Dansk Brodag 2006

Fra Lillebælt til MessinaLars HaugeDirector, COWI

Storebælt, East Bridge

Stretto di Messina

Messina Strait CrossingBasic Considerations

Stretto di Messina S.p.A. was established in 1981

The current financial arrangement based on no direct contribution from the Italian State was approved in 2004

Shareholders : Fintecna 68,8%; Rfi 13 %; ANAS 13%; Calabria Region 2,6%; Sicily Region 2,6%

Tendered as Design-Built based on a reference design

Depreciation of at least 50% after 30 years of concession

Budget

bn €Total 4.43Superstructure 2.23Landworks & Foundations 1.66Design & Supervision 0.43

Organisation

Stretto di Messina SpA

ATI Impregilo

COWI(Design Suspension Bridge)

Sund & Bælt Partner

Dissing + Weitling

Buckland & Taylor

Ben C. Gerwick

Messina Bridge

Pre-bid Investigations

Technical Studies (December 2003 – January 2004):

Global FE-model (IBDAS)

Articulation of the Bridge Structure

Optimisation of the Cables

Optimisation of the Towers

Optimisation of the Bridge Deck

Review (April 2004):

Review of Tower Foundations

Review of Anchor Block Foundations

Messina Bridge

Bid Design to be carried out for:

Suspension bridge with 3,300 m main span

On land: 20 km roadway (13 km in tunnel) and 20 km railway (18 km in tunnel)

Toll station

Contract Documents:

24 Preliminary Design drawings (2004)

250 informative drawings (1992)

125 specifications, test reports etc. (2 m3)

Italian and Euro Codes

Messina Bridge

Tender Design of Suspension Bridge comprises:

Structural design of substructures incl. foundation models

Structural design of superstructures incl. global IBDAS model

Design of secondary structures and systems (wind screens, service lanes, access facilities, pavement, rails, expansion joints, bearings, buffers etc.)

Basic studies (design basis, seismic, aerodynamics, risk analyses, runability, safety and comfort analyses etc.)

O&M incl. LCC and RCM

Technological systems (management & control system, electrical and mechanical installations, structural monitoring system, anti-sabotage facilities etc.)

Messina Bridge

TENDER EVALUATION MAX ATI IMPREGILO

ASTALDI

Price 45 45

Finance 5 5

Organisation 15 13,5

Technical % Aesthetic 15 15

Use & Maintenance 10 9,6

Construction Programme 5 5

Sub-contractors 5 5

Total 100 98,1 52,5

The crossing of the Strait of Messina

Challenges:

The world’s largest suspended span of 3300 m

Road as well as rail traffic

Triple box concept for the deck

Seismic

Wind

Design life 200 years

Messina Bridge

Global IBDAS Model - Geometry Model

Messina Bridge

Messina

Akashi Kaikyo

Great Belt

Humber

Jiangyn

The Great Suspension Bridges

Messina Bridge

Suspension Bridges - Top 10:

Span Year Location

Messina 3300 Italy

Akashi Kaikyo 1991 1998 Japan

Great Belt 1624 1998 Denmark

RunYang 1490 2005 China

Humber 1410 1981 UK

Jiangjin 1385 1999 China

Tsing Ma 1377 1999 Hong Kong

Verrazano Narrows 1298 1964 USA

Golden Gate 1280 1937 USA

Höga Kusten 1210 1997 Sweden

Messina Bridge

Triple Box Concept for the Suspended Deck:

Main elements: cross girders spacing 30 m

Secondary elements: two longitudinal roadway girders and one central railway girder spanning between the cross girders

Messina BridgeMono-, twin- and triple deck concept

Messina Bridge

Triple Box Concept for the Suspended Deck

Messina Bridge

Suspended Deck:

Steel quantities - total 62,500 tons:

- Cross girders: 22,000 tons- Roadway girders: 29,500 tons- Railway girders: 11,000 tons

