting is of information and store it for further utmost importance to ensure the A special recording system, the review by a third party. The VSL DAU durability of post-tensioning tendons. VSL Data Acquisition Unit (DAU), can be considered as a “black box” When using bonded post-tensioning acquires and continuously records (similar to the one of an airplane) systems, VSL’s cementitious grout the stressing data, including the that registers all events. In case of provides excellent bonding and tendon forces and elongation. Such unexpected event, issues are protection for prestressing steel. VSL a system allows full traceability of identified and remedied. has developed a comprehensive

NEWS N°1-2010 ADDRESSING THE NEW GENERATIONS’ CHALLENGES COVER STORY

process dedicated to improving and Clients and partners insuring the quality of grouting « We share a similar culture » materials and grouting activities on site: VSL HPI®. Optimised grout mixes INTERVIEW designed for the specific use and Jong Cheol Lee, manager of the safety equipment design team environment, using selected local for Doosan’s Nuclear Business Group. cements and admixtures have been analysed and optimised for exclusive use in the network.

Additional verification that grouting has been properly executed is provided by the VSL Grout void sensor. It is installed at potentially critical points on a tendon and allows checking the existence of any voids left after grouting. Electrically isolated tendons and PT-Plus® ducts can be provided if required. Extra requirements for duct sealing are met, such as the welding of outlet vents to coupling pipes for steel-to-steel connections without any intermediate pieces. What is the role of post-tensioning has replaced it since the UCN 5&6 14 in the design of your nuclear project. VSL-Hong Kong is located VSL has been involved in containments? much nearer and we share a similar construction projects requiring The containment building of a PWR culture and time zone and for this special skills and innovative in Korea is a post-tensioned reason our cooperation is very engineering solutions since 1956 reinforced concrete structure strong and well-suited. and has been providing services in enclosing a nuclear coolant the nuclear market since 1974. system. It is designed to contain You have recently had great Integrated quality assurance is the the escape of radiation in any success in the Emirates. What are final achievement of the VSL emergency. The 1.2m-thick your perspectives about your comprehensive services to address containment is the final barrier to development within the clients’ challenges, with radioactive release. The international market? commitment and reliability. Today’s containment building itself is Korea's highly experienced team R&D is another proof – if need be. typically an airtight steel and can transfer the knowledge gained concrete structure enclosing the from the 30 years of successful reactor and normally sealed off nuclear industry operation. from the outside atmosphere. The steel liner is attached to the inside What particular skills do you need of the concrete containment. from your partners for this international development? You have worked with VSL for a We will experience quite different long time, since the 1980s. Any working conditions, regulations comment? and cultures on overseas sites. We Doosan is the only and top-ranked have to provide very high quality company for nuclear power plants in and short delivery times despite Korea. VSL is the global number one these kinds of difficulties and this company for post-tensioning work. will not be achieved easily without The cooperation in Korea between our partners’ cooperation. VSL has VSL and Doosan has been a great so much experience and many success for the last 20 years. At the branch offices throughout the beginning, our partner was VSL in world and so we are sure that it is the USA and now VSL-Hong Kong well-placed for this. Jack installation on the vertical tendon at Shin Kori 1-2 plant.

NEWS N°1-2010 Clients and partners “Ability to cater for modifications!” INTERVIEW Pavel Mozerov, technical director of the LAES-2 project for VSL’s client Metrostroy

What are the objectives and VSL’s post-tensioning system are its functions of the post-tensioning usability and the provision for system in a nuclear containment? permanent control with the The post-tensioning system monitoring instrumentation. Another increases the load-carrying important advantage is that the capability of the nuclear greased, sheathed strands can be re- containment to safeguard against tensioned, de-tensioned or replaced. any damage that could happen inside the containment. It protects How do you evaluate the from internal damage while the cooperation with VSL? external shell protects from VSL is distinguished by its technical external damage - even from a competence. Staff members provide plane crash! detailed information about how the system will be installed and how it Do you see any risks in connection will work. There are no issues with cages. As much of the preparatory with this system’s installation? equipment delivery and VSL works as possible should be carried No, this system has proved its provides a serious and responsible out off site - on site we should only value. I do not see any risks if there approach to technical assistance. handle the installation. 15 is a competent technical approach But the difficulty of saving time is and a correct installation. In your judgment, what are the that we live in a country with severe prospects for nuclear expansion in winter frost. We must spend time Why have you chosen VSL Russia? building enclosures around the on the LAES project? A massive programme of nuclear concrete structure for the winter The system was tendered and VSL plant construction has been created period. Construction times increase suggested a more technically up-to- in Russia. As far as I know, 24 or accordingly. date approach, in which monitoring is 26 reactor blocks will be built soon. also used. The main advantages of Electricity consumption is What are you expecting from increasing in Russia and there is a businesses that apply to tender? power shortage in Europe. For Equipment has to be the most up- example, the Baltijskaya nuclear to-date and very manoeuvrable and power plant will supply electricity the production team needs to be to nearby countries. highly technically competent. Construction technologies may not What about technical development be fully worked out even when the in the nuclear industry? technical drawings have been Blocks of the current VVER-1000 issued by the designer. That's why design are used for the an enterprise aiming to participate LAES-2 Nuclear Power Station Leningradskaya nuclear power plant in the construction has to have in St Petersburg, Russia The VSL post-tensioning system is being and the same blocks will be built at sufficient engineering staff to be installed on the 67.7m-high inner Baltijskaya. The general director of able to suggest the best containment shell at LAES-2. The project meets the latest nuclear containment Rosatom [the state nuclear energy construction solutions. requirements for post-tensioning and uses corporation], Mr. Kirienko, said that A requirement for joint work to be 55 greased and sheathed 15.2mm strands, the aim is to carry out block carried out on site is that there is with 76 horizontal hoop tendons anchored in one or two buttresses, 13 extra horizontal construction in three to three and a sufficient flexibility in the ducting tendons in the dome and 50 vertical half years. For such a decrease in system as well as the ability to inverted “U” shape tendons over the dome stressed from a stressing gallery. The timescales, it is necessary to cater for modifications occurring system allows checking of the residual load, develop the construction technology. during construction - and believe re-tensioning or replacing the tendons if required, and this at any time during the life One of solutions could be me, there will be many different of the structure. preassembly of the reinforcement modifications!

