Design (Bridge Construction Machines)

Dr. Rosignoli has designed special construction equipment for bridge projects in 13 countries on four continents. The equipment includes 2 heavy lifters for 860t dual-track high-speed railway spans, 2 modular underslung Movable Scaffolding Systems (MSS) for high-speed railway bridges, 7 falsework assemblies for prestressed concrete (PC) overpasses, the launch systems of 23 incrementally launched bridges, a pair of form travelers designed for fast splitting at the pier-table, modular lifting forms for in-place casting of haunched-slab overpasses, the self-centering paved platform of a 7-lane jacked tunnel, self-propelled hydraulic supports for the soffit slab of a cut-and-cover tunnel, strand-jacking systems for closure spans and precast footing shells, and a cable-stayed system to control the time-dependent stress redistribution of staged construction in continuous high-speed railway spans.

Maltauro-Delma JV (2005). São Vicente Bridge over the Cacheu River, Guinea Bissau. This project includes a 730m PC bridge built by balanced cantilever construction on 85m spans. As contractor’s consultant, Dr. Rosignoli analyzed the construction means & methods and designed a strand-jacking platform for lowering of floating precast footing shells onto pre-drilled foundation shafts.
Santos CMI (2005). Rio Ambato Cable-Stayed Bridge, Ambato, Ecuador. For this small PC cable-stayed bridge, Dr. Rosignoli analyzed the construction means & methods and designed for the contractor a pair of overhead cable-stayed form travelers for fast splitting at the pylon-table.
Eiffage-Pizzarotti JV (2005). Direttrice Cremona-Mantova Regional Highway, Parma, Italy. In this assignment, Dr. Rosignoli designed for the contractor a set of modular lifting forms for in-place casting of 51 haunched-slab overpasses.
Adige Bitumi-Maltauro JV (2003). Connection of the Industrial Area of Lavis with Highway A22 and the Custom Interport of Trento, Trento, Italy. The pre-award design of this project included a 205m, 27m-wide cable-stayed span to be launched over Highway A22. As contractor’s consultant, Dr. Rosignoli’s duties included analysis of construction means & methods and the design of erection platform (the cable-stayed span was assembled on 18m-tall temporary piers) and the span launch systems (launch nose, reaction beams, rear thrust cylinders, and geometry and foundations of the erection platform).
Sembenelli Consulting (2002). Reggiolo Interchange, Reggio Emilia, Italy. A skewed 26m multi-cellular PC span with width ranging from 17 to 24m was designed for casting behind the abutment and launching over an electrified railroad. As designer’s subconsultant, Dr. Rosignoli analyzed the construction means & methods, designed the span launch systems (braced PC launch noses, temporary pier, casting cell, reaction beams, rear thrust cylinders, and geometry and foundations of the casting yard) and provided on-site assistance during the launch of the span.
Pizzarotti (2002). Duplication of the Milano-Brescia Highway, Bergamo, Italy. The pre-award design of the 2120m Adda River Bridge, the 1200m Serio River Bridge, and the 870m Oglio River Bridge provided for incremental launching construction on 46m spans. As contractor’s consultant, Dr. Rosignoli analyzed the construction means & methods and designed the deck launch systems (launch nose, self-reacting casting cell for transverse pre-tensioning of the 40m-wide steel-composite top slab, temporary piers, re-deployable friction launchers with hydraulic clamps, and geometry and foundations of the casting yard).
Comtec-DEAL JV (2001-2002). Taiwan High Speed Rail Project, Contract C-215, Taiwan. The Obayashi-Futsu JV required two hydraulic gantry cranes to handle 860t dual-track bridge spans. As equipment manufacturer’s consultant, Dr. Rosignoli designed the gantry cranes according to FEM Norms and Taiwan HSRP seismic criteria for construction equipment.
Pizzarotti (2001). Modena Bridges, TAV High Speed Railway, Modena, Italy. This project includes five 3-span single-track PC bridges. As contractor’s consultant, Dr. Rosignoli designed temporary cable-stayed pre-flexure systems that avoided time-dependent stress redistribution of staged construction within the bridges.
