Incremental Launching Technique for Railway Bridge Construction

4
Incremental launching
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SECONDINO VENTURA BRIDGE (ASTI) Incremental launching continuous beam
Politecnico di Torino
Department of structural and geotechnical engineering Bridge design
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SECONDINO VENTURA BRIDGE Geographical positioning
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SECONDINO VENTURA BRIDGE What could it have been the typical solution?
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The typical l ti Th t i l solution f a railway for il deck is the use of simply supported beams
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This common solution has the following features g

Good speed of construction Computation simplicity Widely tested solution in term of rail traffic safety and passengers comfort Practically no p y problem of interaction between track and structure Necessity of accessibility from the bottom to the construction site (or utilization of high dimensions and expensive launching girders) High number of bearings and joints (with consequent problems of durability and substitution) Large width piles and capitals to accommodate t d t two rows of b i f bearings (3.0 m, 4.1 m) Non optimal distribution of the stresses and low slenderness L/h15 /
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SECONDINO VENTURA BRIDGE A little history
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A LITTLE HISTORY
Flooding in Piedmont in 1994 concerned principally Tanaro basin with a flow measured in Alessandria of about 3800 m3/s Old Corso Savona bridge in Asti was made of a upper way road deck, realized with 4 prestressed precast concrete beams with cast in situ slab of about 20 m span, and a lower railway deck made of steel Both the decks were supported by huge masonry piers that left very little free span between them them.
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During the flooding the bridge presented: Insufficient hydraulic clearance: water reached the intrados of the th prestressed concrete d k t d t deck. Violent impacts of transported material against the upstream beam (and consequent damage) Drifting of material against the piles with consequent dam effect During post-flooding repair works of river Tanaro, the river bed in correspondence of the bridge has been enlarged. The two decks, road and railway, had then to be replaced
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DESIGN RESTRAINTS
Larger spans, to interfere as little as possible with the river and with th water fl ith the t flow (200 years return period) t i d) No significant variation of the railway level (railway station is nearby) Possibility of future reutilization of the rail deck as road deck, as a consequence of modification of railway line and transfer of the railway station in another zone Similar transverse section for deck radically different ( y (road deck and railway deck) Construction method able to guarantee the safety of the structure and working force during construction phases
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SOLUTION
Both road and railway decks made of prestressed concrete. Two continuous beams with 5 spans each (end spans 29.70 m and central spans 33.20 m), Incremental launching. Total depth of the beams = 165 cm (l/h20). Diaphragm piers with a transverse thickness of 150 cm.
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BEARINGS
Free Fixed Long. Long Free / Transv. fixed Transv Long. fixed / Transv. free
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Cross section of the two independent decks
Railway
Road + cycle track
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Cross section of the railway deck
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Comparison between construction techniques
Construction of one span (33 m) in ten days Lauching time: 3 hours

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SECONDINO VENTURA BRIDGE Launching technique
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a) Uplift ) p
) b) Trust
c) Down lift
d) Repositioning
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Geometrical limitations:
In vertical plane horizontal circular linear i li ti li inclination circular In horizontal plane straight or circular straight circular i l circular
In the last two cases the projections on the horizontal plane are ellipse circles
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NOSE DESIGN
We can assume Ln= nose length L = typical span of the bridge (temporary or final) qn = k Ln qn = dead weight of nose , , g k = 0,012 0,020 for road bridges 0,018 0,030 for rail bridges The ratio between dead weight of nose and deck can be assumed assumed, at a first approximation, as: qn/q = 0,10 The effect of relative flexural rigidity EnIn/EI on the limitation of stress variation during the launching should be evaluated.
Ln 0 65 L 0,65
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For i lifi ti F simplification, as a fi t approach, we can analyze a continuous b first h l ti beam with ith an infinite number of spans and axial baricentric prestressing, to avoid the hyperstatic bending moments due to prestressing, which can assume different values for each bridge position position.
B B
The launching internal actions as a function of parameter = x/L, are x/L analyzed with: nose cantilevering 0 1-Ln/L nose on the pier pie 1-L 1 Ln/L 1
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Variation of MB during the launching for Ln/L = 0,80 and qn/q = 0,10 with the relative rigidity ratio EnIn/EI
Variation of MB during the launching for Ln/L = g 0,50 and qn/q = 0,10 with the relative rigidity ratio EnIn/EI
Incremental launching 8-8 25/66 Incremental launching
With qn/q = 0,10 the bending moment at maximum cantilevering is equal to EOL for Ln/L = 0,65 ,
Variation of MB for Ln/L = 0,65 and EnIn/EI = 0,200 as a function of the ratio qn/q. q
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SECONDINO VENTURA BRIDGE Launching nose
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Launching nose anchoring system

