OUR PASSION FOR INNOVATION AND THE IMPLEMENTATION Deal Magazine OF A PROACTIVE RESEARCH AND DEVELOPMENT POLICY TOGETHER WITH CONTINUOUS TRAINING OF OUR TECHNICAL STAFF ALLOW US TO KEEP PACE WITH OUR PARTNERS’ AND CUSTOMERS’ EXPECTATIONS DEALMAG 2

/ DEALMAG 2 / 2017 / INDEX

02 DEAL SOLUTIONS THAT MAKE 22 RIYADH METRO PROJECT 44 DOHA’S NEW CONNECTING THE DIFFERENCE / Saudi Arabia HIGHWAY VIADUCT / Qatar 04 DEAL ALL AROUND 45 HONG KONG-ZHUHAI-MACAO BRIDGE 06 GRAN MANGLAR VIADUCT / China / Colombia 46 AL SEWYRAH BRIDGE / Iraq

48 THE LIANTANG PROJECT 28 WADI HANIFA BRIDGE / China / Saudi Arabia 49 HANGZHOU BAY BRIDGE PROJECT 30 JAMAL ABDUL NASSER STREET / China / Kuwait 10 MANHATTAN WEST 50 THE GREAT NORTH ROAD DEVELOPMENT INTERCHANGE / USA / New Zeland

34 KUALA LUMPUR MRT / Malaysia

14 THREE MAJOR CABLE-STAYED 36 ULU JELAI HYDRO-ELECTRIC 52 M4 WIDENING BRIDGES IN NORTH AMERICA POWER STATION / Australia / Canada / USA / Malaysia 53 SYDNEY METRO 16 LESNER BRIDGE REPLACEMENT 38 MRT SYSTEM FOR / Australia / USA HO CHI MINH CITY / Vietnam 54 TAJUNG PRIOK ROAD 18 THE EVERGREEN LINE PROJECT / Indonesia / USA 40 DOHA METRO / Qatar 55 VIADUCT CONSTRUCTION 20 MOSES WHEELER BRIDGE FOR RENNES METRO RECONSTRUCTION / France / USA 56 SPECIAL EQUIPMENT 21 ROUTE DU LITTORAL HIGHWAY / La Reunion Island

Edited by Graphic Design Printed in Italy by DEALMAG Deal Advertising Dept. Polystudio.net Grafi che GFP +39 0432 607900 Photographs [email protected] Archivio Deal DEAL SOLUTIONS THAT MAKE THE DIFFERENCE

We continue our mission to adapt to the new needs and requirements arising from changes in technology and clients’ expectations

2 DEAL MAG he continued and significant increase in Deal’s revenue in recent years - despite the global Tfinancial crisis - confirms the high quality and focused positioning of both our equipment and our services. Our passion for innovation and the implementation of a proactive research and development policy together with continuous training of our technical staff allow us to keep pace with our partners’ and customers’ expectations. Acquisition of Tensa gave Deal the ability to complete the range of products and services offered to its clients. I’m proud to report that more and more customers are looking at Deal not only as an equipment supplier but also as a long-term partner with whom to develop innovative solutions. Furthermore, the increasingly frequent involvement of Deal in permanent structural design, as well as in the provision of technical assistance during the construction phase, allows us to provide a fully integrated package that ensures the most efficient, reliable and economic solutions. I’m privileged to present in this publication a selection of the more challenging and innovative projects around the world that Deal has been involved in. Deal continues its mission to adapt to the new needs and requirements arising from changes in technology and clients’ expectations.

Alessandro Rovera DEAL CEO

DEAL MAG 3 DEAL STRATEGIES DEAL ALL AROUND

Talking with Gilberto Dreas, Deal Engineering Department Director

ow were Deal’s Engineering Ser- 3. Construction engineering vices born and what makes Deal In addition to detailed design, a wide Hdifferent from other engineering set of engineering activities is required companies in development of such ser- to enable construction managers to vices? perform in a safe and timely manner. Construction efficiency is the prima- To understand how Deal’s engineer- ry goal for Deal in developing construc- ing services department was created, tion engineering services. That’s why we need to take a step back in time and Deal’s project engineers have under- start from the ‘80s, when a new divi- gone training on construction sites sion, specialized in bridges and viaduct around the world and ‘speak the same construction, began to develop with- language’ as contractor teams. in Rizzani de Eccher’s technical office. A few years later, in 1994, this division — Could you highlight the last success- became a full-scale company named ful projects for Deal’s engineering depart- Deal which concentrated exclusively on ment? provision of specialized equipment for construction of bridges and viaducts. Yes, among the projects of recent years, Soon, however, it was clear to all that I would like to highlight these two in Deal could not just act as a supplier. particular: The market needed a partner, capa- ble of developing design which took The first is the Gran Manglar Viaduct into account not only convention- project, in Cartagena de Indias, Colom- al demands, but, above all, work con- bia. Initially, when we started work- structability. ing with Consorcio de Diseños Costera, This is how the Engineering Depart- which is responsible for implementing ment was born. this project, the task was envisaged as a traditional construction which would — Which engineering services does Deal involve invasive interventions into the offer? lagoon area. Based on the experience of designing Deal’s engineering services can be according to client’s specifications but and building pile-driving equipment grouped into three major categories: offers value engineering solutions to for the Washington Bypass project, help reduce life cycle costs, improve Deal has proposed a similar but revised 1. Tender and concept design quality and reduce environmental im- solution, taking into account the spe- Particularly for design&build projects, pacts. cific characteristics of the site – first of Deal can assist the tenderers by pro- all, the high seismicity of the region. viding design concepts for specialized 2. Detailed design The concept design for this technolog- works, developing construction meth- To produce an efficient and buildable ical solution, delivered together with a odology and schedules, preparing ten- design, constraints imposed by con- cost budget, has been approved, result- der submittals and coordinating the struction methodology should be con- ing in a very limited environmental activities of other specialist designers sidered, as well as project specific impact. involved, in order to develop together design criteria. Deal’s long-term expe- Under the agreement between Rizza- the most suitable design and technical rience in precast and erection of pre- ni de Eccher Colombia and Consor- solutions. stressed concrete structures adds sig- cio de Diseños Costera, Deal has been When Deal is involved in post-tender nificant value to development of any responsible for implementing detailed stages, it not only executes the works part of the design package. design, construction engineering, and

4 DEAL MAG DEAL STRATEGIES

construction sequences, by identify- struction of similar works and intro- used the span-by-span method to erect ing specific solutions for this proj- duced a series of optimizations in the a section which included 52-m-long ect, among which: 1) seismic isolation structural concept which have allowed spans with a U-shaped cross-section. to reduce stress and 2) introduction of significant cost savings for the client. The work involved creating a continu- joints in the piles, due to continuous After the award of the project to the RLR ous deck unit, composed of four spans geological conditions that require lon- JV, Deal has been entrusted with the with lengths of: 34m + 52m + 52m + ger piles. detailed design and construction engi- 30m. This was a first for this kind of neering of all decks, and, at this stage, structure, and Deal had to push the lim- The second project is Doha Metro - all optimizations, proposed at the ten- its both in the span-by-span method- Red Line North, Elevated and at-grade, der stage, were put into practice. Con- ology and for the erection equipment, in which Deal was engaged, as early as sequently, prefabrication and launch- in order to achieve this challenging from the tender stage, in the study of ing of decks were completed without goal. The innovative solution has also the structural solution. any problems and ahead of the sched- secured / gained cost benefits, com- At this phase, Deal has applied the ule. Furthermore, in November 2016, a pared to employment of the tradition- experience gained in design and con- new record was set on this project: Deal al balanced cantilever method

DEAL MAG 5 CARTAGENA /COLOMBIA / AMERICAS GRAN MANGLAR VIADUCT CONSTRUCTION OF COLOMBIA’S LONGEST BRIDGE

Use of an alternative construction method has overcome site challenges and brought considerable benefits in the construction of a major viaduct across environmentally sensitive wetlands

olombia’s National Infrastruc- ture Agency – ANI – is building C a 146km motorway to link the cities of Cartagena and Baranquilla. The goal is twofold: firstly, a wish to devel- op the Caribbean Coast into the most important logistics route in the country and, secondly, to facilitate better traf- fic flow, guaranteeing easy journeys for both tourists and locals. Consorcio de Diseños Costera entered into a design, build and finance con- tract with ANI for the scheme, which is officially called ‘Proyecto Cartage- na-Barranquilla y circunvalar de la prosperidad’. Only two out of 10 groups that took part in the prequalification process submit- ted a tender in 2013 for the challenging design, construction and maintenance of the highway. The contract required the route to pass through marshland that had already been seriously damaged by infrastructure that obstructed the water flow towards the Caribbean Sea. The marshland has now been restored and has become a nature reserve.

6 DEAL MAG GRAN MANGLAR VIADUCT

The call for tenders required construc- ly by access from the section that had tion input for the 5.4km-long viaduct, been already built. A twin set of special- 5.4km-long viaduct which was categorised as a cast-in-si- ly designed launching trusses had been ‘Top-down’ construction tu balanced cantilever bridge. The con- deployed in North Carolina to drive the method – enabling struction method for this type of bridge precast piles, complete the setting of has two major issues. From an environ- the precast pier caps and then launch construction of the whole mental point of view, installation of the and place the precast girders in record viaduct, including foundation elements themselves pres- time. The system reached an impres- foundations, with access ents challenges and there was also a sive monthly production rate of five social issue as the delivery of the proj- spans - typically 36m long - with mini- only needed from ect would have prevented local people mal impact on the wetlands below. the section that has from continuing their fishing activities. Adopting a similar solution for the already been built The main contractor had to demon- project in Colombia was dramatical- strate that it could solve these issues. ly different from the original proposal Solutions to Rizzani de Eccher and Deal present- and resolves all of the project require- environmental, social, ed an ingenious solution that led to the ments and issues: programme and cost team winning the tender as the proj- ect’s exclusive, strategic partner. — Environmental – it avoids the need challenges The innovative ‘top-down’ construc- for dredging, concrete slabs and the tion method is extremely high-tech but construction of access roads, which requires only a minimum amount of otherwise would have damaged the manpower and operations. The meth- environment for years; od had already been developed by Deal and used on the Washington Bypass — Social - despite the construction project (North Carolina, USA), where works, the local population can contin- it enabled the construction of the whole ue using the wetlands for fishing and viaduct, including foundations, entire- agriculture;

DEAL MAG 7 GRAN MANGLAR VIADUCT CONSTRUCTION OF COLOMBIA’S LONGEST BRIDGE

— Programme - the use of precasting and industrial processes on the project allows the main contractor to keep in line with the scheduled delivery times;

— Costs - Rizzani de Eccher is able to deliver lower costs than the original tender estimates, thanks to high-quali- ty value engineering and the input from the many companies of the de Eccher Group involved in the process

The innovative ‘top-down’ construction method is extremely high-tech but requires only a minimum amount of manpower and operations

