VSL_News_2006_2

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NEWS

VSL & PARTNERSHIPS

Attractive networkfor business

ETA for VSL

Casino in Macao

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FACTS&TRENDS 6Protection of critical assets:

New tests for Ductal® 6

Tanks: Cryogenic success in Fujian, China 7

SUSTAINABLEDEVELOPMENT 4Global issues at local level: VSL objectives

to help ensure sustainable development 4

SITE INSIGHTS 14Australia: Gateway to alliance 14

Dubai: Record pace for world’s biggest mall 18

France: Landmark win for VSoL® 23

Chile: 30,000m2 distribution centre in Santiago 23

Hong Kong: Shatin T3 bridge nears completion 17

COVER STORY 8VSL and partnerships:

Attractive network for business

Some of VSL’s new trump cards for relevant

services: JV partnerships recently signed…

FOCUS 24European Technical Approval (ETA)

for VSL post-tensioning systems

This provides VSL with the most

comprehensive range (from 1 to 55

strands) of ETA approved of the market.

TECH SHOW 27Playing mega scale in Macao

Venetian Macao Phase I is a large scale

development to build another giant casino.

For VSL, it is a large scale precast beam

installation project

Cover photo: the Venetian Macao Resort Hotel Phase I

CORES 6

SUSTAINABLEDEVELOPMENT 4

PARTNERSHIPS8

SLABS 21

PRECAST 27

NEWS, magazine published by VSL International Ltd. • Bern, Switzerland and VSL • Challenger - Saint-Quentin-en-Yvelines, France. Director of Publication: Jean-Philippe

Trin • [email protected] Editor in chief: Jane Rousseau • [email protected] Co-ordinators: Carlos Such, Renata Tamburrino, Doris Tong. Distribution:

Sandra Puel • [email protected] Design: Red Line Photos: D. Allan, F-X. de Larminat, J. Roussseau, others. Copyright: VSL •

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EDITORIALI S S U E T W O • 2 0 0 6

Sustainable development:our responsibility

J e a n - P h i l i p p e T r i n

For over 50 years, VSL has made valuable contributions

towards innovative and highly-efficient construction solutions

focusing on raw material consumption (concrete, steel, etc.). Our

local facilities spanning more than 40 countries and our

training policy are both aimed at long-term sustainability, by

promoting integration and economic development across

many nations.

The term sustainable development is in vogue today, but the

prime focus needs to be placed on personal and collective

responsibility.

We must adapt our mode of operations and make the most of our team spirit inside the

company to expand the approach and convert our broad-based drive for environmental

protection into decisive actions.

Sustainable development is more than a concept, it embodies a daily practice derived

from a visionary objective and from the will to work for a future to preserve a high-

quality planet for our children's sake.

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developed areas of the world, andis not enough to control theproblem, especially in developingareas. As development continuesand grows in intensity, new andlarger problems will emerge. Forexample there simply is notenough fuel in the world forcountries like China and India usecars like North America does. The effects on the world of Asia’srecent demands for naturalresources can clearly be seen (e.g. steel shortages). It hasrecently been reported that China’sgreenhouse gas emissions willexceed the USA’s 20 years earlierthan predicted.

New ways of doing businessHigher energy costs, a growingdemand from consumers andgovernments are putting greaterpressure on businesses to change.

However, thesechallenges are alsoopportunities toimproveperformancethrough reducedinput costs, betterexternal relationsand greaterinnovation. In tomorrow's

world, sustainability will morevisibly impact on businessperformance. Increasingly, socialand environmental issues are anarea of risk for businessesalongside traditional economic

A round the world, fromgovernments and industryto the public, there is a

growing realisation that currentmethods of development areunsustainable. In 1987 the UNsuccessfully promoted the mostwidely used definition ofsustainable development“Development which meets theneeds of the present withoutcompromising the ability of futuregenerations to meet their ownneeds”. Current levels of resourceusage and wastage are placing tohigh a burden on the planet.Globally we are not meeting theneeds of the present let aloneconsidering the future.

A part to playWe are using up our naturalresources quicker than we arereplenishing them. We face afuture that will be less secure. We all need toreduce ourenvironmentalimpact, not justbecause it is theright thing to do,but also because it is in our ownlong-term bestinterests.The standardapproaches in the past to theenvironmental problemsgenerated by business have beenlegal driven "end-of-the-pipe"clean-up efforts. This approachhas had limited success in

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risks. For example consumerboycotts due to poor performancerisk corporate reputation.Companies that anticipate changesin resource availability andacceptability of working practiceare in a stronger position. Leaders in business, government,academia, and communities areproviding innovative new solutionsto sustainability issues. Largecorporations, as well as smallbusinesses are going beyond legalcompliance to conserve resources. Perhaps the single most influentialfactor that has emerged is therealization that waste reduction,energy efficiency, and pollutionprevention make economic sense.Companies are starting tounderstand that sustainabilityinvolves more than ethicalconsiderations - it improves thebottom line and is good business.

How to survive? Sustainable Development is not anew thing to VSL though it has notbeen called this before. Few

SUSTAINABLE DEVELOPMENT

CONSTRUCTION AND SUSTAINABLE DEVELOPMENT

Global issues at VSL is constantly reassessing its way of working and looking to best

practice, quite simply to ‘be the best’. Sustainable development is already

firmly on the agenda. During 2006 objectives have been developed.

“”

Development which

meets the needs of the

present without

compromising the ability

of future generations to

meet their own needs(Definition used by UN and many

other organizations).

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businesses survive for 50 years, asVSL has done, that have notalready embraced aspects ofsustainability. For example VSLinvests heavily in R&D and iscontinually introducing newtechniques (e.g. PipelineRehabilitation).An important aspect ofsustainability for VSL is being partof the local community. This hasbeen done by adopting adecentralized business model,which better meet the needs oflocal markets and allows greaterflexibility in decision making. VSLalso produces high quality work,more safely and with less wastethan its competitors, and of courseVSL’s core activities reduce theresources used by clients andincrease efficiency (e.g.prestressing, precasting).Additionally VSL also looks afterits employees better than thenorm especially in ‘terms andconditions’ (30 year service awardsare not uncommon in VSL). Theyare also active in supportingcharities (e.g. the Lighthouse ClubConstruction Charity in HongKong) and industrydevelopment initiatives.

Global issues at a local level Until now there hasbeen no clearstrategy in relation tosome of the wideraspects ofsustainability such asenvironmental impacts.The full power of the groupnetwork has not been used atthe local level to address allsustainability issues. Alsowhile VSL may be good,

• Assessing customersatisfaction systematically

and in relation to a widerrange of businessconcerns;• Aiming to be a

leader in health& safetystandards in allareas; • Improving the

ratio of womenin technical

andoperational

roles;

• Providing educational support toemployees and their families.

VSL operates in over 40 countries,employing 80 differentnationalities usually as a small ormedium sized company. VSL istherefore in a position tounderstand global issues at a locallevel, and also local issues. This isnot something new, and is not amarketing slogan, it has been acornerstone of VSL’s success todate. The new measures aresimply expanding the scope ofwhat is meant by ‘sustainabledevelopment’. ■

5

t local level• Improving the capability of staff

to assist in designing and implementing sustainabledevelopment initiatives;

• Auditing of suppliers on qualityand social issues;

• Initiating research projectsfocused on sustainabledevelopment;

• Encouraging reduction, reuse,recycling;

improving is even better.As such during 2006 objectiveshave been developed to ensurethat VSL is covering ‘thefundamentals’, and targeting itsefforts. These include reducingimpacts on the environment,employees and the widercommunity. In particular thefollowing areas will be focused onin 2007:

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6

FACTS&TRENDS

Formtravelers

Record insight forClimbform> Gammon Construction is using

VSL’s Climbform system for therapid construction of the core wallof Hong Kong’s 70-storey OneIsland East tower. A key factor inchoosing Climbform was its abilityto incorporate the projecting lintelbeams. Installation started at the

basement and the system will bebuilt up to the 308m-high roof. Theclient plans to accelerate work to athree-day cycle which would be anew Climbform record,considering the restricted workinghours.■ Contact: [email protected]

intrafor.com

Network

New Turkishlicensee

> VSL has welcomed Mega Yapi as

its newly-appointed licensee in

Turkey to cover this growth market.Ankara-based Mega Yapi worksthroughout the country. The rangeof services will include post-tensioning, supply and installationof bearings and joints and as wellas bridge deck erection. Mega Yapiand VSL are already workingtogether: a recent success hasbeen the award of a project for theseismic retrofit of major bridges inIstanbul where VSL will beresponsible for the post-tensioning.Other projects include a 90m-spanfootbridge in Konya where MegaYapi and VSL are supplying thestays and carrying out the erection.This is only the second bridge inTurkey with stays made of parallelstrands inside an HDPE pipe usingthe VSL SSI 2000 system. ■ Contact:

[email protected]

