BURIED FLEXIBLE STEEL STRUCTURES. SuperCor

Transcription

1 BURIED FLEXIBLE STEEL STRUCTURES SuperCor N E W G E N E R A T I O N B R I D G E S

2 Table of contents 1. Introduction 2. Application 3. Production 3.1. Production of corrugated plates 3.2. Corrosion protection 3.3. Bolts, nuts, anchor bolts, base channels 4. Design / construction 4.1. Scope of design 4.2. Design algorithm 4.3. Dimensioning 4.4. Selection of structure cross section 4.5. Cover depth 4.6. Geometry of a structure in longitudinal direction 4.7. Skew angles 4.8. Reinforcing ribs 4.9. Multiple installation Foundation Bedding and backfill End treatment (inlet/outlet) Concrete collar Fittings Durability 5. Installation and construction procedures 5.1. Delivery 5.2. Assembly 5.3. Torque of bolts 5.4. Assembly equipment 5.5. Assembly time 5.6. Deformation during backfilling 5.7. Shape control 6. Relining 7. Tolerances 8. Tests 9. Profiles 10. Case studies page 1 page 3 page 4 page 4 page 6 page 7 page 8 page 8 page 8 page 9 page 9 page 10 page 11 page 12 page 13 page 15 page 16 page 18 page 19 page 20 page 21 page 22 page 24 page 24 page 25 page 26 page 27 page 27 page 28 page 29 page 30 page 31 page 32 page 34 page 45-52

3 1. Introduction SuperCor structures are the new generation of flexible structures made of galvanized corrugated steel plates of a very high stiffness. To take the loads, those structures use interaction with surrounding backfill soil. The load capacity of SuperCor is far higher than traditional structures made of corrugated steel. SuperCor structures are used for building engineering objects above and under roads and railways. Spans can reach 25 m. Structures are simple and easy to assembly. Average assembly time takes a few days in assistance with small crew. The beginning of SuperCor use dates back to the middle of 80 in 20 th century. Nowadays they have been used in many countries all over the world, in Poland used since ViaCon group manufactures SuperCor in Scandinavia and Poland. ViaCon Polska has been producing SuperCor structures since 2008 in Rydzyna, Poland. 1.

4 1. Introduction Typical sequence for construction of SuperCor bridges: - foundations - delivery - assembly - backfilling - finishing works SuperCor structures have many advantages over traditional bridge solutions: - simple design due to fewer details, drawings and calculations database for standard application - easy and fast assembly - possibility to assemble in temperatures below zero - possibility to assemble structures without traffic stop - possibility to assemble of partial or total prefabrication of structures - due to lightweight, corrugated plates can be delivered easily and economically to remote locations - reduction in total time and cost of building a bridge 2.

5 2. Application SuperCor versatile structures are used for roads and railways and industrial applications: - bridges - overpasses - tunnels - culverts - underpasses - pedestrian tunnels - ecological crossings, hangars - shelters - underground storages - belt conveyor protection Furthermore, SuperCor structures can be used for reinforcement and reconstruction of existing structures (bridges, culverts, tunnels, underpasses). 3.

6 3. Production 3.1. Production of corrugated plates We manufacture SuperCor using TQM approach. Our production is certified in accordance to ISO 9001:2008 and ISO 14001:2004. The process of SuperCor production consists of mechanical forming of steel flat plates to the shape of corrugated curved plates which are later hot-dip galvanized. Producing of holes, cutting is done prior to galvanizing. Corrugated plates can be epoxy painted on request. Whole process is located indoor. 4.

7 3. Production Steel used for production of SuperCor conforms to EN or EN Steel grade: S315MC. Yield stress for this steel is min. 315 MPa. [mm] Fig. 1. Cross section of SuperCor plate [mm] Fig. 2. Geometry of a SuperCor plate (total length, i.e. multiple S=406,4 mm) Table 1. Section properties for Supercor plate. Plate thickness [mm] Area [mm 2 /mm] Moment of inertia [mm 4 /mm] Section modulus [mm 3 /mm] 5,5 7,0 6,968 8, , ,45 235,62 297,92 Other plate configurations are available upon request. Selection of plate thickness depends on structure shape, span, depth of cover and live load. Before you specify any of SuperCor structures, please take the opportunity to consult with ViaCon technical representative for advice and assistance on your project. 5.

8 3. Production 3.2. Corrosion protection Hot dip galvanizing is the most durable method of corrosion protection. Galvanized coating is metallurgically- bonded to the steel surface, providing extended service life. In order to extend the durability of SuperCor structures, especially in an aggressive environment, there is a possibility to apply an additional corrosion protection by applying epoxy paint. Corrosion protection of SuperCor structures is made in a production plant and consists of: - hot-dip galvanizing of steel plates and additional fitting elements - epoxy painting galvanized plates (if specified additionally) SuperCor structures are protected by hot galvanizing as a standard, with zinc coating layer according to EN ISO 1461 (table 2). Other thickness of zinc layer is possible on request. Please contact ViaCon representative for advice. Table 2. Zinc layer in acc. to EN ISO 1461 Characteristics Minimal local zinc coating thickness [μm] Requirements acc. to EN ISO 1461 Minimal average zinc coating thickness [μm] Steel plates: 6 mm thick 3 mm up to <6 mm 1,5 mm up to < 3 mm Bolts, nuts, anchor bolts Base channel The protection of structures both by hot-dip galvanizing and epoxy paint creates ViaCoat system conformed to EN ISO Paint coat thickness is controlled by EN ISO Minimum adhesion of the epoxy paint to the zinc base measured by pull - off method shouldn t be less than 4 MPa, and an adjacent test is conducted acc. to the norm PN-EN ISO In order to obtain right adhesion galvanized plates are sweep blast prior to application of paint. In order to obtain the proper protection effect, paint coatings are applied in special conditions i.e. inside of closed halls with controlled temperature, humidity. Keeping a technological regime is crucial for successful performance of the protection system..