NEWS N°1-2010 SITE INSIGHTS

Australia Six months ahead!

Image courtesy of Queensland Motorway, Gateway Upgrade Project

16 > The Leighton-Abigroup-VSL construction, six months ahead of built using the cast-in-situ Alliance has carried out the schedule. The Alliance’s scope balanced cantilever method. The closing pour at the centre of the covered full construction of the adjacent 1980s crossing will be main span of the Gateway Bridge 1.65km bridge including the refurbished to give a combined duplication, 65m above the 260m-long main span, which was capacity of six lanes in each Brisbane River. October’s closure built by form traveller. It is one of direction by early 2011. Contact: marked the end of 30 months of the world’s longest bridges to be [email protected]

Australia Hong Kong Eye catcher Channel providing an eye-catching entrance to a major piece of infrastructure that has involved substantial crossing bridge construction and access > A joint venture of Kaden and ramps. Leighton Contractors VSL won a Highways design and awarded VSL a contract to design build contract at Tseung Kwan O and supply the VSoL® Retained New Town in December. The Earth Walls. The various required project’s major feature is a 140m- finishes for the walls were cast in long channel crossing, whose main VSL moulds using form liners, span will be precast on site on a each 2m by 2m facing panel was flat-top barge for installation by painted after installation. Design of heavy lifting and lateral launching. the walls allows for crash barrier The 10m-wide bridge has a footpath loads, horizontal loads at the and cycle track, which can also be > Queensland’s Ipswich/Logan abutments while used as formwork used for emergency vehicle access. Motorway Interchange has now at these areas. Contact: Contact: lewis.wong@vsl- been completed, with VSoL® walls [email protected] intrafor.com

NEWS N°1-2010 Australia Aqueduct alliance > The Pipelines Alliance, comprising Melbourne Water, Fulton Hogan, Jaydo and GHD, engaged VSL to assist in replacing Melbourne’s primary sewer. Critical in the upgrade was the launched 70m-long, continuous together with 33 precast deck construction over the structure has a 5.3m by 5.3m units and the hand rails. VSL also environmentally-sensitive square cross-section with a 4.7m- carried out the design, supply, Werribee River of a new sewer diameter HDPE-lined circular pipe. fabrication and operation of the aqueduct, adjacent to the heritage- The final launch was completed in launching system and post- listed existing sewer and early December. VSL’s scope tensioning of the structure. Melbourne’s high pressure gas included precasting and vertical Contact: gioannidis@vsl- pipeline. The new, incrementally- prestressing of the 11 pier units australia.com.au

NOTE PAD 17 Deep cut. Two Intrafor diaphragm wall shafts for Hong Kong’s harbour area treatment scheme are well under way, including one by cutter in Sai Yin Pun where the rockhead depth is 91m. The 12.3-diameter shaft should be the deepest diaphragm wall ever built which will be exposed over its full height, as bulk excavation will proceed in rock down to 150m. Panels have New Zealand achieved outstanding minimal deviations of less than 1 in 900, despite massive boulders. Staged delivery Challenging logistics. Intrafor’s work on Hong Kong’s Central > Newmarket Viaduct, which was cast in early May. Cranes erected Reclamation Project includes a built in Auckland in the mid-1960s, the first balanced cantilever wall with a particularly is being replaced and VSL in New sections to create a 120m-long challenging client design requiring Zealand is part of the Alliance deck, allowing assembly of the unusual reinforcement logistics. delivering the staged project. The launching gantry. Segment Three layers of 50mm-diameter New Zealand Transport Agency erection by gantry started in steel mean that conventional awarded the contract in November February 2010. The staged lapping of the bars is not feasible. 2008 to NGA Newmarket, which construction means that the The only solution is to transport, includes Leighton Contractors, 680m-long southbound structure lift and place the 55t, 38m-long Fulton Hogan, Beca, URS New will open in October, allowing cages as single sections using a Zealand, Tonkin & Taylor, Boffa removal of the existing southbound three-crane multiple lift and Miskell and VSL. Foundation works structure to free up space for the paying great attention to safety of this very challenging project new northbound viaduct. and detail, including use of started on the piers in April 2009 Contact: [email protected] bespoke equipment. and the first of 468 segments were

NEWS N°1-2010 SITE INSIGHTS

Hong Kong Anderson milestones

Malaysia 500 precast units

> More than 500 precast units have place 200km from the site and 18 been successfully installed for the segments were erected using the Jalan Hang Tuah elevated viaduct on balanced cantilever method. a busy Kuala Lumpur road. VSL Erection involved mobile crane use worked in joint venture with a local and an AF-65 segment lifter, which precasting company on a was particularly needed on a subcontract to cast and erect challenging section where an 37 crossheads and 469 segments for existing monorail track runs parallel the twin carriageway single-cell to the viaduct at a distance of just 2m. box-girder structure. Casting took Contact: [email protected]