Geotechnics

Long cores> Intrafor’s steerable long hole

coring method is attracting

considerable interest among tunneldesigners in Hong Kong. It will beused to gather information about thecomplex geology of fault zones atthe ends of a 5.5km-long drainagetunnel to be built from Tsuen Wan toTing Kau. The advanced technologyof horizontal directional coring willenable coreholes of 935m and 660mto be drilled from the portals acrossthe fault zones. ■ Contact: [email protected]

intrafor.com

Bener Yildirim Gokhan Kutlu

> VSL is carrying out its first

ground engineering project in the

UAE, with Intrafor’s installation of diaphragm walls for Burjumanstation and a cut and cover tunnelas part of the new Dubai Metro.Japan Turkey Metro JV has beenbuilding the metro since late 2005.Excavations vary from 20m to 60m deep and require a range of tools as there are four differentwall widths, ranging from 600mm

to 1,200mm. A BC40 cutter and fivecranes were mobilised from HongKong and Perth. They will shortlybe joined by a second cutter, anMBC30. The project team has achallenging task in installing73,000m2 of diaphragm wall bymid-2007. Work takes place aroundthe clock and temperaturesapproach 50ºC in summer.■ Contact: [email protected]

intrafor.com

Ground engineering

First project in the UAE

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7

> VSoL® is enjoying significant

market growth in Australia, theMiddle East and Spain. Recenthighlights include: 1st Keystonewall project in Hong Kong (fullinstallation of a 13m-highKeystone® segmental block wallfor main contractor China StateConstruction); 1st VSoL® Polymericwall project in Thailand (16,000m2);1st Geogrid reinforced steep slopeproject in Hong Kong; (24,000m2 ofnoise barrier panels supplied withVSoL® walls on Albury Wodongaby-pass in Australia); 1st VSoL®

Projects in Egypt and Morocco.News contracts also include:125,000m2 of VSoL® Polymericwalls in Oman (92,000m2 on theSouthern Expressway project);47,000m2 of VSoL® Polymeric wallon NH28 at Lucknow, India;88,000m2 of VSoL® Steel systemwalls on 17 No. projects in Spain.■ Contact: [email protected]

intrafor.com

Double win. VSL has recently

received two awards from the

Post-Tensioning Institute, USA.

The first was for efficient use

of light-weight concrete and post-

tensioning the Union Station

parking garage expansion in

Washington, DC which called

for wide areas uninterrupted

by columns. The other was for

LeJeune Road Flyover in Miami

for repair, rehabilitation and

strengthening with post-

tensioning as an economical way.

General industry. Coca-Cola’s

largest Latin American bottling

plant has been inaugurated in

Mexico by Grupo Tampico. The

plant was built using cutting-edge

technology, including 25,000m2 of

slab on grade by VSL Mexico.

VSL officer as fib president.

The General Assembly of fib has

elected Hans Rudolf Ganz,

currently Chief Technical Officer

at VSL International Ltd, as fib

President for 2007 – 2008. H.R.

Ganz was appointed Chairman of

the FIP Editorial Board in 1997,

and served as member of the fib

presidium since 2002. Further

affiliations include membership in

ACI, ASCE, IABSE and other

national organisations in France,

Switzerland and USA. Since 1996

he has served as Chairman of FIP

then fib Commission 9

“Reinforcing and Prestressing

Materials and Systems”.

Offices

Year of the slab> This is proving to be the “year

of the slab” in Chile, with thecompletion of more than 400,000m2

of post-tensioned slabs, especiallyoffices, together with projects suchas Territoria (91,000m2), ParqueAraucano (56,000m2) and PlazaOeste (39,000m2). Almost all havebeen won by proposing bondedpost-tensioning using theBondtech monostrand system withpolypropylene ducting. Clients haverecognised its economicadvantages in rebar reduction. Forinstance, VSL provided the mostcompetitive solution for PlazaOeste, where more parking wasneeded in time for Christmas. ■ Contact: [email protected]

VSoL®

Wall firsts

> VSL’s involvement in the rapid

expansion of LNG tank developmentin China continues with a contractto supply all the post-tensioningmaterial for a major new facility inFujian. The contract also includesdesign and supervision work andthere was a special requirement forVSL to complete cryogenic tests attemperatures of -170°C. ChinaNational Offshore Oil Company hasinvested in the project. Engineering,procurement, and construction ofthe facility’s two LNG tanks andreceiving terminal are being carriedout by Chicago Bridge & IronCompany, in collaboration withdesigner Chengda EngineeringCorporation. The tanks are eachdesigned with a storage capacity of160,000m3. They have VSL’s GC6-27horizontal prestressing while thevertical prestressing is made up ofU-looped tendons of size GC6-12. ■ Contact: [email protected]

Tanks

Cryogenicsuccess

Bridges

PT in Riga> Post-tensioning supplied by VSLis being installed on the concreteapproaches of a new bridge overthe Daugava River in the Latviancapital, Riga. Major constructioncompany BMGS is contractor forthe bridge and VSL is providingsupervision and equipment as wellas the post-tensioning system.Work is due for completion in 2008.■ Contact: [email protected]

N O T E P A D

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COVER STORY

8

VSL & PARTNERHIPS

Attractive network for In line with VSL’s successful corporate strategy

to integrate new business venture synergies,

several JV partnerships have recently been

launched. Here are some of VSL’s new trump

cards for relevant services.

Whether as a springboard fromexisting activities or by offering theVSL network as a ready-made toolfor distribution of products andservices, VSL strongly believes indeveloping through businesspartnerships. Bars in the boomingMidlle-East, pipeline rehabilitation inHong Kong and Australia, a new slablifting system in New Zealand andAustralia, FRP in post-tensioningsystems, vibration control of cablestructures are some of the newpaths. Whatever field, the quality ofthe partners selected is a must, as is the resulting benefit to clients.

Threaded bars toaddress Gulf boomCommencing from the beginningof this year, VSL Middle Eastlaunched a partnership withStahlwerk Annahuette (SAH) of Germany –the oldest existingsteelworks in Europe with a historyof more than 460 years. Thispartnership combines SAH’stechnical expertise & quality of their products (threadbars in reinforcing and prestressingquality for large constructionrprojects ) combined with VSLMiddle East’s active presence in the region & their marketleadership in the field of post-tensioning and specializedconstruction systems. More than $1 trillion worth ofconstruction projects are plannedor underway in the Gulf region. JV operations are planning tosupply SAS Threaded Bars toactivities such as tunneling,reinforcement, marine, form ties,post-tensioning, soil nails, groundanchors & micro piles. SAS Threadbars are produced in various

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r business

9

Admiralty pipeline rehabilitation

project in Hong Kong.

grades such as SAS 500 (grade 75),SAS 670 (grade 97), SAS 950/1050(grade 150), SAS 900/1100 (grade160) and Cold rolled SAS 850(grade 120). These threaded barsare available in diameters 12mm to75mm. These threaded bars and allthe accessories are complying tothe relevant standards as well aswith the project requirements. Inaddition, any specific request /requirement to the constructionindustry are being developed andtested by SAH’s Research andDevelopment Department.

For VSL Middle East who is in theforefront with its activities as a“Solutions Provider” in the region,this partnership will definitelycontribute and provide value addedservices to their ever expandinglist of satisfied customers. The JVoperations have recently receivedan order for the supply of rockbolts for the Portal works forDaftah-Shis Road & Tunnel Project

in Fujairah, UAE. Moreover, ordersfor form ties, stress bars &accessories, have been received.

Trench-less pipelinerehabilitation In August 2006, InsituformTechnologies®, Inc.and VSLformally agreed to start InsituformAsia Ltd. as a 50:50 joint venture.Established in the United Kingdomin 1971, Insituform® has grown tobecome an international pipelinerehabilitation company with annualrevenues of 2500m. While its corebusiness focuses on sewer piperehabilitation, Insituform® alsorestores steel, iron, concrete, PVCand asbestos cement (AC) pipesconveying a variety of fluids.Because Insituform®’s techniquesavoid digging up existing pipelines,disruption to the public isminimized. Disposal problems withAC pipes are also eliminated sincethe pipes remain safely in theground following rehabilitation.

For VSL this strategic merger willincrease its already determinedinvolvement in the repair andstrengthening sector. ForInsituform®’ VSL provides aplatform in the Asia Pacific region.This platform will allow them toquickly establish new businessventures backed by the supportand establishment of a contractorwith considerable expertisedelivering specialist services to thecivil engineering sector.

The initial business targets areHong Kong, Macao, Australia andTaiwan. The Hong Kong and Macaolocations have been in operationsince October 2005 and havecompleted work for the WaterSupplies Department and theHong Kong Mass TransitCorporation. A steady stream ofrehabilitation contracts is alsobeing tendered by Hong Kong’sWater Supplies Department.Opportunities are being explored inAustralia, particularly in theheavily populated areas of Southand East Australia

In addition to operating as acontractor, IAL has exclusiverights for sale of the MTube® brandCured-in-Place Pipe (CIPP) tubingfor Hong Kong, Macao, Australia

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V S L & P A R T N E R S H I P S

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COVER STORY

and Taiwan. IAL has non-exclusiverights for a wide range of AsiaPacific countries (with theexceptions of Japan, Singaporeand Malaysia) and sales havealready begun in both Korea andHong Kong. The IAL Taiwanoperation is in the initial stages ofdevelopment and should be fullyincorporated early in 2007.