9 3. Production 3.3. Bolts, nuts, anchor bolts, base channels SuperCor structures consist of corrugated plates and additional elements. Table 3 lists these elements. Table 3. Parameters of additional elements Type / dimensions Length [mm] Norm Bolts M20 class , 63, 70 EN ISO Nuts M20 - EN ISO Anchor bolts Ø 20 mm 225, 365 EN Base channel 157 x 190 x 38 x 5 mm 3035 EN Corrugated steel plates are joined by bolts M20 (class 8.8 ). The lengths of bolts are related to thickness of connected plates and type of connection. There are two types of bolt heads (Fig. 3): - oval - shaped - cone - shaped All joint elements mentioned above are delivered in marked boxes together with the structure. a) b) Fig. 3. The shape of bolt head: a) oval, b) cone Fig. 4. Connection of ribs to main barrel plates Anchor bolts for concrete collar [mm] [mm] [mm] a) b) Fig. 5. Anchor bolts used to mount structure in foundation (a) and anchor bolts for concrete collar (b) Fig. 6. Base channel used to connect structure to foundation 7.

10 4. Design / construction 4.1. Scope of design Design process includes the following: - design of SuperCor structure (including assembly and backfilling procedure) - design of engineered backfill - design of foundation - design of in and outlet fitting elements SuperCor structures are designed for all road and railway live load classes acc. to Eurocode 1 EN and for national standards as well as for (STANAG 2021) loads Design algorithm The following algorithm should be used when designing of SuperCor structures: - specify the function of a structure bridge (culvert, viaduct, ecological crossing, etc.) - choose the shape (for underpasses, ecological crossings, adjust to box clearance) - determine water flow and light (for culverts and bridges) - choose the type of foundation and specify material - specify the cover depth - determine type of dead and live load (for seismic areas specify seismic zone) - specify the engineered backfill material and its installation procedure - make static calculations as well as specify deformations during construction - select the corrosion protection depending on required durability - choose the assembly procedure (estimate the labor and the cost of assembly) - design of inlet and outlet - design skewed part of a structure 8.

11 4. Design / construction 4.3. Dimensioning SuperCor structures are dimensioned with use of Swedish design method developed by prof. Sundquist and prof. Pettersson. They can also be designed with the use of other methods, approved by producer of the structures, e.g. CHBDC. In complex cases finite element method (FEM) can be used. Contact us for help in static calculations of SuperCor structures Selection of structure cross section In order to select a typical shape of a structure please use tables provides on (pages 34-44). These tables include standard shapes. Other shapes are available on request. A profile of a structure should fit to a clearance box. Allow for tolerances of structure dimensions. Acceptable tolerances are given in chapter

12 4. Design / construction 4.5. Cover depth Definition of the cover depth for road structures: Vertical distance between top of a steel structure main barrel and top of the pavement including the pavement layer. Definition of the cover depth for railway structures: Vertical distance between top of a steel structure main barrel and bottom of railway sleeper. Box structures Depth of cover for box structure should be: 0,45 h c 1,5 [m] Minimum cover depth also depends on the thickness of the pavement layer (G n ) and should not be less than: h c = G n + 0,15 [m] Other shapes For arch, round, elliptical shapes estimated cover depth is calculated using the formula: h c = 0,1 B [m] where B span of the structure [m] Lover cover depth is permissible when appropriate static calculations are conducted. Maximum depth of a cover is always designed individually. For high cover depth load reduction techniques are available. Please contact us for advice. 10.

13 4. Design / construction 4.6. Geometry of a structure in longitudinal direction Bottom length of SuperCor structures should conform to the following formula: Ld=38+n [mm] where n number of full rings alongside length Top length of a structure is determined individually (in and outlets). Ends of SuperCor structures can be vertical or beveled to match the embankment slope (Fig. 7). For beveled ends minimum X-step is 0,18 m. For structures curved in plane use bends to align to designed curvature (Fig. 8) 1:n x x 1 1:n x 2 Fig. 7. End finishes Fig. 8. Supercor bend 11.

14 4. Design / construction 4.7. Skew angles Fig. 9. Skewed structure Minimum permissible angle for skewed ends is 55º. Concrete collars are used for large skews. Steel meshes attached to SuperCor structure can be also used for skewed areas. Please contact us for advice. 12.

15 4. Design / construction 4.8. Reinforcing ribs Reinforcing ribs should be used when flexural capacity of the section is exceeded. Ribs can be used for all shapes of structures. Reinforcing ribs: in cross section (Fig. 10) in haunch and crown on whole perimeter in longitudinal section (Fig. 11) - continuous placed on the whole top length of the structure - spaced at intervals of 762 mm, 1143 mm or 1524 mm In order to get a bigger capacity, space between main barrel and reinforcing ribs can be filled with concrete (EC ribs).the use of EC ribs can be necessary for large span structures. C25/30 concrete is used as filling acc. to EN 206-1:2000. Thanks to such a sulution used for arch structures, bigger cross sectional area is achieved, which leads to decrease of compression stresses in steel wall. For boxes, higher flexural capacity is reached by connecting ribs to the main barrel. Fig. 10. Placement of the ribs in cross section of the structure 13.