DEAL (2000). Megalorema Bridge, Ioannina, Greece. This project includes two adjacent PC bridges with 43m spans to be incrementally launched on steep uphill gradient. As equipment manufacturer’s consultant, Dr. Rosignoli analyzed the construction means & methods and designed the deck launch systems (launch nose, casting cell for two-phase casting, synchronized friction launchers on abutment and cable-stayed pier, and geometry and foundations of the casting yard).
Siforms (2000). Taiwan High Speed Railway, Lot 230, Taiwan. Span-by-span casting of 9.3km of dual-track PC bridges required the design and fabrication of four custom MSS’s for 40m spans. As equipment manufacturer’s consultant, Dr. Rosignoli designed a modular system of 690t covered underslung MSS’s with short main girders and self-repositioning pier brackets compatible with cage prefabrication behind the abutment and weekly cycles.
Codelfa (1999-2000). Tiziano Bridge, Alessandria, Italy. The final design of a 17m-wide, 200m PC bridge provided for incremental launching construction of a first 8m-wide box girder, 9m side shifting of this first deck half, incremental launching of the second half of the deck, and connection of the two box girders with a cast-in-place central curb. Four temporary piers halved the launch spans to save post-tensioning. As contractor’s consultant, Dr. Rosignoli’s designed the entire deck launch system (launch nose, temporary piers, thrust systems, lock devices, skidding shoes and pier brackets for side shifting, long-line casting bed for 10m segments, long-line casting cell for two-phase casting, and geometry and foundations of the casting yard).
Protende (1999). VD-08, VD-09 and VD-10 Viaducts of the Rodovia dos Imigrantes, Saö Paolo, Brazil. This project includes three PC bridges (530, 470 and 270m, respectively) built by incremental launching on steep downhill grade. As contractor’s consultant, Dr. Rosignoli analyzed the construction means & methods and designed the downhill launch systems (launch nose, casting cell for two-phase casting, hydraulic brakes acting in a curved reaction beam, deck lock devices, and geometry and foundations of the casting yard).
Delma (1998). Structural retrofitting of the Wadi El-Kouf Bridge, Al-Beida, Libya. A 520m PC bridge with rigid stays and a 280m main span required replacement of the roll bearings of the central 40m closure span. As contractor’s consultant, Dr. Rosignoli conceived and designed the span lifting systems for bearing replacement and deck realignment, and provided site assistance during operations.
Siforms (1998). Helland Bridge, Hellandsas, Norway. The pre-award design of two adjacent 600m PC bridges provided for incremental launching construction on 70m spans. As equipment manufacturer’s consultant, Dr. Rosignoli analyzed the construction means & methods and designed the launch systems for the two bridges (two launch noses, two hydraulic front systems with masts and stay cables, re-deployable friction launchers with hydraulic clamps, two adjacent casting cells for simultaneous launching of the two decks, movable coverings for casting cells and rebar jigs, and geometry and foundations of the casting yard).
Siforms (1998). Korea High Speed Railway, Lot 2-1, Korea. Span-by-span casting of 1.3km of dual-track PC bridges required the design and fabrication of a custom MSS for 45m spans. As equipment manufacturer’s consultant, Dr. Rosignoli designed a 720t covered underslung MSS with short main girders and self-repositioning pier brackets for cage prefabrication behind the abutment and weekly cycles.
Siforms (1998). Sykkylven Bridge, Sykkylv, Norway. Client: Selmer. The pre-award design of an 880m PC bridge provided for incremental launching construction on 61m spans over a fjord. As equipment manufacturer’s consultant, Dr. Rosignoli analyzed the construction means & methods and designed the deck launch systems (launch nose, synchronized friction launchers on abutment and cable-stayed pier, casting cell for two-phase casting, rebar jig, portal crane with lifting truss for cage transfer, mobile covering for the casting cell, and geometry and foundations of the casting yard).
Tensacciai (1997). Rio Agueda Bridge, Portugal. This 14.800m² PC bridge was designed for incremental launching construction. As equipment manufacturer’s consultant, Dr. Rosignoli analyzed the construction means & methods and designed three configurations of thrust systems and a full deck launch system (launch nose, casting cell for two-phase casting, and casting yard geometry and foundations).