8 DEAL MAG PROJECT TEAM DEAL SUPPLIED Precast moulds: beam mould for girder 37m long Client: Agencia Nacional Design: pile mould for pile 42m long de Infraestructura Final design of superstructure pile mould for pile 36m long Contractor: MHC and substructure. pile mould for pile 24m long and MECO Consortium Launching equipment: long line pile cap mould Sub-contractor: 2 launching girders 3 pile moulds bulkhead Rizzani de Eccher for driving piles and beam erection. Engineering services: Sucursal Colombia Precast yard equipment: Support for precast yard logistics Designer: Deal 2 gantry cranes 10t and design 2 gantry cranes 25t Temporary works design 2 straddle carriers 55t Geometry control Erection sequences Temporary structure pile driving

DEAL MAG 9 10 DEAL MAG NEW YORK CITY / USA / AMERICAS

MANHATTAN WEST DEVELOPMENT

Placing a deck over live railway tracks in the ‘city that never sleeps’

Bridge construction technology Jersey Precast, a local fabricator located has been used in an innovative in New Jersey – where labour rates are — An unprecedented application to create a large plaza significantly cheaper than Manhattan – precast solution above busy rail lines in Manhattan for integration into its plant. — Creation of a 10,200sqm The length of the spans combined with segmental post-tensioned the level of segmentation required platform highly accurate geometry control. The — Launching of 16 adjacent scarcity of buildable land in large number of segments derived from ‘bridges’ to make the NYC meant that the city’s lead- the need to limit the size of each one to platform A ing real estate developer was in 56t to allow for transportation through — Installation of 2,400t search of a creative solution to maxi- Manhattan. As a result, the maximum precast/post-tensioned mise use of the limited space available length for a typical segment was only segmental beams on a prime development site. 1.93m and the pier segments were as — Adoption of a PT ratio Brookfield Office Properties, own- short as 1.27m. three times higher than for er and developer of the Manhattan There were between 37 and 39 seg- standard bridge applications West Project, needed to close a large ments per beam, which meant that — Construction above 15 live gap above the busy railway tracks in even a slight deviation on the horizontal rail lines the middle of the 7-million-sq-ft site. plane would have caused a major prob- — Use of a launching girder The solution came from observing the lem. The geometry control system pro- with a 3,600t lifting capacity bridge construction industry and using vided by Deal and precise management — Remote connection of the high-tech bridge erection machinery to of the moulds allowed the subcontrac- lifting girder to engineers create a deck over the lines. tor to achieve excellent accuracy in the and technicians in Italy The result is the Manhattan West Plat- alignment. form, a 10,200sqm segmental post-ten- Cycle efficiency for the segment pre- sioned deck made up of 16 adjacent fabrication was maximised by Deal’s ‘bridges’, each with a length of 73m. It provision of three short-line moulds covers a record 73m x 146m gap over for the typical segments, a mould for 15 live rail tracks that transport about pier segments and an adjustable short- 800,000 people per day, in and out of line mould able to cast segments with a Penn Station. variable web thickness. Spanning the gap required extensive A straddle carrier supplied by Deal ser- engineering work, which resulted in viced the staging area in Manhattan and a custom-built launching gantry (LG) was used to off-load the segments that being used to position the 2,400t pre- were brought in at night and place them cast/post-tensioned segmental beams in their temporary storage locations. above the live rail lines and their elec- The segments had to be double-stacked trified power systems. These beams to maximise storage capacity. now support a public plaza and a park- Two factors in particular contributed ing area between two high-rise build- to the success of the Manhattan West ings. Project: Precasting was an essential part of the project but these activities were not — The skills of the deck engineer, carried out in downtown Manhattan. McNary Bergeron, which designed Instead, the moulds were provided to a precast concrete beam that could

DEAL MAG 11 MANHATTAN WEST sioning, the lowering system was con- PROJECT TEAM DEVELOPMENT nected to the pier segments by means of Project: 9th Avenue eight threaded bars and then the span Development - Manhattan West was moved to the second-stage area Platform where the remaining 10 PT cables were Client: Brookfield Properties tensioned and the final grouting was Designer: McNary Bergeron & carried out before erecting the span in Associates its final position. Design and build general contractor: Rizzani de Eccher The LG was connected remotely to (USA) Ltd. engineers and technicians in Italy who monitored its functionality and DEAL SUPPLIED accommodate 100t of post-tensioning ensured that all sensors and indicators Launching equipment strands inside; were working properly. After the first Design and fabrication of: — The ability of Deal to manufacture two beams were set in place, the TPP Launching gantry for span a high-tech LG with the capacity for was removed and the assembly bed was fabrication and span launching smooth placement of the 16 beams. relocated over spans 3 and 4 and used Segment transporter on rails to The LG was essentially a gantry able to as the stage from which subsequent feed the launching equipment move sideways on rails; its main com- beams were assembled. with segments ponents were a winch and a lower- The PT ratio for this project – the weight Straddle carrier on tyres for the ing system. It was made from 1,100t of of the steel PT strand per square metre segment storage area steel with a capacity to lift 3,600t and of deck area - is three times higher than Mobile stressing platform featured a 90t winch for handling the for standard bridge construction appli- Precast segment moulds individual segments before they were cations. Design and fabrication of: joined with epoxy and post-tension- 3 short-line moulds for typical ing to create a single giant beam. Every Each beam required 100t of post-ten- segments component was designed and manu- sioning supplied by Tensa, a subsidi- 1 short-line variable mould for factured in Italy and the LG was bro- ary of Deal, using 20 tendons with 37 transition segments ken down into more than 90 containers strands and 14 with 31 strands. 1 pier segment mould to allow transportation by sea to New Preliminary assessment of anchorage 1 segment manipulator York. performance was through dedicated 1 special trolley to transport The assembly process for the deck tests carried out in the Structural Lab- segments to storage was very similar to that of a sequen- oratory of the University of Padua in tial span-by-span bridge. The key dif- Italy. All the types of anchorages used TENSA SUPPLIED ference was that a single platform was on the project (37MTAI15, 31MTAI15, Post-tensioning system being built so there was no need for a 9MTAI15) underwent load transfer Supply of 320 complete tendons gantry that could launch segments from testing under the scheme’s design con- made up of 37 strands together pier to pier. Instead, the equipment ditions, including the correct concrete with anchorages of type moved sideways to place one complete strength (9,500psi) and the anchorage 37MTAI15 bridge span adjacent to the next. spacing at the end segments Supply of 212 complete tendons made up of 31 strands together with anchorages of type CONSTRUCTION 31MTAI15 SEQUENCE Supply of 72 complete tendons made up of 9 strands together The first activity on site was the instal- with anchorages of type lation of a steel temporary protection 9MTAI15 platform (TPP) over the rail lines. This Total quantity of 0.6”steel served the dual purpose of protecting strand: 1,600t the railways and providing an assembly Installation equipment bed - the ‘beam factory’- from where Multi-strand stressing jacks the LG could be assembled and beam complete with hydraulic pumps numbers 3 and 4 could be set into place. for use with 37-strand tendons The whole operation was designed to Multi-strand stressing jacks minimise the time needed for PT bar complete with hydraulic pumps tensioning and for the completion of for use with 31-strand tendons the connections. The winch picked up Multi-strand stressing jacks each segment using a C-hook and car- complete with hydraulic pumps ried it into place on top of adjustable for use with 9-strand tendons screw jacks, over the two steel I-girders Strand threading machines that made up the assembly bed. Epoxy Grouting pumps was then applied to the joints and the first-stage tendons (24 cables) were Technical assistance on site connected with temporary PT bars and and engineering services tensioned. After the first-stage ten-

12 DEAL MAG DEAL STRATEGIES

A CONTRACTOR WHO OVERSEES FULL-CYCLE DEVELOPMENT OF INNOVATIVE CONTRUCTION EQUIPMENT

the principal players of our industry cast cap and pre-cast beams, reducing and have worked on signature projects, the damage to environment to nearly such as: the Oakland Bay Bridge in San nothing, as direct site access was pro- Francisco, Port Mann Bridge in Van- vided only from the top. This resulted couver, Palmetto Interchange in Mia- in a winning bid and an extremely suc- mi, Central Artery in Boston, the Dal- cessful and profitable project. las High-Five Interchange, and many Over the years, Deal has dominated more! the North American market due to one primary difference over our competi- Starting from the design of the casting tors: we were contractors before beco- yards, we have gone all the way to the full ming equipment suppliers, and this supply of custom-designed equipment, background is paramount in enabling including technical assistance, to help us to understand the entirety of issues manage such equipment and projects. at hand and in finding the right solu- A prime example of innovation is the tion that addresses such problems in Talking with creation of the ‘Pile Driver’ which was the safest and most practical manner, used to construct the seven-mile-long giving us a distinct advantage. Riccardo Castracani, Washington Bypass bridge, completely Our past period of over 20 years has Deal Business in top down, by driving piles out in can- been a great success and has given us tilever using an overhead truss, then the tools to continuously deliver safety Development, USA using the same truss to erect the pre- and efficiency

eal’s North American presen- ce started over 20 years ago with Dthe supply of a balanced can- tilever launching gantry, on one of the most prestigious projects at that time – the Confederation Bridge to Prince Edward Island in Canada – and conti- nues to date, solidifying its presence and becoming, in essence, the comple- te solution, from a means and methods point of view, to complex pre-cast seg- mental bridge projects. Our scope has gradually grown from supply of existing equipment to the full-cycle development of innovative equipment solutions, influencing, at times, the actual design of bridges and bringing winning solutions to the table for our clients. We have had the privilege of develo- ping long-lasting relationships with

DEAL MAG 13 VANCOUVER / CANADA LONG BEACH / USA AMERICAS

A single type of advanced technology to serve three major cable-stayed bridges in North America

— GOLDEN EARS BRIDGE (2007) — PORT MANN BRIDGE REPLACEMENT (2009) — GERALD DESMOND BRIDGE REPLACEMENT (ONGOING)