CFRP laminate post-tensioning system Since the development of CFRP(Carbon Fibre Reinforced Polymer)in the late sixties these materialshave been used increasingly forstructural strengthening. Duringthe last ten years, they have alsobeen used as post-tensionedstrengthening tendons forapplications on bridges and otherstructures. Sika and VSL are co-operating in the worldwide marketwith their newly developedcomposite CFRP laminate post-tensioning system. By combiningtheir respective know-how,expertise, products and networksin this field, the parties havedecided to create this year andmarket a “quality controlled pre-stressed CFRP system” under thetrademark CarboStress®, withlocal expertise and site supportfrom the global network of bothcompanies.

for difficult access sites orstructures; easy and fastinstallation without specialequipment; strengthening at lowtemperatures (down to -10°C non-bonded) without additional curingequipment; minimal breakout onsite. Easy and economic to bond to the structure; can also be usednon-bonded; short load transfer of external PT force into soundconcrete; increased ductility fornon-prestressed structures. Last but not least, for the owner, advantages are longer life

The synergy of quality materialsfrom Sika and innovativeengineering from VSL providesignificant advantages andbenefits for clients. For thedesigner, advantages are: highflexibility in anchorage design tosuit specific structural situations;standard solutions for bridges,roofs, floors and walls; thin CFRPplates make tendon cross overspossible. For the contractor,advantages are: very light weight(a10m-tendon weighs only 3,5kg;can be rolled easily; good solution

expectancy and low maintenancedue to non-corrosive CFRP tendons,good fatigue characteristics, pre-assembly in quality controlledfactory conditions, active PT force(reduction of passive steel stress,crack widths and stressamplitude), and cost effective andsafe strengthening solutions forexternal prestressing.

Multi-pointsynchronised slablifting system VSL and Jacking Systems Ltd NZhave come together to combinemodern computerized jackingtechniques and slab post-tensioningto deliver an innovative flooringconstruction system: VSL Climbfloor.

CFRP laminate post-tensioning

for bridges

CFRP laminate post-tensioning

for buildings

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11

VSL Climbfloor is used for theconstruction of cast in-situ post-tensioned slabs without the use ofconventional formwork. In a typicalClimbfloor application, each slab iscast on top of the previous slabthen lifted into place by acomputer-controlled multi-pointsynchronised jacking system. The system can combine voidformers, edge formwork, self-climbing perimeter accessplatforms with edge protection andsafety screens. VSL Climbfloorprovides a comprehensive self-climbing and self-contained slabforming system allowing infinitecombinations of flat slab and bandbeam configurations.

This system provides a safe and a very cost competitive alternativeto labour intensive conventionalformwork and crane intensive pre-cast concrete operations.

The key advantages are:• Substantial cost savings over

timber formwork and pre-castconcrete systems.

• Larger spans and thinner slabsinherent in PT slabs, whilstretaining the benefits of pre-castsystems.

• Significant reduction in cranage.All formwork, screens and edgeplatforms are self-climbing.

• Allows the continuation of thenext floor cycle as soon as theconcrete starts setting on theprevious slab. There is no need to wait for the erection of the nextlevels formwork to commence theinstallation of the reinforcement& PT for the next level.

• Superior surface finishes,especially in flat plate slabs.

• Slabs can be lifted to 5.2 metreseliminating costly high propping.

• Improved safety with safetyscreens, edge boards and edge

protection being automaticallycarried up.

• Environmentally friendly throughreduced formwork materials andwaste.

The 121 Strand in Auckland NewZealand is a 4 level car park with 3 floors being lifted with a totalarea of 3,300m2: 36 synchronisedscrew jacks elevated each of theslabs within a relative accuracy of0.1mm. The entire slab could belifted the 2.1m in only 20 minutes.In the case of the three-storeyMiddlemore Hospital car park, 40 jacks were set-up to lift the slabin two parts; each slab measured1,300m2 and weighed 700t, creatingone half of a 2,600m2 level.

Vibration control of cable structuresVSL has signed an exclusivepurchase and distributorshipagreement with SRI Hybrid forspecial damping devices. Thisproprietary rubber mix namedGensui gives the material uniqueproperties both for monotonic andfor cyclic loading. Presently, twotypes of Gensui rubber areavailable, standard and highdamping types with loss-factors of ≥ 0.50 and ≥ 0.63, respectively.The Gensui rubber has other quiteexceptional properties whichresult in a loss-factor which is verylittle dependent on actual sheardisplacement/strain, temperature,frequency of cyclic displacements,and age of the rubber. Theseproperties make Gensui rubber an excellent material of choice for damping devices to controlvibrations of stay cables and othercomponents or entire structures.

The Gensui rubber damper has beeninstalled first in 1994 on theOdawara Blueway cable-stayedbridge in Japan. Since then morethan 36 cable-stayed and extradosedbridges have been equipped withGensui dampers in Japan. Spanlengths of these bridges rangedfrom less than 80m to more than400m. Typically, the Gensui dampers

Middlemore Carpark,

Auckland, New Zealand

40 jacks lifted the slab in two parts; each slabmeasured 1,300m2 andweighed 700t.

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COVER STORY

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were installed at a distanceequivalent to about 2.5-6.0% of thecable length from the deck cableanchorage and typically containedbetween two and six pads.

Significant number of projects inJapan have shown that the actualdamping is equal or typically

10-20% larger than thetheoretically determined damping.In mid 2006, VSL tests with theKorean Highway Corporationconfirmed again the excellentbehaviour of the Gensui damper.VSL is right now supplying Gensuidampers for the Richmond-Vancouver Airport North FraserRiver Crossing cable-stayedproject in Vancouver/ Canada, thefirst application outside of Japan.

However, the one additional veryappealing characteristics of theGensui damper is maintenance:apart from the steel components,the rubber pad in fact needs nomaintenance at all. VSL is now inthe very comfortable position of

Gensui dampers on record bridge in the US

The John James Audubon Bridge to be built insouth central Louisiana, USA is set to becomeNorth America’s longest cable-stayed bridgewith a main span of 482.5m over theMississippi River and back spans of 195.5m.The bridge will be supported by 900t of stays upto 256m long. VSL has recently been awardedthe contract to supply 400 Gensui high-damping rubber dampers The project is beingconstructed by Audubon Bridge Constructorsand is due for completion in 2010.

being able to offer two excellentdamping systems for stay cables toclients: the VSL Friction damperand the Gensui damper. TheGensui damper will be thepreferred choice for cables wherethe required installation positionfor the specified damping ratio iswithin the practical limitations ofthe guide pipe length and/or forcases where damping at smallamplitudes is desired. The VSLFriction damper and/or acombination with the Gensuidamper will be preferred for caseswhere high damping ratios have tobe provided with dampers installedclose to the deck as it is often thecase for long stay cables anchoredabove the bridge deck.

VSL has secured the contract forthe first bridge in Canada to usethe Gensui damper system. Theprecast segmental extra-dosedcable-stayed bridge is part ofVancouver’s Canada Line light railsystem. Installation of the 24 Gensui high damping rubberdampers is expected to take placein the first quarter of 2007. VSLhas also been awarded thecontract to supply 400 Gensuihigh-damping rubber dampers forthe John James Audubon Bridge,Louisiana, USA, set to becomeNorth America’s longest cable-stayed bridge.VSL and SRI started with thebridge damper but such apartnership could expand toanother area in near future. ■

Gensui damper

The damper is made of supporting elements attached to cable and guide/structure between which anumber of Gensui rubber pads are installed which provide damping when the cable moves relative tothe structure

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Gensui flagship

What is Gensui?

Mr. Toji: The Gensui damper is a rubber damping systemdeveloped for, but not limited to,stay cable bridges. It is used tomitigate stay cable vibrations thatcould be induced for example byrain and wind. This system stemsfrom our core technology, rubber,which made Sumitomo RubberIndustries the number one in theworld. As a rubber manufacturerwe concentrate on Gensui’sdevelopment. In Japan, in the lasttwelve years, we installed Gensuidamper on 38 bridges and wehave been keeping the top share(about 90%) for the last few years.

How do you explain such a

successful development?

Mr. Toji: First of all, technicalreasons.Dr. Matsumoto: Indeed, ourdamper is easy to install due to itssmall size. Besides, it is basicallymaintenance free. It is designedto last around 60 years on bridgesapplications. In comparison withother damping systems, it offersless temperature dependency andless frequency dependency, andalso our damper has the samedamping performance whateverthe frequency, from very lowmode to very high mode.Mr Shimizu: And, its cost is verycompetitive.Dr. Matsumoto: Aesthetics isvery important too. Our damper issmall and compact and matcheswell with the structure it isinstalled on.Mr. Toji: Our product also meetsthe bridge industry needs inJapan, where as you know, wehave many bridges. Key people in

the industry and in the university–as for example the researchcentre of Kyoto University–recognize the quality of theGensui damper.

