WaiweraWaiwera bridge bridge - Convention Management · 2015-02-09 · WaiweraWaiwera bridge bridge AUSTROADS 2009, AUCKLAND, NEW ZEALAND The Construction Of The Waiwera Viaduct

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WaiweraWaiwera bridgebridgeTogether

AUSTROADS 2009, AUCKLAND, NEW ZEALAND

The Construction Of The Waiwera Viaduct

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Solving the Construction OfSolving the Construction OfSolving the Construction Of Solving the Construction Of Waiwera BridgeWaiwera BridgeWaiwera Bridge Waiwera Bridge

Using Balanced Cantilever and Using Balanced Cantilever and Matched Precast Segmental Matched Precast Segmental

E ti Vi O h d G tE ti Vi O h d G tErection Via Overhead GantryErection Via Overhead Gantry

By David By David TraynerTraynerVSL Australia Pty LtdVSL Australia Pty Ltd


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WaiweraWaiwera ViaductViaductTogether

•• Part of the ALPURT B2 NZ$330m 7km extension to the motorway north of Part of the ALPURT B2 NZ$330m 7km extension to the motorway north of A kl dA kl dAucklandAuckland

•• Delivered to Transit New Zealand by the Northern Gateway Alliance (NGA)Delivered to Transit New Zealand by the Northern Gateway Alliance (NGA)

•• NGA comprises Leighton Contractors, Fulton Hogan, Tonkin & Taylor, URS NGA comprises Leighton Contractors, Fulton Hogan, Tonkin & Taylor, URS NZ, NZ, BoffaBoffa MiskellMiskell & Transit NZ& Transit NZ,,

•• Major elements of the project include: twin 300m tunnels, several small Major elements of the project include: twin 300m tunnels, several small Super T’s & the twin precast segmental balanced cantilever 521m longSuper T’s & the twin precast segmental balanced cantilever 521m longSuper T s & the twin precast segmental balanced cantilever 521m long Super T s & the twin precast segmental balanced cantilever 521m long bridges over the bridges over the WaiweraWaiwera River.River.

•• Construction of theConstruction of the WaiweraWaiwera bridge superstructures were executed by a subbridge superstructures were executed by a sub•• Construction of the Construction of the WaiweraWaiwera bridge superstructures were executed by a sub bridge superstructures were executed by a sub alliance between NGA and VSL. The structures were built using match prealliance between NGA and VSL. The structures were built using match pre--cast segments manufactured on site, erected as balanced cantilevers via an cast segments manufactured on site, erected as balanced cantilevers via an

h d l t th d l t t


overhead placement gantry.overhead placement gantry.

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Waiwera Viaduct is located here:


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Waiwera Viaduct Plan

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Form Of BridgeForm Of BridgeTogether

•• Form of bridge selected for:Form of bridge selected for:

•• Optimum cost solutionOptimum cost solution

•• ConstraintsConstraints•• CostCost

G hi l ( t i i fl t )G hi l ( t i i fl t )•• Geographical (steep ravines, river flats) Geographical (steep ravines, river flats) •• Foundations (suited larger spans, high piers)Foundations (suited larger spans, high piers)•• Road alignment (steeper grades entry exit levelsRoad alignment (steeper grades entry exit levelsRoad alignment (steeper grades, entry exit levels Road alignment (steeper grades, entry exit levels

determined by connections to other parts)determined by connections to other parts)•• Weather constraints (propensity for rain, high Weather constraints (propensity for rain, high

wind, river valley / floods)wind, river valley / floods)•• Environmental sensitivity (native scrub, aesthetics)Environmental sensitivity (native scrub, aesthetics)

L i ti li it d b l l l b id tL i ti li it d b l l l b id t W iW i RdRd


•• Logistics, limited by low level bridge at Logistics, limited by low level bridge at WeranuiWeranui RdRd