16 4. Design / construction Fig. 11. Placement of the ribs in longitudinal direction of the structure 14.

17 4. Design / construction 4.9. Multiple installation For multiple structure installations, the smallest clear spacing between adjacent structures should be sufficient for the placement and compaction of soil (Fig. 12). The minimum spacing requirement depends upon the shape and size of structures. When the required distance can not be achieved, space between structures should be filled with C10/15 concrete or cement stabilized soil to the level where the distance between structures is not less than 10% of structure span. Please contact us for advice. Fig. 12. Minimum clear spacing for multiple installations 15.

18 4. Design / construction Foundation SuperCor structures with closed shapes (round, elliptical, pipe-arch) are placed on soil bedding as follows: - thickness of soil bedding minimum 60 cm - top portion of the bedding should be shaped to fit to the bottom plates of a structure - particular care should be exercised in compacting soil under haunches - upper 15 cm layer of the bedding should be relatively loose material so that the corrugation can seat in it SuperCor structures with open shapes (arches, boxes) are placed on concrete footings, steel footer pads or a full steel invert. Connection of the structure to the concrete footings is realized by the means of anchor bolts, taking the following into account: - anchor bolts for concrete foundations to be installed in concrete footings prior to delivery of a SuperCor structure - anchor bolts should not stick out from the top of the footing more than 40 mm - placing of anchor bolts should conform to assembly drawing; the allowable tolerance is ±3 mm in longitudinal direction and ±2 mm in the transverse direction - to minimize a risk of mistake, the location of each anchor should always be measured from the starting point (first anchor) - parallel placement of anchor bolts on each footing and perpendicular placement of each pair of anchor bolts for individual rings are of great importance; better accuracy, easier assembly of the structure Fig. 13. Connection of SuperCor structure with concrete footing 16.

19 4. Design / construction SuperCor Wall Base channel Steel footing Fig. 14. Connection of SuperCor structure with steel footer pads of a full steel invert Steel footings must have appropriate erosion control measures. For design of steel footing (width, thickness, depth, erosion control etc.) please contact us for advice

20 4. Design / construction Bedding and backfill Material: - gravel, sand - gravel mix, all - in aggregates and crushed stone can be used as bedding and backfill material - aggregate grain size depends on size of corrugation profile; for 381x140 mm maximum size is 120 mm - aggregate grain size should be mm, ununiformity coefficient is C u >5,0, curvature coefficient 1<C c <3 and permeability k>6 m/24 hours - soil restrictions apply for area adjacent to a structure (please contact us for advice) - the use of cohesive soils, organic soils and soils included permafrost is not acceptable Placing: - backfill material around the structure should be placed in uncompacted layers maximum 300 mm thick and then compacted - the fill should be placed on both sides of the structure at the same time, or alternating from one side of the structure to the other side, to keep it close to the same elevation on both sides of the structure at all times. No more than one layer difference in elevation on each side should be allowed. Each layer must be compacted to the specified density before adding the next - backfill material should be compacted to minimum 95% standard Proctor density in the area of 20 cm next to the structure, 98% standard Proctor density in the remaining area In order to increase load bearing capacity/ soil stiffness of surrounding soil geosynthetic and galvanized steel which can be used. 18.

21 4. Design / construction End treatment (inlet/outlet) End treatment depends on the way the ends of structure are cut. For beveled ends, slopes can be finished by paving with stones blocks, etc. For bevel ends with gabion mattresses, waterproof solutions must be applied. Please contact us for advice. As an alternative to concrete headwalls MSE Walls (for instance ViaWall system) or gabions can be applied

22 4. Design / construction Concrete collar Concrete collar is used: - in order to stiffen inlet and outlet of SuperCor structure with beveled ends - as finishing element used as support of end treatment Concrete collar is applied mostly in following cases: - structures with skew angles to the road axis, when skew angle on outlet and inlet is 65 and span is > 3,5m - structures exceed 6,0 m span - large skews 200 Fig. 15. Example of a concrete collar on inlet and outlet of the structure Contact us for application of steel collars. Formwork for concrete collar 20.

23 4. Design / construction Fittings SuperCor structures can be equipped with additional elements depending on function of the structure e.g.: - lighting boxes - ventilation - shelves for animals - technical holes - others Please contact us for advice

24 4. Design / construction Durability Hot-dip galvanization is a basic anti-corrosion protection of SuperCor structures. Durability of SuperCor structures can extend over 100 years. SuperCor structures are hot-dip galvanized according to EN ISO If necessary, SuperCor structures can be provided with an extra layer of zinc or additional corrosion protection by epoxy coating called ViaCoat. These solutions are applied for aggressive environments. In most cases the extend of corrosion protection by epoxy coating is as follows: - inside and/or outside on the whole area of a structure - at inlet and outlet of the structure (1,5 m inside the structure) - inside up to 0,5 m above mean water level - as a combination of above mentioned Fig. 16. Epoxy coating protection Most common thickness of epoxy paint is 200 μm, however other thicknesses are possible. Please contact us of advice. Following factors have an influence on structure s durability: - aggressiveness of an environment - application of structure - draining solutions - abrasion - installation damages - corrosion protection - plate thickness - quality and frequency maintenance 22.

