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structurae
Expansion Joint Opens Horizontally In The Middle Of The Bridge
The new Clyde Crossing in Glasgow is a double swing bridge that opens at the centre, thanks in part to the special expansion joint from MAURER (Type DS 4 HL). With its unique hydraulic system, it can control the open-ing and closing of the bridge, as well as compensating for expansions caused by temperature, wind and traffic load like a conventional expansion joint. The Clyde Crossing is Scotland’s latest iconic feat of engineering. It crosses the River Clyde in the Glasgow suburb of Yoker and connects the neighbouring towns of Clydebank and Renfrew. The imposing white steel bridge consists of two swing bridges and was built by a joint venture between JV Hollandia Infra (southern half) and Smulders Iemants (northern half). Two pairs of pylons close to the river bank extend outwards like cranes and pivot with the bridge when it opens. The Clyde Crossing is 184 m long and 12.3 m wide, making it suitable for vehicles, pedestrians and cyclists alike. Bridges of this size usually have an expansion joint at each end next to the abutments. This bridges the gaps in the structure required to compensate for horizontal expansions caused by wind, traffic loads or temperature differences, for example. On the new double swing bridge, however, the pivots are located so close to the abutments that it was neither necessary nor possible to have expansion joints there. As the longer bridge sections were located at the middle of the river, the expansion joint also had to be there, at the point where the bridge opens. From a technical perspective, this was a unique challenge. It called for a single system that would combine the horizontal opening and closing of the swing bridge, as well as the longitudinal expansion and rotation. “The initial enquiry came back in 2019, which shows just how challenging the project was”, recalls Jeroen Melief, Branch Manager at MAURER Netherlands BV. The development of this special construction involved engineers from multiple companies. MAURER took the lead with its experts in Munich, Lünen and Culemborg. The construction also had to comply with both Eurocode and the British standard, while the highly intensive development and coordination phase was delayed by the effects of Brexit and the pandemic. The solution was based on modern MSM® swivel joist expansion joints. Similar systems have been used successfully in demanding bridge projects for decades. They allow for longitudinal movements of up to 3 m and more, as well as rotations in all directions. The parallel profiles, also known as intermediate beams, sit on top of the swivel joists and run transverse to the direction of travel. The joists run at a slight angle to the direction of travel, therefore ensuring that the bridge’s opening and closing movements are spread evenly across the sealing elements between the profiles. On the latest generation of MAURER’s swivel joist expansion joints, the intermediate beams run in w-shaped MSM® bearings instead of simple elastomeric ones. Known as a catamaran support, this improves the performance of the entire expansion joint. The MSM® sliding material and special bearing shape allow the profiles to slide more easily and precisely over the joists. This prevents restraints and increases the service life. For the project in Glasgow, the already sophisticated MSM® swivel joist expansion joint was also fitted with hydraulic control, sliding bearings and defined contact surfaces, before being installed on the southern swing bridge. MAURER provided an MSM® swivel joist expansion joint measuring 13.2 m in length and with a movement of 320 mm (MAURER type DS 4 HL modular joint). Unlike most conventional expansion joints, it is only welded on one side. As a result, MAURER also supplied a 40-cm-wide strip to bridge the gap to the northern side. The steel structures are protected by MSM® strips in the contact surface. Both halves of the bridge were produced in Rotterdam/Holland. There, the entire special construction was installed on the southern bridge at the start of 2024. The hydraulic system was also put through its paces here by an external specialist company. “For such a unique construction, we wanted to be sure”, explains Melief. “The greatest success was the moment when we tested it and it worked exactly as we had imagined.” Once the system arrived in Glasgow in April, it was simply a matter of making a few small adjustments. Renfrewshire Council of Glasgow City Region plans to approve the bridge for use by traffic before the end of this year. Fields marked with a red asterisk * must be completed for the message to be sent.