India > VSL has been achieving a Aggregate transport series of milestones since it won a contract over a year ago to design scope of work includes the full and build nine VSoL® Retained design of the bridge structure, Earth walls totalling 22,000m2 in pylon and deck elements and the preparation for high-rise housing at design, supply and installation of the Anderson Road site in Kowloon. the 515m-long main cables. The The VSoL® walls stand between remoteness of the site and the 25m and 36m high and are being requirement for accurate built using 4m2 rectangular fabrication led to all special steel masonry-finish panels. A major components being produced under milestone was December’s VSL’s strict supervision 1,200km completion of a load-bearing VSoL® away in Kolkata and brought to site bridge abutment. Panel production > A 300m-span suspension by barge. Treacherous river has continued to push ahead, with bridge is being built to carry a currents mean that lifting has to 20% of the total delivered by the conveyor transporting aggregates take place as soon as the barge is end of 2009 and 10% of the VSoL® for a 2,000MW hydro-electric dam anchored in position. Contact: Steel system wall area installed. on India’s Subansiri River. VSL’s [email protected] Contact: [email protected]

NEWS N°1-2010 India Complex cycles for BOT project

> VSL is achieving an average The viaduct involves erection of cycle time of less than two days 1,421 segments using a VSL per span - with a record of overhead launching gantry. About 36 hours - on a complex 4.2km two thirds of the 120 spans have elevated highway being built in horizontal curvature, including Bangalore for Navayuga several S-curves with crossfalls Bengalooru Tollway Private and a gradient. VSL has achieved Limited, India. Construction time 80% completion and has also is critical on the build, operate successfully erected spans and transfer project and a peak for a lay-by area, which includes production of 18 spans in January a challenging 44m span. comfortably beat the 2.5 day cycle Contact: [email protected] that VSL committed to.

Hong Kong Australia Air-lifted drilling rigs Realigning mountains 19

> Building two reinforced soil walls nearly 20m high for the Conjola Mountain Realignment involved difficult site access as the walls were built on the mountain slopes. The subcontract for BMD Constructions involved VSL’s design and supply of 3,500m2 of VSoL® panels and soil reinforcement. One of the walls was cut into rock and the use of a stepped reinforced soil block allowed minimising excavation costs by reducing the length of the soil reinforcement near the wall’s base to approximately 40% of the height. Contact: fwagner@vsl- australia.com.au

> Two drilling rigs are being Kong’s border with China. Intrafor mobilised by helicopter as part of is drilling about 315m down to the a subcontract that Intrafor is invert level of the future traffic carrying out on behalf of LAM tunnel. The NQ wireline drilling Geotechnics. The works involve system will be used once the hole drilling a vertical hole and an reaches 100m. The client is Hong inclined one to obtain geological Kong’s Civil Engineering & and geotechnical information for Development Department and the the design of a traffic tunnel as part engineer is Mott MacDonald. of capacity improvements at Hong Contact: [email protected]

NEWS N°1-2010 SITE INSIGHTS

Abu Dhabi Access to Formula One > Yas Island I Abu Dhabi is famous for the Formula One fans as the final race on the F1 calendar. The brand new circuit was opened in October 2009, a few weeks ahead of last year’s inaugural race. VSL was heavily involved in the main access infrastructure works on Yas Island working for the main contractor Sixco and their client Aldar on two large packages of 10 + 9 bridges providing 3,000T of post-tensioning 20 incorporated in the many bridges and ramps as well as over 90,000m2 of MSE walls. Contact: [email protected]

Scotland Successful ground anchors Abu Dhabi > Following the success of the ongoing Thames Tidal Defence Parisian prestige project, Scottish & Southern Energy has awarded VSL Systems > Abu Dhabi now houses a a retaining back stay. The lifting (UK) a contract to carry out testing replica of France’s prestigious cables were connected to the of ground anchors for five dam Sorbonne University that is dome’s compression ring below its projects throughout Scotland. designed to emulate the original’s centre of gravity. In total 26 of The ground anchors, installed at educational standards and VSL’s SLU 40 strand jacks were various stages over the past appearance including the activated simultaneously to lift the 20 years, have been regularly impressive 22m-high cupola. 150t dome. VSL’s safe and cost- tested by VSL as part of an ongoing VSL lifted the new 20m-diameter effective strand jacking method crucial maintenance regime. Site dome to its final 19m level using allowed work to continue in work to carry out the latest testing eight temporary towers with two parallel underneath the load. is taking place in spring 2010. inclined pulling cables and Contact: [email protected] Contact: [email protected]

NEWS N°1-2010 Syria Power lift > VSL and Kahele Technical Group have worked together in successful heavy lifting works for a power plant close to Damascus. The adopted approach on the challenging scheme involved a special gantry and lifting frame design, which shortened the cycle time by more than 50%. A 250t generator and a 175t turbine had to be installed. Use of a single SMU 330 for lifting and lowering allowed the load to be rotated in midair, without a turntable. The gantry with the suspended load was skidded into position before lowering. Contact: [email protected]