25 4. Design / construction Procedure of calculating durability of SuperCor structures: - define the function of a structure - define the required durability (lifetime) of a structure - define the aggressiveness of the environment (water, backfill, air) - select the type of a structure - specify the plate thickness based on static calculations (acc. to Sundquist-Petterson method) - specify the corrosion protection (thickness of zinc coating, paint coating, extend of painting, painting procedure) - define annual loss of the protection layers in upper and lower part of a structure - calculate the structure durability by considering corrosion progress over service lifetime - compare calculated durability with the required - adjust the anticorrosion solution and if required repeat the calculations In cases, when the durability of SuperCor structure is not enough, following measures can be taken : - change corrosion protection (thickness of zinc layer, paint coat) - increase the plate thickness - adjust the shape of a structure and section stiffness to allow for more corrosion reserve Durability of the ViaCoat system is higher than sum of durability of the protection layers and can be calculated as: SD=α * (SC+SZ) where: SD total durability of the protection layer [years] SC durability of zinc coat [years] SZ durability of the epoxy coat [years] α synergy factor (from 1,5 to 2,5) for 200 μm thick paint layer α = 1,5; for 400 μm thick paint layer α = 1,

26 5. Installation and construction procedures 5.1. Delivery SuperCor structures are delivered to the building site with following elements: - plates are shipped nested in bundles, complete with wall, bolts and nuts necessary for erection. Each bundle includes plates with the same type and radius. The weight of each package not exceed 3,5 tons - plates are color coded for easy identification, corresponding to the enclosed assembly drawing. - outer plates with cuts (inlet and outlet of the structure) are numbered. - bolts, nuts, anchor bolts, technical drawing, as well as assembly tools (crowbar, bolts feeder, gripper, punch) are delivered in one separate package - the cans of paint are also provided to repair damages - base channel for footing connection can be delivered earlier, when foundation is prepared, in separate package on request. - all elements delivered to the building site are listed on packing list. While unloading, each delivery should be checked in comparison with a packing list. The number of plates should be equal to the amount listed on assembly drawing. Other elements such as: bolts, nuts, anchor bolts, base channels and assembly tools are listed on the assembly list. Unloading can be realized with a crane or an excavator and with use of belts. It s not allowed to use equipment that can damage protective layers. Make sure to adjust the carrying capacity of equipment to weight of bundles. Small damage appeared during transport, loading and unloading could be repaired on the building site, after assembly. There is always repair paint kit delivered with the structure. 24.

27 5. Installation and construction procedures 5.2. Assembly Assembly of SuperCor is quick & easy. It is important to study carefully the assembly drawing and hints before installation. Assembly drawing presents the position of each plate in the structure area and describes the assembly rules. It is necessary to follow the assembly guide step by step. Detailed assembly instructions are delivered with each structure. For profiles with a closed shape, placed on soil foundation, the assembly process starts after preparing the bedding. For profiles with an open shape, placed on concrete foundation, the assembly process starts after making concrete foundation with fixed anchor bolts. Anchor bolts are used to connect base channels, which allows to mount the structure elements. When tightening the bolts during assembly allow for some loose on bolting connection. It will allow for better adjustment of plates. Fully torque will be applied after completion of assembly. The position of nuts (inside or outside) is not important from static point of view. In case when ribs are used, the bolts position should be as in the assembly drawing. Nuts, situated with no access to use wrench machine, should be fully torqued in the first stage

28 5. Installation and construction procedures 5.3. Torque of bolts For connection of corrugated plates in SuperCor structures bolts M20 with nuts are used. Bolts and nuts are color coded for ease in identification and delivered together with steel plates in separate packages. Final torque should be done after whole structure is assembled but before backfilling. Bolts should be tighten progressively and uniformly, starting from the center of the structure towards both ends. During backfilling checks of torque should be done as the actual bolt torque can decrease slightly due to deformation. The recommended torque is: Minimum of 300 Nm, maximum of 360 Nm for structures with spans up to 7,0 m Minimum of 360 Nm, maximum of 450 Nm for structures with spans more than 7,0 m Control of torque. 5% of the whole number of bolts should be checked for torque. Minimum 95% of checked bolts must have required torque and the torque of remaining 5% can not be less than 250 Nm. The measurements are realized with use of dynamometrical key, with a valid calibration certificate. 26.

29 5. Installation and construction procedures 5.4. Assembly equipment - hand wrenches - power wrenches - scaffoldings and ladders - feeders for bolts - belts and ropes - torque wrench - etc Assembly time In good weather conditions, experienced assembly crew (6-8 people) equipped with assembly tools is able to install about 50 corrugated plates per day (within 8 hours) In order to estimate assembly the following data is required: - structure destination - building site conditions - available assembly tools - shape and size of structure - range of ribs - etc. Please contact us for advice

30 5. Installation and construction procedures 5.6. Deformation during backfilling During backfilling SuperCor structure will deform developing soil - structure interaction. The Supercor structure with surrounding soil, constitute soil - steel composite structure with soil being a major load carrying component. Deformations of the structure should be controlled. Please contact us for estimation of deformation of SuperCor structure during backfilling. w - vertical deflection z - cover depth Fig. 17. Example of structure deformation during backfilling (Machelski 2008) 28.