Why did you choose VSL

as a partner?

Mr. Toji: We have been quitesuccessful in Japan, so I believethat the world market should bebigger than Japan. We werelooking for an internationalpartner able to open up the worldmarket for our product.Mr Shimizu: Particularly for staycable bridges, we thought weshould tie to a stay cable supplier.In Japan, general contractorshave cables supplied from cablesuppliers and have damperssupplied from a dampermanufacturer such as us. But inEurope it is often the cablesuppliers who decide what kind of dampers should be installed onthe bridge. We learned a dampersupplier should have the cablesupplier as a partner. Dr. Matsumoto: We recognizedVSL is a reliable partner throughdiscussion particularly with Dr. Ganz and Mr. Bournand. Inaddition, we think VSL could be thebest damper supplier by havingtwo options: VSLoriginal frictiondamper and Gensuidamper which could beapplied up to 250m or300m cable length.Mr. Toji:

Moreover, whilethe other twocable suppliersonly concentrateon the bridges

market; we think that VSL and itsvarious activities can offer otherapplications to Gensui dampers.

Since our agreement in 2005,

how about the first steps?

Mr Shimizu: We hope VSL willinstall Gensui damper at least over1600 pieces annually. Judging fromJapanese market, we thought itwas a reasonable estimate. Dr. Matsumoto: Among thisquantity, we also expect VSL toinstall Gensui damper to theexisting small medium sizebridges having vibration problemand not only newly built largebridges because the Gensuidamper is quite easy to install andwe think the cost is interestingconsidering other dampers.Mr. Toji : We always believed thatVSL will meet our expectation. Werealized that exporting our Gensuisolution could take time, but nowwith a project coming inVancouver, an extradosed staycable bridge, and anotherpotential project in the USA inSaint-Francisville, longest spanstay cabled bridge in the US, wefeel very confident.

What does “Gensui” mean?

Mr. Toji: The direct meaning ishigh damping. But as we useChinese characters, depending onthe pronunciation it can beunderstood as “admiral”, a topranking officer. My wish is that ourGensui system will be the flagshipof VSL range of dampers! ■

Interview with Mr Toji, general manager

of Sumitomo Rubber Industries, and director

of SRI Hybrid, Mr. Shimizu, marketing manager

and Dr. Matsumoto, technical manager.

Dr Matsumoto, Mr Toji, Mr Shimizu.

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SITE INSIGHTS

14

> VSL Australia, in alliance with

Abigroup Contractors and

Leighton Contractors, has beenawarded the contract for theconstruction of the GatewayUpgrade Project in Queensland,Australia. This project worth 1.35 billion USD comprises 10kmof new freeway, 10km of existingfreeway to be upgraded and onemajor bridge to be duplicated. Theduplicate bridge is a posttensioned concrete structurecomprising 260m-long main spansand 70 to 80m long approachramps. The main deck will beconstructed using formtravellersutilising cast in-situ balanced

cantilever techniques. VSL's scopeas main bridge alliance partnerincludes assisting in theconstruction engineering,provision of key personnel andspecialist plant & services for theentire bridge structure from itsfoundations (piles caps, piers,abutments) up to and including thesuperstructure. The main bridgealliance is 15% of the total projectbudget, the construction of whichwill be shared collectively betweenthe three partners and representsapproximately 4 years of activityfor VSL Australia. ■ Contact: sgrogan@vsl-

australia.com.au

Australia

Gateway to alliance

Australia

New testsfor Ductal®

> Successful tests were conducted

this year for resistance of Ductal®

against rife and fragmentprojectiles, the effects of close-charge threats and large-scale blasteffects. A prototype modular Ductal®

Protective Solution buildingconstructed from 100mm thickpanels connected with steel plates,was subjected to the effects of 500kgof industrial grade AmmoniumNitrate Fuel Oil (ANFO) at a distanceof only 12m. In a separate test, 2mlong and 1m high Ductal® ProtectivePanels were subjected to the effectsof a 5,000kg packed TNT charge atdistances of 20 and 30m. The testsdemonstrated the superiorprotective performance of Ductal®

in direct comparison to ordinaryreinforced concrete panels. Similarpanels are currently in use as roofprotection against mortar threats for a government building in a high-threat zone.■ Contact: mrebentrost@vsl-

australia.com.au

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15

> Achievement of fast deck erection times means that thesuperstructure for a new bridge near Sydney is now on track to finish twomonths early. VSL-Abigroup Alliance is building the bridge as part of theWindsor flood evacuation route. Twenty two of the bridge’s 800t spans havebeen erected since the work started in June, with cycle times as little as24 working hours. The 1,500m-long bridge is being constructed using thesegmental match-cast method with an under-slung erection system. It ismade up of 34 simply-supported spans, each 44.3m long and consisting of15 segments with 18t of external prestressing.■ Contact: [email protected]

> VSL’s July completion of its

work on a bridge over the OkhtaRiver marked its second majorstructure for the St PetersburgRing Road. The bridge follows onfrom a first cable-stayed bridgeover the Neva River and VSL’sinvolvement continues with asecond Neva bridge (see note pad).Site constraints had led to thedesign of a steel arch withcomposite deck. The arch reachesa maximum height of 28m, with aspan of 160m. VSL was awardedthe supply and installation contractfor cables from its SSI 2000 staycable system, based on the quality,performance and experience ofearlier Russian schemes. Fifteenpairs of SSI 2000 suspensionhangers were used, ranging from16 to 19 strands. ■ Contact:

[email protected]

Taiwan

Concretesavings forHannStar> An alternative design by VSL is

achieving a substantial cost savingin construction of the three-storeyHannStar TFT-LCD CUB factory inTaiwan’s Tainan Science Park. The building was originallydesigned to use structural steelbut the dramatic rise in steelprices led VSL to suggest the useof post-tensioned reinforcedconcrete. More than 44,000m ofpost-tensioning is needed for theproject, using tendons up to 71mlong. Floor-to-floor height is 9m as the factory will house theequipment to manufacture verylarge LCD monitors and TV screens.■ Contact: [email protected]

Neva again. Stay installation for

the second Neva River cable-

stayed bridge on the St Petersburg

Ring Road is due to start in

December 2006. The contract for

the 382m-span bridge follows

VSL’s successful completion in

2004 of work on the first crossing,

using VSL SSI 2000 stay cable

system in extreme temperatures

of below –30°C.

Centenary upgrade. VSL in

Australia has won a contract for

the supply and installation of soil

nails as part of the Centenary

Link Alliance project for the

upgrade of an intersection in

Queensland. The work involves

more than 680 fully-encapsulated

soil nails up to 12m long as well

as almost 2.5km of slotted PVC

drains.

Dual success. Two VSoL®

contracts have been won by VSL

in Queensland. Work at the

Wesfield North Lakes shopping

centre builds on VSL’s

relationship developed on the

Westfield Chermside project. The

second project involves panels for

abutments and wing walls for the

RG Tanna Dozer Overbridge,

which is part of a coal terminal

upgrade.

Flying success. A joint venture of

Kajima, Taisei, Obayashi and

Maeda has awarded VSL Vietnam

a sub-contract to supply and

install 280t of post-tensioning on

the new terminal at Tan Son Nhat

International Airport. VSL

anchorages and couplers are

being used on slabs beams and an

access viaduct.

Reinforced tee-off. VSL Hong

Kong is undertaking a geogrid-

reinforced steep slope project for

Hong Kong Jockey Club’s third

golf course on Kau Sai Chau

Island. Soil reinforcing geogrids

and erosion protection matting

will be installed on 10 steep

slopes up to 8m high.

N O T E P A D

Russia

Ring roadreturn

Australia

High-speed cycle at Windsor

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SITE INSIGHTS

> The final segment of the Lai

Chi Kok Viaduct has been erectedand the closure pour completed.VSL Hong Kong formed an alliancewith Acciona (formerly known asNECSO) for the project which is onRoute 8, connecting Tsing Yi Islandto Shatin. The scope of the alliance includes the erection of 1,766 precast segments and theinstallation of post-tensioning,bearings and movement joints. The project is situated in a highly-populated area of Kowloon. Thedeck is supported on piers up to45m high, with the majority beingabout 25m. The 172m-longlaunching gantry, weighing about1,000t, had the capability to movesideways across a 45m range andcould be used to erect four parallelbox girders simultaneously. VSL’sstrand lifting system allowedsegments to be lifted from the

ground on either side of theparallel bridge decks. A liftingframe was used at piers withsingle box girders where access atthe pier was possible but wherethe ground below the cantileverwas inaccessible. A sliding supportsystem was used to take precastsegments to inaccessiblelocations. The segments werelifted by crane onto one end of thesliding system and then moved upto 80m. This method faced severalchallenges, such as the fact thatthe bridge was curved, had alongitudinal gradient of up to 4%and that the piers were obstructingthe slide. A tie-down system wasalso designed to countermovement and hold the boxgirders in the correct positionduring construction. ■ Contact: [email protected]

intrafor.com

> Singapore’s Land Transport

Authority has embarked on a

series of projects to repair andstrengthen vehicular bridges totake increased loadings. VSL hasbeen involved as a specialist mainsub-contractor for the upgrade of11 bridges. The scope of workincluded concrete repair,protective coatings, bearingrehabilitation, expansion jointreplacement, external post-tensioning and the application ofcarbon fibre reinforced polymers(CFRP).Bridge soffit protection took theform of a three-coat anti-carbonation system comprising alayer of siloxane-silane and twoacrylic-based coats. Deck parapetwalls were given a two-coatprotective system made up of anepoxy undercoat and apolyurethane resin sealer. Externalpost-tensioning was used tostrengthen five of the bridges. Thenew concrete anchorage blocksincorporated lateral CTA 40 stressbars and main external post-tensioning systems.Calculations had shown that thestrengthening work wouldincrease the structural capacity byat least 20% and up to 60%.■ Contact: [email protected]

Singapore

Diverseapproachto bridgeupgrades

Hong Kong

Alliance overcomesproject challenges

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17

Team building. Leading

contractor Dragados picked VSL’s

post-tensioned slabs for its new

headquarters building in Madrid.