Innovative engineering has allowed of special lifting frames with the same — Provision of equipment Deal to adapt, reuse and develop the characteristics as the previous pair. The suitable both for erection design of its special lifting frames new project was the replacement of the of single components and for to suit the requirements of three of old Port Mann Bridge, which had been erection of an entire steel grid North America’s most significant built in the early 1960s when the popu- — Designed to ensure bridge projects of recent years lation of Metro Vancouver was 800,000 accuracy in the positioning inhabitants. By the time of its replace- of elements ment, the bridge was supporting traf- — Lifting capacity: he Golden Ears Bridge spans the fic flows of over 800,000 vehicles every Gerald Desmond 230t, Port Mann Fraser River to connect the com- week. The five-lane bridge and adja- and Golden Ears 100t T munities of Pitt Meadows and cent highway could not meet the growing — Record-breaking width Maple Ridge to Langley, Surrey and needs of the area and, as a result, there of 46.7m Gerald Desmond beyond. The combination of the six- was congestion for up to 14 hours per — Equipment lifting stroke: lane bridge and a 14km road network has day. The newly completed Port Mann/ Gerald Desmond 75m, created a quick and convenient link that Highway 1 Improvement Project has now Port Mann and Golden Ears 60m reduces travel times and regional traffic significantly reduced this congestion congestion for both residents and busi- and was the largest transportation infra- nesses. structure project in the history of British For this project, Deal designed and sup- Columbia. plied a pair of special lifting frames for The 2km-long bridge is made up of the erection of the grid of steel elements three key sections: the cable-stayed and the precast concrete panels for the main crossing of the Fraser River, the hybrid cable-stayed/extradosed bridge. South approach in Surrey and the North The equipment was flexible in design approach in Coquitlam. and was suitable both for erection of an The new ten-lane Port Mann Bridge is entire steel grid by lifting it from the one of the widest bridges in the world, ground or, alternatively, for erection of as it is also designed to accommodate single components, lifting them up from light rail rapid transit in the future. the back. One of the main characteris- The project also involved the widening tics of the equipment is its accuracy in of 37km of highway between Vancou- positioning the elements, which is par- ver to Langley, including 30km of new ticularly important in the case of bolted lanes for high-occupancy vehicles and joints. the replacement of nine highway inter- Two years later, the same equipment changes. was required for a new project in Cana- In 2016, Deal became involved in the da, and this time Deal supplied two pairs project to replace the Gerald Desmond

14 DEAL MAG Bridge. The through-arch bridge in of the equipment are similar to those On the first two projects, a steel frame Long Beach, California, was built in proven on the two previous projects - called a ‘spider’ was used to deform 1968 across Cerritos Channel to pro- Golden Ears and Port Mann – the new bridge elements that were ready for vide a link to Terminal Island. The old project has posed real challenges for erection to match the joints with those bridge has recently been encountering Deal’s engineers. These have included already assembled, which had been structural and maintenance problems, the necessity of increasing the capacity deflected by the deck loads. so the Port Authority decided to replace of the lifting frames from 100t to 230t, A new concept for the ‘spider’ has it with a new cable-stayed bridge with the massive dimensions of the bridge been developed for the Gerald Des- 61m of vertical clearance. The new (width of 47.6m), and the equipment’s mond Bridge project in order to min- bridge will allow access into the port for required lifting stroke of 75m. In addi- imise the equipment weight, which is the tallest container ships and will be tion, particular attention has had to be always critical in terms of the struc- the first long-span cable-stayed bridge dedicated to the shape of the equip- tural capacity. The innovation involves in California. ment’s main structure as it cannot be creating the required counter-camber allowed to interfere with the tempo- of the steel elements by means of a ten- For the erection of the main spans, Deal rary stabilising structures of the tower sioning system made up of cables and is suppling two pairs of special lifting cranes used for the construction of the hydraulic jacks, which are remotely frames. Even though the capabilities main pylons. controlled

GOLDEN EARS BRIDGE PORT MANN BRIDGE GERALD DESMOND BRIDGE

PROJECT TEAM PROJECT TEAM PROJECT TEAM Client: TransLink Client: Province of British Columbia Client: State of California Contractor: Golden Crossing Contractor: Kiewit-Flatiron Department of Transportation JV - Bilfinger&Berger and CH2M General Partnership Contractor: SFI Shimmick – Designer: Buckland&Taylor FCC – Impregilo JV DEAL SUPPLIED Designer: ARUP DEAL SUPPLIED Launching equipment Launching equipment 2 pairs of LF-100 lifting frames DEAL SUPPLIED 2 pairs of LF-100 lifting frames Launching equipment 2 pairs of LF-230 lifting frames

DEAL MAG 15 VIRGINIA BEACH / USA / AMERICAS

LESNER BRIDGE REPLACEMENT OVERSLUNG OR UNDERSLUNG: ONE PIECE OF EQUIPMENT DOES BOTH

orrosion had made replacement structed in 1957. The vital route along The gantry enabled of the Lesner Bridge a necessi- US60 carries 41,000 vehicles daily and segments to be delivered Cty and the twin segmental struc- connects the Northern part of Virginia tures of the new crossing now span Beach to the tourist destination at the from the previously- Chesapeake Bay in the City of Virginia oceanfront. erected deck, avoiding Beach, Virginia. The replacement has been built using a The replacement bridges have a curved the need for large specially refurbished launching girder box-girder superstructure on slender cranes to be positioned that can be used in either ‘underslung’ piers, which are accented with alternat- in the waterway or ‘overslung’ configurations. ing sweeping curves intended to imitate The aggressive marine environment the waves of the Lynnhaven Inlet. or in close proximity to had caused the corrosion that was Each of the two bridges feature a the adjacent power lines found in sections of the original John 16.4m-wide deck that accommodates A. Lesner Bridge, which had been con- two lanes of traffic, with shoulders on

16 DEAL MAG THE PALMETTO DOLPHIN INTERCHANGE

— Typical span length 45.7m — Max span length 68.6m — Provision of a refurbished launching girder — Operation in underslung and overslung configurations

each side and a multi-use path in each direction. The eastbound and west- bound structures could, if required, accommodate three lanes of traffic in each direction in the future.

Deal entered into an agreement for the supply of the refurbished launching girder, including carrying out the nec- PROJECT TEAM essary modifications to enable con- Client: City of Virginia Beach, struction of the segmental superstruc- Virginia ture. Typical span length is 45.7m; Contractor: McLean Contracting Co. however, the operation of the equip- Designer: FIGG ment can be tailored so that it can also erect the 68.6m-long main span. DEAL SUPPLIED The gantry enabled segments to be Erection equipment delivered from the previously-erected Launching girder for deck, avoiding the need for large cranes span-by-span construction to be positioned in the waterway or in close proximity to the adjacent power lines.

The most innovative aspect of the refurbishment is the use of the ‘sec- ond-hand’ 123m-long launching gird- er, which was originally designed with an ‘underslung’ configuration and then reconfigured in ‘overslung’ mode for the current project. As a result, the cli- ent has the benefit of a sophisticated piece of equipment that can be used in either erection mode on future proj- ects

DEAL MAG 17 VANCOUVER / CANADA / AMERICAS

THE EVERGREEN LINE PROJECT SAVING MONEY THROUGH RETROFITTING OF DEAL’S EQUIPMENT

Innovative adaptation of existing casting and launching equipment has resulted in an efficient and flexible solution for the elevated section of an LRT project in Vancouver

he Evergreen Line is the exten- — DEAL’s 3rd LRT project sion in East Vancouver of the in Vancouver Millennium Line, which was con- T — An innovative solution structed in the late 1990s, also using to deliver flexibility aiding Deal equipment. The overall exten- overall project performance sion involved a length of tunnel, var- — Adaptation and retrofitting ious at-grade sections and also about by Deal of existing casting 3.5km of elevated guideway, which was machines to reduce costs built using precast segmental-by-span — Installation using a ‘hinged erection method was not new to British type’ self-launching overhead Columbia, as two other elevated light span-by-span truss rail systems had already been built with — An on-time and on-budget the same technology. For the Evergreen performance Line Project, existing casting machines The ‘hinged’ feature of the equipment — Reduced learning curve that had been previously supplied by enabled a single launching truss to be — A complete design-build Deal were adapted and retrofitted to used for the entire section of elevated solution work on the new extension. Reusing line, with little disruption to the local — Design choices driven the equipment eliminated the need for traffic and neighbourhoods. by equipment availability major investment, which was a particu- The state-of-the-art equipment de- lar benefit as the project’s elevated sec- ployed on the scheme ensured on-time tion was in itself not very long. and on-budget performance, and greatly reduced the learning curves for Deal carried out the retrofit of the a project of this size, particularly as the PROJECT TEAM equipment and successfully reused the equipment was not new to the area. Client: Province of British Columbia same casting machines without any Deal worked closely with the designer Contractor: EGRT Construction impact on productivity or the quality of to ensure that all aspects of the equip- Designer: International Bridge the segments. ment were factored into the final design Technologies Inc. The erection was carried out using a requirements, anticipating any issues self-launching overhead span-by-span before they arose. This was the perfect DEAL SUPPLIED truss, which was of a ‘hinged’ type in example of a design-build approach, Erection equipment order to accommodate the alignment’s with equipment availability driving the An articulated launching girder for tight radius of curvature. This equip- design choices as much as possible, and a segmental elevated guideway ment had also been used previously on with the designers of both the equip- Prefabrication equipment another section of elevated rail line in ment and the bridge working hand in 4 sets of short-line moulds Vancouver and was adapted for the new hand in order to deliver the most effi- project. cient solution to the contractor

18 DEAL MAG LRT PROJECT IN VANCOUVER

DEAL MAG 19 CONNECTICUT / USA / AMERICAS

MOSES WHEELER BRIDGE RECONSTRUCTION SMART TECHNOLOGY: USE OF A BESPOKE GANTRY CRANE ON A CURVED RUNWAY

— A special gantry crane moving along a curved alignment — Different gradients and levels for each rail — ‘Smart’ electronic control system to enable a speed special gantry crane, given the jacks are then automatically extended/ of up to 40m/min code name ‘G19’, has been de- retracted, to keep the top winch plat- — High productivity A signed by Deal for the recon- form in a horizontal position. and a safe work struction of the Moses Wheeler Bridge The wheel groups are arranged with environment while working linking Stratford and Milford in Con- vertical pins to allow adjustment along in a challenging location necticut, USA. the curved rail. In addition, the power output of the motors for the wheels on The project demonstrates how the outer rail is greater than that of the an extraordinary mechanical inner motors, to give a higher speed for solution coupled with ‘smart’ the outer wheels on curved sections. electronics can work together The equipment moves along its runway to produce high-end equipment with a speed of up to 40m/min. As the for a challenging task runway’s alignment and curvature vary so rapidly, it would be impossible for an PROJECT TEAM The most distinctive feature of the spe- operator to adjust the various parame- Client: Connecticut DOT cialist equipment is that its runway rails ters manually. A ‘smart’ control system Project: New Moses Wheeler have a curved alignment, with different monitors the position of the equipment Bridge levels and gradients for each rail. through field sensors and automatically Designer: STV Inc. and GM2 The left side of the gantry is arranged adjusts the telescopic legs and the trav- Associates Inc. with a pendular leg to allow for the el speed as well as checking the load on Contractor: PCL Walsh variation in rail gauge. This addition- the wheels to prevent derailment or al requirement for a variable gauge overturning. DEAL SUPPLIED was born from the necessity to work on The crane operator performs the same Lifting equipment two different alignments, in order to activities as on a normal crane but is, Design and fabrication of: demolish the old bridge and build its in fact, managing a piece of sophisti- 3 special gantry cranes of type wider replacement. cated equipment that gives higher pro- GC 63/16.6 An electronic system controls in real ductivity and a safer work environment, time the alignment of the top plat- despite operating in extreme locations form of the gantry to take account of that would be inaccessible for standard the changes in level and gradient. The gantry cranes