31 5. Installation and construction procedures 5.7. Shape control Structure must be checked periodically during the backfilling procedure to ensure the shape is consistent with the producer s recommendation. Once one full ring of structure is assembled, preliminary shape control should be performed. Shape checks should be carried out both during and after assembly. It is recommended that the producer s representative be present during erection and backfilling of the structure. Control of compaction during construction is the responsibility of the contractor. Please contact us for advise in shape control

32 6. Relining SuperCor structures are also commonly used to repair old bridges where there are no possibilities to build a new one. This method is called relining. Corrugated steel structure is placed inside the existing structure (bridge / culvert / underpass) and space between an old bridge / culvert and new structural plate is filled with concrete C12.5/15. This method allows to strengthen the structures without any traffic stops and eliminates the necessity of remaining the old structure. The control of pouring concrete between existing structure and new steel structure should be done by revision holes. During pouring concrete it is necessary to control deformations of SuperCor. They shouldn t exceed maximum allowed in section No. 7 Tolerances. In a case where so called open shapes will be used for relining there is a need to make concrete footings which could be connected to existing one. Existing footings can be used also but it will require separate analysis or expertise. 30.

33 7. Tolerances Plate dimensions tolerances: - length and width of the plate ±7mm - length and height of the corrugation ±5mm - distance between the holes ±3mm - plate thickness acc. to EN A1 - radius of curvature ±10mm Tolerances of structure geometry (all profiles excl. Boxes): Structure dimensions after torque shouldn t be different than designed with following tolerances: - span +2% - rise ±2% - length ±0.5% Deformation of cross section after backfilling shouldn t exceed 2% of the span measured after assembly. Tolerances of Box structure geometry: Structure dimensions after torque shouldn t be different than designed with following tolerances: - span +2% - rise +2% / -4% - length ±0.5% Deformation of cross section after backfilling shouldn t exceed 1% of the span measured after assembly. Based on experience those deflections are much smaller

34 8. Tests In order to continuously improve design method we cooperate with science centers and research institutes in Europe. Effect of this collaboration is number of research programs including SuperCor structures. SuperCor tests done in Poland: - Nowa Ruda SCA-13, SCA-19 Special, SC-48B and SC-23B. Deformations of steel structure were measured during backfilling (long term test)and under live load (Class A (4x200 kn/axle) acc. to PN-85/S Polanica Zdrój-Szczytna SC-48B and SC-56B. Strain and deflections measurements. Live load test (Class A (4x200 kn/axle) acc. to PN-85/S Pieńsk SC-33B (bridge under railway). Live load test. Strain and deflections measurements Class k+2 acc. to PN-85/S Rydzyna SC-57S. Strain and deflections measurements. Dead load test. - A4 Motoway SCA-33. Strain and deflections measurements. Dead load test. 32.

35 SuperCor abroad tests (selected): - Giman (Sweden) SC-56B. Strain and deflections measurements. - Jarpas (Sweden) SC-35B and SC-60B - Male Zernoseky (Czech Republic) SC-19B - Alberta Stone Mine White Horse Creek (Canada) SC-92SA - Tests of composite effect (barrel+rib) (Canada) Tests mentioned above were done to: - scale and verify the calculation methods - optimize design process - confirm safety of solution especially large span structures 33.

36 9. Profiles SC-R SC-B SC-SA SC-NA SC-OA SC-HA 34.

37 9. Profiles SC-R Type B [mm] H [mm] A [m 2 ] Rc [mm] Total S* SC-66R , SC-68R , SC-70R , SC-72R , SC-74R , SC-76R , SC-78R , SC-80R , SC-82R , SC-84R , SC-86R , SC-88R , SC-90R , SC-94R , SC-98R , SC-102R , SC-106R , SC-110R , SC-114R , SC-118R , SC-122R ,

38 9. Profiles SC-B Type B [mm] H [mm] A [m 2 ] Rt [mm] α [º] Rs [mm] β [º] L [mm] δ [º] Total S* SC-1B , , , ,00 11 SC-2B , , , ,00 13 SC-3B , , , ,31 14 SC-4B , , , ,98 17 SC-5B , , , ,37 13 SC-6B , , , ,68 16 SC-7B , , , ,05 14 SC-8B , , , ,05 18 SC-9B , , , ,74 15 SC-10B , , , ,06 17 SC-11B , , , ,05 20 SC-12B , , , ,42 21 SC-13B , , , ,76 18 SC-14B , , , ,43 20 SC-15B , , , ,53 17 SC-16B , , , ,44 22 SC-17B , , , ,22 18 SC-18B , , , ,80 24 SC-19B , , , ,49 19 SC-20B , , , ,50 21 SC-21B , , , ,50 25 SC-22B , , , ,60 20 SC-23B , , , ,19 22 SC-24B , , , ,20 24 SC-25B , , , ,29 21 SC-26B , , , ,98 22 SC-27B , , , ,97 24 SC-28B , , , ,26 26 SC-29B , , , ,67 23 SC-30B , , , ,67 25 SC-31B , , , ,66 27 SC-32B , , , ,67 29 SC-33B , , , ,38 22 SC-34B , , , ,08 24 SC-35B , , , ,07 26 SC-36B , , , ,09 26 SC-37B , , , ,10 28 SC-38B , , , ,

39 9. Profiles SC-B Type B [mm] H [mm] A [m 2 ] Rt [mm] α [º] Rs [mm] β [º] L [mm] δ [º] Total S* SC-39B , , , ,94 27 SC-40B , , , ,94 29 SC-41B , , , ,95 31 SC-42B , , , ,91 29 SC-43B , , , ,92 31 SC-44B , , , ,92 33 SC-45B , , , ,89 31 SC-46B , , , ,89 33 SC-47B , , , ,89 35 SC-48B , , , ,33 32 SC-49B , , , ,32 34 SC-50B , , , ,32 36 SC-51B , , , ,71 34 SC-52B , , , ,71 36 SC-53B , , , ,60 38 SC-54B , , , ,68 36 SC-55B , , , ,69 38 SC-56B , , , ,68 40 SC-57B , , , ,61 39 SC-58B , , , ,61 41 SC-59B , , , ,28 42 SC-60B , , , ,26 44 SC-61B , , , ,24 44 SC-62B , , , ,25 46 SC-63B , , , ,19 48 SC-64B , , , ,