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•• ConsiderationsConsiderations•• Material costs (efficiencyMaterial costs (efficiency -- haunchedhaunched / continuous)/ continuous)Material costs (efficiency Material costs (efficiency -- haunchedhaunched / continuous)/ continuous)•• Labour availability & costsLabour availability & costs•• Resource availability existing plant & personnel.Resource availability existing plant & personnel.y gy g•• Combination of standard segments plus variable Combination of standard segments plus variable

depth segmentsdepth segmentsQ lit ( t)Q lit ( t)•• Quality (precast)Quality (precast)

•• Safety (maximum rationalisation)Safety (maximum rationalisation)

•• SolutionSolutionBalanced Cantilever, preBalanced Cantilever, pre--cast segmental by over head cast segmental by over head gantrygantry


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•• SummarySummary•• 356 match pre356 match pre--cast segments (Approx 1.040Km)cast segments (Approx 1.040Km)

16 (2 i16 (2 i 8 h)8 h)•• 16 spans (2 carriageways 16 spans (2 carriageways -- 8 spans each)8 spans each)•• Highest point off existing ground level = 30.5mHighest point off existing ground level = 30.5m•• 9 500m9 500m33 of concreteof concrete•• 9,500m9,500m33 of concreteof concrete•• 1,300T of reinforcement1,300T of reinforcement•• 12,130m2 of bridge deck12,130m2 of bridge deck, g, g•• 480T of PT (cantilever 173t + continuity 307t)480T of PT (cantilever 173t + continuity 307t)•• Segments were “glued” and initial stressed with temp Segments were “glued” and initial stressed with temp

PT BPT BPT BarsPT Bars•• Min / Max Min / Max segseg wghtwght 50T (50T (midspanmidspan), 83T (pier)), 83T (pier)•• Min / Max span 64 4m / 76m & 41 1m (end span)Min / Max span 64 4m / 76m & 41 1m (end span)•• Min / Max span 64.4m / 76m, & 41.1m (end span)Min / Max span 64.4m / 76m, & 41.1m (end span)•• TypTyp segment length 2.9msegment length 2.9m•• Variable depth 4.3m (pier) to 2.4m Variable depth 4.3m (pier) to 2.4m midspanmidspan


p (p )p (p ) pp•• 11.7m deck width & nominal 3% cross fall (varying)11.7m deck width & nominal 3% cross fall (varying)

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Free Cantilever Method


Free Cantilever Method

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Tunnel entrances at

h d fnorthern end of structure


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Typical SequenceTypical SequenceTogether

• Typical Sequence• Launch Truss so that FSL is on next pier (N)• Place, orientate & nail pier segment (on brg)

Relocate FLCB on to pier N launch truss into• Relocate FLCB on to pier N, launch truss into segment placement position.

• Erect cantilever segments “balanced”Erect cantilever segments balanced• Acid etch, Apply epoxy “glue” & apply closure

prestress with PT bars• Install permanent PT & stress

• Erect Closure Pour Segment & construct closure pourpour

• Install permanent continuity PT, stress & grout


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Gantry OperationGantry OperationTogether

•• GantryGantry•• Two parallel truss frames to support two overheadTwo parallel truss frames to support two overheadTwo parallel truss frames to support two overhead Two parallel truss frames to support two overhead

gantry winchesgantry winches•• Truss was from a project from HK. Modified from Truss was from a project from HK. Modified from jj

Span by Span simply supported with 46m long spans Span by Span simply supported with 46m long spans to become a BC OH Gantryto become a BC OH GantryO ll l th f 140 d f 15 i l tO ll l th f 140 d f 15 i l t•• Overall length of 140m made up of 15 main elements Overall length of 140m made up of 15 main elements in each trussin each truss

•• Maximum element weight of 26TMaximum element weight of 26TMaximum element weight of 26TMaximum element weight of 26T•• Total weight of truss and all its auxiliary components Total weight of truss and all its auxiliary components

is 730Tis 730T•• Truss height of 4.0m, individual truss widths 1.6m.Truss height of 4.0m, individual truss widths 1.6m.•• Underside of truss sits 7.0m above deck levelUnderside of truss sits 7.0m above deck level