20 DEAL MAG LA REUNION ISLAND / AFRICA

Provision of a safe and innovative gantry crane capable of resisting 240km/h winds

ROUTE DU LITTORAL HIGHWAY

— New coastal highway built over the Indian Ocean — 5.4km viaduct on columns rising out from the sea — Able to withstand 144km/h hurricane winds and waves of up to 10m — Longitudinal travelling speeds pushed to the limit (20m/min fully loaded; 60m/min unloaded)

he wave erosion process brings Denis, the administrative capital of La at 20m/min fully loaded and 60m/min constant danger for the coastal Réunion, with La Possession. unloaded. Strong winds and typhoons T road around La Reunion Island, are common on the island and so the which is located East of Madagascar, in One of the most complex aspects design of the ‘parking’ system has been the Indian Ocean. Landslides and high of the work is the construction challenging too, in order to resist winds waves force up to 40 closures a year of the 5.4km viaduct on columns with speeds of up to 240km/h of the existing route at the foot of the rising out of the sea island’s cliffs. As a result, the French local authori- The structure is being built to withstand ty decided to relocate the coastal road 144km/h hurricane winds as well as PROJECT TEAM onto a bridge running parallel to the waves of up to 10m. Project: Nouvelle Route du island’s perimeter, standing on col- The project involves the use of a large Littoral, Reunion Island (France) umns rising out of the Indian Ocean at fleet of heavy machinery. Deal has Contractor: Chantier NRL Viaduc a distance of 100m to 200m from the delivered a special gantry crane with a shoreline. Once completed in 2018, it 65m span capable of handling the 350t DEAL SUPPLIED will be the most expensive road ever prefabricated segments in the precast Heavy lifting gantry crane with funded by France in terms of cost per yard. 350t capacity and 65m span kilometre. The challenges of the project meant The new 12.3km offshore highway - pushing the equipment’s longitudinal Route du Littoral - will have three lanes travelling speeds to the limit: the crane in each direction and will connect Saint was designed to handle safe movements

DEAL MAG 21 — A newly built, 178km-long metrosystem / 6 lines / 85 stations — Deal provision of engineering services, equipment and post-tensioning to all three consortia

22 DEAL MAG RIYADH / SAUDI ARABIA / ASIA RIYADH METRO PROJECT DEAL OFFERS ITS EXPERTISE AND EQUIPMENT TO ALL THREE CONSTRUCTION CONSORTIA

iyadh’s population currently stands at about 5.7 mil- — Civil Works Joint Venture, a joint venture between Bechtel lion but is expected to reach up to 8 million in the com- (USA), Almabani (Saudi Arabia), CCC (Saudi Arabia) and Sie- R ing decade. However, only 2% of commuters use pub- mens (Germany); lic transport and this led the Saudi Government to the idea — FAST Consortium, a joint venture between FCC Construc- of developing a 178km-long metro system for Riyadh. The cion (Spain), Samsung (South Korea), Alstom (France), resulting network, with its six planned lines and 85 stations, Strukton (Holland), Freyssinet SA (Saudi Arabia), Typsa is the largest infrastructure project ever undertaken in the (Spain) and Setec (France). Kingdom of Saudi Arabia. The metro comprises a mix of underground, elevated and Deal has been subcontracted by all three consortia to be at-grade sections. The work has been divided between three involved in the project, providing engineering services, consortia: equipment and post-tensioning materials. This is an incred- — Arriyadh New Mobility Civil Work Group, a joint ven- ible achievement, as well as an significant challenge that ture formed by Salini Impregilo Spa (Italy), Larsen & Toubro demonstrates once again that the company is a worldwide (India) and Nesma & Partners Contracting JV (Saudi Arabia); leader in the bridge construction industry

DEAL MAG 23 RIYADH / SAUDI ARABIA / ASIA RIYADH METRO PROJECT BLUE AND GREEN LINES (LINES 1 AND 2)

Efficient construction by the span-by-span method

The span-by-span method is being used to achieve high erection rates in the construction of the elevated sections of two metro lines

ivil Works Joint Venture made up of Cthe well-known companies Bech- tel, Almabani, Consolidated Contrac- tors Company and Siemens, is respon- sible for the design and build works of Lines 1 and 2 of the Riyadh Metro net- work.

Line 1 (Blue Line) runs in the North- South direction along Olaya and Batha Streets, starting from an area slight- ly North of King Salman Bin Abdul Aziz Street and ending in the Dar Al Badia neighbourhood in the South. The met- ro will be mostly underground, running in a bored tunnel along Olaya and King Faisal Streets, though it will be elevat- ed on a viaduct along Batha Street and at the Northern and Southern ends. Line 1 extends over a length of approx- imately 38km and features 22 stations, in addition to four interchange stations providing connections to the other five lines.

Line 2 (Green Line) runs underground in a bored tunnel along King Abdulaziz Street, between King Abdul Aziz His- torical Centre and the Riyadh Airbase, before connecting with King Abdul- lah Road. The line stretches for about 12.9km and features 10 stations, in addition to two stations connecting Lines 1 and 2.

All the elevated sections are being con- structed using the span-by-span seg- mental method. The span-by-span method is based

24 DEAL MAG PROJECT TEAM and storage in the precast yard Client: Arriyadh Development Moulds for precast segments Authority (ADA) Design and fabrication of: Contractor: Bechtel – Almabani 13 short-line moulds for typical – CCC - Siemens JV (BACS) span-by-span segments Designer: Aecom 6 short-line moulds for span-by-span pier segments DEAL SUPPLIED 2 short-line moulds for typical Launching equipment single-track span-by-span segments Design and fabrication of: 1 short-line mould for single-track 5 launching girders for span-by-span pier segments span-by-span erection 2 short-line moulds for typical 2 new lifting frames for balanced balanced cantilever segments cantilever erection 1 short-line mould for balanced 2 second-hand lifting frames cantilever pier segments for balanced cantilever erection 1 short-line mould for balanced Gantry cranes for the precast yard cantilever expansion joint segments Design and fabrication of: 3 short-line moulds for station 4 gantry cranes for segment handling segments

on a production cycle that starts in the logistics effort, particularly as Deal ment to Riyadh. Once ashore, Deal’s precast yard, where the segments are designs all of its products in house and supervisors coordinate with local per- manufactured, and ends with the erec- then involves a team of suppliers, locat- sonnel and liaise with the BACS team in tion equipment that physically builds ed mostly in Europe and China, in all order to get the equipment assembled, the bridge. All the items of equipment of the manufacturing activities. All the tested and ready to work. required for the entire process - 29 components then have to be partial- The first segment was cast in April precasting moulds, four gantry cranes, ly assembled and tested before final 2015 and within just 18 months half of five launching girders and four lifting delivery to the site. the elevated section had been erected frames – have been provided by Deal. More than 200 containers and flat thanks to the drive of the BACS team, Deal has to design, manufacture and racks – open-topped containers - have with constant support from Deal’s main deliver all of the equipment in accor- crossed the Mediterranean Sea and the office and Deal’s supervisors, who are dance with a strict schedule - a huge Indian Ocean to deliver Deal’s equip- always present on site

DEAL MAG 25 RIYADH / SAUDI ARABIA / ASIA

RIYADH METRO PROJECT RED LINE (LINE 3) Astonishing productivity in span erection for the longest metro line

PROJECT TEAM Client: Arriyadh Development Authority (ADA) Contractor: Arriyadh New Mobility Civil Work Group: Salini Impregilo Spa Larsen & Toubro Ltd. Nesma & Partners Contracting Co. Ltd. JV Designer: International Bridge Technology (IBT)

DEAL SUPPLIED Launching equipment Design and fabrication of: 7 launching girders for span-by-span erection 2 new lifting frames for balanced cantilever erection 2 second-hand lifting frames for balanced cantilever erection 3 towers for launching girder Deal has worked closely with equipment required for the prefab- erection the contractor for the metro’s rication and erection of the elevated 2 towers for span erection along longest line to achieve structures. Eleven simultaneous work curved sections an extremely high rate of span fronts along Line 3 required the sup- 1 tower for launching girder erection for the elevated section ply of an impressive quantity of spe- load tests cialised equipment with a total weight 8 towers for balanced cantilever of approximately 7,000t, delivered to stabilisation xecution of the civil works for Saudi Arabia from overseas by means of Moulds for precast segments Ethe infrastructure of Line 3 (Red 360 standard 40’ containers. Design and fabrication of: Line) has been awarded to Arriyadh Thanks to close and continuous coor- 6 short-line moulds for typical New Mobility Civil Work Group, a JV dination between the contractor’s span-by-span segments between Salini Impregilo, Larsen & construction team and the Deal engi- 3 short-line moulds for Toubro and Nesma. The Red Line is neering team, the design of the equip- span-by-span pier segments the longest on the new Riyadh Metro, ment was defined and tailored to suit 4 short-line moulds for typical running from East to West for a total of the actual construction requirements. balanced cantilever segments 41.2km - of which 26.7km are formed The benefits of this collaboration were 2 long-line moulds for station by a viaduct – with 22 stations and six recently confirmed by the achievement segments park-and-ride locations. of an astonishing productivity rate of Arriyadh New Mobility Civil Work just 1.5 days per cycle for span erec- Group assigned to Deal the design and tion, using launching girders supplied supply of almost all the construction by Deal

26 DEAL MAG RIYADH METRO PROJECT LINES 4,5 AND 6 Rapid construction of almost 12km of viaducts

The FAST consortium is living targets for some activities. The results designed, produced, delivered and up to its name, with rapid achieved by Freyssinet SA are due in assembled in just six and a half months. progress on Lines 4, 5 and 6 part to Deal’s involvement in the proj- The order was issued at the beginning of the Riyadh Metro ect both as a supplier of equipment and of March and the first segment was through the presence of supervisors ready at the end of September. and Deal employees on site for the pre- Segment production reached the pro- he consortium, which is led by FCC fabrication and the launching of seg- grammed one-segment-per-day rate TConstruccion, is designing and ments. for the span-by-span work and one constructing the three lines, which Key achievements have included: segment every two days for the balanced involve extensive elevated sections. Commissioning in 2016 of a third cantilever spans of 52m and 72m. Seg- In total, 11,904m of viaducts are being launching girder for ‘span-by-span’ ment installation, which is current- built using precast segments, with pro- erection. This was manufactured, ship- ly ahead of programme, has averaged duction taking place in a nearby casting ped and assembled on site in only five 2.5 spans per week, using two work- yard. Most of the viaducts - 10,420m months - the order was issued at the ing shifts per day. A maximum output - will be constructed by the span-by- beginning of March and the first span of four spans a week has been achieved span method, with the balanced can- was launched in August. with the two shifts tilever method used for the remaining In 2016, two sets of additional moulds 1,484m. were commissioned for the construc- The planned number of segments for tion of segments: one for 96m balanced the span-by-span sections is 2,914, cantilever erection and the other for with a further 404 for the balanced can- 120m balanced cantilever erection. Key tilevers; all should be produced within a geometrical characteristics of the seg- period of just 18 months. ments that had to be achieved included The FAST consortium work that has a height of approximately 7.5m. Despite been subcontracted to Freyssinet Saudi the challenging design, the two types Arabia achieved all its objectives set for of moulds - one for typical segments 2016, even surpassing expectations and and one for pier head segments – were