40 9. Profiles SC-SA Type B [mm] H [mm] A [m 2 ] Rc [mm] α [º] Total S* SC-27SA , SC-28SA , SC-29SA , SC-30SA , SC-31SA , SC-32SA , SC-33SA , SC-34SA , SC-35SA , SC-36SA , SC-37SA , SC-38SA , SC-39SA , SC-40SA , SC-41SA , SC-42SA , SC-43SA , SC-44SA , SC-45SA , SC-46SA , SC-47SA , SC-48SA , SC-49SA , SC-50SA , SC-51SA , SC-52SA , SC-53SA , SC-54SA , SC-55SA , SC-56SA , SC-57SA , SC-58SA , SC-59SA , SC-60SA , SC-61SA , SC-62SA , SC-63SA , SC-64SA ,

41 9. Profiles SC-SA Type B [mm] H [mm] A [m 2 ] Rc [mm] α [º] Total S* SC-65SA , SC-66SA , SC-67SA , SC-68SA , SC-69SA , SC-70SA , SC-71SA , SC-72SA , SC-73SA , SC-74SA , SC-75SA , SC-76SA , SC-77SA , SC-78SA , SC-79SA , SC-80SA , SC-81SA , SC-82SA , SC-83SA , SC-84SA , SC-85SA , SC-86SA , SC-87SA , SC-88SA , SC-89SA , SC-90SA , SC-91SA , SC-92SA , SC-93SA , SC-94SA , SC-95SA , SC-96SA ,

42 9. Profiles SC-NA Type B max [mm] B [mm] H [mm] A [m 2 ] Rt [mm] α [º] Rs [mm] β [º] δ [º] Total S* SC-1NA , , ,29 2,32 30,0 SC-2NA , , ,57 4,04 33,0 SC-3NA , , ,81 6,53 35,0 SC-4NA , , ,68 5,66 36,0 SC-5NA , , ,66 15,64 39,0 SC-6NA , , ,49 4,75 37,0 SC-7NA , , ,54 7,11 39,0 SC-8NA , , ,52 17,09 42,0 SC-9NA , , ,15 6,06 40,0 SC-10NA , , ,71 5,00 41,0 SC-11NA , , ,19 12,78 47,0 SC-12NA , , ,44 7,15 43,0 SC-13NA , , ,71 5,90 44,0 SC-14NA , , ,68 13,79 50,0 SC-15NA , , ,80 4,52 45,0 SC-16NA , , ,03 6,35 47,0 SC-17NA , , ,37 8,79 54,0 SC-18NA , , ,03 8,03 49,0 SC-19NA , , ,42 6,19 50,0 SC-20NA , , ,17 11,56 58,0 SC-21NA , , ,84 7,50 52,0 SC-22NA , , ,65 7,45 52,0 SC-23NA , , ,28 8,88 59,0 SC-24NA , , ,18 9,51 54,0 SC-25NA , , ,33 8,20 55,0 SC-26NA , , ,38 7,57 61,0 SC-27NA , , ,38 6,82 56,0 SC-28NA , , ,65 8,69 58,0 SC-29NA , , ,46 8,30 64,0 SC-30NA , , ,48 7,14 59,0 SC-31NA , , ,51 8,83 61,0 SC-32NA , , ,07 6,68 66,0 SC-33NA , , ,07 7,08 62,0 SC-34NA , , ,83 8,57 64,0 SC-35NA , , ,47 7,00 69,0 SC-36NA , , ,06 6,57 65,0 SC-37NA , , ,44 7,77 67,0 SC-38NA , , ,56 7,43 75,0 40.

43 9. Profiles SC-NA Type B max [mm] B [mm] H [mm] A [m 2 ] Rt [mm] α [º] Rs [mm] β [º] δ [º] Total S* SC-39NA , , ,59 8,79 69,0 SC-40NA , , ,36 8,60 68,0 SC-41NA , , ,23 7,68 77,0 SC-42NA , , ,23 10,53 70,0 SC-43NA , , ,58 8,76 74,0 SC-44NA , , ,55 8,94 82,0 SC-45NA , , ,47 7,79 75,0 SC-46NA , , ,80 9,27 77,0 SC-47NA , , ,80 7,80 84,0 SC-48NA , , ,46 8,09 78,0 SC-49NA , , ,06 6,88 79,0 SC-50NA , , ,57 8,22 87,0 SC-51NA , , ,17 8,19 81,