21 Abu Dhabi Hangers for dunes

> The Special Projects of three pairs of steel arches, which installation is expected to be Department of VSL has recently are shaped to resemble desert completed by the end of 2010. completed the first phase of sand dunes. It has a main span of Opening of the bridge will provide a hanger installation at Abu Dhabi’s 126m and the twin concrete deck is third link between Abu Dhabi Island new landmark crossing, the Sheikh supported by 36 stay hangers in and the UAE mainland. Contact: Zayed Bridge. The bridge consists various sizes up to 6-127. Hanger [email protected]

NEWS N°1-2010 SITE INSIGHTS

Czech Republic Post- tensioned gallery

> Close coordination was needed for the construction of Prague’s Harfa Gallery, with PT works often carried out in four locations simultaneously. The five-storey mixed-use development is in one of the city’s best locations, near the Norway O2 Arena, which was another key VSL project. VSL’s work at the gallery for main contractor Strand-by-strand debut Metrostav has involved installation of almost 100t of PT bonded slab > Spennarmering Norge and VSL Glomma. A slender 90m-high pylon have combined their expertise to will support a composite deck with manage a cable-stayed project that a main span of 142m and an 22 introduces strand-by-strand stay approach span of 102m. technology to the Norwegian The 28 stay cables vary in size market using VSL’s proven SSI 2000 from 6-43 to 6-85 with lengths up system. Bilfinger Berger is main to 126m. Gensui dampers are to be contractor for the Smaalenene installed on all stays. Contact: Bridge spanning the River [email protected]

Switzerland Alternative solution

> VSL’s proposal of an alternative post-tensioning method secured it the contract for work on the Mülimatt sports training centre being built jointly by the Swiss canton of Aargau and the city of Brugg. A particular feature of the Z-6-6 anchors proposed by VSL is tendons and multistrand PT. that they allow post-tensioning at Prefabricated cables were used in any intermediate point of the areas where there was insufficient cable. The piers and roof are made space for strand-pushing jacks. from very thin concrete, with Space constraints also dictated 160mm panels forming a “V” stressing from underneath the shape. VSL’s scope of work slabs through openings, which included the installation of about were subsequently reinforced and 100t of stand as well as 15,000m filled. Contact: [email protected] of PT-Plus® ducts. Contact: [email protected]

NEWS N°1-2010 Switzerland Poland Seismic upgrade Silesian

refurbishment of the Central viaducts Hospital for Haut Valais in Viège. The results showed that the buildings required strengthening. VSL has achieved this by means of 33 vertical post-stressed VSL CarboStress® laminates, which are up to 24m long and connect the roof to the foundations. Permanent VSL micropiles had been installed Designer: Mosty Katowice previously to transfer loads directly into the ground for maximum > Valais as Switzerland’s most earthquake protection. The vulnerable earthquake region proposed method proved to be updated its requirements when the most economical and best seismic standards were updated in compliance with the requirement 2003. Seismic safety measures of the owner. Contact: were evaluated as part of the [email protected]

Switzerland 23 New slide for mega move

> VSL Polska has supplied and the stay systems for two contrasting viaducts as part of the Sosnica Interchange between the A1 and A4 highways in Poland’s Silesia region. The 101m-long WD467a viaduct features an oblique concrete and steel pylon. > VSL Heavy Lifting has supported on four VSS-500 lift- It has 85t of stays, made up of successfully transported a 2,500t and-slide skid shoes and propelled between 33 and 65 strands, with tunnel boring machine (TBM) by eight SLU-40 strand jacks in 4m two sets of seven stays for the 625m overland to its next location cycles at a ‘cruising speed’ of main and back spans. Traffic will in Biel, Switzerland. Client 7m/h. A bridge had to be lifted off continue to run underneath on the Herrenknecht opted to move it in its abutments to allow the 110m- A4 while the stays are installed. one piece rather than dismantle it. long vehicle to pass along the The WD464 viaduct has a 25m-high The move to the next drilling route, which included curves and arch and its six pairs of hangers of location required the development slopes of 2.5% uphill and 3.7% up to 55 strands were installed at of a completely new sliding downhill. Contact: the end of the year 2009. procedure. The TBM was [email protected] Contact: [email protected]

NEWS N°1-2010 SITE INSIGHTS

Mexico Matching towers Argentina > The 28-storey Escondido Tower has been developed by First cable-stayed Inmobiliaria Rotacion as the first of three matching buildings at Mazatlan in Sinaloa. Mazatlan is road bridge one of the most important ports on > VSL Argentina has completed a 110m main span, VSL supplied the Pacific coast and is known as installation of the Río Cuarto and installed 40 stays, using 57t of the ‘Pearl of the Pacific’. 24 cable-stayed road bridge. The sheathed galvanised strands and VSL developed the structural bridge is the first of its kind in the SSI 2000 system. The owner is design for the project as well as Argentina using the method of Córdoba province's DPV and the supplying and installing PT prefabrication for this type of main contractor was a joint venture materials. The work involved 62t of bridge. Its steel pylons were of Paschini Construcciones, Boetto 0.5” (12.7mm) strand for the prefabricated before being lifted y Butigliengo, Estructuras and 21,300m2 of post-tensioned slabs. into position and the precast deck Marinelli. The engineering VSL Corporation Mexico will beams were installed on temporary consultants were Setec and continue with the post-tensioning supports, which were removed after Ingroup. Contact: of the other two towers. Contact: stay installation. For the bridge with [email protected] [email protected] Portugal Seismic step forward > VSL has taken a major step themselves carried by six parallel forward in the repairs market with arches. Project consultant A2P’s VSL Portugal’s completion of a analysis concluded that the highly complex project on a key structure could not fulfill seismic motorway viaduct across the safety requirements. The solution Trancão valley. Bridge owner Brisa was to eliminate intermediate deck decided to carry out strengthening joints and provide base isolation to improve concrete protection and complemented by passive damping. ensure the structure’s seismic The work involved installation of a resilience. Main contractor Soares total of 120 longitudinal and da Costa appointed VSL to carry out 30 transverse dampers as well as the seismic upgrade and other steel beams. The isolation system repairs. The viaduct has a incorporates a cut-out, calibrated 329m-long deck slab and is to break under seismic loads while supported on cross beams and allowing service loadings. longitudinal beams, which are Contact: [email protected]

