Aquilino Raimundo, Author at Strukturas

TB Heubach Bridge demolition

Implenia, a leading construction services company, decided to use an Strukturas Movable Scaffolding System (MSS) Underslung for the demolition of existing concrete decks on the TB Heubach Bridge in Germany.

Moreover this same MSS is also used for the construction of the bridge’s new TT section decks.

The Heubach valley bridge consists of two parallel structures, which will be demolished and rebuilt in two construction phases.
Bridge info:
Year of construction of existing building: 1968
Length: 184 meters
Width: 16.5+16.5 meters
Bridge spans: 30,6 + 37,5 + 45 + 37,5 + 30,6 meters
Max. height above ground: 18 meters

Demolition of the old bridge and the construction of the new Heubach bridge was awarded by Die Autobahn GmbH des Bundes.

MSS at assembling final stage

Deck demolition

The Strukturas MSS solution is particularly innovative because it allows the conversion of the MSS formwork from a box section, which is used during the demolition phase, to a TT section, which is used during the construction of the new bridge decks. This approach saves time and resources, making the construction process more efficient.

The challenging conditions on the job site made the assembly of the MSS particularly demanding, and the Strukturas MSS assembly team had to plan and execute the operation to the best of their ability.

Movable Scaffolding System ensures the minimal intervention to existing infrastructure.
Using MSS for demolition allows the existing highway and the road bellow to remain open throughout most of the demolishing period.
The engineering challenge – to avoid an overload of the superstructure during the demolition and to ensure a safe load transfer within the load capacity of the MSS.

MSS general cross section view when used to demolish the existing concrete decks.

Highlights & Facts:
Max Span: 45,0m
Max MSS Span: 45,0m
Weight of the concrete bridge: Approx 250 KN/m
Width Of Bridge Slab: 16.5m
Min. Hor. Radius: R= 2500m
Max Crossfall: 2.1%
Max Long Slope: 0,63%
Deflection of MSS: MAX L/400

The demolition of old bridge structures with MSS is an effective and safe solution for many bridges.

See the video below and do not hesitate if you wish to consult about your bridge!

STRUKTURAS

WE MAKE IT SIMPLE!

Special services for one of our first customers!

Our client, Mota-Engil, currently the largest Portuguese construction company present in various markets worldwide, has awarded Strukturas the redesign project of an Overhead MSS originally not provided by us and which had been stored for several years in their yard in Poland.

Strukturas’ redesign introduced significant modifications to the MSS, including a hinge joint between the main girder and the front nose, allowing it to be used on plan view curved decks, the addition of a rear concreting support, which allows for the transportation of pre-assembled U-shaped reinforcement using electrical winches, and the supply of a hydraulically operated internal formwork.

Mota-Engil transported the MSS from Poland to Portugal, where it is currently being used in the construction of railway viaducts. The rebuilt MSS steel structure was done in Portugal. Mota-Engil gave a special attention to pre-assembly and testing both at the workshop and at their central yard, due to the MSS being stored in Poland for several years.

Strukturas has been supplying various bridge building equipment, including Formtravellers FT and Movable Scaffolding Systems MSS, to Mota-Engil for around 30 years. Our the first supply was made in 1994 of an Underslung MSS to the company, that was then called Engil and later included in the Mota group, giving rise to the current Mota-Engil.

Strukturas Overhead MSS for Bridge SO 203

Early 2021 the Strukturas Overhead MSS named SO 203 was ready to cast the first span at the first long deck of the bridge project D3 in the Czech Republic, close to Ceske Budejovice.

Krondorf Bridge demolition

The Strukturas rental Underslung MSS Randselva was dismantled autumn 2021 in Norway and sent directly to Germany for the demolition of the Krondorf Bridge on the A3 south of Nürnberg.

The northbound deck is being demolished as the traffic is running on the southbound deck. After domolished deck and new construction on the north bond deck, the Strukturas rental Underslung MSS will be used to demolish and build also the south bond deck.

Start MSS assembling

Deck demolition

MSS operation

FT Sibiu: casting deck segments in Romania

In Talmaciu near the historic city of Sibiu two Strukturas FT pairs was delivered to Hünnebeck to concrete the central cantilever deck of a bridge integrated in the new highway under construction.