44 9. Profiles SC-OA Type B max [mm] B [mm] H [mm] A [m 2 ] Rt [mm] α [º] Rs [mm] β [º] δ [º] Total S* SC-1OA , , ,76 2,64 36 SC-2OA , , ,74 13,47 40 SC-3OA , , ,76 3,85 37 SC-4OA , , ,41 12,01 40 SC-5OA , , ,99 3,71 38 SC-6OA , , ,60 12,81 42 SC-7OA , , ,40 5,66 40 SC-8OA , , ,74 18,23 44 SC-9OA , , ,76 2,67 39 SC-10OA , , ,20 9,12 42 SC-11OA , , ,67 15,26 45 SC-12OA , , ,99 2,48 40 SC-13OA , , ,08 11,40 43 SC-14OA , , ,40 16,99 46 SC-15OA , , ,76 6,63 42 SC-16OA , , ,08 12,17 44 SC-17OA , , ,91 17,71 48 SC-18OA , , ,20 6,96 43 SC-19OA , , ,41 15,23 46 SC-20OA , , ,68 19,64 49 SC-21OA , , ,40 6,39 44 SC-22OA , , ,41 16,10 47 SC-23OA , , ,80 18,55 50 SC-24OA , , ,08 11,43 46 SC-25OA , , ,41 15,66 48 SC-26OA , , ,72 13,46 51 SC-27OA , , ,50 10,49 47 SC-28OA , , ,62 19,14 50 SC-29OA , , ,23 15,28 53 SC-30OA , , ,41 14,55 49 SC-31OA , , ,68 16,40 51 SC-32OA , , ,44 17,42 54 SC-33OA , , ,80 11,38 50 SC-34OA , , ,80 15,86 52 SC-35OA , , ,97 19,09 56 SC-36OA , , ,30 10,60 51 SC-37OA , , ,85 14,69 53 SC-38OA , , ,30 16,

45 9. Profiles SC-OA Type B max [mm] B [mm] H [mm] A [m 2 ] Rt [mm] α [º] Rs [mm] β [º] δ [º] Total S* SC-39OA , , ,68 16,15 53 SC-40OA , , ,82 13,95 54 SC-41OA , , ,66 19,02 58 SC-42OA , , ,62 19,94 54 SC-43OA , , ,45 11,12 55 SC-44OA , , ,74 14,01 59 SC-45OA , , ,80 16,21 55 SC-46OA , , ,82 17,00 57 SC-47OA , , ,74 15,80 61 SC-48OA , , ,99 16,17 56 SC-49OA , , ,11 16,50 58 SC-50OA , , ,91 14,55 62 SC-51OA , , ,40 13,68 57 SC-52OA , , ,45 14,51 59 SC-53OA , , ,24 16,64 63 SC-54OA , , ,66 15,85 58 SC-55OA , , ,95 12,67 60 SC-56OA , , ,24 18,96 65 SC-57OA , , ,86 10,67 59 SC-58OA , , ,55 12,15 61 SC-59OA , , ,78 18,

46 9. Profiles SC-HA Type B max [mm] B [mm] H [mm] A [m 2 ] Rt [mm] α [º] Rs [mm] β [º] Rc [mm] γ [º] δ [º] Total S* SC-1HA , , , ,56 9,57 40,0 SC-2HA , , , ,14 10,14 43,0 SC-3HA , , , ,89 10,89 47,0 SC-4HA , , , ,34 11,34 50,0 SC-5HA , , , ,58 10,58 53,0 SC-6HA , , , ,92 10,92 57,0 SC-7HA , , , ,57 10,57 60,0 SC-8HA , , , ,39 10,40 66,0 SC-9HA , , , ,10 11,10 70,0 SC-10HA , , , ,40 12,41 75,0 SC-11HA , , , ,81 11,81 78,0 SC-12HA , , , ,48 12,49 83,0 SC-13HA , , , ,48 12,49 87,0 SC-14HA , , , ,24 10,25 92,0 SC-15HA , , , ,47 10,48 96,0 SC-16HA , , , ,37 10,38 100,0 SC-17HA , , , ,43 10,44 104,0 44.

47 10. Case studies Location: Railway line E20 near Rzepin town (West border of Poland) In 2007 r. over international double truck electrified railway line E20 Section Rzepin - Polish German border two animal overpasses were built. Two SuperCor SCA-35 low profile Arch s set on the concrete foundations were used in two different locations. Basic parameters are following: - span 20,00 m - rise 5,97 m - bottom length 57,988 m - corrugation 381 x 140 mm SuperCor SCA-35 structures were corrosion protected by zinc coat acc. to EN ISO 1461:2000 Assembly was realized parallel by two independent crew and took 19 days only. Structures were assembled using plate by plate method and partially preassembled using one crane/structure and two basket elevators/structure. Arches were backfilled with sand-gravel mix (0-32mm) and compacted to min 98% Acc. to standard Proctor density. Height of cover is 1.5 m. Over each structure geosynthetic (NV geotextile + geomembrane +NV geotextile ambrella were used to protect against rain water leak. On the top of the overpasses antidazzle fences were built with height 2.5 m

48 10. Case studies Location : Highway A2, section Konin Koło In 2006 over highway A2 section Konin Koło two animal overpasses were built. Both overpasses are consist of two corrugated steel arch structures SuperCor SC 57S with span 17,7 m and two MultiPlates structures MP200 G30 with PipeArch profile. There are the biggest structures of these types in Europe. The structures were galvanized acc. to EN ISO 1461:2000 and additionally epoxy painted 200 µm acc. to EN ISO Each Supercor SC-57S structure has the following parameters: - rise 5,461 m - span 17,667 m - bottom length 60 m - corrugation 381 x 140 mm Each MultiPlate G-30 structure has the following parameters: - rise 8,12 m - span 9,36 m - bottom length 76 m - corrugation 200 x 55 mm The structure was designed to carry a live load class E acc. to PN 85/S Assembly of these 4 structures lasted 2 months. Structure was assembled acc. to plate by plate method with the use of two cranes situated on either side of the structure and movable scaffold. 46.

