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Anna Jagiellon Bridge construction in Poland (Warsaw) using 3 different systems

Anna Jagiellon Bridge construction in Poland (Warsaw) using 3 different systems

The project:
 
The new Vistula crossing integrated into the S2 Expressway and consists of two parallel decks with the following lengths:
•   Central bridge MG04-02 measuring 536.5 m per deck;
•   MG04-01 and MG04-03 access viaducts with a total of 970 m per deck.
 
The client:

GP Mosty JV
Gülermak Heavy Industries Construction & Contracting Co. Inc Branch in Poland and Road and Bridge Construction Company Sp. z o. o.
The Balanced Cantilever FT solution:
The main characteristic of the Vistula cantilever bridge deck crossing the river, is the fact that it has pre casted concrete struts to support the outer wings, as well as another precast strut installed inside the deck box in between the webs.The prefabricated struts normally difficult the Form traveller operation, as they interfere with the webs and top slab formwork. 
 
In the Vistula case the solution allows to operate the Form travellers basically in a standard way, since the webs formwork panels incorporate some slots aligned with both ends of the precast concrete struts. These slots are closed during the concerting stage, being opened before the formwork is prepared for the Form traveller launching.

The installation of the external precast struts is made as soon as the Form traveller is adjusted to its position at the new segment. The external deck wings top slab formwork panels are equipped with an opening through which the pre cast struts will pass. This opening will be closed by a plywood plate before the rebar works start. The pre cast struts will stay on top of adjustable supports delivered with the Form traveller formwork system.

The internal pre cast strut will be placed in a awaiting position on top of the bottom slab rebar, inside the deck box before the Form traveller internal formwork is launched forward. After the internal formwork is launched to its final position and adjusted, then the internal precast strut will be lifted, rotated and installed at its final position in between the deck webs.

The OHMSS and WFT solution:
 
Taking into account conditions and location of construction site, Overhead Movable Scaffolding System (OHMSS) combined with a Wing Formtraveller (WFT) solutions were implemented.
 

The OHMSS was used for concreting the central deck box and the WFT used to install the pre­ cast struts and concrete the wings.

The broad range of technical requirements used during the design phase of the OHMSS included the following features: 

  • the outer formwork of the OHMSS must be possible to open when free distance to the ground is only 3.0m;
  • the outer formwork must be able to pass in the closed position over the existing railway without reaching a height of more than 0.7 m;
  • the rebar U-cages (bottom slab and webs) of the deck must allow for assembly in 12 m sections and in the final position using the transport devices that equip the OHMSS;
  • the sections of the rebar U-cages of the deck must allow for lifting from ground level or as an alternative be transported over the deck that has already been built and later moved through the inside of the OHMSS main structure through its rear support;
  • the deck shall be concreted in two phases, the first phase involving the concreting of the central box using the OHMSS, the second phase involving the installation of the pre-fabricated struts of the deck wings and the concreting of the wings itself using the WFT;
  • allow for the OHMSS to move backward to the abutment and proceed with a side-shift to the alignment of the second deck parallel to the first one;
  • allow for the passing of the OHMSS through the WFT, after dismantling the OHMSS external formwork and without needing to dismantle the WFT (only its 4 legs are dismantled);
  • allow for the forward movement of the OHMSS passing over the deck of the central bridge to the opposite shore of the Vistula River.

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