Steel quality: S355 (32%) / S420 (14%) / S460 (54%)

Fatigue governing for design: for the roadway girder detailed analyses using a local IBDAS-model concluded that 16 mm deck plate and 7 mm trough stiffeners are required to obtain 200 years design life

Save weight: 1 ton less in deck 1 ton less in cables and related savings in towers and anchor blocks

Min. plate thickness roadway girder: bottom plate 8 mm and trough stiffeners 5 mm

Messina Bridge

Aesthetics

Severe impact from seismic loading

Aerodynamic behaviour

– Vortex shedding

Optimise thickness/stiffeners

Tight construction schedule

– Fabricate/Erection 100.000 ts. in 24 month

Towers - Key Issues

Messina Bridge

Towers:

Steel structures

48,500 tons steel S460 per tower

Top level at +382.6 m

Leg dimensions 20 x 12 m

ULS seismic load combination governing for the tower legs

Plate thickness in tower legs 30-85 mm

Messina Bridge

Weight (166.000 ts)

Availability of cable steel(World production capacity 3-4years)

Stiffness (1:11)

Erection time, how to erect 166.000 ts in 12 m (14.000ts/m - Great Belt 4.000 ts/m)

Corrosion Protection 200 years service life (by dehumidification)

Cables - Key Issues

Messina Bridge

Main cables:

Sag to span ratio fixed to 1:11

Twin cables spaced 1.75 m – i.e. total of 4 cables required

PPWS-method

One cable: 324 strands each consisting of 127 Ø5.33 mm wires - i.e. totally 41148 wires - outer diameter 1.20 m

153,000 tons - fu = 1860 MPa

77% of cable force comes from dead load

Wires can reach 22 times around the World

Messina Bridge

Bridge Main Span

Cables(ts)

Bridge Girder(ts)

TowerSteel (ts)

TotalSteel (ts)

Ratio

Lillebælt Bridge (DK) 600 m 4.100 13.800 Concrete 17.900 1,1

Askya Bridge (N) 850 m 3.100 4.200 Concrete 7.300 0,4

Höga Kusten Bridge (S) 1.210 m 6.000 11.000 Concrete 17.000 1

Great Belt Bridge incl. Approach Br. (DK)

1.624 m 20.000 76.000 Concrete 96.000 5.6

Akashi Bridge (J) 1.991 m 56.000 82.000 50.000 186.000 10,9

Chacao Bridge (Chile) 2x1.100 m

10.000 19.000 Concrete 29.000 1,7

Messina Bridge 3.300 m 166.000 66.500 100.000 332.500 19,5

Messina Bridge

The bridge is a flexible structure

Deflection mid-span (SLS) (Vertical 4.3m/Horizontal 13m)

large movements (+/- 5.9m)

pronounced wear of e.g. expansion joints

repair and replacement

interruption of the traffic

discomfort for the bridge users

Articulation - Key Issues

Messina Bridge

Solution:

Introduce a system of devices that prevents movement at normal operation conditions but during severe load conditions such as earthquake will allow movements of the girder and will be able to dissipate energy

Messina Bridge

Buffer system:

Acts as a damper combined with a spring

Reduces the maximum movement of the deck in seismic load comb.

Blocks longitudinal movements for buffer force < 10 MN

Messina Bridge

Deck free at towers

-0.400

-0.300

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0.000

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0 50 100 150 200

Time (s)M

ov

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t o

f th

e e

xp

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sio

n j

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ts a

t th

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l s

tru

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(m

)Sicily Calabria

Suspended deck free at towers:

Accumulated yearly expansion joint movements due to repeated longitudinal movements of the bridge girder for trains passing the bridge would be 65 km

Excessive wear of the expansion joints

Impossible to achieve a reasonable life time of the expansion joints

Discomfort for bridge users and unreasonable maintenance costs

Messina Bridge

A bridge with buffer system:

The buffer force is limited to 3 MN during passage of a freight train

Longitudinal movements are limited to the movements from local deflection of the towers and the bridge deck.