VSL’s contract involved 27,500m2

of PT slabs, using the VSL

Bondtech. Three PT slab designs

were developed. All buildings

have an 8m cantilever transferred

by just two beams at first floor

level, hidden in the façade.

Police drill. Intrafor is installing

64 horizontal ties by the

Horizontal Directional Drilling

method at a project to turn the

former Marine Police

Headquarters in Tsimshatsui into

a hotel. The building stands on top

of a small hill and needs retaining

works. Precise drilling is needed

and the Eclipse walkover

surveying system is being used.

Sound performance.

VSL Australia’s successful

installation of 4,000m2 of VSoL® on

the first section of the Albury

Wodonga Bypass Project has led

to a further order for 6,000m2 and

the subsequent supply of

24,000m2 of architectural sound

barrier panels. At peak

production, VSL Australia was

casting 24 panels every day.

Mexican silo. VSL in Mexico was

the main contractor earlier this

year for the rapid construction of

39.6m-high cement storage silo

for Holcim-Apasco. Some 14t of

vertical 36mm-diameter PT bars

were used to join the foundation

to the superstructure, while the

superstructure contains 22t of

vertical and horizontal ring

tendons.

N O T E P A D

> Segment erection on the T3

road project in Shatin, Hong Kongis due to be completed in February2007. The scope of VSL’s work is toerect 1,807 segments, which varyfrom 30t to 90t, and to install1,240t of internal and external PT.The segments are erected by thebalanced cantilever method, usinga 450t, 108m-long overhead gantryand various sizes of hydrauliccranes. This is the third segment

erection project for this gantry,which had worked previously inKorea and Singapore. The T3 teamis made up of people from 15countries. Their greatest challengeto date has been the erection of a65m-span cantilever where thesupporting lower cross beamswere launched onto the cantileverwhile it was being erected. ■Contact: [email protected]

intrafor.com

> VSL is playing a major role in a

bridge to link Singapore and theluxury apartment developments ofKeppel Bay Island. Seven staycables support the 90m-long mainspan, with four more supportingthe back span. The cables are fromthe VSL SSI 2000 Stay CableSystem and range in size from 22 to 85 strands. The inclinedconcrete pylon reaches almost50m above deck level. VSL is incharge of superstructureconstruction above the piers, with

a wide-ranging scope of workincluding casting the 77 segmentsand erection using a 400t bargecrane and a custom-made erectionframe. VSL Singapore led a keydesign change that was neededbecause of height restrictions onthe use of floating cranes imposedby a nearby cable car. The designfor the anchorage at the top of thepylon was therefore changed fromthe original steel box to reinforcedconcrete. ■ Contact: [email protected]

Singapore

Bridge to luxury

Hong Kong

Shatin T3 bridgenears completion

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SITE INSIGHTS

> The world’s largest shopping

mall -a million square metres- isunder construction in Dubai andVSL is working around the clock tomaintain the exceptionally fastpace of construction. In severaloccasions, more than 200t ofstrand have been installed within asingle month. It would normallytake nine months to install thisquantity in a typical building withpost-tensioned slabs in Dubai. Thestructure has been designed withpost-tensioned beams and slabs.VSL’s scope of work coversapproximately 30% of the total floorarea –some 300,000m2. The mallstands next to the world’s tallestbuilding, the Burj Dubai tower. VSLhas also recently won the post-tensioning for an adjacent project,involving some 3km of bridge deckon one of the major vehicularaccesses to the new district. ■ Contact: Y S Li [email protected]

Dubai

Complex cells for new LRT> The first mould has been

delivered from China for thecantilever sections of the DubaiMetro Light Rapid Transit system andsite installation and commissioningis under way. Five cells, made fromapproximately 450t of steel, will bedelivered by January 2007,including all the mechanical,electrical and hydraulic systems.VSL Switzerland was appointed bythe VSL-Freyssinet-Rizzani JointVenture to design and fabricate thecell formwork. Cell design wascomplex because of the shape andvariable geometry of the segments.Design has been closely managedby the VSL Technical Centre inSwitzerland, with the manufacturein China supervised by VSL. ■ Contact: [email protected]

Dubai

Record pace for world’s biggest mall

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> VSL has been working as the

specialist contractor for lifting andtensioning the cable net structuresupporting the roof membrane of astunning new stadium underconstruction in Kuwait. The projectfollows on from the company’sinvolvement in many sportsstadiums worldwide. Local timber-built merchant ships have inspiredthe architecture of the Jaber Al-Ahmad International Stadium. Thecircular structure has a diameterof 250m and rises at opposite endsto 65m. The elegant wave-shapedroof is carried on a structural

skeleton made up of 52 wall pierswith inclined cantilever beams.Thecable net is made up of 52 radialcables and a central tension ring.VSL supported the contractor withan innovative scheme to optimisethe installation and tensioning.The construction schedulerequired the work to be carried outin the hottest season, whentemperatures in the stadiumreached 60°C. Crews workedseven-day weeks and the stadiumis on track for completion in 2007.■ Contact: wschroeppel@vsl-

schweiz.ch

Kuwait

Hot season at Stadium

> VSL has been working with

Jacobsen Hunt Joint Venture tosupply and install a bonded post-tensioning system as part of the

USA

Supporting Utah’s Capitol

Dual role. VSL Thailand has

erected more that 109 spans of

the elevated Suvarnabhumi

Airport Rail Link. VSL Thailand

was awarded a subcontract for

superstructure erection and

5,600t of post-tensioning works.

The work involves the erection of

612 of the project’s 900 spans and

PT works for the remainder.

VSoL® record for ME. VSL Middle

East, in JV with VSL Hong Kong,

has secured its largest ever

VSoL® win with the award by

Galfar Engineering & Contracting

of a sub-contract for the Oman

Southern Expressway: design,

supply and supervision of more

than 92,000m2 of the VSoL®

polymeric wall system. Panels

will be installed at a peak rate

exceeding 120m2 a day.

Imported gantries. VSL India is

set to start gantry erection for a

scheme to build an 8km viaduct to

carry four lanes of traffic above

an existing six-lane highway

near Bangalore. A total of

2,860 segments are to be erected.

The three launching gantries have

been fabricated in China and

shipped in 90 containers. This was

two months quicker than making

them locally.

Noiseless. VSL Hong Kong has

recently completed a full scope

supply and installation package

for VSoL® retaining walls on Hong

Kong’s T3 project. Working on a

congested site, the VSL site team

installed 1,725m2 of VSoL® wall

together with associated parapet

barriers and noise barrier

support walls.

Spanish showcase.

CTT Stronghold has completed

the installation of stay cables for

the new exhibition centre in

La Coruña in northern Spain. The

VSL SSI 2000 Stay Cable System

was used for the 18 stays that

support the 160m by 50m roof

from three steel pylons.