NEWS N°1-2010 Spain Spain Three-directional Large accuracy for a TBM production

> CTT Stronghold (VSL in Spain) 2.4m stroke fixed on the wall of the area has successfully replaced the gallery opposite to the TBM and a drilling heads of a tunnel boring flat skidding equipment installed machine in the Habaneras shaft, on the transport frame plus two Barcelona. VSL designed a specific lateral steel extensions, it was transport steel frame for the possible to achieve the required skidding manoeuvres of both geometrical accuracies to allow drilling heads inside the gallery, the extraction/fitting of the TBM on two skidding tracks. By means drilling heads. Contact: of three hydraulic jacks with a [email protected]

Spain > Lleida’s largest industrial Tight squeeze company in Spain, Grup Alimentari Guissona, has begun operations at > CTT Stronghold has and five back-up trailers of 750t a new food production complex. 25 successfully moved a 1,300t through a 300m tunnel scarcely VSL was appointed to work with tunnel boring machine (TBM) wider than the machine. The Constructora de Calaf on the 11.54m-diameter TBM for design and construction of the Barcelona’s underground system latest three phases, which is 12m long with 80m of trailers. together provide a production area The VSS-500 skidding system was exceeding 120,000m2. Key design used to move the TMB and requirements included live loads SLU/SMU to pull/hold the trailers. ranging from 15kN/m2 to 25kN/m2 Tunnel geometry was the most as well as a major reduction in difficult issue as the size of some expansion joints with operational sections is just 250mm wider than temperature ranges of between the TBM and there were also -20ºC and 30ºC. Two phases have different complex curves and a been successfully completed and 3% downhill slope. Contact: the other is under construction. [email protected] Contact: [email protected]

Turkey Largest span > The 190m-long main span of double box deck platform, the Beylerderesi Bridge being constructed by form traveller. built in Turkey’s Malatya province Main contractor for the bridge is is the country’s longest ever to use VSL’s Turkish licensee Mega Yapi the balanced cantilever method. on behalf of the highways The 420m-long bridge crosses a authority. The project involves deep valley in three spans about 700t of post-tensioning supported by slipformed piers using tendons equipped with VSL about 60m high. The superstructure E6-19 anchorages. Contact: is formed by a 24m post-tensioned [email protected]

NEWS N°1-2010 R&D

NEW LNG TANK FORMWORK SYSTEM One system, one cycle Extensive worldwide involvement in the construction of LNG tanks has enabled VSL to analyse data and obtain feedback from site production teams to identify typical and specific problems associated with tank construction, subsequently developing innovative and unique solutions. The optimised VSL LNG tank Formwork system is one such example of this development.

Nowadays, the storage of liquefied gas is provided by two elements: • the primary or inner containment of the tank, which is typically constructed of steel with a high nickel content, aluminium, 26 stainless steel or in some cases post-tensioned concrete to meet the extreme demands of cryogenic conditions. The containment must independently be able to withstand the hydrostatic load of the liquid. • the secondary or outer containment, which is most commonly constructed from post- tensioned concrete. It is designed to withstand abnormal loads of external origin as well as retaining the liquefied gas and vapours should there be a fracture of the primary containment. Comprehensive modular system VSL has developed a modular system for this secondary Optimised layout for fast-track construction containment. It can be used to The construction schedule is designed to allow for accurate planning and build entire circular containment helps avoid delays by optimising the formwork requirements and PT structures without the need for arrangement. The improved quality that results provides greater control to time-consuming and costly meet the permanent tolerance requirements. Fast construction cycles are modifications to the climbform achieved as there is no need for additional components to cater for system after installation on site. unexpected clashing of post-tensioning and form ties. Faster cycles save time and money. The surface finish is improved due to reductions in form- The VSL LNG Formwork system is tie relocation holes in the form face. Major adjustments and additional a comprehensive solution form-tie holes are avoided because the locations of the ducts are taken into account - a form tie cannot be positioned through a hollow duct. This avoids providing suitable solutions for the unused form-tie holes, which would have to be closed with plastic plugs construction of all components of leaving marks that would have to be removed. a typical LNG tank wall including

