general in situ

cast in situ

MOvable scaffolding systems

AUGUST / 2014

The Movable Support SystemsThe most common movable support system in utilization are: !

- The ones used on the construction of continuous prestressed concrete decks by the cantilever method.

- The ones used on the construction of continuos prestressed concrete decks, but casting from 1/5 of the span to the 1/5 of the next span. !

In the first case we named our machines as Form Traveller FT, while in the second case we named them as Movable Scaffolding Systems MSS.

Boxh solutions exist in the underslung and overhead versions. i.; working under or above the decks.

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Table of Contents

Movable Scaffolding System: !!

Underslung solution;... 3 ! Overhead solution;................................. 14 ! Self-launching underslung solution;.......... 20 ! Self-launching overhead solution............ 27 !!!!!!!

Form Travellers: !!

Overhead solution;. 31 ! Underslung solution.. 38

! 2SCAFFOLDING SYSTEMS & LAUNCHING GANTRIES FOR CONCRETE BRIDGES-BRIDGE ENGINEERING CONSULTANTS!

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MOVABLE SCAFFOLDING SYSTEM

The MSS is a modern equipment designed to allow in situ casting of full viaducts and bridges spans, with double beam or box decks cross sections, built as a prestressed concrete structure. The concept was

developed after appearance of the pre-stressing technology used at the concrete decks construction, with the goal of increasing productivity, in the construction of bridges and viaducts, mechanizing some phases

of the construction cycle.!!The MSS includes: a steel structure, working platforms and ladders, internal and external formwork and a set of hydraulic systems that allows to operate the formwork, launch the MSS and transmitte the

reactions to the columns and deck already castel.

Underslung solution

Where to use the MSS

The Movable Scaffolding System MSS is used in the

bridges and viaducts full span cast in situ construction


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TT cross section deck solutionSolution currently used on road decks for spans up till aprox. 55m (in

between columns center).

The internal formwork is launched together with the MSS main structure, in a folded position. The opening and closing internal

formwork folding movements is hydraulic operated, moving all panels together as one set.

A- Main girder B- Noses C- Suspension gallows D- Transverse beams E- Supporting brackets F- Launching wagons G- Main cylinders H- Plataforms and ladders I- External formwork J- Internal formwork L- Counterweight

Main components:


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Box cross section deck solution Main components:A- Main girder B- Noses C- Suspension gallows D- Transverse beams E- Supporting brackets F- Launching wagons G- Main cylinders H- Plataforms and ladders I- External formwork J- Internal formwork L- Counterweight K- Transport trolley

Solution currently used on road and railway decks for spans bigger than 55m (in between columns center).

The internal formwork doesnt move together with the MSS main structure. The opening and closing internal movements are made hydraulically through an internal formwork transport trolley. The

internal formwork panels are transported one at a time.


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Simple and effective!

The demand for simple but effective solutions has guided

the STRUKTURAS efforts over all these years.

Construction companies recognise our efforts by being

able to minimize the labor.!We try not only to find

enginneering solutions, but fiding the simpliest!

STRUKTURAS was founded in 1991 in the continuity of Olav Opedal AS project, an AKER group company specialized in mechanical engineering. Engineer Tore Gjolme still active in

STRUKTURAS, developed at Olav Opedal AS the MSS concept, the first equipment was used in 1971 in Norway. !

STRUKTURAS company in recent decades became norwegian leading provider of this type of equipment, being present in more than 200 projects worldwide. !

We strive for creating solutions that exceed the expectations of our customers.

A little bit of the history of the MSS!


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The MSS is easily adaptable to cross sections ranging from double T to single box and span lengths from 20m to 70m.

Special design solutions from some of our most challenging projects:

Spliting of the Main structure into three sections ( Front Nose Main Girder Rear Nose ) and design of a unique hinged connection between the parts has made it possible to build superstructures with a horizontal radius as small as 200m.

Arebar trolley and portal crane can be integrated onto the MSS system for prefabricated reinforcement cages.

Placement of concrete pumps and cranes onto the MSS system.

The STRUKTURAS MSS put the bridge construction in a new era!