N O T E P A D

seismic isolation of the dome ofUtah’s Capitol building. VSL’sresponsibility includes supply andinstallation of a bonded post-tensioning system as part of theseismic isolation of the dome.Post-tensioning was chosenbecause it allowed for the transferof dome loads from existingfootings to new seismic isolatorsand deep foundations. Large post-tensioned tendons have had to beplaced under difficult accessconditions. ■ Contact: [email protected]

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SITE INSIGHTS

Czech Republic

Team success at Rybny Potok

> VSL UK’s method of post-

tensioning two LNG tanks in Waleshas saved time on the critical pathfor the main contractor, Whessoe-Volker Stevin Joint Venture. OwnerDragon LNG commissioned thetanks at Milford Haven. One of thekey aspects of VSL’s proposal wasto use the new AF floweranchorage system for the verticaltendons instead of the originaldesign with stressing at both ends,or the U-shaped system that iscommonly used for this kind ofstructure. The vertical tendons areanchored in the bottom with thetype AF dead anchorages. Theproposal saved time by avoidingexcavation and subsequent backfilling below the tank slab. Morethan 52km and 6,500 couplers ofthe PT-PLUS® system have beeninstalled. The 700mm-thick wall isreinforced with 144 vertical and158 horizontal tendons. High-performance Ductal® G2 grout hasbeen used. ■ Contact: [email protected]

> Excellent coordination between

all participants has led tosuccessful completion of work on abridge over Rybny Potok on the D8highway. VSL installed secondaryexternal cables on the bridge,following the launch of the 20,000tsuperstructure. The cables, whichare up to 360m long, consist of 31-strand replaceable CS 2000tendons. VSL also carried out allthe lifting works needed to replace

UK

Flower forsavings

temporary bearings withpermanent ones. The maximumlift on a single pier was 3,500t,provided by eight 500t jacks. Aconsortium of Strabag andSkanska was the generalcontractor for this section ofhighway, with Metrostav as bridgecontractor. Bridge design wascarried out by SHP with assistancefrom VSL.■ Contact: [email protected]

VSLNews2-2006 29/11/06 17:47

> VSL Switzerland has recently

started building the deck of themain bridge of the Rades–LaGoulette project in Tunis for TaiseiCorporation. The extradosedbridge is 260m long, with a mainspan of 120m and end spans of70m. VSL is supplying two piertable formwork units, two pairs ofform-travellers, PT componentsand all the necessary constructionsupervision. Components andsupervision are also beingsupplied for another part of theproject, which involves four post-tensioned ramps constructed onscaffolding. Completion is due inNovember 2007.■ Contact: k.doghri@bouygues-

construction.com

Tunisia

Worksstart

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21

> Post-tensioning has recently

been completed by VSL on floorslabs for the extension of a carpark in Lausanne. The lower threelevels were made up of 350mm-thick prestressed slabs with VSLSO-H 6-4 post-tensioning cables.Cycle times were reduced to lessthan a week, thanks to VSL’s post-tensioning method and the use ofthin prefabricated slabs, which

doubled as lost formwork. Thefourth level, the roof slab, has tosupport heavier loads and so is600mm thick and post-tensionedwith VSL EC-H 6-12 cables. Theflexibility and adaptability of theVSL system also facilitated an easytransition between the newextension and the existing carpark.■ Contact: [email protected]

Out or rain. VSL Argentina has

been appointed to build two PT

water tanks to prevent flooding

inside the Repsol-YPF Refinery in

La Plata. Each water tank is

approximately 70m by 70m with

3.5m-high walls. VSL is using the

Bondtech system with 0.5”

strands.

Carbon plate. VSL France has

installed a 15m-wide, 100m-long

suspended floor underneath the

deck of a motorway viaduct over

the River Yonne as part of a

project to repair the structure.

CFK 150/2000 carbon plates are

being bonded to the beams as

strengthening.

N O T E P A D

Switzerland

Flexible build

> VSL is carrying out post-

tensioning on the tallest tower in

Liverpool. A construction boom isunder way in this World HeritageCity and future European Capital ofCulture, with new sports, culturaland shopping facilities as well asan impressive skyline of towers.Tallest is the 120m-high BeethamWest Tower, for which VSLdesigned the post-tensioned slabsand is carrying out the installationusing the SO 6-4 system. ■ Contact: [email protected]

UK

Towers reaching forthe skies

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SITE INSIGHTS

Ecuador

Achievements in deep forest > Installation of 128 stays for a

183m-span bridge over the

Pastaza River in the Amazonian

forest has been completed threemonths ahead of schedule, despitedifficult site conditions. The staysfor the new bridge on the Baños-Puyo road were installed in justfive months. The composite deck

of the steel bridge with itsconcrete slab is being supportedby SSI 2000 stays, sized between6-12 and 6-31. A total of 81t ofreplaceable stays were used.Galvanised and waxedmonostrands were placed in anexternal polyethylene pipe.■ Contact: [email protected]

> The fast-growing list of

liquefied natural gas storage

tanks built with VSL post-tensioning now includes the SouthPars Gas Field project inAssaluyeh, Iran. VSL is providingthe post-tensioning for twopropane and two butane storagetanks for the ninth and tenthphases of the huge project. PT-PLUS® duct is being used for all

the semi-circumferentialhorizontal tendons and U-shapedvertical loops. The system’ssuperior friction coefficientsallowed a significant reductionfrom the strand quantities initiallyestimated. Further benefits camefrom the robustness and ease ofinstallation. VSL’s CS 2000anchorage is used throughout. ■ Contact: [email protected]

Iran

Tough tanks

> VSL has been playing a key role

in major scheme under way in St Petersburg. A new protectivedam will guard against the dangerof flooding and an elevatedhighway is also being built. Theelevated structure is largely madeof precast beams but also includesa 122m-long, 1,500t section ofsteel deck, which was assembledat ground level and raised 22mto its final level. VSL’s computer-controlled laser levelling systemproved ideal for this as thestructure was very flexibletransversely. The lift wassuccessfully carried out in a single,smooth operation.■ Contact: [email protected]

Russia

High and dry

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> An exceptional VSoL® project

has recently been undertaken

along the French banks of Lake

Geneva as part of the Thonon-les-Bains bypass. The scheme usedalmost 9,000m2 of VSoL®, made up

of more than 3,000 concrete facingpanels measuring 1.68m wide byup to 2.80m in height. All panelsfeature complex architecturalfinishes with patterns measuringup to 200mm. VSL’s role rangedfrom design through toconstruction and includedsecuring the architect’s approval.The project specification alsocalled for nearly 22,000m2 ofVSoL® Steel with a mineral facing.The VSoL® Steel Mesh system wasapplied over straight and curvedwall segments, for structuralbridge abutments and forreinforced fill approach ramps.The first VSoL® Steel panels wereinstalled during June 2006and the team began setting upthe concrete panels in mid-September.■ Contact: jp.vernier@bouygues-

construction.com

France

Landmark win for VSoL®

> Major renovation has now been

completed of the Grau Saint-Ange

coastal bridge alongside theMediterranean. VSL France wasawarded the project which wasfinanced by the local council ofPyrénées-Orientales. The 15-monthproject restored damaged areasand brought safety features up tostandard. Proximity to the sea hadled to chloride contamination inthe double-deck structure’sconcrete. Hydrodemolitionremoved some 800m2 ofcontaminated concrete, which wasreplaced using shotcrete. ■ Contact: [email protected]

France

Seaside repairs

Chile

Superflat and smooth > A “superflat” slab surface has

been achieved at a major Chilean

distribution centre, far exceedingthe project’s already demandingrequirements. Expansion ofFalabella, one of Chile’s top threeretail companies, prompted theconstruction of a new 30,000m2

distribution centre in Santiago. The slab needed to be very flat forefficient performance of the

centre’s specialised fork-lifttrucks. VSL’s ability to produce ajoint-free finish provided additionalbenefits. The high specificationwas achieved through the use ofspecial formwork and narrow 4m-wide pouring strips. VSL’sscope of work also includedengineering advice, supervisionand liaison. ■ Contact: [email protected]

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European Organisation for Technical Approvals (EOTA)

ETA for VSL post-tensioning systems

FOCUS

On 31st July 2006, French Approval Body SETRA has issued the

European Technical Approval (ETA) for VSL post-tensioning systems

for a period of five years. This provides VSL with the most

comprehensive range (from 1 to 55 strands) of ETA approved of the

market. VSL’s ETA is valid in all EU and EFTA countries.

The introduction of ConstructionProducts Directive (CPD) (see box)represents a giant step in the aimof harmonisation and setting ofhigher standards in post-tensioning systems. Structureswill be safer and also morereliable thanks to the ETA process.To have certified systems that canbe used in all EU/EFTA countrieswithout need of further country bycountry approvals certainly is themain objective of the CPD.

Upon mandate from EU/EFTA andin order to guarantee that allregulated characteristics weretaken into consideration, VSLassisted EOTA in the drafting of theETAG 013 which is the onereferring to post-tensioningsystems. VSL’s ETA has beenissued on 31-07-2006 by theprestigious French Approval BodySETRA and is valid for a period offive years. VSL had to submit anapplication including full details ofour systems and their intendeduse as well as test reports and acomprehensive description of ourVSL manufacturing centres.Testswere carried out at the prestigiousSwiss laboratory EMPA andcomprise mainly static load,

tensile, fatigue and load transfertests, as well as many other testsrequired to check the performanceof our post-tensioning system.

Full range approval

The ETA has been granted for VSLfull range of systems:• The VSL Multistrand System

(anchorages from 1 to 55strands), intended more formassive civil engineeringstructures with either metallicducts or VSL PT-PLUS®.

• The VSL Slab System (from 1 to 4 strands), intended forthinner construction elementssuch as building slabs or bridgedecks, is used along with eitherbare strands inside metallicducts or VSL PT-PLUS® as wellas individually greased andsheathed strands.