The accumulated yearly expansion joint movements for train traffic is reduced to 1.6 km

A long life time of the mechanical components is secured and comprehensive reductions of maintenance costs are achieved.

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s (

m)

Sicily Calabria

Buffer system at towers included

Messina Bridge

Angle of attack

Internal wind screen on

roadRailway wall

Aerodyn damping ζa

54 m/s

Aerodyndamping ζa

75 m/s

FlutterUc m/s

Deck rotation at

75 m/s

-40

00

+40

yes yes6.0%3.0%7.0%

6.5%5.9%

10.3%

> 103 116> 103

4.0%

SdM accept criteria 2% 1% 75 m/s

Wind Tunnel Test, Section Model

Messina Bridge

Soil Improvement

Seismic

Construction Schedule

QuantitiesAnchor Blocks

Sicilia: 315.000 m3Calabria: 220.000 m3

Foundation - Key Issues

Brobyggerdagen 2006Messina BridgeBrobyggerdagen 2006Messina Bridge

Messina Bridge

Anchor Blocks

Sicilia: 315,000 m3 concrete

Calabria:220,000 m3 concrete

Messina Strait BridgeMessina Strait Bridge

Messina Strait BridgeShear stresses along the surfaces of the anchor block.Messina Strait BridgeShear stresses along the surfaces of the anchor block.

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2

4

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Messina Strait BridgeMessina Strait Bridge

Messina Strait BridgeMessina Strait Bridge

Messina Strait BridgeMessina Strait Bridge

Messina BridgeMessina Bridge

Messina BridgeMessina Bridge

Load case Sicilian tower foundation Calabrian tower foundation

safety factor

settlement horiz. displace

ment

safety factor

settlement horiz. displacem

ent

mm mm mm mm

SLS2

>1.8 80 25 >1.0 30 45

ULS

>3.7 70 55 2.0 40 75

SILS

>1.8 90 65 >1.2 40 50

MessinaKey Dates for Tender

28 Oct 2004 Invitation to Tender for General Contractor (3 groups)

18 Apr 2005 One month postponement of Tender Submission

25 May 2005 Submission of Tender for General Contractor (2 groups)

12 Oct 2005 Temporary award to ATI Impregilo (Opening of Financial Prop.)

24 Nov 2005 Final award to ATI Impregilo

Dec 2005 Filing of Claims by the Astaldi group

Jan 2006Filing of counterclaim by ATI Impregilo

08 Feb 2006 Court Meeting no 1 : the tribunal requests 1 month postponement

08 Mar 2006 Court ruling : PdM are allowed to continue with signature

27 Mar 2006 Signing ceremony

Messina BridgeThe Future

Future Services:

Progetto Definitivo (180 days)

Approval Phase (max 540 days)

Progetto Esecutivo (120 days)

Construction (approx. 2007-2012)

Messina BridgeStaffing

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Messina Bridge

Dansk Brodag 2006

Fra Lillebælt til Messina

Messina Strait BridgeMessina Strait Bridge

Strabag

Bouygues

Dragados

Consorzio Risalto

Baldassini

Tognozzi

(Mott)

(Cleveland Bridge)

Strabag

Bouygues

Dragados

Consorzio Risalto

Baldassini

Tognozzi

(Mott)

(Cleveland Bridge)

ATI IMPREGILO

IMPREGILO

Condotte d’Acqua

CMC

Sacyr

Ishikawajima Harima Heavy Industries (IHI)

Consorcio Stabile

(COWI)

(IN.CO)

ATI Astaldi

Astaldi

Impresa Pizzarotti

CCC

Grandi Lavori Fincosit

Vivanini Lavori Ghella

Maire Engineering

Nesco Entrecanales Cubiertas

Ferrovial Agroman

Nippon Steel

(Chodai)

Strabag