PORR România took one more engineering adventure, this time TEN-T Sibiu-Pitești Motorway in Romania.

Main activities:
🔸 Motorway with two lanes in each direction, hard surface width of 26m along the length of 13.170km
🔸Two road junctions: Sibiu and Boița
🔸Two service spaces of type S1 at km 8.200 left, km 8.200 right
🔸A maintenance and coordination centre in the area of the Boița road junction
🔸A viaduct with 10 spans at km 10.470, at a length of 414.70m
🔸A viaduct with 8 spans at km 12.375, at a length of 651.40m
🔸27 bridges and passages
🔸27 culverts

Two Strukturas as FT pairs was delivered to Hünnebeck by BrandSafway to concrete the central balanced cantilever deck of a bridge integrated in the new highway under construction.

Do you want to create something really great
Let’s talk about how Strukturas as can supply you bridge building technical solutions and equipment.

The bellow two YouTube videos shows

Huennebeck Project of the year 2021 video;
and an interesting time-lapse of an early project stage.

Randselva Bridge – Norway (built with no drawings)

Randselva Bridge project in Norway – the 1st world’s longest bridge built with no drawings.

Strukturas is proud to have contributed with one Movable Scaffolding System and two Form Traveller pairs to the construction of the deck of this emblematic bridge.

Nestled in the stunning Norwegian landscape near Hønefoss, this remarkable bridge stands as a testament to a groundbreaking approach that redefines the future of engineering.

Few years have passed since the construction of this architectural marvel began, and throughout this remarkable journey remarkably, NOT A SINGLE PAPER DRAWING WAS USED. In an era where paper drawings have long been the cornerstone of construction, the Randselva Bridge project in Norway represents a journey into uncharted territory.

Randselva bridge project in Norway isn’t just a means of crossing a river; it’s a symbol of innovation and a shining example of what’s achievable when visionary design meets cutting-edge technology.

Here is the story of the Randselva Bridge, where the absence of paper drawings signifies a bold leap into the future of engineering.

KEY QUANTITIES:

CONCRETE: – 17040m3 (Abutments and Foundations 2 600 m3, Piers 2 540 m3, Decks 11 900 m3)

PRESTRESSING STEEL: – 620 ton

MILD STEEL: 2 445 ton

COST: 52 M €

Crafting a Vision. The journey of the Randselva Bridge began with a visionary concept design. Architects and designers embarked on a mission to create not just a functional bridge. However, a structure that seamlessly integrated with its stunning natural surroundings. Moreover the design principles prioritized both form and function as well as setting the stage for a bridge that would be as aesthetically pleasing as it was utilitarian.

The Randselva Bridge project in Norway isn’t merely a means of crossing a river; it’s an architectural masterpiece that enhances the landscape. The designers understood the importance of ensuring that the bridge harmonized with the natural beauty of the Norwegian terrain. This commitment to a holistic approach laid the foundation for a truly unique structure.

BIM & Paperless: The Digital Backbone

The project of Randselva bridge embraced a paperless revolution that changed the landscape of construction. In a departure from conventional practices, the entire project was driven by Building Information Modeling (BIM). Evidently this revolutionary approach allowed the project to progress for four years without a single traditional drawing.

BIM became the digital backbone of the Randselva Bridge, facilitating collaboration, communication, and decision-making. It streamlined information transfer, ensuring that everyone involved, from architects to contractors, had access to real-time data. The result was unparalleled efficiency and precision in construction.

The success of the Randselva Bridge project was a result of close cooperation among professionals from different countries. Leveraging the latest communication and data sharing technologies, they created a bridge that transcended boundaries.

Participants that use the BIM model

Sweco modeling teams:

Oslo, Norway – BIM model coordination and quality control,

Copenhagen, Denmark – Parametric design, reinforcement,

Tampere, Finland – Parametric design, form and post-tensioning,

Katowice, Poland – Tekla reinforcement.