Longitudinal section
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Section S1
20/20 L70cm welded to the plate
(interface with the nose)
Concrete bed for the plate Rck >45 MPa
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Section S3 (2m from the nose)
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SECONDINO VENTURA BRIDGE Evaluation of the internal actions during launching and launching prestressing
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INTERNAL ACTIONS DURING THE LAUNCHING: BENDING MOMENT Static scheme :
Definitive restraint Temporary restraint Actions: Self weight Temperature variation between intrados and extrados of 5 Maximum differential settlement between two consecutive bearings of 5 mm
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Bending moment at end of launching (values in kN*10*m) g g
Step 95 Fase 95
-1200.0 -1100.0 -1000.0 -900.0 -800.0 -700.0 -600.0 -500.0 -400.0 -300.0 -200.0 -100.0 0.0 0.0 100.0 100 0 200.0 300.0 400.0 500.0 600.0 700.0 20.0
Mg
M sett. Mced
M temp
M+
M-
Mtot+
Mtot-
40.0
60.0
80.0
100.0
120.0
140.0
160.0
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Bending moment during launching g g g

Fase Step 20
-1200.0 -1100.0 -1000.0 -900.0 -800.0 -700.0 -600.0 -500.0 -400.0 -300.0 -200.0 -100.0 0.0 0.0 100.0 200.0 300.0 400.0 500.0 600.0 700.0 20.0 40.0 60.0 80.0 100.0 120.0 140.0 160.0
Mg
Msett. Mced
M temp
M+
M-
Mtot+
Mtot-
Fase 30 Step 30
-1200.0 -1100.0 -1000.0 -900.0 -800.0 -700.0 -600.0 -500.0 -400.0 -300.0 -200.0 -100.0 0.0 0.0 100.0 200.0 300.0 400.0 500.0 600.0 700.0 20.0
Mg
Msett. Mced
M temp
M+
M-
Mtot+
Mtot-
40.0
60.0
80.0
100.0
120.0
140.0
160.0
Fase Step 40
-1200.0 -1100.0 -1000.0 -900.0 -800.0 -700.0 700 0 -600.0 -500.0 -400.0 -300.0 -200.0 -100.0 0.0 0.0 100.0 200.0 300.0 400.0 500.0 600.0 700.0 20.0
Mg
Msett. Mced
M temp
M+
M-
Mtot+
Mtot-
Fase 50 Step 50
-1200.0 -1100.0 -1000.0 -900.0 -800.0 -700.0 700 0 -600.0 -500.0 -400.0 -300.0 -200.0
Mg
Mced Msett.
M temp
M+
M-
Mtot+
Mtot-
40.0
60.0
80.0
100.0
120.0
140.0
160.0
-100.0 0.0 0.0 100.0 200.0 300.0 400.0 500.0 600.0 700.0
20.0
40.0
60.0
80.0
100.0
120.0
140.0
160.0
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Bending moment during launching g g g

Fase 60 Step 60
-1200.0 -1100.0 -1000.0 -900.0 -800.0 -700.0 -600.0 -500.0 -400.0 -300.0 -200.0 -100.0 0.0 0.0 00 100.0 200.0 300.0 400.0 500.0 600.0 700.0 20.0 40.0 60.0 80.0 100.0 120.0 140.0 160.0
Mg
Msett. M temp Mced
M+
M-
Mtot+
Mtot-
Step 70 Fase 70
-1200.0 -1100.0 -1000.0 -900.0 -800.0 -700.0 -600.0 -500.0 -400.0 -300.0 -200.0 -100.0 0.0 0.0 00 100.0 200.0 300.0 400.0 500.0 600.0 700.0 20.0
Mg
Msett. Mced
M temp
M+
M-
Mtot+
Mtot-
40.0
60.0
80.0
100.0
120.0
140.0
160.0
Fase 80 Step 80
-1200.0 -1100.0 -1000.0 -900.0 -800.0 -700.0 -600.0 -500.0 -400.0 -300.0 -200.0 -100.0 0.0 0.0 100.0 200.0 300.0 400.0 500.0 600.0 700.0 20.0
Mg
Msett. Mced
M temp
M+
M-
Mtot+
Mtot-
Fase 90 Step 90
-1200.0 -1100.0 -1000.0 -900.0 -800.0 -700.0 -600.0 -500.0 -400.0 -300.0 -200.0
Mg
Msett. Mced
M temp
M+
M-
Mtot+
Mtot-
40.0
60.0
80.0
100.0
120.0
140.0
160.0
-100.0 0.0 0.0 100.0 200.0 300.0 400.0 500.0 600.0 700.0
20.0
40.0
60.0
80.0
100.0
120.0
140.0
160.0
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As the bending moments are almost constant in all the sections and g the positive values are only half of the negative ones baricentric prestressing is introduced for the launching phases.
A [m2] 7.897
Enlargedsection Wsx,sup Wdx,sup Wsx,inf [m3] [m3] [m3] 2.828 2.631 2.171
Wdx,inf [m3] 2.237
A [m2] 6.458
Currentsection Wsx,sup Wdx,sup Wsx,inf [m3] [m3] [m3] 2.498 2.290 1.590
Wdx,inf [m3] 1.629
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Longitudinal stresses during launching g g g