NEWS N°1-2010 tapered walls with reducing Less time on thicknesses, walls of constant adjustment thickness and ring beams. Safety of form work standards and national codes have panels been taken into account with VSL has optimised standardised fixed access ladders the interfaces for increased safety on the between climbform. The system is highly watertight form- efficient with fast and safe ties, climbing stripping and closing as well as cones, tendon easy and quick assembly of the ducts and vapour integrated ring beam support. barrier plates. The working cycle The system development has been has been based on clearly defined criteria. shortened by Firstly, it was important that the minimising the concrete tank construction could time-consuming be completed without the need for adjustment any major modification once the of formwork system was assembled and panels. No modification once assembled commissioned. This applied to all aspects including lower tapered Improvement tank walls, typical wall sections, of operational ring beams and buttresses. efficiency beam can all be built without The system guarantees an modification of the standard 27 A second factor was to minimise optimised working schedule that components. Adaptability for interference with other activities brings accurate planning and variable lift heights and wall such as post-tensioning and avoids delays. The fast cone thicknesses makes the system installation of mechanical anchor assembly improves the suitable for all LNG tanks embedded plates and inserts. formwork system’s operational worldwide. The system may also Clear, unobstructed access to all efficiency. Furthermore, there is be used on other structures work areas had to be provided. no need for additional components including piers, columns, buildings to take account of unexpected and any circular containment And, as for all VSL developments, clashing of the post-tensioning structures. safety features are vital, including and form-ties. The surface finish is permanent fixed access to the top improved due to a reduction in the working and trailing platform, easy number of form-tie relocation Customer-involved testing stripping, ergonomic components holes in the form face. Clients who visit the VSL mock- and an integrated ring beam up gain an invaluable insight into lowering device. Single system for standard the system and are able to sections and ring beam witness firsthand the many Optimising tank The VSL LNG tank Formwork benefits that this new system will bring to their projects. Different construction system allows casting of both the site conditions are simulated While designing this new formwork standard sections and the ring following a theoretical system for tank construction, beam using the same form with presentation. VSL has focused on five points: simple adjustment and only minor The demonstration incorporates: additional elements. • stripping Enhanced safety • closing The system meets international Modular components • fixing standards and features safe for more flexibility • adjustments working areas on the climbform, The majority of components for the • assembly and adjustment of the including a fully-integrated stair VSL LNG tank Formwork system ring beam soffit form. ladder, hand-rails and toe boards. are modular and there is no need The climbing cones with back for advanced training to operate Mock-up location: VSL Singapore Pte. Ltd. anchors are designed with them safely and efficiently. The Contact: Michael Jentsch consideration of hollow tendon tapered starter walls, vertical shell mail: [email protected] ducts. walls, buttresses and the ring

NEWS N°1-2010 FOCUS Fast track road construc Highway owners and users demand quick and low-cost infrastructure construction with minimal impact on the environment and low long-term maintenance. A VSL precast prestressed concrete pavement (PPCP) can provide the ideal solution with pleasing aesthetics.

Precast and post-tensioned Today’s infrastructure and road The panels are fabricated at a concrete has a proven track record projects need to be built rapidly, precast plant, ensuring thorough as a durable high-performance not only in terms of how quickly quality control under ideal factory product for bridge and commercial the road can be built but also how conditions. building construction. VSL is a soon it can be opened to traffic. leader in the field of post-tensioning Conventional cast-in-place Reduced slab thickness 28 and has for decades designed, pavement requires several days of and cracking manufactured and installed additional curing after the concrete Reasons for specifying thinner durable, state-of-the-art post- is placed before it is strong enough slabs and a borded post-tensioning tensioning systems that meet to withstand traffic loading. In system include concrete savings, international standards and contrast, a PPCP can be opened to easier replacement or meeting approval guidelines. traffic almost immediately. height restrictions where a bridge crosses the road. Prestressing Rapid opening to traffic The advantages in terms of durability furthermore reduces the tensile As a result, all it took to apply this and performance are manifold, stresses. By putting pavements experience to road construction starting from the production of the into compression there is less projects was to adapt proven panels and the related quality control likelihood of cracking, increasing technology to produce innovative right through to installation and the design life. solutions. post-tensioning on site.

The 35km-long Kanci-Pejagan Toll Road in Indonesia was completed in 14 months

NEWS N°1-2010 uction with PPCP

How it works

Traffic flow

Joint panel Base panel Central stressing Base panel Joint panel (Multiple) panel (Multiple)

Panel assembly The precast prestressed pavement consists of a series of individual precast panels that are post-tensioned together in the longitudinal direction after installation on site. Ducts for the longitudinal post-tensioning are cast into the panels. Each of the panels is pre-tensioned in the transverse direction along its long axis during fabrication. The system consists of three types of panels. It is best to provide a flat, stable platform for the precast panels to rest on, although they can span over voids and "soft" base materials. 29

Central stressing pockets

Ducts for Ducts for Ducts for post- post- tensioning post- tensioning tensioning Pretensioning Pretensioning Pretensioning strands strands Continuous Continuous Continuous shear key strands shear key shear key

Base panels Central stressing panels Joint panels Base panels make up the majority of Post-tensioning is carried out at the The joint panels are located at the the post-tensioned pavement section. central stressing panels, where the ends of each post-tensioned section They are placed between joint panels strands are fed into the ducts. Strands of pavement. The joint panels and central stressing panels. are fed in both directions to the anchors contain dowelled expansion joints in the joint panels. The strands from which "absorb" the expansion and either side of the central stressing contraction movements of the post- pockets are then coupled together and tensioned section. The joint panels tensioned. also contain the post-tensioning anchorage for the longitudinal post- tensioning tendons. The anchors are cast into the joint panels on either side of the expansion joint. Up to Post-tensioning 100mm of movement can be The post-tensioning strands are threaded through the installed expected at the expansion joints, so panels, anchored at the ends and tensioned. Grouting provides they must be robust. Both armoured an additional layer of corrosion protection for strands and bonds joints (similar to those used for the tendons to the pavement so that the post-tensioning system bridge decks) and plain dowelled will remain intact if ever it is necessary to replace a panel. Road joints have been used, with the construction by means of PPCP provides rapid pavement choice depending on the expected construction at reasonable cost, with high performance and traffic and slab movements. Dowels durability and simple maintenance. across the joint are essential for providing load transfer.

