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Dansk Brodag 2006 Fra Lillebælt til Messina Lars Hauge Director, COWI

Dansk Brodag 2006 Fra Lillebælt til Messina Lars Hauge Director, COWI. Storebælt, East Bridge. Stretto di Messina. Messina Strait Crossing Basic Considerations. Stretto di Messina S.p.A. was established in 1981

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Dansk Brodag 2006 Fra Lillebælt til Messina Lars Hauge Director, COWI

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  1. Dansk Brodag 2006Fra Lillebælt til MessinaLars HaugeDirector, COWI

  2. Storebælt, East Bridge

  3. Stretto di Messina

  4. Messina Strait CrossingBasic Considerations • Stretto di Messina S.p.A. was established in 1981 • The current financial arrangement based on no direct contribution from the Italian State was approved in 2004 • Shareholders : Fintecna 68,8%; Rfi 13 %; ANAS 13%; Calabria Region 2,6%; Sicily Region 2,6% • Tendered as Design-Built based on a reference design • Depreciation of at least 50% after 30 years of concession

  5. Organisation

  6. Messina Bridge Pre-bid Investigations Technical Studies (December 2003 – January 2004): • Global FE-model (IBDAS) • Articulation of the Bridge Structure • Optimisation of the Cables • Optimisation of the Towers • Optimisation of the Bridge Deck Review (April 2004): • Review of Tower Foundations • Review of Anchor Block Foundations

  7. Messina Bridge Bid Design to be carried out for: • Suspension bridge with 3,300 m main span • On land: 20 km roadway (13 km in tunnel) and 20 km railway (18 km in tunnel) • Toll station Contract Documents: • 24 Preliminary Design drawings (2004) • 250 informative drawings (1992) • 125 specifications, test reports etc. (2 m3) • Italian and Euro Codes

  8. Messina Bridge Tender Design of Suspension Bridge comprises: • Structural design of substructures incl. foundation models • Structural design of superstructures incl. global IBDAS model • Design of secondary structures and systems (wind screens, service lanes, access facilities, pavement, rails, expansion joints, bearings, buffers etc.) • Basic studies (design basis, seismic, aerodynamics, risk analyses, runability, safety and comfort analyses etc.) • O&M incl. LCC and RCM • Technological systems (management & control system, electrical and mechanical installations, structural monitoring system, anti-sabotage facilities etc.)

  9. Messina Bridge

  10. The crossing of the Strait of Messina Challenges: • The world’s largest suspended span of 3300 m • Road as well as rail traffic • Triple box concept for the deck • Seismic • Wind • Design life 200 years

  11. Messina Bridge Global IBDAS Model - Geometry Model

  12. Messina Bridge The Great Suspension Bridges • Messina • Akashi Kaikyo • Great Belt • Humber • Jiangyn

  13. Messina Bridge Suspension Bridges - Top 10: Span Year Location • Messina 3300 Italy • Akashi Kaikyo 1991 1998 Japan • Great Belt 1624 1998 Denmark • RunYang 1490 2005 China • Humber 1410 1981 UK • Jiangjin 1385 1999 China • Tsing Ma 1377 1999 Hong Kong • Verrazano Narrows 1298 1964 USA • Golden Gate 1280 1937 USA • Höga Kusten 1210 1997 Sweden

  14. Messina Bridge Triple Box Concept for the Suspended Deck: • Main elements: cross girders spacing 30 m • Secondary elements: two longitudinal roadway girders and one central railway girder spanning between the cross girders

  15. Messina BridgeMono-, twin- and triple deck concept

  16. Messina Bridge Triple Box Concept for the Suspended Deck

  17. Messina Bridge Suspended Deck: • Steel quantities - total 62,500 tons: - Cross girders: 22,000 tons - Roadway girders: 29,500 tons - Railway girders: 11,000 tons • Steel quality: S355 (32%) / S420 (14%) / S460 (54%) • Fatigue governing for design: for the roadway girder detailed analyses using a local IBDAS-model concluded that 16 mm deck plate and 7 mm trough stiffeners are required to obtain 200 years design life • Save weight: 1 ton less in deck  1 ton less in cables and related savings in towers and anchor blocks • Min. plate thickness roadway girder: bottom plate 8 mm and trough stiffeners 5 mm

  18. Messina Bridge Towers - Key Issues • Aesthetics • Severe impact from seismic loading • Aerodynamic behaviour • Vortex shedding • Optimise thickness/stiffeners • Tight construction schedule • Fabricate/Erection 100.000 ts. in 24 month