E d t t d i b th dE d t t d i b th d


•• End spans constructed using span by span methodEnd spans constructed using span by span method

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Together GantryGantry OperationOperationTogether yy pp•• Gantry (Continued) Gantry (Continued)

•• The original trussThe original truss req’dreq’d lengtheninglengtheningThe original truss The original truss req dreq d lengtheninglengthening•• an additional 40m was addedan additional 40m was added•• Extended truss still not long enough to launch Extended truss still not long enough to launch g gg g

and place on the longest spans without an and place on the longest spans without an intermediate step. intermediate step. N t i d th f t t t b l dN t i d th f t t t b l d•• New truss required the front support to be placed New truss required the front support to be placed 10m in front of the pier and the rear support to be 10m in front of the pier and the rear support to be placed nearplaced near midspanmidspan This increased the loadsThis increased the loadsplaced near placed near midspanmidspan. This increased the loads . This increased the loads on the deck and meant that full continuity on the deck and meant that full continuity stressing & grouting of the span was required stressing & grouting of the span was required before launching the trussbefore launching the truss

•• It also put casting of the diaphragm and segment It also put casting of the diaphragm and segment ili th iti l thili th iti l th


nailing on the critical pathnailing on the critical path

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Together Gantry OperationGantry OperationTogether y py p•• Gantry (Continued)Gantry (Continued)

•• The linked criticality of the gantry operation to pier The linked criticality of the gantry operation to pier segment erection was solved by erecting the pier segment erection was solved by erecting the pier segments in advance with a 400t crawler cranesegments in advance with a 400t crawler cranesegments in advance with a 400t crawler crane.segments in advance with a 400t crawler crane.

•• Other challenges:Other challenges:Other challenges:Other challenges:•• Precast accuracies Precast accuracies ––

•• Duct alignment Duct alignment –– strand pushing, ducts strand pushing, ducts leakingleaking

•• Insert locationsInsert locations•• Wet weatherWet weather segmental gluing water damagesegmental gluing water damage•• Wet weather Wet weather –– segmental gluing, water damage segmental gluing, water damage

to controlsto controls


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TogetherPakse Gantry

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Deep Bay Link Gantry


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End Span Span by SPan


End Span – Span by SPan

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Pier Segment Placing

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Pier Segment Placement


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Pier Segment Erection By Crane

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Pier Segment Erection By Crane

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TogetherSegment CastingSegment Casting

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•• PrecastingPrecastingT ldT ld “A” d i t d t d d d th“A” d i t d t d d d th•• Two moulds Two moulds –– “A” designated standard depth “A” designated standard depth (2.95 to 2.4m) + “C” variable depth mould (4.3 to (2.95 to 2.4m) + “C” variable depth mould (4.3 to 2 95m)2 95m) –– also used to cast the smaller segmentsalso used to cast the smaller segments2.95m) 2.95m) –– also used to cast the smaller segmentsalso used to cast the smaller segments

•• TypTyp cycle 1 cycle 1 segseg per day for per day for stndstnd depth 1 to 2 depth 1 to 2 ypyp yy gg p yp y ppdays for more complex variable depth segmentsdays for more complex variable depth segments

C l t h d t i it tiC l t h d t i it ti•• Complex segments had cast in situ sections Complex segments had cast in situ sections ––diaphragm / deviators. (Gantry limitations).diaphragm / deviators. (Gantry limitations).

•• Each mould had rebar jigs (top & Each mould had rebar jigs (top & btmbtm separate)separate)


•• Rebar cages moved by OH Cranes / ForkliftsRebar cages moved by OH Cranes / Forklifts

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Segment Transporter & Straddle Carrier


Segment Transporter & Straddle Carrier

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TogetherSegment CastingSegment Casting

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•• PrePre--casting (continued)casting (continued)•• Casting yard purpose built factory built on the alignmentCasting yard purpose built factory built on the alignment

•• Segments moved using the transfer carts & straddle Segments moved using the transfer carts & straddle g gg g

carrier.carrier.