road-bridge
Apr 12, 2024
structurae
Spherical Segment Bearings In Lieu Of Roller Bearings
As part of the rehabilitation of the A 81 federal motorway at the Kocher Viaduct, MAURER replaces the old roller bearings made of stainless steel with modern spherical segment bearings. The patented bearing type was developed precisely for this application and is approved by a European Technical Assessment. The Kocher Viaduct is a nine-span prestressed concrete box girder bridge at a total length of 478 m. In order to prepare it for future requirements, it is strengthened with an external prestressing and equipped with new expansion joints, among other things. Another very important measure is the replacement of the existing bearings with modern sliding bearings. The roller bearings in the structure were replaced with 24 spherical segment bearings with a vertical force of up to 19 MN, 16 spherical bearings, and 2 horizontal force bearings. The special feature of spherical segment bearings is their geometric design in the transverse direction of the bridge, so that the load can be transferred from the superstructure to the piers in precisely the same way as with the roller bearings. This avoids the need for structural strengthening or reconstruction. In addition, this modern bearing type can accommodate rotations about the longitudinal axis of the bridge without any problems. Roller bearings cannot rotate about the longitudinal axis of the bridge, which is why the roller can be deformed and even break. Thanks to the high-performance sliding material MSM®, the new spherical segment bearings have a guaranteed service life of 50 years. The rolling friction coefficient relevant for the pier load was set at 1.5% when the roller bearings were installed. The spherical segment bearings were designed with a coefficient of sliding friction of 2% in accordance with the approval; the actual friction is lower. As the sliding surfaces are protected against environmental influences, the coefficient of friction will not change in the future. In roller bearings, on the other hand, rolling friction may increase to values above 2 % due to wear and contamination. A spherical segment bearing is a modern sliding bearing that simulates a roller bearing – a “hybrid” of spherical and cylindrical bearing. When it comes to roller bearing rehabilitations, it is crucial that the friction and the geometry of the mating surfaces do not change. Additionally, the segment bearing can rotate about all axes like a spherical bearing, thus preventing the sliding material from being overloaded. Roller bearings have a rectangular plan view. They become very wide in the transverse direction of the bridge when high loads occur, as is the case with the Kocher Viaduct. In the longitudinal direction, the roller does not require much space. In terms of forces and movements, an MSM® spherical bearing can easily replace a roller bearing, but it is either round or square. Given that after a bearing replacement the forces have to be transferred in the same way again to the greatest extent possible via the concrete structural interfaces (concrete compression/splitting tensile reinforcement), MAURER developed the spherical segment bearings ten years ago. Segment bearings can be visualised as spherical bearings, which have been “cut off” on the right and left. At that point, of course, a number of technical challenges had to be overcome, such as: How can the curvature of the calotte be kept flat enough to evenly distribute the pressure, yet sufficiently curved so that the calotte segment cannot slip out sideways? How can the calotte segment be prevented from rotating out? In addition, the manufacture and surround of the MSM® sliding material had to be rethought, as the rectangular bearing shape complicated the geometry of the calotte segment: it is curved in all directions. Conclusion: This modern special bearing is the optimal replacement for roller bearings, with the least possible intervention into the structure. Autobahn GmbH des Bundes, represented by DEGES Deutsche Einheit Fernstraßenplanungs- und -bau GmbH, is the developer for the renovation of the Kochertal Viaduct on the A 81 motorway. The general contractor is the Max Bögl Group. The exchange of bearings began in autumn 2023 and is scheduled for completion in summer 2024. Fields marked with a red asterisk * must be completed for the message to be sent.
road-bridge
Feb 09, 2024
structurae
Special Bearings And Noise Reduction For Leverkusen
Special restraints for the bearings and noise reduction on the expansion joints – MAURER supplied high-quality special elements for the first new section of the bridge over the Rhine in Leverkusen. The previous Leverkusen Rhine bridge on the A1 motorway had been in operation since 1965, and due to cracks in the steel loadbearing structure, could only be used by vehicles of up to 3.5 tonnes at a maximum of 60 km/h since 2014. This caused major traffic problems in the region, as delivery traffic had to use other bridges. Since February 2024, the problem has been partially alleviated. The first cable-stayed bridge – of two directional lanes – of the replacement construction was inaugurated and now carries the entire traffic of 150,000 vehicles per day. The bridge is a total of 1,068.5 m long (main bridge 690 m) and has two distinctive A-shaped pylons. The width of over 33 m is currently used for three narrowed lanes in each direction towards Koblenz and towards Dortmund. In future, it is designed for four lanes, two access and exit ramps plus hard shoulder and a 3.25-metre-wide cycle path. The old bridge with the reddish stays is currently being dismantled. From 2025, the second parallel section of the bridge is planned to be built and inauguration is scheduled for 2027. Both of the new, separated bridge structures consist of a main span and an approach bridge on the left bank of the Rhine. The main span with a steel superstructure as well as the approach bridge in a concrete box girder variant are supported by modern bridge bearings with special functions. MAURER supplied and supplies 44 MSM® spherical bearings for each of the two bridges. Spherical bearings are sliding bearings that can accommodate arbitrary rotations in all directions without noticeable resistance and transfer them to the substructure with virtually no restraint. The main span as a cable-stayed bridge transfers an enormous superimposed load of approximately 100,000 kN to the MSM® spherical bearings below the pylon. The patented MSM® – MAURER Sliding Material – proves its worth here. In contrast to alternatives such as PTFE, it is PFAS-free. Additionally, MSM® has a much longer service life (more than 50 years) and twice the compressive strength. The bearings can therefore be built smaller. A special construction method enables part of the bridge bearings to be temporarily restrained in the horizontal direction and monitored and gradually released and loosened as required. This increases work safety during the construction process and protects the adjacent components against uncontrolled impact load. The approach bridges used these temporary restraints to implement a shifting fixed point for the construction of the bridge; the main spans activated the restraints when bearings needed to be replaced. MAURER Project Manager, Dirk Wilming, explains: “Such smart bearing systems are exemplary and make life easier on site.” The three expansion joints also supplied by MAURER are exceptional due to their length alone. The largest, an XLS 800, is 36.3 m long and has 7 profiles as well as 2 edge profiles. It is installed in axis 10 at the beginning of the main span. The other two expansion joints bridge the end of the main span and the end of the approach bridge. The expansion joints compensate for the longitudinal movements of the bridge. Regarding design, these are so-called swivel joist expansion joints. Their special feature is that they allow movement in all directions: Displacements transverse, longitudinal and vertical to the direction of traffic as well as any kind of rotations. All three expansion joints are noise reduced. Specially profiled rhombs welded on top reduce the noise level by 30 to 50 percent. Welded on top, as this lasts significantly longer than screwed elements, which can loosen due to the continual crossings. Fields marked with a red asterisk * must be completed for the message to be sent.
road-bridge
Feb 09, 2024