  19. Messina Bridge Towers: • Steel structures • 48,500 tons steel S460 per tower • Top level at +382.6 m • Leg dimensions 20 x 12 m • ULS seismic load combination governing for the tower legs • Plate thickness in tower legs 30-85 mm

  20. Messina Bridge Cables - Key Issues • Weight (166.000 ts) • Availability of cable steel (World production capacity 3-4years) • Stiffness (1:11) • Erection time, how to erect 166.000 ts in 12 m (14.000ts/m - Great Belt 4.000 ts/m) • Corrosion Protection 200 years service life (by dehumidification)

  21. Messina Bridge Main cables: • Sag to span ratio fixed to 1:11 • Twin cables spaced 1.75 m – i.e. total of 4 cables required • PPWS-method • One cable: 324 strands each consisting of 127 Ø5.33 mm wires - i.e. totally 41148 wires - outer diameter 1.20 m • 153,000 tons - fu = 1860 MPa • 77% of cable force comes from dead load • Wires can reach 22 times around the World

  22. Messina Bridge

  23. Messina Bridge Articulation - Key Issues The bridge is a flexible structure Deflection mid-span (SLS) (Vertical 4.3m/Horizontal 13m) • large movements (+/- 5.9m) • pronounced wear of e.g. expansion joints • repair and replacement • interruption of the traffic • discomfort for the bridge users

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

  25. Messina Bridge Buffer system: • Acts as a damper combined with a spring • Reduces the maximum movement of the deck in seismic load comb. • Blocks longitudinal movements for buffer force < 10 MN

  26. Messina Bridge Suspended deck free at towers: • Accumulated yearly expansion joint movements due to repeated longitudinal movements of the bridge girder for trains passing the bridge would be 65 km • Excessive wear of the expansion joints • Impossible to achieve a reasonable life time of the expansion joints • Discomfort for bridge users and unreasonable maintenance costs Deck free at towers

  27. Messina Bridge A bridge with buffer system: • The buffer force is limited to 3 MN during passage of a freight train • Longitudinal movements are limited to the movements from local deflection of the towers and the bridge deck. • The accumulated yearly expansion joint movements for train traffic is reduced to 1.6 km • A long life time of the mechanical components is secured and comprehensive reductions of maintenance costs are achieved. Buffer system at towers included

  28. Messina Bridge Wind Tunnel Test, Section Model

  29. Messina Bridge Foundation - Key Issues • Soil Improvement • Seismic • Construction Schedule • QuantitiesAnchor Blocks Sicilia: 315.000 m3 Calabria: 220.000 m3

  30. Brobyggerdagen 2006Messina Bridge

  31. Messina Bridge Anchor Blocks • Sicilia: 315,000 m3 concrete • Calabria: 220,000 m3 concrete

  32. Messina Strait Bridge

  33. Messina Strait BridgeShear stresses along the surfaces of the anchor block. 4 3 2 1

  34. Messina Strait Bridge

  35. Messina Strait Bridge

  36. Messina Strait Bridge

  37. Messina Bridge

  38. Messina Bridge

  39. MessinaKey Dates for Tender • 28 Oct 2004 Invitation to Tender for General Contractor (3 groups) • 18 Apr 2005 One month postponement of Tender Submission • 25 May 2005 Submission of Tender for General Contractor (2 groups) • 12 Oct 2005 Temporary award to ATI Impregilo (Opening of Financial Prop.) • 24 Nov 2005 Final award to ATI Impregilo • Dec 2005 Filing of Claims by the Astaldi group • Jan 2006 Filing of counterclaim by ATI Impregilo • 08 Feb 2006 Court Meeting no 1 : the tribunal requests 1 month postponement • 08 Mar 2006 Court ruling : PdM are allowed to continue with signature • 27 Mar 2006 Signing ceremony

  40. Messina BridgeThe Future Future Services: • Progetto Definitivo (180 days) • Approval Phase (max 540 days) • Progetto Esecutivo (120 days) • Construction (approx. 2007-2012)

  41. Messina BridgeStaffing

  42. Messina Bridge Dansk Brodag 2006Fra Lillebælt til Messina

  43. Messina Strait Bridge ATI Astaldi Strabag ATI IMPREGILO IMPREGILO Condotte d’Acqua CMC Sacyr Ishikawajima Harima Heavy Industries (IHI) Consorcio Stabile (COWI) (IN.CO) Astaldi Impresa Pizzarotti CCC Grandi Lavori Fincosit Vivanini Lavori Ghella Maire Engineering Nesco Entrecanales Cubiertas Ferrovial Agroman Nippon Steel (Chodai) Strabag Bouygues Dragados Consorzio Risalto Baldassini Tognozzi (Mott) (Cleveland Bridge)

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