NEWS N°1-2010 FAST TRACK ROAD CONSTRUCTION WITH PPCP FOCUS

Panels were installed by crawler crane, each team achieving 100m a day

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Precast panels were Successful PPCP implementation in Indonesia delivered by trailer The Kanci-Pejagan Toll Road, which is 35km long and includes 40 overpasses, was built in just 14 months and completed in December 2009. This major project by contractor Adhi Karya (Persero) and investor Semesta Marga Raya (Bakrie Group) forms part of the masterplan for Indonesia’s 1,000km Trans Java Toll Road. Kanci-Pejagan is Indonesia’s longest toll road and the first ever to be built there with a PPCP. The system was chosen as an alternative to the conforming cast-in-situ rigid concrete pavement. As a result, the slab thickness was reduced from 300mm to 200mm and the lean concrete was cut from 100mm to 50mm thick. The major considerations for choosing PPCP lay in its quality, speed of construction, durability, reduction of expansion joints and cost-effectiveness. The toll road has two 12.2m-wide carriageways, with the 8.2m for the two traffic lanes constructed using PPCP while the shoulders are of 200mm-thick cast-in-situ rigid concrete pavement. Each PPCP panel is 2.5m long and pre- tensioned transversally at the casting yard and then post-tensioned longitudinally on site into 100m-long sections. More than 21,500 panels were manufactured in a 5.2 hectare casting yard. Production reached about 234 panels a day in a 16 hour pouring cycle using 156 moulds in 12 lines and steam curing. Contact: Johannes Tjintatmijarsa ([email protected])

Slab thickness was reduced from 300mm to 200mm

NEWS N°1-2010 TECHNICAL REPORT

TESTING THE SSI SADDLE In the field VSL’s saddles are manufactured in Barcelona and Hong Kong. In addition to the 20 saddles installed on Catumbela bridge (Angola), 60 saddles Continuous (sizes 6-31 / 6-37) were fabricated in 2009 for Delhi’s Moolchand bridge (India), Tisza M43 bridge (Hungary) performance and Mumbai’s WEH bridge (India). The testing in 2009 of a VSL SSI Saddle under typical cable-stayed bridge loading is now being followed up with a second test to demonstrate performance with extradosed cables. Angola Successful completion of first saddle project The bridge for an expressway crossing the Catumbela River was designed by Armando Rito Engenharia and By the end of March, construction was awarded to a 31 the VSL R&D team had consortium of Soares da Costa and Mota-Engil. The 438m-long cable- successfully completed stayed bridge has a 160m-long main the 2,000,000 cycles of a span and its concrete deck is fully full-scale fatigue test of the supported by two pylons. Each pylon VSL SSI Saddle 6-37 system. tower integrates ten stay cables and uses saddles for seven, with anchorages for the remaining three. The system simplifies VSL Portugal’s work included the stay detailing of cable cables, post-tensioning, bearings and stayed bridge pylons dampers. Contact: by replacing a pair of [email protected] upper anchorages with a Hungary single saddle that the M43 Tisza Bridge cables pass through. shows saddle’s potential Current tests are on a The first set of stays has been installed saddle with a base radius of successfully on Hungary’s M43 highway bridge, spanning 180m over the Tisza 2.4m and an opening angle of 60°. Independently guided and replaceable strands River. The project’s highlight lies It was fabricated in VSL’s inside the two 30m-high pylons where Barcelona factory and installed in emulate conditions in extradosed the VSL SSI 6-37 Saddle is showing its January in the test frame at bridges. The specimen’s ultimate true potential as an alternative to Germany’s Technische Universität capacity will be determined by a conventional pylon anchorages. Berlin. final tensile test. Contact: [email protected]

The set-up consists of a full cable In addition to the saddle test, VSL’s specimen with the saddle, two SSI R&D team is supervising combined 2000 DR anchorages, two tension fatigue and tensile stay cable tests rings and saddle transition boxes. in three different European Testing involves applying a stress laboratories to comply with range of 140MPa at 1Hz for two specific project requirements. The million cycles. The stress range is test specifications follow the lower than in the original test but recommendations of fib Bulletin the upper load of 60% breaking No. 30 and involve specimens of strength is significantly higher to 37, 61 and 85 strands.

NEWS N°1-2010 TECH SHOW

VSL HEAVY LIFTING We shelter the fun South Africa will soon be hosting the FIFA World Cup ™. VSL’s goal in the event was to place the arch above the Moses Mabhida Stadium, Durban and lift the cable net roof structure. Here is how it scored.

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Be aware of challenges Situated at the Indian Ocean in Kwazulu, Durban is the second biggest city in South Africa 1 and presents, like no other city the Rainbow Nation. For the FIFA World Cup™, the Moses Mabhida Stadium was built, the second biggest stadium in South Africa seating more than 70,000 fans. The roof structure of the new stadium is exceptional: the giant Y-shaped arch represents the South African flag. VSL’s scope of work was guying of temporary arch support towers; support and tie back of arch during free cantilever erection; lifting and tensioning of cable net roof structure- performed by VSL for the owner South African Football Association and roof contractor Pfeifer Seil- und Hebetechnik Memmingen (Germany).

