Bridge constructionusingprecastconcreteelements

SkanskaNorgeAS

1
Prefabricationhasbeendoneinmanydifferentways
BrandangersundetBridge
Mainspanfabricated5kmfrom
bridgelocationandbroughttositeby
twocranevesselsforinstallation.

SjernaryBridge
Large precastconcreteelements
producedatfabricationyard,transported
andinstalledbycranevessel.

Bjrvikasubmergedtunnel,Oslo
Tunnelelementsproducedindock
outsideBergenontheNorwegianWest
coast,towedtoOsloandinstalled.
2
Portandogbridgeconstruction usinglargeprecast
concreteelements.
ElementproductionstartedinJttvgeninStavanger(90s).
(Theold construction sitefor concrete platformsfor theNorth Sea)
MovedtoForsandinRyfylkei2008
Local construction siteshavebeenestablishedforindividualprojects.

3
Today's topic:SjernaryBridge

254meters.
9spans,longestspan 31meters.
Theentirebridge,apartfrom the
abutments,wereprecast.
23concreteelements.

4
Today's topic:SjernaryBridge
Thebridgewasfully
designedandapproved
asan insitucast
constructionbyStatens
vegveseninNorway.
Redesignedand
constructedusing
precastconcrete
elementsbySkanska.
Newapprovalofdesign
wasrequired.

5
 Element production at
Skanskasconstruction
siteinForsand.
Theelementswerelifted,
transported byacrane
vessel(barge)and
installedatthebridge
location.

6
Elements:
Pilecapandcolumns

Bridgedeck

Columns

Foundationandpillars

7
Phase1 Foundationandpillars

6elements:
Axis3 8

8
Preparationforinstallationoffoundations

therocksurfacewascleaned
andsurveyed.
Temporarysupport blocks
cast tospecifiedheightwith
stricttolerances.
9
Installationofthe pillar/foundation
Thepillars wereproduced
withlengthaccording to
the heightofthe
temporarysupport
blocks.
A guide system was
establishedattheseabed
toensurecorrect
placementofthe
foundation. Shimswere
usedtomakethepillar
vertical. Operation
monitoredusingdivers.
10
Productionofpillars Pillar/foundation
(PicturefromForsand) placedonthebarge

11
Loweringofpillars(Conlift) Installed ontothetemporary
supportblocks
12
Interfacebetweenseabedandpillar/foundations.
Grouting:
Groutingbetweenthe rock
surface andfoundation
through recessesfor
molding pipes
Fixedsupport:
Rockboltsinstalled
through recessesinthe
foundationperimeter.
Fixedconnection

13
Phase2 Pilecap/columns

2elements(axis2and9)

14
 Protrudingreinforcement
(50Gewibars/splicingbars)
Loweredintothesteelpipe
Pilecapandcolumn. piles.
(PicturefromForsand)

15
Phase3 Columns

6elements

16
Thepillarsaremanufactured Correspondingholesinthe
withprotrudingreinforcement columns.(Socket/Plug).
(63,5Gewibarsassplicing Holesgroutedthrough
bars).Splicebetweenpillar groutingtubes.
andcolumnabovewater!
17
Phase4 Bridgedeck

9elements:
Installationfrombothsides
Thecentreelementinstalledas
thelastelement.
18
Connectionbetweencolumnandbridgedeck:

Protrudingreinforcementfromcolumn(63,5Gewibars)
Correspondingholesinthebridgedeckelements

19
Protrudingreinforcementlockedwithsteelplatesandnutsinupper
faceofbridgedeckelement.Fixedconnection.

20
Connectionbetweenbridgedeckelements:

Console/Corbel
21
 Reinforcement:
Allreinforcementsplicedwith
mechanicalcouplers(HRC).
9025
3032
(Taperedthread)
Posttensionedreinforcement:
7cables.
5cablesinstalledand
posttensionedduring
elementproduction.
2continuouscables.

22
Advantagesusinglargeprecastelements:
Fasterconstructiontime:
Pilingandelementproductioncanbeperformedin
parallel.
Moreefficientproductiononsuitable/wellorganizedsite.

23
 Betterqualitycontrol:
Establishedproceduresbyfactoryproduction.
Knownconcretesupplier,shorttransportofconcrete.
Minimizeconcreteworkinthemarineenvironment.
Minimizecastingunderwater.

Fabricationatlowercost
HealthandSafety:
Reducedworkusingdivers.
Moreworkatgroundlevel.

24
Issuestobeconsideredintenderphase:
Distancefromfabricationyardtobridgelocation
Localyardsshouldbeconsidered!
Accessforcranevesselisarequirement.
Elementweight<400tonns(Taklift/Eidelift,Norway).
Elementweight<600tonn(Uglen,Norway).
Biggercranevesselsavailablefromothercontries

LiftingdiagramforEideLift6:
Elementweight/sizemustbe
consideredaccordingtocrane
capacity.
25
Transitionfrominsitucasttoprecastconstruction:
Firstofall;theclientmusthaveapositiveattitudeto
theconstructionmethod.
Second:Thebridgeconceptmustbesuitablefor
prefabrication.
Someadditionalengineeringwasrequired:
Layout/divisionintoelements
Layoutandengineeringofelementconnections.
Engineeringofbuildingphases,liftingetc.
Drawingsofeachelement;formworkandreinforcement.
(About80drawingsforprefabricationofSjernaryBridge).
TheadditionalengineeringwascarriedoutbySkanskas
engineeringdepartementinNorway.

26
Tolerances Weprepareda
connectionwitha100
mm"wiggleroom"inthe
longitudinaldirection.
Wecalculateddown
throughthecolumnand
pillars,andfound
tolerancerequirements
forthefoundation
position.
Tolerancedrawingswere
prepared,andclosely
followedupbysurveyer.
27
Summary:
Asuccessfulproject!
Communicationbetweendesignersandproductionteam
areimportant.Especiallyintheplanningphasewherethe
conceptforelementsandconnectionsareworkedout.
Closefollowupinrelationtothegeometryisimportant.
Tolerancerequirementsmustbethoughtcarefullythrough.

28