Bridge Beams. Product brochure

Size: px

Start display at page:

Download "Bridge Beams. Product brochure"

Logan Harvey
6 years ago
Views:

1 Bridge Beams Product brochure

2 Bridge Beams Stahlton offers economic bridge systems to suit a variety of spans, loadings and site conditions. Our Super Tee and Single or Double Hollowcore elements are manufactured to length in moulds, which give a smooth and light broom top finish, providing grip for vehicles, topping concrete or an asphalt layer if required. Pre-stressed concrete bridges are well proven to survive the test of time in the harshest of environments. The bridge deck units do not require temporary propping or works and once in place provide an immediate working platform. Our products are made of high strength concrete and has an accelerated curing time, meaning that the bridge can be used just a few days after it is manufactured. Durability Stahlton Super Tee and Single or Double Hollowcore bridge deck units meet exposure classifications A2, B1, & B2 as per table 3.7 of NZS3101:Part 1:2006 for a 100 year life. By specific design we can cater for harsh marine environments. Loadings Stahlton Super Tee and Single or Double Hollowcore bridge deck units are designed to meet the traffic loading criteria described in the New Zealand Transport Agency Bridge Manual (SP/M/022) third edition Our design applies HN-HO-72 & HN loadings in accordance with section 3 or we will apply appendix D for lightly trafficked rural bridges if your bridge is a one lane bridge that has: A traffic count less than 100 vehicles per day A road that cannot become a through route An alignment is such that speeds are generally below 70Km per hour The route is unlikely to be used by logging trucks and No significant overloads are expected to occur or the bridge can be bypassed. We do not expect there to be an asphalt layer applied in the 85% of HN rural bridge cases and we make allowance for the weight of a light handrail or barrier. For the HN-HO loaded bridges we allow a minimum of 1.75kPa for asphalt surfacing and services plus additional superimposed dead load if there is a levelling layer. Barrier loads are either TL-3, TL-4 or TL-5 traffic impact loadings. End seating, topping & connections NZTA Standard Pre-stressed Concrete Bridge Beam Drawings provide typical support and connection details for Stahlton Super Tee and Single or Double Hollowcore bridge deck units. Refer to NZS3109 Table 5.1 for manufacturing tolerances. Stahlton s Single or Double Hollowcore units do not normally need in-situ topping concrete when they have cast in ducts for post-tensioning the deck units together transversely that are later grouted on-site. Our design can incorporate an in-situ topping slab that eliminates post-tensioning. We can also cast in inserts for bolting a handrail or guard rail of your design. Stahlton s Super Tees require in-fills between the webs and cast in-situ reinforced concrete deck slab. Exposed steel hardware for these connections is generally hot dipped galvanised. In a marine environment the hardware is usually required to be stainless steel. Design scope An excellent resource is the NZTA Standard Precast Concrete Bridge Beams Drawings. The specifications are included in this document. At Stahlton, we pride ourselves on providing our customers quality, safety driven, products and services. All Fulton Hogan businesses are ISO9001 certified and our Stahlton Auckland and Christchurch plants have been certified by Precast New Zealand Incorporated. Page 3

Super Tee beams being placed Typical span arrangements Stahlton Super Tees with 180mm thick in-situ deck topping slab Unit Depth mm 5kPa Footbridge 2.4m unit 85% of HN HN-HO 2.4m unit 2.

0 Max span (m) Longer spans can be achieved by reducing the of the Super tee flanges. For example 2m wide spacing extends maximum span to 30m for a 1225mm deep Super tee with 180mm deck topping slab.