supM+[MPa] (supM+)+prec 6.00 4.00 2.00 0.00 infM+[MPa] (infM+)+prec supM [MPa] (supM)+prec infM [MPa] (infM)+prec
[MPa]
2.00 4.00 6.00 8.00 8.00 10.00 12.00 14.00 0.00 20.00 40.00 60.00 80.00 100.00 120.00 140.00 160.00 180.00
x[m]
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Shear at end of launching (values in kN*10*m) g
Fase 95 Step 95
-300.0 -250.0
Vg
V sett. Vced
V temp
V+
V-
Vtot+
Vtot-
-200.0
-150.0
-100.0 100 0
-50.0 0.0 0.0 20.0 40.0 60.0 80.0 100.0 120.0 140.0 160.0
50.0
100.0
150.0
200.0
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Shear during launching g g

Fase 20 Step 20
-300.0 -250.0
Vg
Vsett. Vced
V temp
V+
V-
Vtot+
Vtot-
Fase 30 Step 30
-300.0 -250.0
Vg
Vsett. Vced
V temp
V+
V-
Vtot+
Vtot-
-200.0
-200.0
-150.0
-150.0
-100.0
-100.0
-50.0 0.0 0.0 20.0 40.0 60.0 80.0 100.0 120.0 140.0 160.0
-50.0 0.0 0.0 20.0 40.0 60.0 80.0 100.0 120.0 140.0 160.0
50.0
50.0
100.0
100.0
150.0
150.0
200.0
200.0
Fase 40 Step 40
-300.0 -250.0
Vg
Vsett. Vced
V temp
V+
V-
Vtot+
Vtot-
Fase 50 Step 50
-300.0 -250.0
Vg
Vsett. Vced
V temp
V+
V-
Vtot+
Vtot-
-200.0
-200.0
-150.0
-150.0
-100.0
-100.0
-50.0 0.0 0.0 20.0 40.0 60.0 80.0 100.0 120.0 140.0 160.0
-50.0 0.0 0.0 20.0 40.0 60.0 80.0 100.0 120.0 140.0 160.0
50.0
50.0
100.0
100.0
150.0
150.0
200.0
200.0
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Shear during launching g g

Fase 60 Step 60
-300.0 -250.0
Vg
Vsett. Vced
V temp
V+
V-
Vtot+
Vtot-
Fase 70 Step 70
-300.0 -250.0
Vg
Vsett. Vced
V temp
V+
V-
Vtot+
Vtot-
-200.0
-200.0
-150.0
-150.0
-100.0
-100.0
-50.0 0.0 0.0 20.0 40.0 60.0 80.0 100.0 120.0 140.0 160.0
-50.0 0.0 0.0 20.0 40.0 60.0 80.0 100.0 120.0 140.0 160.0
50.0
50.0
100.0
100.0
150.0
150.0
200.0
200.0
Fase 80 Step 80
-300.0 -250.0
Vg
Vsett. Vced
V temp
V+
V-
Vtot+
Vtot-
Fase 90 Step 90
-300.0 -250.0
Vg
Vced Vsett.
V temp
V+
V-
Vtot+
Vtot-
-200.0
-200.0
-150.0
-150.0
-100.0
-100.0
-50.0 0.0 0.0 20.0 40.0 60.0 80.0 100.0 120.0 140.0 160.0
-50.0 0.0 0.0 20.0 40.0 60.0 80.0 100.0 120.0 140.0 160.0
50.0 50 0
50.0 50 0
100.0
100.0
150.0
150.0
200.0
200.0
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SECONDINO VENTURA BRIDGE SLS Verifications
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Static scheme:
Actions: Self weight Prestressing (considering anchorage draw in and friction) Prestressing losses Permanent loads Termic variation between intrados and extrados of 5 Traffic loads
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Prestressing layout 1st span
19 T15 strands tendons
Couplers for 19T15
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Prestressing layout section AA