PROJECT TEAM Design and fabrication of: 1 short-line mould for typical Client: Arriyadh Development 2 gantry cranes for handling segments Authority (ADA) and storage of segments in the 1 set of accessories for expansion joint Contractor: FAST Consortium: precast yard segments FCC Construccion – Samsung Moulds for precast segments Engineering services – Alstom – Strukton – Freyssinet Design and fabrication of: Production of the erection manual Saudi Arabia – Typsa – Setec JV 6 short-line moulds for typical and loading sequence Subcontractor: Freyssinet Saudi span-by-span segments Construction analysis Arabia 3 short-line moulds for span-by-span Provision of a geometry control Designer: Atkins pier segments system and drawings For balanced cantilever spans Shop drawings for the segmental and DEAL SUPPLIED of 52m to 72m balanced cantilever superstructure Launching equipment 1 short-line mould for pier segments Precasting yard and temporary works Design and fabrication of: 2 short-line moulds for typical design 3 launching girders for span-by-span segments erection 1 set of accessories for expansion Supply of post-tensioning equipment 1 lowering system for launching of the joint segments and materials final spans of the viaduct (using span- For balanced cantilever spans by-span methodology) of 96m to 120m Technical assistance on site – Gantry cranes for the precast yard 1 short-line mould for pier segments precasting yard and erection

DEAL MAG 27 AL HAIR / ARRIAYADH REGION / SAUDI ARABIA / ASIA

WADI HANIFA BRIDGE A LANDMARK STRUCTURE COMPLETED IN RECORD TIME

— Successfully completed in just one year — A 77m span erected each week Deal involved in: estimating, engineering, procurement of special equipment, supervision of precasting and erection, quality control, cost control, scheduling and general management

fficient adaptation of available di Arabia. The valley runs for 120km equipment has enabled Wadi from North to South, cutting through EHanifa Bridge to be completed the country’s capital, Riyadh. successfully in just one year, from the The new crossing of the 40m-deep val- start of activities at the precasting yard ley is a 16.33m-wide two-way bridge to the erection of the last segment. with a length of approximately 512m Adding to the challenges of the proj- made up of six 77m spans and two use of everything that had been built ect were the need to incorporate Rama- 25m-long side spans. The deck is a pre- previously - in particular the piles and dan into the schedule and the need to cast segmental concrete box girder with the foundation plinths of the piles and work through the summer in one of the internal post-tensioning, erected using abutment - but would also allow for world’s hottest areas, with tempera- the balanced cantilever method. maximum optimisation of the erection tures reaching 50°C. The location and The project, which was awarded to local process. related difficulties made the speed of contractor Al Ayuni, had been put on The geometry and positions of the piles execution particularly remarkable; the stand-by for various reasons, but fail- were preserved, while the superstruc- erection reached a completion rate of a ure to complete it would have com- ture - originally designed to be cast 77m span each week following the ini- promised the opening to traffic of the ‘in situ’ on falsework, was completely tial learning curve. entire highway. re-engineered by Deal. The new solu- The bridge crosses the Wadi Hanifa It was therefore necessary to devise a tion involved precast segments, mak- area in the Nejd Region of Central Sau- new design solution that would make ing use of prefabrication and launching

28 DEAL MAG PROJECT TEAM Client: Ministry of Transportation, Kingdom of Saudi Arabia Contractor: Al Omaier Trading & Contracting Company Subcontractor: Al Ayuni Investment & Contracting Company General designer: EURO CONSULT Superstructure design: Deal

DEAL SUPPLIED Erection equipment 1 launching truss for balanced cantilever construction 1 trailer for segment transportation 2 finishing platforms Moulds for segment precasting 3 short-line moulds for constant-height segments 1 short-line mould for variable-height segments 1 mould for pier segments 4 segment manipulators Precasting equipment 1 gantry crane (100t capacity) for segment handling 5 jigs for segment rebar cages 10 moveable sheds for segment moulds and rebar jigs Specialised materials Supply though subsidiary of: Post-tensioning hardware and specialised equipment Pot bearings, shear keys and shock transmitter devices Expansion joints Engineering services Redesign of the superstructure from the original cast-in-situ to precast segmental Construction engineering and shop drawings for the superstructure Detailed design of the temporary equipment that was already available Deal provided the client with extensive works and precasting yard and almost ready to use. Fabrication of support throughout the project, includ- Project management the precast elements was able to start ing estimating, engineering, procure- Provision of staff and just four months after the award of ment of the special equipment and management to ensure: the contract, thanks to the work done supervision of the precasting and erec- Timely execution of the bridge during the ‘re-engineering’ stage to tion operations, as well as quality and The required quality of works prepare and ship to site all of the spe- cost control together with programme Remaining within the agreed cially modified prefabrication equip- and general management. budget ment. At the same time, the launching equip- Deal was involved in the redesign of ment that was available was customised the viaduct, the supply of all the spe- for the project and shipped to the site cial equipment and the supply of all in time for the launching and erection post-tensioning materials and equip- phase of the segments and girders to ment as well as bearings and expansion start in March 2015. joints. In addition it provided the engi- The first carriageway was completed neering for all construction phases and and opened to traffic in August 2015, – most importantly – full work super- while the entire project was delivered vision for the viaduct construction, in November 2015. through its seconded technicians

DEAL MAG 29 KUWAIT CITY / KUWAIT / ASIA

JAMAL ABDUL NASSER STREET UPGRADE OF KUWAIT CITY’S MAIN TRANSPORT ARTERY INTO A MOTORWAY

Use of an alternative method to erect most of the precast segments for a 7.2km-long elevated highway has enabled Deal to increase production rates and save materials

PROJECT TEAM Client: Kuwait Ministry of Public Works (MPW) – Roads Engineering Department (Motorways) Contractor: Rizzani de Eccher Spa, OHL SA, Boodai Construction, Trevi Spa Joint Venture Designer: Louis Berger

DEAL SUPPLIED Launching equipment 2 launching girders for span-by-span construction a pair of lifting frames for balanced cantilever construction he Jamal Abdul Nasser (JAN) the route. The scope of works also Precast segment mould design Project, also known as RA 167, includes diversion and upgrading of a and fabrication T is one of the main infrastructure number of utility networks, including 6 short-line moulds and road development projects taking electrical and communications cabling, for segments of types ‘A’ and ‘DA’ place in Kuwait and is part of the Min- sewerage and stormwater drainage. 1 short-line mould istry of Public Works’ strategic plan to for segment type ‘DB’ improve motorways and other roads. The project features: 7 short-line moulds The project will transform and upgrade a 7.2km-long elevated highway (ap- for segments of types ‘C’ and ‘DC’ the existing street into a motorway that proximately 8,500 precast segments); 1 short-line mould meets international standards, with a six different types of segments (types for segment type ‘E’ structural design life of 100 years and ‘DA’, ‘DB’, ‘DC’, ‘A’, ‘C’, and ‘E’); Other equipment capacity to accommodate growing traf- six to eight lanes on the elevated high- Design and fabrication of: fic flows for many years to come. The way; 4 gantry cranes for upgrade will be achieved by construct- a four-level interchange at Ghazali Road; the precasting yard ing several complex bridges and ele- three other interchanges. Engineering services vated highway sections along the full Support for precasting yard length of Jamal Abdul Nasser Street and The original design solution assumed design and logistics at intersections. that all 8,500 segments would be erect- Temporary works design The scheme will guarantee smoother ed using the balanced cantilever meth- Geometry control and more efficient traffic flow, as well od. Instead, Deal proposed adopting the Erection engineering as easier access to universities, hospi- span-by-span method for most of the tals and other key city buildings along project, in order to increase the produc-

30 DEAL MAG JAMAL ABDUL NASSER STREET

DEAL MAG 31 KUWAIT CITY / KUWAIT / ASIA

32 DEAL MAG JAMAL ABDUL NASSER STREET

— One of Kuwait’s key infrastructure and road development projects — Use of precast segmental erection methods to construct 395,000sqm of viaducts — Design life of 100 years In order to increase the production rate and to optimise the quantities of materials (rebar and tendons), Deal proposed an alternative construction method for part of the project — Longest span 57m

tion rate and to reduce the quantities of vation enables faster and easier instal- the mobile configuration allows the rebar and tendons needed. lation while avoiding the need for any lifting frame to raise the segments from Both systems are used on the project: transverse hanging beams for the seg- any position underneath the portion of 6,800 segments erected using the ments. cantilever already erected, transport span-by-span method (80% of seg- Another challenge is the great vari- the load along the viaduct and install ments); ability in the length of the spans on the the segments in place; 1,700 segments erected using the bal- project; the shortest span has a length the static configuration allows the lift- anced cantilever method (20% of seg- of 32.5m, whereas the longest is 57m. ing frame to raise the segments from ments). The equipment deployed by Deal has the tip of the cantilevers and place them A twin set of specially designed launch- the capability to use a dual approach to in their final positions. ing girders has been provided by Deal construct the longest spans, by erect- to carry out the span-by-span erection. ing a small section by the balanced can- Deal has also supplied 15 sets of moulds The equipment is capable of erect- tilever method and then completing to cast all 8,500 segments, as well as the ing three different types of segments - the erection using the span-by-span four gantry cranes for their handling. types ‘DA’, ‘DB’ and ‘DC’. Each type has approach. In addition, a pair of lifting In addition, Deal’s technical office has a different distance between the webs frames has been supplied to support been involved in the: and so Deal decided to develop a ‘tele- erection of the balanced cantilever por- design of the precasting yard; scopic’ system that allows automatic tion of the project. The lifting frames temporary works design; adjustment to take account of the dis- can be set both in static and mobile geometry control; tance between the girders. This inno- configurations: erection engineering

DEAL MAG 33 KUALA LUMPUR / MALAYSIA / ASIA

KUALA LUMPUR MRT SUPPLYING OPTIMISED CONSTRUCTION TECHNOLOGY FOR A MAJOR EXPANSION OF METROPOLITAN RAIL INFRASTRUCTURE

— Part of Kuala Lumpur’s massive infrastructure improvement — The launching gantry has a ‘lowered configuration’ operating mode to allow work in areas with restricted clearance such as airports — Use of Deal’s methods and guidelines ensured maximum savings and efficiency