Tensacciai (1997). Ribeira das Insuas Bridge, Portugal. This project includes two adjacent PC bridges built by incremental launching; total deck surface 22.900m². As equipment manufacturer’s consultant, Dr. Rosignoli analyzed the construction means & methods and designed the deck launch systems for the two bridges (two launch noses, re-deployable friction launchers with hydraulic clamps, two adjacent casting cells for simultaneous launching of the two decks, and geometry and foundations of the casting yard).
Tensacciai (1997). Val Benoit Bridge, Belgium. This project includes a 5300m² cable-stayed PC bridge to be launched over the Meuse River on temporary piers and suspended from the pylon on launch completion. As equipment manufacturer’s consultant, Dr. Rosignoli analyzed the construction means & methods and designed the deck launch systems (launch nose, thrust systems, casting cell for two-phase casting, and casting yard geometry and foundations) and the permanent steel pylon.
DEAL (1997). Petra Tou Romiou Viaduct, Limassol-Paphos Highway, Cyprus. The project includes two adjacent PC bridges to be launched incrementally on tall piers; total deck surface 8.800m². As equipment manufacturer’s consultant, Dr. Rosignoli analyzed the construction means & methods and designed the launch systems for the two bridges (two launch noses, re-deployable friction launchers with hydraulic clamps, two adjacent casting cells for simultaneous launching of the two decks, and geometry and foundations of the casting yard).
Bonatti (1994). Palizzi Cable-Stayed Bridge, Milan, Italy. A 160m dual-track cable-stayed light-rail-transit bridge was incrementally launched over six electrified railroads with the help of two temporary cable-stayed piers; on launch completion, the deck was suspended from twin pylons. As contractor’s technical director, Dr. Rosignoli led the design of the deck launch systems (launch nose, rear thrust systems, casting cell, two temporary cable-stayed piers, and casting yard geometry and foundations) and provided site assistance during bridge construction.
Bonatti (1993). Bergamo Road Interchange, Seriate, Italy. The 805m PC deck of the Serio River Bridge was built by incremental launching on 43m spans; the project also included seven 3-span PC overpasses cast on ground falsework, and a 7-lane roadway tunnel jacked into the embankment of Highway A4 with traffic running on a self-centering paved platform on the top slab. As contractor’s technical director, Dr. Rosignoli led the design of the launch systems of the Serio River Bridge: launch nose, axial friction launcher, hydraulic casting cell for two-phase casting, modular interior forms, rear rebar jig, gantry crane and lifting beam for prefabricated cages and interior forms, and casting yard geometry and foundations. He also led the design of 7 ground-falsework assemblies for PC overpasses and the self-centering paved platform for the roadway tunnel, and provided site assistance during bridge construction.
Bonatti (1993). Palizzi Bridges, Milan, Italy. Two adjacent 95m PC bridges were incrementally launched over six electrified railroads with the help of a central temporary cable-stayed pier. As contractor’s technical director, Dr. Rosignoli led the design of the deck launch systems (launch nose, rear thrust systems, wood casting cell for two-phase casting, modular interior forms, temporary cable-stayed pier, and casting yard geometry and foundations) and provided site assistance during bridge construction.
Bonatti (1991). Avellino Road Interchange, Avellino, Italy. The project included 4600m² of cut-and-cover tunnels built by in-place casting over precast slab panels. As the contractor’s technical director, Dr. Rosignoli led the design of self-propelled hydraulic towers supporting the precast slab panels.
Cogefar (1990). Aronde Viaduct of the TGV Atlantique High Speed Railway, Lyon, France. This 460m dual-track PC bridge was built by incremental launching on eight 49m spans and two 34m end spans. As contractor’s expert of bridge launching, Dr. Rosignoli led the design of the deck launch systems (launch nose, friction launchers, casting cell for one-phase casting, self-extracting interior tunnel form, rear rebar jig, portal crane and lifting beam for half-span cages, and casting yard geometry and foundations).
Cogefar (1989). Lyon Viaduct of the TGV Atlantique High Speed Railway, Lyon, France. This 560m dual-track PC bridge was built by incremental launching on 49m spans. As contractor’s expert of bridge launching, Dr. Rosignoli led the design of the deck launch systems (launch nose, friction launchers, casting cell for one-phase casting, self-extracting interior tunnel form, rear rebar jig, portal crane and lifting beam for half-span cages, and casting yard geometry and foundations).