! 7SCAFFOLDING SYSTEMS & LAUNCHING GANTRIES FOR CONCRETE BRIDGES-BRIDGE ENGINEERING CONSULTANTS !

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The accumulated experience in recent decades has allowed STRUKTURAS meet special requirements of different projects, developing customized solutions. !

We are also proud to have designed, engineered and delivered the largest ever used MSS's.

Some of our largest MSSs! ! RING ROAD-Thailand; Span 67,5m; deck weigh 67,5ton/m; deck width 30,5m ! GERALD DESMOND BRIDGE, Long Beach USA; Span 70,1m; Deck weight 47,0ton/m;

Deck width 24,6m (currently in manufacture)

Special projects require special solutions

!8SCAFFOLDING SYSTEMS & LAUNCHING GANTRIES FOR CONCRETE BRIDGES-BRIDGE ENGINEERING CONSULTANTS !

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Hydraulic Systems

Operations such as opening / launching of internal formwork, lift and lower the MSS between the

concreting and launching positions, side shift and longitudinal launching to the next span, are

preformed by different hydraulic systems powered by electricity.

Typical MSS cycle

-Lower the system after prestressing is installed

-Side shift boxh MSS halves

-Launch boxh MSS halves to the next span

-Close boxh MSS halves

-Lift the MSS to the concreting position (close the internal formwork if the cross section is a TT one. If the cross section is a box then the internal formwork will be launched to the next span just after rebar cage of the boxtom slab and webs is installed.)

-Concreting

-Relocate supporting bracket front rear column to the front column


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Internal formwork rolling wagon starting the rails transport

View from the internal formwork front panel towards the new span to be built. Assembling stage of the boxtom slab and web rebar at the new span.

View of the boxtom slab and webs rebar partial instalation. Internal formwork still awaiting at previous span.

Transport of an internal formwork panel using the rolling wagon hydraulic operated

Installing rebar cage deck elements using a mobile crane

Rails instalation on top of precast concrete blocks

Arrival of the panel do its opening and fixation position

General view of the internal formwork and its transport rolling wagon.

Detail of the diaphragm opening above column alignement to permit to pass with the internal formwork panel and its transport rolling wagon


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Temporary suspension of the 1st supporting bracket awaiting fot the 2nd supporting bracket of the pair

External formwork and railsLaunching wagon detail

Deck TT cross section without concrete diaphragms

View from the MSS frontView from the MSS rear

Overview showing two MSSs Internal formwork of a TT deck cross section

MSS during launching process


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Internal formwork folding cylinders

Detail of the formwork plywood fixation

Overview of an MSS

Launching wagonRear suspensionSupporting brackets installed of columns

Front nose Front support Suspension gallows


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The cambering adjustment

STRUKTURAS developed a simple system of adjustable mechanical screw jacks and adjustable struts that serve boxh do allow transverse

adjustment due to the deck transverse slope and

cambering adjustment to compensate for the elastic

deformation of the MSS due to the span casting.


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The MSS is generally composed by: a steel

structure, working platforms and ladders, internal and

external formworks and a set of hydraulic systems which

allow to operate the formworks, lauch the MSS in between different spans and

transmit the forces to the columns and decks already

concreted.

Movable scaffolding system

overhead solution

Like the Underslung MSS, the Overhead MSS is a modern equipment designed to allow cast in situ prestressed TT or box

section full span concrete decks, in bridges or viaducts. The main diference between the two MSS underslung and overhead systems lies in the position of the main structure in relation to the

concrete deck. !In the Overhead MSS the main structure is placed above the concrete deck and the formwork is suspended while at the

Underslung MSS the main structure is placed under the concrete deck and the formwork is supported on it.


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Main components:

A- Main girder B- Noses C- Rear support D- Transversal beams E- Main supports F- Launching wagons G- Main cylinders H- Working platforms and ladders I- External formwork J- Internal formwork K-Hangers L- Boxtom platform

Suspended Formworks

The Overhead MSS is supported on top of columns and the formwork panels are suspended by threaded bars of high strength.After

prestressing is installed the formwork panels are open using chain hoists, winches or hydraulic cylinders, leaving the panels suspended

from the hangers.