Improvements being put in place Right from the tender stage, Deal has Deal established a close working rela- for Kuala Lumpur’s MRT system had a successful cooperative arrange- tionship with the client and the bridge are designed to bring about ment with a local company, Acre designer from the very beginning of the a dramatic enhancement Works. This has involved deploying an project to ensure well-defined guide- of the coverage of the city’s public in-house solution - including the pro- lines and methods so that savings and transportation network vision of optimised construction meth- efficiency would be maximised during odology - that had been developed for a the prefabrication process. The spe- previous project in Vancouver. cial structures were erected using three For the KL project, Deal supplied sets of lifting frames that employed tru- he aim is for transport in the Acre Works with four sets of launch- ly ‘state-of-the-art’ technology for this Greater KL metropolitan area ing girders for span-by-span erec- field. In particular, in addition to the Tto achieve the same ranking as tion. The equipment had been spe- usual static and mobile configurations, the world’s most modern and devel- cifically designed to suit the project the lifting frames were designed to col- oped cities. As part of this upgrade requirements; in particular, one of the lect a bridge segment previously stored programme, the existing Ampang Line launching girders has a ‘lowered con- on the deck, travel forward fully load- is being significantly extended in its figuration’ operating mode that allows ed and then - once anchored at the tip South-West direction. Contractors work in areas with low clearance, par- of the cantilever - finally erect the seg- have invested heavily in technology and ticularly in close proximity to airports. ment in its place. equipment in order to stay at the tech- nological forefront and capitalise on For the special structures being erect- Deal’s scope of works also includ- the many opportunities offered by the ed by the balanced cantilever method, ed provision of geometry control for new rail infrastructure projects in Kua- Deal is providing three sets of short- prefabrication and the erection of the la Lumpur. line casting moulds. bridge segments

34 DEAL MAG KUALA LUMPUR MRT

Talking about us PROJECT TEAM Client: Kerajaan Malaysia Kementerian Pengangkutan, Venugopal Nambiar, Executive Director Acre Works Prasarana Contractor: Bina Puri DEAL, PARTNER – Tim Sekata JV Subcontractor: Acre Works MORE THAN SUPPLIER Sdn. Bhd. Designer: Opu Ace Vector Konsortium, Hssi Consulting Engineers, MMSB Consult the end-user, such as ourselves, in our Sdn. Bhd. pursuit for innovation. Deal was able to listen and respond accordingly to our DEAL SUPPLIED specific requirements. Launching equipment 4 sets of launching girders — How important was Deal’s background 3 sets of mobile lifting frames and know-how for the success of the proj- Precast segment moulds ect? 3 sets of moulds for balanced — We were able to work closely with cantilever segments Deal on some very complex sections, Engineering services by jointly developing some innovative Geometry control — Why did you chose Deal as a technical solutions partner project? — Deal has a strong global reputation — What is, in your opinion, Deal’s best fea- as a launcher/lifter solution provider. ture that you would recommend to other Deal has a comprehensive expertise in Clients? design, fabrication and support of the — Deal is an honourable, reliable and end-user of specialist launching equip- fast-responding partner. They treat us ment. This rare combination supports more as a partner than just as a client

DEAL MAG 35 KUALA LUMPUR / MALAYSIA / ASIA

ULU JELAI HYDRO-ELECTRIC POWER STATION SETTING NEW STANDARDS DEEP IN THE GROUND

Reaching high elevations isn’t always the biggest challenge for lifting equipment

n the case of a Malaysian hydro project, Deal was requested to Iprovide a gantry crane to trans- port personnel, materials and equip- ment down a vertical shaft, to a depth of 500m. The demanding safety require- ments and exceptional depth as well as the constraints of a confined and barely accessible environment required a new approach to the design of the crane. The result has set new standards for equip- ment operating in this field of con- struction.

The work was for the Ulu Jelai hydro- electric power station. The crane’s working platform can either carry the people involved in the shaft construction or it can be used as a ‘hook’ with a 30t capacity to deliver drilling equipment down to the bottom. Site personnel travel in an elevator bas- ket at the considerable speed of 60m ble emergency brakes; a protection sys- per minute; this speed was necessary — Demanding safety tem is in place to prevent objects from to optimise the travelling times for the requirements falling while people are boarding the workers and to guarantee rapid evacua- — Exceptional lifting range elevator. tion in case of emergency. involving a 500m-deep shaft In the unlikely event of a power break- — Confined and barely The gantry crane has two configura- down, the gantry crane can still bring accessible environment tions: one for 15m-diameter shafts and people back to the top of the shaft as — Speeds of 60m per minute the other to set up equipment in small- it has also been equipped with a high- complete with personnel er, 9m-diameter shafts. In both con- performance, self-propelled safety winch. — Two configurations figurations, the crane can also be set up of the gantry crane for use inside restricted-height tunnels In addition to the safety winch, some thanks to its low profile. other equally demanding safety require- The complexity of the equipment sup- ments have guided the design of the plied coupled with the need to trans- equipment. A ‘double-rope’ system is port people meant that obtaining a CE automatically activated in case of rope stamp required the approval and moni- failure; winches are equipped with dou- toring of a third-party certifier

36 DEAL MAG ULU JELAI HYDRO-ELECTRIC POWER STATION

Talking about us Giuseppe Gelmi, Technical Director Edilmac BE ABLE TO UNDERSTAND THE CLIENTS REQUIREMENTS

— Why did you choose Deal as a technical partner in this project? — We were evaluating the option of refurbishment or the replacement of our major piece of equipment: a gan- try crane, used to reach the bottom lev- els of shafts, with depth up to hundreds meters. One of our freelance supervisors, who is working for Deal too, proposed Deal as a possible supplier, and it was the right choice!

— How important was Deal’s background and know-how for the success of the proj- ect? — Very important, as from the begin- ning we have worked as a team: we pro- posed the methodology, while Deal provided technical guidance in the development and upgrade of the equip- ment, using the most innovative tech- nological solutions.

PROJECT TEAM DEAL SUPPLIED — What is, in your opinion, Deal’s best Contractor: Salini Impregilo Spa Shaft gantry crane feature that you would recommend to oth- Subcontractor: Edilmac er clients? dei F.lli Maccabelli Srl — Surely, the capability to understand the client’s requirements and to design equipment that satisfies such needs

DEAL MAG 37 HO CHI MINH CITY / VIETNAM / ASIA

MRT SYSTEM FOR HO CHI MINH CITY THE FIRST METRO IN THE VIETNAMESE MEGALOPOLIS

High levels of quality and productivity are being achieved on the construction of the Ho Chi Minh City metro project, which is using Deal equipment

he aim of the first line of the new metro system is to provide alter- Tnative transportation methods to relieve heavy traffic congestion in Viet- nam’s southern economic capital. An elevated viaduct approximately 11km long will connect the North-East- ern part of the city to its centre, starting from a depot area and passing through six stations. On the first section, the alignment runs parallel to an existing highway, while the second section, at the entry to the urban area, becomes curvy and crosses the Saigon River. The U-shaped cross section of the via- duct takes as inspiration, in terms of both aesthetics and noise-reduction characteristics, the excellent results achieved by the Dubai Metro Project in the United Arab Emirates. Of note is that the same joint venture that execut- ed the works in Dubai is now prefab- ricating and erecting the segments for had been previously used on the Dubai the new project. Metro and have now been adapted to — Supply of a full package Deal has been asked to supply a full suit the specific characteristics of the of specialised equipment package of specialised equipment: Ho Chi Minh project. — 11km-long elevated viaduct three sets of long-line moulds for the An excellent level of quality and pro- — U-shaped cross section straight spans, three sets of short-line ductivity is being achieved through- inspired by the Dubai Metro moulds for the curved spans and four out the project thanks to the equipment project sets of short-line moulds for pier seg- supplied by Deal: every day 11 segments — Excellent levels of quality ments. In addition, Deal’s scope has are cast in the precasting yard and every and productivity included modification and refurbish- week six spans with a length of 37m are ment of three launching girders that erected

38 DEAL MAG HO CHI MINH LRT SYSTEM

PROJECT TEAM Rizzani de Eccher JV) Moulds for segment precasting Client: Ho Chi Minh City People’s Designer: Systra Design and fabrication of: Committee Management Authority for 3 long-line moulds Urban Railways DEAL SUPPLIED for straight spans Contractor: Sumitomo Cienco6 Launching equipment 3 short-line moulds Consortium Design and fabrication of modifications for curved spans Contractor for civil works: GS E&C to three existing launching girders for 4 short-line moulds Subcontractor: FVR (Freyssinet – VSL – use in span-by-span construction for pier segments

DEAL MAG 39 DOHA / QATAR / ASIA

DOHA METRO CONSTRUCTION OF THE WORLD’S MOST TECHNOLOGICALLY ADVANCED RAIL TRANSIT SYSTEMS

he Doha Metro will service both the piers using a launching girder. Both The extensive preparatory studies Qatar’s capital and the city’s sub- the span-by-span and balanced canti- enabled the prefabrication and launch- Turbs, providing easy and conve- lever methods are being used. ing works to be completed without any nient access to all key locations. The main contractor, the RLR Joint problems and ahead of schedule. The metro system is being built in two Venture, brought in Deal right from the phases: tender stage to work on the analysis of In November 2016, a new record was the first involves construction of three the structural solution for the elevated set on the Red Line North Project: Deal of the four lines (Red, Gold and Green) section of Red Line North. Deal drew on used the span-by-span method to con- and 37 stations. The lines are expected its experience in the design and con- struct a section that included 52m spans to come into use in late 2019; struction of similar works and intro- with a U-shaped cross-section. The the second phase will be completed by duced a series of optimisations in the work involved creation of a continuous 2026 and will involve the expansion of structural concept, which also allowed deck unit composed of four spans hav- the phase one lines and the construc- significant savings. ing lengths of 34m+52m+52m+30m. tion of the fourth route – the Blue Line. This was a first for this kind of structure In total, another 72 stations will be built Following the award of the project to and Deal had to push to the limits both in phase two. RLR, Deal has been involved in the the span-by-span methodology and the About 2,200m of the alignment runs on detailed design and engineering for erection equipment in order to achieve an elevated double-track viaduct com- the construction of all the decks and the challenging goal. The innovative posed of precast segments. The seg- has been able to put into practice all the solution has also achieved cost benefits ments are fabricated in a dedicated pre- optimisations proposed during the ten- compared to the traditional balanced casting yard and then launched across der stage. cantilever method

PROJECT TEAM DEAL SUPPLIED Gantry crane for segment handling Project: Doha Metro project - design Launching equipment and storage in the precasting yard and build – Red Line North elevated and Design and fabrication of: Transporter for segment handling at-grade sections Launching girder for span-by-span behind the launching girder Client: Qatar Rail erection Contractor: RLR Joint Venture – Rizzani Precast segment moulds Deck design de Eccher – Lotte – Redco International Design and fabrication of: Designers: Typsa & Progin JV. 2 short-line moulds for typical Engineering services Alignment design, geotechnical design, span-by-span segments and geometry control station design, cut & cover and trough 1 short-line mould for span-by-span design, viaduct substructure design; pier segments Post-tensioning equipment Salfo: design of traffic diversion and 1 short-line mould for typical and materials utilities relocation and protection; and special segments Rizzani de Eccher: design of bridges