The VSL Post-Tensioning Systemmay be used for new structuralworks or repair and strengtheningworks for existing structures. Itmay also be employed instructures made of othermaterials than concrete asmasonry, steel, wood orcombinations of several materials.

The tendons assembled as part ofthe VSL Post-Tensioning Systemmay have the following basic usecategories:• internal bonded tendon

for concrete and compositestructures,

• internal unbonded tendon for concrete and compositestructure,

• external tendon for concretestructures with a tendon pathsituated outside the crosssection of the structure ormember but inside its envelope.

The following optional usecategories are added:• restressable tendon

(internal or external),• exchangeable tendon

(internal or external),• internal bonded tendon with

plastic duct,• encapsulated tendon,• electrically isolated tendon,• tendon for use in composite

construction as external tendon,• tendon for use in structural

masonry construction as internaland/or external tendon,

• tendon for use in structuraltimber as internal and/orexternal tendon.

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EU/EFTA countries

Belgium Cyprus Czech Republic Denmark

Austria

Estonia Finland France Germany

Greece Hungary Iceland Ireland

Italy Latvia Liechtenstein Lithuania

Luxembourg Malta Netherland Norway

Poland Portugal

Spain Sweden Switzerland United Kingdom

Slovak Republic Slovenia

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FOCUS

VSL differenciation

Other post-tensioning systemswith ETA approvals had only up tonow anchorages ranging from 1 to27 or 31 strands, whereas VSLgoes up to 55 strands, allowingcustomers and consultants a muchwider variety of choices. VSL’s ETAis valid in all EU/EFTA countries(today, 29 countries, in the future,maybe more than 40). This couldalso affect many countries in theworld that have national codes andpractices inspired from BritishStandard, German or Frenchcodes. Conferences will be carriedby VSL during the next months inall subsidiaries affected by theimplementation of ETA in order tofully disclose the importance forthe post-tensioning industry ofthese matters.

VSL will also continue to include newanchorage as well as developmentsof the existing systems in future ETAso that customers and consultantscould have access to an even greater choice of anchorages andapplications.

a European Standard oninstallation and qualification ofpost-tensioning personnel adoptedin EU/EFTA countries A first stephas already been done with thepreparation of the CEN Workshop

Agreement, CWA 14646 which isalready specified in manyEuropean countries and couldeventually lead towards an prENVand thus become a EuropeanStandard in the future. ■

EOTA, how it worksEOTA (European Organisation for Technical Approvals) was born out of

the Construction Products Directive (CPD) 89/106/EC of the European

Union. The goal of the CPD is the removal of technical barriers in the

construction products sector through:

• compliance of works with the six Essential Requirements (6ERs)

• transformation of the 6ERs to product requirements by means of

Interpretative Documents

• determination of performance oriented regulations for products used

in the works by technical specifications

• attestation of conformity of the product

• CE marking of the product

EOTA comprises the Approval Bodies (AB) nominated to issue European

Technical Approvals (ETA) by EU Member States and EFTA States who

have contracted to the European Economic Area Agreement.

An ETA for a construction product is a favourable technical assessment

of its fitness for an intended use, based on the contribution made by this

product to the fulfilment of the six Essential Requirements, as stated in

the CPD for the construction works in which the product is installed. An

ETA can be granted when any of the following conditions apply:

• no relevant Harmonised Standards for the product exist

• no mandate for such a Standard has been given by the European

Commission

• the European Commission considers that a Standard cannot be

developed (yet)

• a product deviates significantly from the relevant Harmonised

Standards

The Attestation of Conformity (AC) procedure with a technical

specification like the ETA, is intended to ensure that the product

specification set out in an ETA is maintained by the manufacturer. The

AC system is decided by the EU for each individual product or product

family and given in the mandate for an ETAG.

Although in certain circumstances it may be possible for an ETA to be

issued on the basis of a common assessment procedure agreed among

EOTA members, in most cases an ETA for a product will be granted to a

manufacturer based on the assessment principles set out in an ETA

Guideline (ETAG) for the relevant product sector.

An ETAG describes how to assess, in an harmonised way, products of a

particular product family, so that the result products, if the AC provisions

are satisfied, can carry CE marking and can be placed on the market in

any of the EU/EFTA countries without further regulatory requirements.

ETAGs are binding for all Approval Bodies, grouped in EOTA.

After contributing to ETAG 13, VSLis pursuing its efforts to guaranteethat customers and consultantsbenefit from state of the art post-tensioning systems as well as safeand reliable methods andinstallation personnel. The aim isthat after a certain period, theexpertise gained with issuing ETAscould be used for making aEuropean Standard for installationof post-tensioning. VSL ispresently working in order to have

Extralong CS 2000 trumpets

on medway bridge deck

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27

TECH SHOW

Venetian Macao phase I

Precast for mega casinoThe Venetian Macao Resort Hotel Phase I is the major

development of another giant casino by Las Vegas Sands

Group in Macao. For VSL, the project involves large scale

precast beam installation.

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TECH SHOW

V E N E T I A N M A C A O P H A S E I – E A S T P O D I U M

VSLNews2-2006 29/11/06 17:47

29

Giant footprint .

The East Podium is on afootprint of 250 x 310m. The mainstructure consists of level 1 at +7mabove ground level, on a column gridof 10 x 10m, followed by level 3 at+18m and level 6 at + 33.0m aboveground level, both on a column gridof 20 x 20m and 20 x 30m. Level 3 iscarrying 2 canal structures and aretail level above and is partiallysupporting a hanging floor below,both composite structures. Level 3and 6 are highly loaded, designed aswind and earth quake resistingframes supporting up to 20kPa live load.

1

N E W S N ° 2 • 2 0 0 6

From left to right: K.F. Au, Erection Foreman;C.W. Chan, Erection Supervisor and GaryHackett, Senior Superintendent

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TECH SHOW


Precast double T beams

at Level 1.

The precast double T beams haveproven to be the most efficient interms of design as well as forerection: 3 numbers of double Tbeams are placed in a 10 x 10mbay, before a topping of 75mmthickness is cast in place.Scaffolding System’s (MSS).

3

Precast wind - and main beams at level 1.

Level 1 is the Casino level on a10 x 10m grid. The main- and wind (framing) beamsare full span precast beams supported on columnheads and made continuous over the columns withcast in-situ stitches. The mainbeams withcontinuous nips on either side are carrying theprecast double T beams.

2

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4-in-1 semi-precast main beams in the sequence of works.

The details of the 4-in-1 semi-precast main beams play a vital role to thesuccess of VSL’s alternative design. The sequence of works is as follows:- Installation of 4 nos. of semi-precast main beams by heavy duty tower crane on

column heads.- Stitching of flanges of precast beams to ensure the structural integrity.- Fixing of steel reinforcement cages and PT ducts in between precast beams.- In-situ concrete in-fill of main beam.- Span by span stressing of continuity tendons across columns.- Installation of precast secondary beams supported by corbels on main beams.- Erection of precast planking supported by secondary beams.- Fix top reinforcement and cast topping.Typical weights of precast beams are 20 to 28 tons

5

Semi-precast pre-tensioned

mainbeams and precast

pre-tensioned phi shaped beams

at level 3 & 6.

Level 3 and Level 6 have typical baylayouts of 20m x 20m and 20 x 30m.The structure consists of continuouspost-tensioned framing beams, madeup of semi-precast pre-tensionedmainbeams and precast pre-tensioned phi shaped beamssupported on column heads. Simply supported precast and pre-tensioned T or I shapedsecondary beams are supported onthe continuous corbels on either sideof the main beams. Precast planksare placed in between the secondarybeams to receive a cast in-situ topping.The precast beams and planks arecast in China, transported by road tothe construction site and installed bycustom made high capacity travelingcranes, which allow placing 25 tonbeams at a 50m radius.

4

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TECH SHOW


High capacity tower cranes.

The large footprint of about 250 x 310m and the heavyprecast beams of up to 28 ton required 4 custom made highcapacity tower cranes made in Denmark, 2 of them rail mounted,capable of traveling under full load. The rail tracks consist ofsteel or concrete beams spanning 20m from pile cap to pile capabove the lower ground floor. The beam installation started nearto the hotel and moved progressively away. The access corridorfor the tower crane was in-filled as the crane retreated. Uponcompletion, the tower cranes are dismantled by crawler cranesplaced on top of level 6, which also fill in the last openings.

7Overlapping post-tensioning

tendons.

The post-tensioning tendons of arespective span typically overlap by1/4 with the previous and next span.The detailing is done such as thetendons can be stressed at eitherend from stressing pockets, bringingthe stressing operation out of thecritical path.

6

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Erection of precast secondary beams

and precast planking.

The precast secondary beams are installed on topof the corbels of precast main beams afterstressing the continuity tendons. The beams areT- or I-shaped to minimize the weight to 28t forerection. Half joints at either end of the beams aredetailed by using strut-and-tie models to ensurethe load transfer at the critical zones. In betweenthe typically 4m spaced secondary beams, 75mmthick precast planks with cast in lattice griders areinstalled. Top slab reinforcement is fixed directlyon top of the lattice girder to receive the in-situcast topping. VSL’s services included as well the coordinationwith the architect and building services engineerfor detailing of the planking layout.