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The special solutions

The Overhead can be designed to special utilization where the columns are too short, or where necessary to ensure free heights as in railways,

roads or navigation channels crossings.

In these cases the formwork can be designed to open horizontally like in a drawer rather than rotate arround

the hangers.

Boxh Underslung and Overhead MSS solution can be made

symmetrical, meaning that they can be used to cast the spans in boxh

directions without having to reverse the MSS.


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Formwork openingOverview of the Overhead MSSSpecial front support using concrete prefab legs.

Installing steel brackets at short columns to support transverse steel beams

Formwork panels at open position during launching

Supports installed on top of transverse steel beams anchored to the columns

View of the external formwork View of the internal formwork Upper part of the main support and launching wagon used at launching and side shift


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Rail and winch used to open and close formwork panels

Main support and access ladderDetail of the launching cylinder

View in the launching formwork direction

External formworkInternal formwork

Transverse beams Temporary support behind the abutment Detail of the winch used to open and close the formwork panels


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Pros and cons

In general terms we can refer the following pros and cons of the Overhead MSS when

compared to the Underslung solutions;Pros:

Usually easier to assemble behind the abutment except in the cases where the ground elevation behind abutment allows the undrslung MSS to be assembled unrestricted.

Usually easier to move from one deck to the paralel one, unless the ground elevation behind the abutment makes it possible to lauch the Underslung MSS till behind the abutment and then perform at this working area the operation in question.

Cons:

Requires to leave more blockouts at the concrete decks which are used to suspend the formworks.

The horizontal reaction forces transmited to the columns are larger than at the Underslung MSS since this one is made by two halves and launching one half at a time alternately transmits a smaller reaction force.

In particular at the box section decks the pre-assembled rebar cage is more dificult installed inside the external formwork than at the underslung MSS.

When there are two parallel decks and we are building at the second one, it is not easy to take advantage of placing a mobile crane on the first deck, because the overhead main structure of the MSS hinders or prevents placement of the rebar cages inside the formwork.

! 19SCAFFOLDING SYSTEMS & LAUNCHING GANTRIES FOR CONCRETE BRIDGES-BRIDGE ENGINEERING CONSULTANTS !!

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The SMSS can relocate the supporting brackets from one column to the next without the need for cranes being by this very fact to

operate on water or in situations of very high columns.

SELFLaunching MOVABLE SCAFFOLDING SYSTEMS

Underslung selflaunching solution

Where to use the SMSS?

The SMSS is used to cast in loco full span concrete decks, in bridges and viaducts being especially suitable for use on water or where the columns

are to high.


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A- Main girder B- Rear nose C- Suspension gallows/ roling support D- Transverse beams E- Supporting brackets F- Launcging wagons G- Main cylinders H- Working platforms and ladders I- External formwork J- Internal formwork K- Transport trolley

Main components:

SMSS main feature

The SMSS is equipped with a supporting bracket transport device eliminating the use of cranes to perform this operation.


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SMSS advantages

No need to use crane to relocate the supporting brackets from one column to the next.

Easy to use on the water or with very high columns.

-Lower the SMSS after the prestressing is installed

-Transfer the load reaction from the suspension gallows/rolling gallowes support to the launching device

-Side shift both SMSS halves

-Launch both SMSS halves to the next span

-Launch the suspension gallows/rolling support

-Close both SMSS halves

-Lift the SMSS to the concreting position

-While the rebar cage are installed the two supporting brackets pairs are transported to the next columns, using the existing device located at the main girders and front nose

-Move the internal formwork to its position on the SMSS as soos as the rebar cage installation of the bottom slab and webs is finished.