40 DEAL MAG Significant savings are being achieved on the Doha Metro project, thanks to optimisation of the design and construction methods

DEAL MAG 41 42 DEAL MAG DEAL MAG 43 DOHA / QATAR / ASIA

DOHA’S NEW CONNECTING HIGHWAY VIADUCT CONSTRUCTION by the balanced cantilever method

onstruction is under way of a Port to the East-West Corridor in the In total, 2,168 concrete segments will new 45km dual carriageway that North as well as to Al Wakra Bypass in be installed by means of crawler cranes Cincludes four grade-separated the East and to the Orbital Highway. equipped with self-propelled remot- interchanges. It is located to the South The interchanges include 6,200m of ed-controlled lifting spreader beams of Doha City and will connect Al Wakra viaducts to be built using balanced can- capable of positioning each segment – Mesaieed Highway and the New Doha tilever precast segmental technology. precisely

PROJECT TEAM DEAL SUPPLIED 9 short-line moulds for typical Client: Public Works Authority, Qatar Equipment segments for balanced cantilever (Ashghal) Design and fabrication of: spans Contractor: J&P-AVAX S.A JV 2 straddle carriers 3 short-line moulds for pier segments Project management consultant: KBR 3 motorised spreader beams for for balanced cantilever spans Supervision consultant: AECOM launching segments using mobile Deck design Design consultant: WSP cranes Engineering services and geometry Subcontractor for design and 6 stressing platforms control design construction of bridges: Rizzani de Precast segment moulds Post-tensioning equipment and Eccher Spa, Qatar Branch Design and fabrication of: materials

44 DEAL MAG HONG KONG / CHINA / ASIA

Hong Kong-Zhuhai-Macao Bridge THE RETURN OF THE RED DRAGON

The ‘Red Dragon’ has returned to equipment to the mythological creature bridge-building after a few years of so popular in Chinese folklore. — Construction inactivity. The distinctive launching Despite a nickname rooted in folklore, of two parallel viaducts girder is being used to construct the launching girder had to be designed — Maximum span length 75m prefabricated viaducts as part of to overcome daunting real-world chal- — Balanced cantilever a major bridge and tunnel project lenges on its latest project. These construction method that will connect the cities of Hong included variable dimensions of spans — Use of a launching gantry Kong, Zhuhai and Macao on the and segments, problematic access to that can be used to erect Pearl River Delta the erection area and a very tight hor- segments of both viaducts izontal radius of curvature, not to men- by shifting transversally tion the high performance standards he longest bridge section of the required of the equipment in terms of Hong Kong – Zhuhai – Macao erection cycles. T Project is 29.6km long and includes three cable-stayed spans with The Red Dragon is capable of picking lengths of between 280m and 460m. up prefabricated segments delivered PROJECT TEAM The equipment is being used for the either from the already erected deck or Client: Hong Kong Highways construction of prefabricated elevat- from barges. During the self-launching Department ed viaducts between the Hong Kong operation, the equipment is positioned Contractor: boundary and Scenic Hill. Work con- symmetrically between the two via- Dragages - China Harbour – VSL JV sists of two parallel viaducts - one for ducts. The main supports are equipped Designer: Mott MacDonald – YWL each carriageway - with a maximum with long rail tracks, which means that Engineering span length of 75m; construction is by the launching girder can then erect the balanced cantilever method. alternate segments for each viaduct, by DEAL SUPPLIED Local people had become fond of the shifting transversally. Launching equipment Red Dragon, which gained its nickname In terms of cycle times, this represents ‘Second-hand’ launching girder when it was deployed on the East Tsing a significant saving for the project as Yi Viaduct. Its red steel coating and post-tensioning operations can be the fabled engineering feats it accom- overlapped with the assembly of the plished led the local press to liken the adjacent bridge, and vice versa

DEAL MAG 45 BASRA / IRAQ / ASIA

Careful planning during design development has brought benefits in the construction of a new bridge in Iraq

AL SEWYRAH BRIDGE DEAL HELPS CROSS THE TIGRIS RIVER

etraco Contracting Offshore car- two 60t-capacity straddle carriers superstructure, in order to select the ried out a successful project to for beam handling and the system best construction methods. Sbuild the bridge over the Tigris employed to launch the bridge girders. The result was optimisation and full River, close to the city of Basra. The client approached Deal with an integration between the design of the The Al Sewyrah Bridge was commis- offer to develop a complete set of effi- permanent structure and the equip- sioned by the State Corporation of Road cient, flexible and easily relocatable ment needed for its construction. For & Bridges of the Republic of Iraq. All equipment for constructing the bridge example, the same mould can be used equipment for bridge construction was deck using precast pre-stressed beams. to cast both T- and I-shaped beam supplied by Deal, including moulds for Deal’s scope also included design cross-sections and can accommodate self-compacting concrete T-beams, review & development for the bridge different beam lengths

46 DEAL MAG Talking about us

Charbet Abdallah, Technical Director Setraco Group DEAL, A TRUSTWORTHY PARTNER THAT HELP CLIENTS WITH FULL COMMITMENT

PROJECT TEAM Client: State Corporation of Road & Bridges, Republic of Iraq Contractor: Setraco Contracting As we expanded our operations to Iraq Offshore SAL in 2012, we continued our coopera- Designer: Deal tion with Deal to execute a 420-m-long bridge over the Tigris river, composed DEAL SUPPLIED of 35-m-long pre-stressed girders, Precast moulds positioned in place using a launching Design and fabrication of a mould girder. for T- and I-shaped beams Launching equipment — How important was Deal’s background Design and fabrication of: and know-how for the success of the proj- 2 straddle carriers ect? of type SC 60/4.5 1 launching girder — Deal’s involvement was a key factor in of type LG 120/40 the success of Al-Sewyrah Bridge con- Engineering services struction. Their technical assistance in optimising the superstructure design, the construction method, as well as their staff presence on site with a day- to-day follow up of any modification — Why did you choose Deal as a technical or adjustment, was a major element of partner in this project? completing the project on time with a zero-accident result. Deal’s know-how — Being one of the leading infrastruc- led to a successful selection and quan- ture contractors in Nigeria, we always tification of pre-stressing equipment search for a reliable and trustful part- and materials, making the on-site exe- ner to successfully deliver our projects. cution in a remote and risky region like When we were awarded contracts for Iraq smooth and punctual. the construction of several long-span bridges in 2001, we began to look for a — What is, in your opinion, Deal’s best fea- world leader in launching equipment ture that you would recommend to other for bridges, supplier of pre-stressing clients? materials, and a strong technical part- ner – which was Deal. — Deal is a trustworthy partner who can The success of this partnership lead to perfectly deliver: several further cooperations in bridge 1. the best suitable method for a bridge construction, such as: superstructure construction; 1. 612-m-long bridge composed of 2. the exact equipment needed to per- 36-m-long pre-stressed girders posi- form the job; tioned in place using a launching gird- 3. cost-effective pre-stressed materi- er; als; 2. 645-m-long bridge composed of 4. detailed superstructure design and, 31-m-long pre-stressed girders, posi- subsequently, all back-ups that might tioned in place using a launching gird- be required during the construction er; phase. 3. 850-m-long bridge composed of On top of that, Deal has very profes- 95-m-long spans, made of pre-cast sional and dedicated commercial and segments, erected with balanced canti- technical staff that do their best to help lever method using a launching gantry. clients with full commitment

DEAL MAG 47 HONG KONG / CHINA / ASIA

The Liantang Project A UNIQUE SOLUTION TO ACHIEVE FLEXIBILITY IN NARROW AND CONGESTED AREAS

An alternative and faster route is being created for the movement of people and goods between Mainland China and Hong Kong

— Unique equipment: the special mobile lifting frame — Maximum flexibility — Just one loading position needed for each cantilever

ontract 3 of the Liantang/Hueng This unique working cycle ensures the Yuen Wai Boundary Control maximum flexibility in terms of seg- PROJECT TEAM CPoint Site Formation and Infra- ment feeding, with just one loading Client: Civil Engineering structure Works (Liantang 3) is located position needed for each cantilever. & Development Department in the New Territories near the border The special mobile lifting frame is a Contractor: Chun Who between Hong Kong and Shenzhen. piece of equipment that had already Construction The project’s contractor is using a been used successfully on the Dallas & Engineering Co. Ltd. unique piece of equipment – a special High-Five Project in Texas and has been Subcontractor: Freyssinet mobile lifting frame - for the erection modified to suit the characteristics of Construction Asia Ltd. of prefabricated viaducts crossing over the new project. In particular, the seg- Designer: Meinhardt the MRT railway. ment spreader beam is now equipped with retractable arms in order to avoid The lifting frame is able to pick up any possible interference with the DEAL SUPPLIED segments along the longitudinal axis already erected and adjacent viaducts. Launching equipment underneath the bridge, move them to For safety purposes, arm extension/ Redesign and adaptation the end of the cantilever and load the retraction and geometrical adjustment of an existing special mobile segments inside the frame above deck of the segment positions are performed lifting frame level. It can then travel with the load up by means of a hydro-electric system to the tip of the other side of the can- powered by an on-board electric gen- tilever, where it finally erects each seg- erator that can be controlled via radio ment in its final position. remote control

48 DEAL MAG HANGZHOU / CHINA / ASIA

HANGZHOU BAY BRIDGE PROJECT Construction of a record-breaking sea bridge

eal’s extensive experience se- — two rubber-wheeled gantry cranes cured it a key role providing the with a capacity of 50t to handle the PROJECT TEAM Dhighly specialised equipment rebar cages in the precasting yard; Client: China Railway Bridge needed for construction of one of the — two rubber-wheeled gantry cranes Bureau Group Co. Limited world’s longest bridges. with a capacity of 800t to handle the Contractor: China Railway The 36km-long Hangzhou Bay Bridge prefabricated elements in the precast- Erju Co. Limited - the world’s longest sea bridge at the ing yard; Designer: Hardesty & Hanover, time it opened in 2008 - is located near — two rail-mounted 800t-capacity gan- LLP where the Qiantang River enters Hang- try cranes for positioning the prefab- zhou Bay, an inlet of the East China Sea. ricated elements on top of previously DEAL SUPPLIED It consists of two parallel structures erected sections of the viaduct; Launching equipment designed to carry a dual-carriage- — a special 1,600t-capacity transport- Launching gantry of 1,600t capacity way road of six lanes; the main span of er to carry the full span to the erection Other equipment the cable-stayed bridge is 448m long, area; 2 straddle carriers of 50t capacity flanked by 50m-long prefabricated — a launching gantry for the final erec- 2 straddle carriers of 800t capacity spans, each weighing 1,500t. tion stage of the 1,500t prefabricated 2 gantry cranes of 800t capacity spans Transporter of 1,600t capacity The main challenge for the proj- ect’s contractor was finding a com- pany capable of designing, manufac- turing and supplying the high-quality Deal’s equipment was specialist equipment needed for safe highly successful, transportation and launching of such heavy spans. demonstrating the importance of entrusting Thanks to its thirty years of experience such complex work in the field, Deal was able to devel- op the most suitable solution and was to only the most appointed to supply: experienced companies