8

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TECH SHOW


Venetian Macao project at a glance

Designed as a luxurious resort and convention destination with Venice’s landmarks, this pro-

ject includes a podium with casino and retail space, with an integrated canal structure to sail

gondolas, a 40 storey hotel, a theatre and an exhibition centre. All are built on the newly re-

claimed land in the Cotai Strip of Macao SAR, China. VSL, in a JV with Dragages and China

Civil, were awarded the construction of the 5 level podium structure.

VSL Hong Kong successfully converted the cast-in situ structure into a partially precast

scheme, which allowed fast track construction and minimized the need of large falsework and

formwork. This enabled a quick handover of the completed bays to the next trade contractor.

The precast unit weights were limited to maximum 28 ton and 19m length and required

custom made high capacity travelling tower cranes for installation. VSL’s erection team un-

der Henry Chan successfully

demonstrated the effective-

ness of the scheme and in-

stalled over 9,300 precast

units in less than 13 months.

The pre-tensioned beams and planks

of level 3 and 5 have been cast by China

Railway in Zuhai (Guangdong Province),

about 30km away from the site, under

close supervision of VSL.

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35

C R E AT I N G S O L U T I O N S T O G E T H E R

www.vsl.com

THAILANDVSL (Thailand) Co. Ltd.BANGKOKPhone: +66 - 2 - 237 32 88 / 89 / 90Fax: +66 - 2 - 238 24 48

VIETNAMVSL Vietnam Ltd.HANOIPhone: +84 - 4 - 8245 488Fax: +84 - 4 - 8245 717

Ho Chi Minh CityPhone: +84 - 8 - 8106 817Fax: +84 - 8 - 9102 596

Australia

VSL Australia Pty. Ltd.NEW SOUTH WALESPhone: +61 2 9 484 59 44Fax: +61 2 9 875 38 94

QUEENSLANDPhone: +61 7 3265 64 00Fax: +61 7 3265 75 34

VICTORIA and SOUTHERNPhone: +61 3 979 503 66Fax: +61 3 979 505 47

Americas

ARGENTINAVSL Sistemas Especiales deConstrucción Argentina SABUENOS AIRESPhone: +54 - 11 - 4326 - 06 09Fax: +54 - 11 - 4326 - 26 50

CHILEVSL Sistemas Especiales deConstrucción S.A.SANTIAGOPhone: +56 - 2 - 233 10 81Fax: +56 - 2 - 233 67 39

COLOMBIASistemas Especiales de Construcción Ltda.BOGOTAPhone: +57-1-633 21 09Fax: +57-1-633 21 09

MEXICOVSL Corporation Mexico S.A de C.VMEXICOPhone: +52 - 5 - 396 86 21Fax: +52 - 5 - 396 84 88

UNITED STATESVStructural LLCBALTIMORE, MDPhone: +1 - 410 - 850 - 7000Fax: +1 - 410 - 850 - 4111

VENEZUELAGestión de Obras y Construcciones C.A.CARACASPhone: +58 - 212 941 86 75Fax: +58 - 212 941 86 75

Middle East

UNITED ARAB EMIRATESVSL Middle East LLCDUBAI, UAEPhone: +971 - 4 - 296 63 99Fax: +971 - 4 - 296 65 52

Africa

EGYPTMatrix Engineering CompanyCAIROPhone: +20 - 2 - 344 19 00Fax: +20 - 2 - 346 04 57

MOROCCORenfor-BatTANGIERPhone: +212 - 39 - 95 80 87Fax: +971 - 39 - 95 80 85

SOUTH AFRICATsala-RMS Construction Solutions (Pty) LtdJohannesburgPhone: +27 11 878 - 6820Fax: +27 11 878 - 6821

Europe

AUSTRIAGrund-Pfahl- und Sonderbau GmbHHIMBERGPhone: +43 - 2235 87 777Fax: +43 - 2235 86 561

BELGIUMN.V. Procedes VSL SABERCHEMPhone: +32 3 230 36 34Fax: +32 3 230 89 65

CZECH REPUBLICVSL Systemy (CZ), s. r. o.PRAGUEPhone: +420 - 2 - 67 07 24 20Fax: +420 - 2 - 67 07 24 06

FRANCEVSL France S.A.TOULOUSEPhone: +33 (0)5 61 00 96 25Fax: +33 (0)5 61 00 96 51

GERMANYVSL Systems GmbHBERLINPhone: +49 30 53 01 35 32Fax: +49 30 53 01 35 34

GREAT BRITAINVSL Systems (UK) Ltd.BEDFORDSHIREPhone: +44 (0) 1480 404 401Fax: +44 (0) 1480 404 402

NETHERLANDSVSL Benelux B.V.OEGSTGEESTPhone: +31 - 71 - 576 89 00Fax: +31 - 71 - 572 08 86

NORWAYVSL Norge A/SSTAVANGERPhone : +47 - 51 58 81 25Fax : +47 - 51 58 81 26

PORTUGALVSL Sistemas Portugal Pre-Esforço, Equipamento e Montagens S.A.S. DOMINGOS DE RANAPhone: +351 - 21 - 445 83 10Fax: +351 - 21 - 444 63 77

VSL GEOSistemas de Aplicação em Geotecnia SAS. DOMINGOS DE RANAPhone: + 351 - 21 - 445 83 10Fax: + 351 - 21 - 445 83 28

Asia

BRUNEI VSL Systems (B) Sdn. Bhd.BRUNEI DARUSSALAMPhone: +673 - 2 - 380 153 / 381 827Fax: +673 - 2 - 381 954

CHINA PRCVSL (China) Engineering Corp. Ltd. HEFEI Phone: +86 551 382 29 18 Fax: +86 551 382 28 78

HONG KONGFT Laboratories Ltd.KOWLOON BAYPhone: +852 - 2758 48 61Fax: +852 - 2758 89 62

INDIAVSL India PVT Ltd.CHENNAIPhone: +91 - 44 4225 11 11Fax: +91 - 44 4225 10 10

INDONESIAPT VSL IndonesiaJAKARTAPhone: +62 - 21 - 570 07 86Fax: +62 - 21 - 573 12 17

JAPANVSL Japan CorporationTOKYOPhone: +81 - 3 - 3346 - 8913Fax: +81 - 3 - 3345 - 9153

KOREAVSL Korea Co. Ltd.SEOULPhone: +82 - 2 - 553 8200Fax: +82 - 2 - 553 8255

MAINLAND CHINAVSL Engineering Corp., Ltd.HEFEIPhone: +86 551 3822918Fax: +86 551 3822878

MALAYSIAVSL Engineers (M) Sdn. Bhd.KUALA LUMPURPhone: +603 - 7981 47 42Fax: +603 - 7981 84 22

PHILIPPINESVSL Philippines Inc.PASIG CITYPhone: +632 672 17 03Fax: +632 672 13 95

SINGAPOREVSL Singapore Pte. Ltd.SINGAPOREPhone: +65 - 6559 12 22Fax: +65 - 6257 77 51

TAIWANVSL Taiwan Ltd.TAIPEIPhone: +886 - 2 - 2759 6819Fax: +886 - 2 - 2759 6821

SPAINCTT StrongholdBARCELONAPhone: +34 - 93 - 289 23 30Fax: +34 - 93 - 289 23 31

VSL-SPAM, S.A.BARCELONAPhone: +34 93 846 70 07Fax: +34 93 846 51 97

SWEDENInternordisk Spännarmering ABVÄSTERHANINGEPhone: +46 - 8 - 5007 3820Fax: +46 - 8 - 753 49 73

SWITZERLANDVSL (Switzerland) Ltd.SUBINGENPhone: +41 - 32 613 30 30Fax: +41 - 32 613 30 15

VSL (Suisse) SAVOUVRYPhone: +41 24 48157 71Fax: +41 24 48157 72

HEADQUARTERS

VSL International Ltd.

Scheibenstrasse 70 – Bern

CH-3014 – Switzerland

Phone: +41 32 613 30 30

Fax: +41 32 613 30 55 VSL LOCATIONS

VSLNews2-2006 29/11/06 17:47

5 0 Y E A R S O F PA R T N E R S H I PVSL operates through 35 subsidiaries as a world-wide network. The company has adapted post-tensioning principles

to civil structures such as LNG tanks, plants, tunnels, off-shore platforms, dams -and stay cables. In addition, the

group's scope of works covers rock and soil anchors, stabilized walls, precasting, formwork systems, launching

gantries, heavy lifting, bearings, repair works, monitoring, deep foundation and soil engineering activities. VSL offers

skilled and trained specialists; an experienced technical center able to benchmark new methods, new equipment and

new materials; specialist equipment designed as modular as possible; innovative contracting approach to focus with

the Main Contractor on what is “best for project”. www.vsl.com

VSLNews2-2006 29/11/06 18:00

VSL_News_2006_2

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