Surface S f inclined 88 Live anchorage for 19 T15
Deck axis
4
Live anchorage for 19 T15
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section 11
section 33
Bearings axis Live anchorage for 19 T15
Bearings axis
section 22 ti
Bearings axis
4
Live g anchorage for 19 T15
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section 55
Deck axis
19 T15 strands tendons Bearings axis
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Prestressing layout section BB
Deck i D k axis
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Prestressing layout section CC
Deck axis
Couplers for 19T15
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section 44
Couplers for 19T15
Pier axis
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Prestressing layout 2nd span
Couplers for 19T15
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Prestressing layout section DD
Deck axis
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Prestressing layout 3rd span
Couplers for 19T15
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Prestressing layout section GG
Deck axis
19 T15 strands t d tendons
4
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section 66
Bearings axis
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Bending moment
Self weight Pesoproprio Permanent loads Permanentiportati
25000 20000 15000 10000 5000
Prestressing Precompressione Temperature Gradiente gradient
Prestressing losses Caduteprecompressione
M[kNm m]
0 5000 10000 15000 20000 25000 30000 35000 0.0 20.0 40.0 60.0 80.0 100.0 120.0 140.0 160.0 180.0
x[m]
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Internal actions (M,N) and relative stresses

DEFINITIVE PRESTRESSING PRECOMPRESSIONE DEFINITIVA
M[kNm]
80000 70000 60000
N[kN]
sup[MPa]
inf[MPa]
0.0 00 2.0 4.0 6.0 8.0 10.0 12.0 14.0 14.0 16.0 18.0 20.0
M[kNm], N[kN]
50000 40000 30000 20000 10000 10000 0 10000 20000 0.0 20.0 40.0 60.0 80.0 100.0 120.0 140.0
160.0
x[m]
58/66

S.L.E. IN ASSENZA DI PERMANENTI PORTATI) S.L.S. WITHOUT PERMANENT LOADS ( t = (t=)
M
60000 60000 50000 40000 40000
sup[MPa]
inf[MPa]
0.0 2.0 40 4.0 6.0 8.0 10.0 12.0 14.0 16.0
M[kNm], ,N[kN]
30000 20000 10000 0 10000 20000 0.0 20.0 40.0 60.0 80.0 100.0 120.0 140.0
160.0
x[m]
Stresses [MPa] Tensioni
Stresses [MPa] Tensioni
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S.L.S. QUASI-PERMANENT COMBINATION ( t ) S.L.E. - COMBINAZIONE QUASI PERMANENTE = (t=)
M+ infM [MPa] inf M+[MPa]
60000 50000 40000 30000 20000 10000 0 10000 0.0 20.0 40.0 60.0 80.0 100.0 120.0 140.0
N supM sup M [MPa]
M infM inf M [MPa]
supM+[MPa]
0.0 2.0 4.0 6.0 6 0 8.0 10.0 12.0 14.0 160.0
M M[kNm],N N[kN]
x[m]
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S.L.S. CHARACTERISTIC COMBINATION ( t = ) S.L.E. - COMBINAZIONE RARA (t=)
M+ infM+[MPa] inf M+ [MPa]
60000 50000 40000
N supM sup M [MPa]
M infM inf M [MPa]
supM+[MPa]
0.0 2.0 4.0 6.0 8.0 10.0 12.0 14.0 16.0
M M[kNm],N N[kN]
30000 20000 10000 0 10000 20000 0.0 20.0 40.0 60.0 80.0 100.0 120.0 140.0
160.0
x[m]
STensioni MPa] Stresses [M T
S Stresses [M Tensioni MPa]
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SECONDINO VENTURA BRIDGE ULS Verifications
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Bending moment diagram g g (excluded isostatic internal actions due to prestressing)

S.L.U. - COMBINAZIONE UII(t=) U.L.S. COMBINATION ( (t=) )
Msd[kNm]
80000 60000 40000
Mrd[kNm]
M M[kNm],N[kN]
20000 0 20000 40000 60000 80000 100000 0.0 20.0 40.0 60.0 80.0 100.0 120.0 140.0 160.0
x[m]
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Ultimate limit state for shear and torsion