-Concreting

Typical SMSS cycle for a box cross section deck


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Suspension gallows, internal formwork and rails

View of the external formwork and internal formwork rolling wagon rails

Suspension gallows hydraulic cylinder detail

Casting 1st spanFront noseInternal formwork and rails detail

SMSS launching stage External formwork Installing rebar


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Rear view before relocate the supporting brackets

Front nose supportTransverse beams and bottom slab formwork

Top view of the rar noseDetail of the rear noseRelocating the supporting brackets

Installing front nose Installing front nose Installing front nose


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Rear supporting bracket before to be moved to the next column

Front nose support at columnFront nose and supporting brackets

Pre-assembling of the internal formwork rolling wagon together with one panel

Pre-assembling of one internal formwork panel

Hinge detail in between front nose and main girder

External formworkLaunching device and accessFront nose and supporting brackets


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The main girders of our MSSs and

SMSSs

Strukturas optimized over all these years and the many

dozens of projects, the main girder design that equips all of

our MSSs and SMSSs whether underslung or

overhead.


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Selflaunching movable scaffold systems

oVERHEAD SOLUTION: SELFLAUNCHING

The Overhead MSS also exist as a selflaunching version, i ; the main supports are relocated by a winch device included on the

equipment instead to use a crane. !This equipment able to transport and install the main supports

themselves, is named Selflaunching Movable Scaffolding System SMSS. !

This SMSS configuration is very usefull when the deck construction is located above water eliminating the use of

marine resources usualy whith very high costs.


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Type and amount of supportsThe type and amount of supports can be ajusted so that the

overall functioning of the SMSS suits the intended deck construction cycle.

Main components:

A- Main girder B- Noses C- Rear support D- Transverse beams E- Main supports F- Launching wagons G- Main cylinders H- External formwork I- Hangers


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Main support and launching wagon Moving upper part of front support and launching wagon

Front support

Front support on top of columnFront support relocationView from the rear

Detail of the formwork openingFormwork openingLaunching wagon detail


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Tailor made solutions

STRUKTURAS design, engineer, built and supply also

many tailored solutions, meeting, specific requirements

of each preject and each client.


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Overhead form traveller

Cast in situ

The Form Traveller is a Temporary support structure supporting the weigh of the bridge and viaduct deck segments cas in situ

built by the cantilever method from the pierhead to the center of the span, and generally consisting of the following components: main steel structure, internal and external formwork for shape in

situ the concrete segment, working platforms and ladders, anchor system to the previous casted segments and hydraulic

equipment used to launch, level and ajust.

Where to use the Form Travellers?

The Form Travellers are used in the in situ construction of the concrete prestressed decks by

the cantilever method.


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Excellent cost-effective solution!

The STRUKTURAS Form Travellers includes a main support structure equiped with a formwork being completed by several launching and adjusting hydraulic systems.

MAIN COMPONENTS:

A- Boxtom slab platform B- Main frame D- Main cylinder E- Pull-down cylinder G- Launching device H- Main rail Y- Rear working platform K- Front beam L- Rear truss M- Rear bogie N- Wind bracing O- Transverse beams P- External formwork R- Internal formwork T- Lower working platform U- Upper working X- Front Bogie

Form Travellers


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MAIN ADVANTAGES !!-Easily adjustable to the segment lenght variations, cross section height, web thickness, deck width, can fit almost any deck cross section. -Reduced weight, saving prestressing in the deck construction phase. -Easy to transport -Easy to assemble -Reduced deformations -Easy to ajust to the curves

Typical weights of the STRUKTURAS Form Travelles

Steel components !- 120 ton segment 32 ton de steel - 180 ton segment 43 ton de steel - 220 ton segment 50 ton de steel - 300 ton segment 68 ton de steel - 450 ton segment 96 ton de steel - 550 ton segment 105 ton de steel

Wooden components !- 10 ton of wood - 15 ton of wood - 18 ton of wood - 25 ton of wood - 35 ton of wood - 40 ton of wood

The weights above are per Form Traveller and must be multiplied by 2 for the pair. The approximate weights listed above are based on deck standart cross sections, with up to 18m wide and 5m segment lenght. The wooden beams can be partially replaced by aluminiym beams. The wooden weights also include the film faced plywood.

Only one concept !Many different applications

The STRUKTURAS Form Travellers are usually made to max.

5m lenght segments, but may in special cases be made to measure.

The segment weights typically range in between 80ton and 550ton


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ASSEMBLING OF THE FORM TRAVELLERS ON THE PIERHEAD

!ASSEMBLING WITH CROSS-SUPPORT !The cross-support is an auxiliary structure specially design to permit completion of the two Form Travellers assembling, on top of the pier head of reduced dimensions. !The use of the cross-support alows to build the pierhead segment as short as possible, leading to savings on the formwork, since it need not be installed with big brackets cantilevering from the columns external surface.