ARMANDO RITO ENGENHARIA, SA (calculations) – IFC export files from Tekla,
Multiconsult (3rd party control) – IFC export files from Tekla,
Vegdirektoratet (Norwegian road authorities) – IFC export files from Tekla,
Statens vegvesen – Norwegian Public Roads Administration (project owner) – IFC export files from Tekla,
PNC PORR Group (Contractor) – IFC export files from Tekla,
Strukturas as (Bridge Building Equipment) – IFC export files from Tekla.

Bridging the Gap. One of the key factors that contributed to the success of the Randselva Bridge project, was the early involvement of contractors, as well as bridge building equipment suppliers.

Construction Method based on rule: Minimum Labor, Maximum Machinery

The Norway’s Randselva Bridge project proved a paradigm shift in the construction industry by embracing the philosophy of “minimum labor, maximum machinery.” Traditionally, bridge construction heavily relied on manual labor. However, this project recognized the advantages of mechanized construction methods.

Mechanized construction not only saved labor but also mitigated risks, shortened project duration, and improved safety and quality. It revolutionized the way bridges were built, leading to greater efficiency and precision.

STRUKTURAS tailored input with MSS and FT Construction Methods

Challenges and solutions:

Long spans for MSS with 3 spans of 60m and first span with 48 m. lead to very optimized MSS design.
Not much space for assembly at the first span. STRUKTURAS underslung MSS solution with assembly behind the abutment was used. MSS was launched into the first span.
The railroad (with traffic) goes diagonally under the bridge at the second span, which makes it impossible to use a traditional scaffolding.
The slope is big at the third and fourth spans with difficult support conditions for traditional scaffolding, nevertheless It was not the restriction for MSS.
Pier at axis 4 is 40m high. STRUKTURAS MSS Supporting Bracket system with block outs in the piers for load transfer to piers was used.
Small horizontal radius -1050 m. STRUKTURAS MSS includes the formwork which is made to adapt a small horizontal radius. However the launching of the MSS at small horizontal radius is possible due to rotation of the noses.
Difficult dismantling after finishing the fourth and last concreting between axis 4/5. The costs for dismantling was kept low by lifting up the MSS on the finished deck and transport back to the abutment for transport.

Outcome:

Revolutionizing Construction: STRUKTURAS spearheaded the transformation of construction methods by introducing advanced MSS and FT technologies. It allowed for a dramatic reduction in labor while maximizing the utilization of machinery.

Maximizing Efficiency: STRUKTURAS delivered 2 pairs of FT and 1 Underslung MSS for 60m spans inclusive assembly, operation and dismantling of the MSS.

Precise Execution: STRUKTURAS involvement ensured precise execution at every stage of construction.

Safety and Quality: STRUKTURAS prioritized safety and quality throughout the planning phase. Their input led to the development of construction methods that not only accelerated the project but also enhanced safety standards and overall quality.

Aquilino Raimundo, construction methods expert at Strukturas as, comments as follows: “The collaborative partnership between the designers, contractor and STRUKTURAS, with a significant focus on advancing MSS and FT construction methods showcased how early contractor involvement can lead to visionary designs that are not only aesthetically pleasing but, as a matter of fact, also constructible, efficient, and innovative in construction.”

STRUKTURAS Integrated Services On-Site

From Supervision to Cambering. STRUKTURAS involvement extended beyond equipment supply. They offered integrated services on-site, ensuring that every aspect of construction was executed with precision. From supervision and mobilization to assembly, launching, and cambering, STRUKTURAS played a vital role in every stage of construction.

Øyvind Karlsen , comments: “The sum of the complex factors from the geometry of the Randselva bridge made the MSS technology from STRUKTURAS perfect. Our integrated services were crucial in ensuring that the project proceeded smoothly”.

Conclusion

The Randselva Bridge stands as a remarkable testament to what can be achieved with visionary design, cutting-edge technology, and global collaboration converge. With a focus on innovative construction methods, the bridge industry is transitioning towards mechanized construction, enhancing efficiency, safety, and quality.

As we look to the future, the lessons from the Randselva Bridge project inspire us to push the boundaries of engineering and redefine what’s possible in bridge construction. It’s a reminder that the future of engineering is not bound by paper but driven by innovation and collaboration.