3 Super Tee beams being placed Typical span arrangements Stahlton Super Tees with 180mm thick in-situ deck topping slab Unit Depth mm 5kPa Footbridge 2.4m unit 85% of HN HN-HO 2.4m unit 2.4m unit Max span (m) Max span (m) Max span (m) Max span (m) Longer spans can be achieved by reducing the of the Super tee flanges. For example 2m wide spacing extends maximum span to 30m for a 1225mm deep Super tee with 180mm deck topping slab. Stahlton Single and Double Hollowcore with no topping slab Unit Depth mm 5kPa Footbridge 1.145m unit 85% of HN HN-HO 1.145m unit 1.145m unit Max span (m) Max span (m) Max span (m) Max span (m) Stahlton can make variations to the depth of the bridge beams shown above. Please contact Stahlton s Technical Department to discuss the most economical solution for your project. Camber Stahlton bridge deck units will arrive at site with some camber (hog). This is unavoidable due to the nature of pre-stressing. The amount of camber will depend on a number of factors, including amount of prestress, how long the units have been manufactured and exposed to the elements and length of the unit to name a few variables. In our design, we do consider long term shrinkage and creep effects. Handling & storage Stahlton bridge deck units are usually designed to be lifted at the ends using Reid Swiftlift type lifting anchors specifically designed and detailed on our shop drawings. If the units are stored on site, they will need to be dunnaged near the lifting eyes. If stacking the units, dunnage blocks need to be aligned on top of each other so as to not induce large point loads on the units below. Care needs to be taken as to the suitability of the ground and dunnage block to resist the weight of the units stored on top. Transport Stahlton Bridge Beams in excess of 18m will need a permit and at least one pilot to escort the specialised truck and extended trailer or truck and jinker unit to site on public roads. Contact us In addition to the standard bridge beam units in this brochure, Stahlton s experienced and qualified Engineers can also design bridge deck units to meet your specific needs. For example, varying depths of the Standard Stahlton Super Tee, Single or Double Hollowcore bridge beams, using other modified Stahlton standard flooring products, as well as prestressed concrete slabs fixed to steel beams. Contact us to discuss your project s specific needs. Page 4 Page 5 Northern Gateway Arterial - Super Tee bridge

Steel bridges Gallery Contact us In addition to the standard

prestressed concrete flatslabs with cast-in pockets for

Contact us to discuss your project s specific needs.

Double Hollowcore bridge beams - Clearwater Resort,

4 Steel bridges Gallery Contact us In addition to the standard bridge beam units in this brochure, Stahlton manufactures prestressed concrete flatslabs with cast-in pockets for connections to steel bridge girders to form a composite deck. Contact us to discuss your project s specific needs. Waikato River Bridge - Prestressed Flatslab on steel girders Double Hollowcore bridge beams - Clearwater Resort, Christchurch East Taupo Arterial Bridge - Steel bridge Sylvia Park, Auckland Page 6 Page 7

5 Gallery Dilworth Footbridge over State Highway 1, Auckland - Precast concrete deck cable stay Blenheim Road Overbridge, Christchurch Ormiston Road Bridge Page 8 Page 9