!NON SYMMETRICAL ASSEMBLY !As an alternative to the use of the cross-support on the pierhead the STRUKTURAS Form Travellers can also be installed in a non symetricall assembly !After first segment is casted at one site of the pierhead first Form Traveller is launched allowing free space required for the installation of the second Form Traveller.


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Form Traveller overview and transversal diaphragms existing at every two segments

Aerial view of the Form Traveller main structure

Transversal diaphragm details close to the pierhead.

Segment weight 170 ton Segment lenght 3,50m Deck width 30m

Constantine

Form Traveller overview showing detail of the precast concrete struts outside of the deck

Pre cast concrete structs outsite of the deck

Form Traveller main structureForm Travellers arriving to the closing segment

Segment weight 264 ton Segment length 6,00m Deck width 28m

Corgo


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General view of the cros support assembling

Main frame and rear bogie view Form Traveller lateral view safety sets

Cross-support side viewSegment weight 100 ton Segment length 4,10m Deck width 11,30m

Salamanca

Main frame and rear bogie view

Form Traveller boxtom viewRebar and blockouts for anchoringSegment weight 225 ton Segment length 5,00m Deck width 18,2m

Mondego


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Cycle General Description

In a very general terms a Form Traveller utilization cycle consists

of the following operations: !-Form Traveller is launched together or not with the internal formwork, to its position at the new segment.

-External formwork is ajusted and fixed

-The rebar at boxtom slab and webs is installed

-The internal formwork is launched or in case that has already been launched together with the Form Traveller, it is just closed

-Segment is casted

-Main rail is launched and anchored

-Asa the concrete attained the required strength

-The formwork is open, and Form Travell is launched to the next segment

!In most cases the execution cycle of a pair of segments is weekly. !

There are even cases where 5 to 7 segment pairs are builted in one

month! !The minimization of the

construction cycles depends on the segment geometry, the rebar design, the concrete quality and

techniques for assessing its strenght.


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The Underslung Form Traveller, as the Overhead one, is a temporary support structure supporting

the weigh of the bridge and viaduct deck segments cast in situ built by the cantilever method from the pierhead to the center of the span, and generally

consisting of the following components: main steel structure, internal and external formwork for shape

in situ the concrete segment, working platforms and ladders, anchor system to the previous casted segments and hydraulic equipment used to launch,

level and ajust.

Form travellers

Underslung solution


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Where to use the Form Travellers?

The Form Travellers are used in the in situ

construction of the concrete prestressed decks by the cantilever method. !These Form Travellers are especially suitable to cast concrete arches or cable stayed build decks, in the cases where the stay is in

conflict with the main structure of the overhead

Form Travellers.

The formwork surfaces in contact with the concrete can be wood, film faced plywood, metal sheet or plastic plate,

depending on the number of reuses envisaged and the concrete architectural requirements.


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AN ALTERNATIVE SOLUTION

The STRUKTURAS Underslung Form Travellers are an excellent

alternative to the classical Overhead Form Travellers. !!

Ask us, we have the solution!

Special solutions: !

The Underslung Form Traveller can be adapted to diferent types of bridges, such as arches and stayed decks, leaving the free space to install the temporary or final stays, as to create the conditions to make an easy launch backwards to the initial assembling position.

In cases where the rebar cage is pre-assembled, the STRUKTURAS Underslung Form Traveller is the perfect choice. The external formwork of this type of Form Traveller is suspended below leaving free space for instaling the rebar cage.

Pre-assembled rebar cage transport system. These systems can be tailor made to different types of rebar cages.


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Our services include: -tender stage quotation preparation -design, fabrication, delivery and technicall assistance to the new equipment -rebuilt design regarding existing equipments delivered by us, for use in different conditions of the original !Ask for out reference list!

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general in situ

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concrete decks construction

construction of bridges

mss main structure

internal formwork doesnt

prestressed concrete

bridges spans

road decks

situ construction