Ultimate verification for shear of prestressed elements can be very complicated because of the necessity to take into account the interaction between compression fields due shear and prestressing. The EN1992 simplify the approach, using a formulation that, in general case, is on the safe side. Practically shear coming from prestressing (in an statically determined structure it is coincident to the vertical component of prestressing force) is subtracted to the shear due to the external actions. The limit resistance of the elements that dont require shear reinforcements ( Rd c) is increased to take q (VRd,c into account the arch-tie resisting system.
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VRd,c = [CRd,ck(100 l fck)1/3 + k1 cp] bwd Where:
CRd ,c =
0.18
c
200 2 d
With d in millimeters
k = 1+
l =
As ,l bw d
k1 = 0.15
With a minimum of: Where:
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Resistance of web compression fi ld (VRd,max) i modified t t k i t R i t f b i fields is difi d to take into account the interaction between longitudinal and inclined compression: VRd,max = cw bw z 1 fcd/(cot + tan ) 1 = 0,6 1 = 0,9 fck /200 > 0,5 cw =1 cw = (1 + cp/fcd) cw = 1,25 cw =2 5 (1 - cp/fcd) =2,5 for fck 60 MPa for fck 60 MPa for non prestressed structure for 0 < cp 0,25 fcd for 0,25 fcd < cp 0,5 fcd for 0 5 fcd < cp < 1,0 fcd 0,5 10
Prestressing reinforcement can also be used to carry the increment of g y the tensile force in the tensed chord due to shear.
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References
CEB FIP CEB-FIP Model Code 1990 Thomas Telford 1990 1990, Eurocode 2 Design of concrete structures, Part 1-1: general rules and rules for buildings - 2003 Eurocode 2 D i of concrete structures P t 2: concrete E d Design f t t t Part 2 t bridges - 2004

Incremental Launching Technique for Railway Bridge Construction

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4

SECONDINO VENTURA BRIDGE (ASTI) Incremental launching continuous beam

SECONDINO VENTURA BRIDGE Geographical positioning

This common solution has the following features g

SECONDINO VENTURA BRIDGE A little history

Cross section of the two independent decks

Road + cycle track

Cross section of the railway deck

Comparison between construction techniques

Construction of one span (33 m) in ten days Lauching time: 3 hours

SECONDINO VENTURA BRIDGE Launching technique

Incremental launching 8-8 25/66 Incremental launching

SECONDINO VENTURA BRIDGE Launching nose

Launching nose anchoring system

(interface with the nose)

Concrete bed for the plate Rck >45 MPa

Section S3 (2m from the nose)

Section S5 (4m from the nose)

Section S7 (5m from the nose)

INTERNAL ACTIONS DURING THE LAUNCHING: BENDING MOMENT Static scheme :

Bending moment at end of launching (values in kN*10*m) g g

Bending moment during launching g g g

Bending moment during launching g g g

Msett. M temp Mced

Wdx,inf [m3] 2.237

Wdx,inf [m3] 1.629

Longitudinal stresses during launching g g g

Shear at end of launching (values in kN*10*m) g

Shear during launching g g

Shear during launching g g

SECONDINO VENTURA BRIDGE SLS Verifications

Prestressing layout 1st span

19 T15 strands tendons

Couplers for 19T15

19 T15 strands tendons

Prestressing layout section AA

Live anchorage for 19 T15

Bearings axis Live anchorage for 19 T15

19 T15 strands tendons

19 T15 strands tendons

19 T15 strands tendons

19 T15 strands tendons Bearings axis

Prestressing layout section BB

19 T15 strands tendons

Prestressing layout section CC

19 T15 strands tendons

Couplers for 19T15

Couplers for 19T15

19 T15 strands tendons

Live anchorage for 19 T15

Prestressing layout 2nd span

Couplers for 19T15

Prestressing layout section DD

19 T15 strands tendons

Prestressing layout 3rd span

Couplers for 19T15

Live anchorage for 19 T15

Prestressing layout section GG

19 T15 strands t d tendons

Live anchorage for 19 T15

Prestressing Precompressione Temperature Gradiente gradient

Prestressing losses Caduteprecompressione

Internal actions (M,N) and relative stresses

Bending moment at end of launching (values in kN10m) g g

Shear at end of launching (values in kN10m) g