49 10. Case studies Location: Wągrowiec By Pass In 2002 at the crossing of a new by pass of Wągrowiec and existing railway line SuperCor SC 50B box structure was designed. The structure has the following parameters: - rise 3,165 m - span 10,990 m - bottom length 40,386 m - corrugation 381 x 140 mm The structure was designed to carry a live load class A acc. to PN 85/S The structures were galvanized in acc. to EN ISO 1461:2000 In order to ensure the required railway clearance the steel structure was founded on concrete footings 5 m high. The full rings of the structure were first prefabricated and next the rings were installed on the concrete footings. The assembly of the whole structure lasted 2 weeks. At the ends of the structure delicate concrete collars were constructed. The slopes were paved by means of concrete blocks

50 10. Case studies Location: Baczyn close to Sucha Beskidzka In 2001 in Baczyn close to Sucha Beskidzka a bridge was destroyed by the flood. Old bridge was replaced with new corrugated steel structure SuperCor SC-20B. The structure has the following parameters: - rise 1,9 m - span 6,165 m - bottom length 12,192 m - corrugation 381 x 140 mm The structures was galvanized in acc. to EN ISO 1461:2000. The structure were installed on the concrete footings. The assembly of the whole structure lasted 6 days. The cost of steel structure was much less than traditional bridge construction. 48.

51 10. Case studies Location: National Road No. 5 Poznań Wrocław, section Komorniki Głuchowo, Trzebaw In 2003 over National Road No. 5 Poznań Wrocław between Komorniki and Głuchowo in Trzebaw building of animal overpass was started with the use of corrugated steel arch structure SuperCor SC 57S. The steel structure has the following parameters: - rise 5,461 m - span 17,667 m - bottom length 55,626 m - corrugation 381 x 140 mm The structures was galvanized in acc. to EN ISO 1461:2000. The structure was designed to carry a class E live load acc. to PN 85/S Assembling of the structure lasted 11 days and was conducted without stopping the traffic. Structure was assembled acc. to plate by plate method with the use of two cranes situated on either side of the structure and movable scaffold. Steel structure was backfilled with the use of sand gravel mix compacted to Standard Proctor density of minimum 97%. The depth of cover over the steel structure is 1,80 m. Costs of the structure is 70% of costs of the structure built in traditional technology

52 10. Case studies Location: Gniezno bypass Three span bridge was built with use of steel box structures SuperCor in Gniezno in Each of the steel box structure SC-59B has the following parameters: - rise 3,07 m - span 14,075 m - bottom length 23,56 m - corrugation 381 x 140 mm The structure were installed on the pile foundation. SuperCor SC- 59B structures are hot dip galvanized acc. to EN ISO 1461:2000 with zinc layer 85 m and additionally epoxy painted 200 μm acc. to EN ISO The structure were reinforced by steel ribs situated on the whole area. The assembly lasted 3 weeks in assistance with 8 people crew. 50.

53 10. Case studies Location: A4 Motorway section B Wykroty Krzyżowa In 2008 over A4 Motorway on Zgorzelec Krzyżowa section construction of two animal overpasses has started. Each of the overpass consists of two SuperCor SCA-33 arch structures placed on concrete footings. Steel structures have following parameters: - span 19,50 m - rise 5,97 m - bottom length 67,89 m - corrugation profile 380 x 140 mm 51.

54 10. Case studies SCA-33 structures are reinforced by means of additional steel plates. In order to decrease the load on middle footing, helically corrugated steel pipe HelCor Ø2400 mm was used. SuperCor SCA-33 structures are hot dip galvanized acc. to EN ISO 1461 and additionally epoxy painted 200 μm acc. to EN ISO HelCor pipes are hot dip galvanized with zinc coating thickness of 42 μm and have polymer Trenchcoat coating 250 μm thick. Assembly of all 4 structures for two passings lasted 12 weeks. Wooden fences on top of the passings are installed to separate the animal passage from view of moving vehicles. 52.

55 ViaCon Sp. z o.o. ViaCon Sp. z o.o. is a member of ViaCon Group established in Sweden and Norway in At present ViaCon Group operates in a dozen or so European countries and belongs to SAFEROAD Group. Thanks to the support from the entire group and the possibility of using the shared experience, each member company can offer professional technical consulting and top quality products. Business profile of the company: manufacture, design, sale and installation of plastic and steel pipes and flexible structures used for construction and repair of culverts, bridges, overpasses, tunnels, farm accommodation underpasses, wildlife crossings, other engineering structures, and used also as belt conveyor housings, manufacture, design and sale of storm water drainage systems and holding tanks, design, sale and installation of geosynthetics, such as non-woven geotextile fabrics, woven geotextile fabrics, geogrids, geomembranes, and bentonite mats, sale and lease of temporary bridges, sale of gabions, design, manufacture and sale of three retaining structure systems from reinforced soil.

56 MP200 pl ok_folder-srodek2.qxd :00 Strona 13 PECOR OPTIMA HelCor HelCor PA MultiPlate MP200 SuperCor Acrow 700XS - temporary bridges Woven and non-woven geotextiles Geogrids Gabions HelCor TC holding tanks HelCor wells PECOR OPTIMA M wells ViaWall A retaining walls ViaWall B retaining walls Pecor Quattro sewage system ViaBlock retaining walls Our goal is to improve products and to cooperate closely with customers, scientific and research centres, public administration and suppliers. ViaCon Sp. z o.o. ul. Przemysłowa Rydzyna, Poland phone: fax: office@viacon.pl That s why our motto is: Let s Create a Better Future Together