S t t th li tS t t th li t•• Segment storage on the alignmentSegment storage on the alignment

•• 4% grade in storage area problematic for gantry cranes 4% grade in storage area problematic for gantry cranes

solved by using Straddle Carrier & segment transporter.solved by using Straddle Carrier & segment transporter.

•• Segment delivered to gantry using Segment TransporterSegment delivered to gantry using Segment Transporter•• Segment delivered to gantry using Segment Transporter.Segment delivered to gantry using Segment Transporter.

•• Straddle Carrier ran on a prepared road and was also Straddle Carrier ran on a prepared road and was also


used to assemble trussused to assemble truss

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Segment Storage & Casting Yard on AlignmentCasting Yard on Alignment


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Casting Yard


Casting Yard

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Segment CastingSegment CastingTogether

• Pre-casting (Continued)• ChallengesChallenges

• Labour skills, motivation, accuracy, supervision• Concrete 60 MPa – challenging spec for long term g g g

creep and shrink properties. • High cement content Proved relatively “sticky” –

diffi lti i ib ti ’d hi h ldifficulties in vibration, req’d high slumps resulted in problems in concrete “slumping” out of web formsof web forms.

• Moved to high slump with accelerators but “unforgiving” led to removal of accelerators and a final mix with high cement content with target slump of 140mm


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ProgrammeProgrammeTogether

•• Project awarded on 9Project awarded on 9thth May 2004, TCE completed Dec 2005May 2004, TCE completed Dec 2005

•• Site handed over Jan 2006 (7 months late)Site handed over Jan 2006 (7 months late)

•• PrePre castingcasting•• PrePre--castingcasting

•• 11stst segment cast Jun 2006. Last cast 19segment cast Jun 2006. Last cast 19thth Dec 2007, target Dec 2007, target

schedule Sept 2007, best average 32 / schedule Sept 2007, best average 32 / mnthmnth

•• Gantry OperationsGantry OperationsGantry OperationsGantry Operations

•• Truss commissioned Jan 2007Truss commissioned Jan 2007

•• 11stst Segment placed Jan 2007. Last placed April 2008, target Segment placed Jan 2007. Last placed April 2008, target

schedule Oct 2007schedule Oct 2007


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ALPURT Baseline vs Actual

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300

350

Abutment A1

Pier B2

Abutment A2

250

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Pier C1

Pier B1

Pier C2

Launch Back to Pier D

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ive Baseline Casting

As Cast

Baseline Erection

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C

As Erected

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100Pier F

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Week Ending

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AcknowledgmentsAcknowledgmentsTogether

We would like to acknowledge and thank the following f th i i t i th j t d thi t tifor their assistance in the project and this presentation:

Transit New Zealand, Leighton Contractors, Fulton Transit New Zealand, Leighton Contractors, Fulton Hogan Tonkin & Taylor URS NZHogan Tonkin & Taylor URS NZ BoffaBoffa MiskellMiskellHogan, Tonkin & Taylor, URS NZ, Hogan, Tonkin & Taylor, URS NZ, BoffaBoffa MiskellMiskell

The Waiwera Bridge is a graceful, efficient and cost ff ti t t d li d i h ll ieffective structure delivered in challenging

circumstances.

The Alliance’s demonstration of its ability in overcoming obstacles has been rewarded by the award of the yNewmarket Viaduct in Auckland with an even more challenging and innovative solution –

“W t h Thi S ”AUSTROADS 2009, AUCKLAND, NEW ZEALAND

“Watch This Space”.

Documents

WaiweraWaiwera bridge bridge - Convention Management · 2015-02-09 · WaiweraWaiwera bridge bridge AUSTROADS 2009, AUCKLAND, NEW ZEALAND The Construction Of The Waiwera Viaduct