DEAL MAG 49 AUCKLAND / NEW ZEALAND / OCEANIA

A state-of-the-art launching girder nicknamed Dennis has been developed by Deal to meet the demanding equipment requirements of a motorway scheme in Auckland

50 DEAL MAG WATERVIEW CONNECTION PROJECT

THE GREAT NORTH ROAD INTERCHANGE (GNRI) ‘DENNIS’ overcomes tight construction space and environmental restrictions

PROJECT TEAM Client: NZ Transport Agency Contractor: Well Connected Joint Operation (WCJO) Subcontractor: Deal

DEAL SUPPLIED Launching equipment Launching girder for beam erection

he Waterview Connection Proj- Right from the tender stage, a truly ect is one of the most import- cooperative spirit has developed natu- — Strict limits T ant infrastructure developments rally between the teams of the contrac- on the equipment weight ever to take place in New Zealand. It will tor and Deal. This resulted in the choice — Tight curvatures, both complete a motorway ring route around of clearly defined and highly suitable horizontal and vertical the city of Auckland and will bypass construction methods and design char- — Variable span lengths central Auckland to the West, State acteristics for the equipment. Highway 1 (SH1) and the Auckland Har- The rather small diameter of the piers bour Bridge). imposed a strict limit on equipment The project includes construction of weight, while the particularly tight ver- a major interchange - the Great North tical radius of the alignment brought Road Interchange - connecting the new additional challenges. As a result, Deal SH20 tunnel with the existing SH16 introduced a new type of support that tunnel over an existing road. The inter- could be easily adjusted hydraulically. change includes four ramps near the In addition, the need to adapt to the northern entrance, with a total length combination of very tight horizontal of approximately 1,700m. and vertical curvatures, variable span lengths and the limitations on equip- Deal has supplied a self-launch- ment weight contributed to the creation ing truss for erecting the beams of the of a ‘state-of-the-art’ solution for this ramps. The choice of this type of equip- type of equipment. ment was dictated by the construction The yellow launching girder nicknamed site’s location within a heritage area Dennis has become a ‘partner’ for and close to sensitive coastal marine Alice, the giant tunnel boring machine environments, which prevented the (TBM) excavating the motorway tun- use of conventional and invasive lifting nels: a friendly face for a very compli- methods. cated and challenging project!

DEAL MAG 51 SYDNEY / AUSTRALIA / OCEANIA

M4 WIDENING MINIMISING TRAFFIC CONGESTION ON AUSTRALIA’S LARGEST INFRASTRUCTURE PROJECT

The need to keep traffic flowing Deal was awarded a contract covering while beams are erected on a site both the design of the project’s elevat- PROJECT TEAM with limited access is among ed structures and the supply of special- Client: New South Wales the challenges that Deal has had ist construction equipment. Government - Roads & Maritime to address on the project to widen The equipment provided includes two Services the M4 in Sydney sets of moulds for casting T-shaped Contractor: WestConnex beams, as well as two gantry cranes Construction JV and two straddle carriers for handling Designer: Deal he project is part of WestConnex, the beams and a beam launcher for the the largest integrated transport erection stage. Tscheme under way in Austra- DEAL SUPPLIED lia. Work includes the renovation and Special attention was needed during the Precasting yard equipment upgrading of both public transport and structural design and equipment design 2 sets of moulds for T-shaped critical road infrastructure. The M4 phases to meet the challenges of erect- beams and M5 motorways are to be extended, ing the structures for the new lanes 2 gantry cranes of 80t capacity widened and joined together to form while keeping traffic flowing on the 2 straddle carriers of 60t capacity a continuous, free-flowing motorway existing ones. Adding to the complexity Launching equipment with connections to the city, airport, were further constraints resulting from Launching gantry type 150/50 port and harbour. limited access and the challenging erec- tion procedures required. The M4 Widening project involves An additional aim was to minimise the upgrading the motorway from three to use of conventional lifting and han- four lanes in both directions. dling equipment at the erection site

52 DEAL MAG SYDNEY / AUSTRALIA / OCEANIA

SYDNEY METRO SAVING TIME WITH DEAL’S INNOVATIVE DE-MOULDING TECHNOLOGY Innovative solutions developed by Deal are helping cut the production times for segments on Australia’s first fully-automated metro rail system

First fully-automated metro rail system in Australia

he Sydney Metro is Australia’s it can then be moved on using a moto- largest public transport infra- rised rail-based system. PROJECT TEAM Tstructure project and includes the Time is crucial on the project and so Client: Transport for NSW construction of 15km of twin tunnels Deal’s designers have paid particular Contractor: Salini Impregilo Spa and 6.3km of prefabricated viaducts. attention to developing technical solu- Australia Branch The project is on track to come into ser- tions that minimise the mould set-up Designer: SMEC vice in the first half of 2019. time needed to adapt to the characteris- Its execution is taking place in two stag- tics of the various segment types. There DEAL SUPPLIED es: firstly the Metro Northwest section are typical, deviator and station seg- Moulds for the precasting (formerly the North West Rail Link) ments, with lengths from 2.5m to 4m. of segments and secondly the Metro City & South- In addition, Deal has supplied the cli- Design and fabrication of: west Section. The system will have eight ent with its state-of-the-art geometry 3 short-line moulds for typical new stations and there will be 4,000 control system, which has been devel- span-by-span segments commuter car parking spaces in Syd- oped and upgraded in recent years. The 1 short-line mould for ney’s growing Northwest area. system is specifically designed to sim- span-by-span station segments Deal has been appointed to supply six plify operations in the precasting yard 1 short-line mould for sets of short-line casting moulds for the and, therefore, minimise the possibil- span-by-span pier segments prefabrication of the viaduct segments. ity of errors during the casting of seg- 1 short-line mould for span-by- ments span station pier segments The main challenge is that the equip- ment has also to be capable of casting Engineering services the station segments, which have rein- forcing ribs under their wings. Deal’s engineers have addressed this by devel- oping an innovative ‘de-moulding’ sys- tem that allows the sides of the moulds to be moved horizontally: this simpli- fies the release of the segment so that

DEAL MAG 53 JAKARTA / INDONESIA / ASIA

Tajung Priok Road A NEW 12.1KM ACCESS ROAD TO INDONESIA’S BUSIEST SEAPORT

nfrastructure cannot keep up with It was important to avoid the use of Use of an innovative the economic growth in Indonesia, large-capacity ground-based cranes for which has a population of 250 mil- the handling of the prefabricated ele- beam lifter has lion.I A new masterplan has been cre- ments and so Deal designed, fabricat- proved ideal for the ated by Japan International Coopera- ed and supplied a special beam-lifter tion Agency (JICA), in cooperation with capable of erecting the 140t, 40m-long erection of precast the Government of Indonesia, to help beams. beams in a congested address shortcomings in the Jakarta Metropolitan Area. The system brought several advantages: area of Jakarta — reduced traffic impact; The Tanjung Priok access road is part — reduced capacity needed for the ser- of this massive programme: the proj- vice crane; ect involves building a 12.1km, six-lane — reduced impact on the permanent toll road to Tanjung Priok Port in order structure, thanks to the light weight of to create a connection between the the equipment. North-Eastern section of Jakarta Outer Ring Road (JORR) and the Jakarta har- Heavy traffic in the project area meant bour road. that the beams were delivered in pieces and assembled underneath the spans. Deal had worked with client Obayashi The equipment supplied by Deal was on a previous project in the Gulf area capable of moving outside the line of and built up a strong spirit of coopera- the pier caps, picking up the beam, tion. This led to Deal developing innova- lifting it to the pier height, shifting it tive equipment for beam erection in the transversally and then setting it in its congested areas of the Jakarta project. final position

PROJECT TEAM Client: Obayashi - Jaya Konstruksi Joint Operation Contractor: Ministry of Public Works Subcontractor: Deal

DEAL SUPPLIED Beam lifter for beam erection

54 DEAL MAG RENNES / FRANCE / EUROPE

Viaduct construction for Rennes Metro DEAL’S FIRST LAUNCHING GIRDER CAPABLE OF ERECTING TWO SPANS SIMULTANEOUSLY

Deal is supplying special equipment for the construction of the segmental superstructure of one of the largest public works projects currently under way in France

— Reduced relocation time for the launching girder — Faster erection cycle — Reduced loads on the spans — On-site support for the client from Deal’s technicians during all operations

he 13.8 km, 15-station Line B structures have been particularly chal- is the second driverless VAL lenging due to restrictions imposed by PROJECT TEAM T(Véhicule Automatique Léger) the architect arising from the futuristic Project: Viaduct de Rennes – Lot route to be built in Rennes and is appearance of the viaduct. 4 – Rennes (France) expected to be used by 110,000 passen- Contractor: Eiffage Genie Civil gers a day. This has, however, given Deal the Designer: Egis Deal’s L105 launching girder (LG) pro- opportunity to design an innovative vides a great advantage compared to the solution with many advantages, such as DEAL SUPPLIED usual span-by-span launching equip- a reduced time for relocation of the LG Double-span launching girder ment designed to erect just one span from one pier to another, faster erec- (two 500t spans, 40m long each) at a time in simply supported condi- tion cycles and reduced loads on the tions (isostatic configuration). Instead, permanent works. the innovative design means that two 40m adjacent spans (also known as Deal’s technicians are supporting ‘bi-travée’) are temporarily hung from the client on site during all assem- the main trusses and then simultane- bly and erection operations because ously lowered into position, with the of the high levels of accuracy required LG operating on three supports, some- in the equipment positioning and the times on a tight horizontal radius too. increased attention needed for load The design of the equipment and the monitoring, geometry control and sur- method for anchoring to the permanent veying checks

DEAL MAG 55 DEAL APPROACH TO CONSTANTLY IMPROVE SPECIAL EQUIPMENT

To face new challanges, we stuck to our trademark approach to first under- standing the client’s specific require- Hoppers Oil&Gas ments and then work out the solution solutions that perfectly serves such requirements. We supply ‘tailor-made’ solutions, not only as a mere equipment supplier, but as a long-term partner with whom to develop innovative systems and meth- ods. Providing design, special equip- ment and assistance, we define the ide- al point of convergence between costs, efficiency and reliability

Underwater construction

56 DEAL MAG

DEAL / INNOVATIVE TECHNOLOGIES FOR BRIDGE CONSTRUCTION

Deal Srl T+39 0432 607900 via Buttrio, 36 F+39 0432 607902 33050 Cargnacco [email protected] (Udine) Italy www.deal.it