6 Specifications Drawing call-up To specify the Stahlton bridge beam on your drawings, we suggest you use the following designation: Stahlton depth bridge beam For example if the project is to be made from 650mm deep Stahlton Double Hollowcore, then the specification would read: Stahlton 650 Double Hollowcore bridge beam If Stahlton 1225mm deep Super Tee with 180mm in-situ deck slab is desired, then: Stahton 1225 Super Tee with 180mm in-situ deck topping Written specification clauses Stahlton Bridge beam products in general comply with the following standards: (i) NZS 3101:2006 Concrete Structures Standard Part 1 & 2 (ii) NZS 3109:1997 Concrete Construction (iii) AS/NZS 4671:2001 Steel Reinforcing Materials (iv) BS 5896:1980 Specification for High Tensile Steel Wire and Standard for the Prestressing of Concrete (v) NZTA Bridge Manual 3rd Edition (SP/M/022) Design (i) The design of Stahlton Bridge beams shall be in accordance with the requirements and recommendations of NZS 3101:2006 Concrete Structures Standard Part 1 & 2 and/or any recognised international Standard or part thereof, for example BS 8110:2007 The Structural Use of Concrete. (ii) The prestress strand pattern in the Stahlton bridge beams shall be designed to sustain the loadings shown on the Consulting Engineer s drawings and allowance will be made for self weight of the unit and topping concrete. (iii) The Stahlton bridge beams shall be designed for exposure classification A1/A2/B2/B2 as per table 3.7 in NZS 3101:2006 for 100 year design life. (iv) The Stahlton bridge beam unit shall have a FRR (Fire Resisting Rating) of 90/90/90. Penetrations through the flooring system shall be reinstated to the required FRR by an approved fire protection system. (v) Stahlton bridge beams shall be designed to have a maximum crack of 0.3mm under full live load conditions. (vi) The Stahlton bridge beam units shall have a minimum end seating detailed by the engineer plus tolerance. Refer NZS 3109 Table 5.1 or this document. Manufacture (i) Materials, execution of stressing prestress strand and workmanship of the Stahlton bridge beam units shall conform with Stahlton Engineered Concrete ISO 9001 Quality Assurance Operating procedures. (ii) Stahlton Hollowcore bridge beam units shall be nominally 1145mm wide and made in the nominal depths not limited to 460mm, 585mm, 650mm and 900mm. Stahlton Super Tee units shall be made between 1800 to 3000mm flange made in nominal depth of 775mm, 1025mm, 1225mm or 1525mm. Materials (i) Concrete shall be specifically mixed depending on environmental conditions and should have a 28 day cylinder strength of 50MPa as a minimum. (ii) Specified Concrete Compressive Strengths Precast beams at transfer - Pretensioning...30MPa Precast beams at 28 days...50mpa Insitu concrete (Deck slab, diaphragms) at 28 days...40mpa (iii) All concrete shall show signs of thorough compaction otherwise rejected if repair cannot be undertaken to bring the unit back to the original specification. (iv) An air entraining agent complying with BS EN may be included in the concrete mix to improve workability. (v) Reinforcement and Prestressing (i) Prestressing strand shall be clean and free from deleterious substances. Superficial rust is acceptable, however strand with corrosion that has caused surface pitting shall be rejected for the main longitudinal reinforcement of the unit. (ii) All reinforcement shall be Grade 500E to AS/NZS4671 (iii) All prestressing strand shall be 12.7mm, 12.9mm or 15.2mm diameter low relaxation stress relieved super grade 7 wire strand complying with AS/ NZS 4672 or BS 5896 (iv) Minimum breaking load of strand 184KN for 12.7mm and 12.9mm, and 250KN for 15.2mm (v) Force in strands immediately prior to transfer shall be accounted for in the jacking force required to achieve this value. Typically relaxation prior to transfer is in the order of 1% where curing at elevated temperatures is employed, high relaxation rates may result and due allowance for this shall be made by the precaster in determining the jacking force required to achieve the minimim force specified. (vi) Ends of strand shall be cut flush and protected with a minimum of 5mm epoxy mortar. (vii) Upward deflection of girders due to prestress is given a beam hog table. These are estimates only. Estimates are made for hog at transfer and minimum 60 days with due allowance for increase in hog due to creep of concrete under sustained load. (viii) Components prefixed RB are reidbar items. Reidbar or approved alternativeshall be Grade 500E to AS/NZ Cast iron components are not allowable. Concrete cover (Minimum) Cover to all prestressing components Cover to all reinforcement exposed surface Cover to all reinforcement internal surface Cover adjacent to cored holes Cover to bridge deck and all cast insitu concrete Cover to barrier fixing steel (within barrier) Design loading 40mm 40mm 30mm 30mm 50mm 50mm HN-HO-72 (Including SLS live load factor of 1.35 x Impact Factor) Tolerances Dimensions at time of erection: Actual overall length and squareness (i) The underside of the beam for the end 700mm shall be true plane (ii) The beam end surfaces shall lie within the Tolerance boxes (iii) Plane surface, deviation from a 1.5m straight edge (iv) Beam hoging (see specification) (v) Cross section dimensions up to 0.5m (vi) Cross section dimensions 0.5m to 2.0m (vii) Horizontal bow of longitudinal axis (viii) Longitudinal steel arrangement 5mm +-5mm +-10mm +-20mm +-10mm (ix) Location of an item in relation to any other item within its group or to the midpoint of the beam ends +-10mm (x) Pretensioning prestressing strands in any direction Handling +-5mm Extremes of vertical lifting points or ground support shown hatched. Central support position as shown is preferred (beam in upright position at all times). Surface finishes Top surface of flange In direct contact with insitu diapgragm Hidden formed surface All other formed surface Type B construction joint Type B constuction joint F1 F4 Page 10 Page 11

7 Stahlton Christchurch 133 Waterloo Road, Hornby Christchurch 8042 Ph: Fax: info@stahlton.co.nz Stahlton Technical department Ph: Stahlton Auckland 47 Airdrie Road, Ranui Auckland 0612 Ph: Fax: info@stahlton.co.nz

Shell Beams. Product brochure

Shell Beams. Product brochure Shell Beams Product brochure Shell Beams A simplified flooring solution If you are looking for a quick and efficient formwork system, the Stahlton Shell beam is the solution for you. Shell beams are commonly