NEWS N°1-2010 Act as specialists 2 VSL was contracted to support the installation of the huge Y-shaped arch and the cable net roof structure. A deciding factor in building the ambitious structure was the ability to provide and install a tremendous amount of strand lifting equipment on time. The central control and monitoring system allowed conducting an orchestra of 100 SLU strand lifting units according a score-like cable net stressing procedure. VSL was involved from the beginning in the design of temporary structures to create task-fit interfaces between permanent/temporary works and the proven lifting system.

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NEWS N°1-2010 VSL HEAVY LIFTING TECH SHOW

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Tie down arch splice support towers 3 The 160m-long lateral stays for the temporary towers are made up of six 6-92 cables, stressed with monostrand jacking. To maintain the verticality of the tower, the stressing had to take place simultaneously from both sides. A control system ensured the same force level on all strands during stressing. The tricky part during installation was to feed the large cables through the adjacent tower.

Readjust once lifted 4 The tie-back stays for the cantilever arch erection used up to four 6-22 cables fitted with SLU-220s for readjustment. The massive forces were anchored through large steel consoles to the concrete base of the arch. The arch was adjusted by pulling or releasing the hinged tip of the temporary towers.

NEWS N°1-2010 Cater for wind The support towers feature massive ties to cater for lateral wind 5 forces. Millimetre accuracy was required for the cantilever adjustments. In addition, the arches were supported in the tower tips by a sophisticated suspension system, allowing for vertical movement and making it possible to rotate the cantilevering arch along its longitudinal axis.

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NEWS N°1-2010 VSL HEAVY LIFTING TECH SHOW

Lower the arch sections 6 The arch sections reached their maximum cantilever in a slightly elevated position. After lifting in place of the closure segment by crane, the arch sections were lowered to close the small gaps and allowed bolting of the last two joints.

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NEWS N°1-2010 Control 50 pairs of jacks 8 Force is nothing without control. The VSL Bravo system made 37 it easy for the operator to guide each of the 50pairs of SLU, climbing up the lifting cables with steadily increasing force to millimetre accurate positioning for pinning.

Use well-proven systems 7 Cable net lifting and stressing used 100 Strand Lifting Units (SLU), made up of SLU-120s, SLU-220s and SLU-330s. All SLUs were specifically prepared to guarantee a smooth overhead operation. Access to SLU suspended above ground between 30 and 100m had to be kept to a minimum.

NEWS N°1-2010 VSL HEAVY LIFTING TECH SHOW

Jawaharlal Nehru Stadium, Dehli (under construction) roof lifting operations by VSL in India in conjunction with VSL in Switzerland

Stadium support VSL has been at the forefront of a key technology to shelter sports venues around the world ever since its lift of the very first cable net roof 38 in 1972. Building on the success of that first lift in Munich, Germany, VSL has continued with other important cable net projects. Among the long list of names are the HSH Nordbank Arena (2000), Pusan Dome Korea (2002), Khalifa Stadium, Qatar (2005), Commerzbank Arena Frankfurt (2005), Kuwait Stadium (2006), and Bayarena Leverkusen (2009). The list continues to grow as VSL is - among others - actively The retractable roof of Miami’s new Marlins involved in Dehli’s Jawaharlal Nehru Stadium and Miami’s New Marlins Stadium will be a welcome feature after the Ball Park. For the Soccer World Cup 2010, VSL was furthermore team suffered record rain delays in 2009. involved in the roof lifting operations for the Greenpoint Stadium in Cape Lifting of girders to support the retractable roof is being carried out by the Florida office of Town, South Africa, with a capacity of 68 000. VSL United States in conjunction with VSL It will host six first-round matches, one second-round, one quarter-final Switzerland, which is supplying equipment and and one semifinal match. In the near future, projects will be carried out technicians. The largest of the girders, which in Warsaw and Chorzow in Poland. weighs 1,450t, has been placed successfully. In total, eight segments will be raised using SLU 330 strand lifting units. VSL is also supplying and installing the post-tensioning for the girders.

© gmp – von Gerkan, Marg und Partner Architekten, Berlin, Germany - SBP Schlaich Bergermann und Partner, Stuttgart, Germany. Architect is JSK Architekci Sp. z o.o., Warsaw, Poland.

VSL will soon be carrying out works on the National Stadium, Warsaw in Poland, in preparation for the 2012 UEFA European Football Championship, for the JV of Cimolai, Monostal and Hightex.

NEWS N°1-2010 HEADQUARTERS www.vsl.com VSL International Ltd. CREATING SOLUTIONS TOGETHER Saegestrasse 76 CH-3098 Köniz - Switzerland Phone: +41 58 456 30 00 Fax: +41 58 456 30 95 VSL LOCATIONS

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NEWS N°1-2010 GROUND ENGINEERING

Ground anchors

VSoL® walls CONSTRUCTION

Bridges D-walls & Piles

Buildings Ground improvement

REPAIR, STRENGTHENING Slab on grade & PRESERVATION

36.25 Structural 3178.25 diagnostics Containment & Monitoring structures

Repair & Strengthening Special structures

Protection & Preservation Heavy lifting

SYSTEMS & TECHNOLOGIES

Formwork & Post-tensioning strand systems Equipment • • Bars & post-tensioning bar systems • Stay cable systems • Damping systems (stays & buildings) • Ductal® UHP concrete • Bearings & Joints

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