Design of Special Equipment

 

Throughout my professional carrier, I have designed special construction equipment for bridge projects in 13 countries on 4 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 PC overpasses, the launch set of 23 incrementally launched bridges, a pair of form travelers designed for fast splitting at the pier-table, modular self-lifting forms for casting solid 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 equipment for 2 closure spans and precast footing shells, and a cable-stayed system to control the time-dependent stress redistribution of staged construction in continuous spans.

  • Maltauro-Delma JV (2005). São Vicente Bridge over the Cacheu River, Guinea Bissau. This project included a 732m PC bridge built by balanced cantilever construction on 85m spans. As freelance consultant, my duties included analysis of construction means & methods and the advanced preliminary design of a strand-jacking platform to lower 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, my duties included analysis of construction means & methods and the advanced preliminary design of overhead cable-stayed form travelers designed for fast splitting at the pylon-table.
  • Eiffage-Pizzarotti JV (2005). Direttrice Cremona-Mantova Regional Highway, Parma, Italy. This assignment included the advanced preliminary design of modular self-lifting forms for in-place casting of 51 solid 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 the project included a 205m, 27m-wide cable-stayed span to be incrementally launched over Highway A22. As freelance consultant, my duties included analysis of construction means & methods and the advanced preliminary design of a piled erection platform (the cable-stayed span is assembled on 18m-tall temporary piers) and the span launch set (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 17m to 24m was designed to be cast behind the abutment and launched over an electrified railroad. As freelance consultant, my duties included analysis of construction means & methods, advanced preliminary design of the span launch set (braced PC launch noses, temporary pier, casting cell, reaction beams, rear thrust cylinders, and geometry and foundations of the casting yard) and on-site assistance during launch of the span.
  • Pizzarotti (2002). Duplication of the Milano-Brescia Highway, Bergamo, Italy. The pre-award design of the 2.120m Adda River Bridge, the 1.200m Serio River Bridge, and the 870m Oglio River Bridge provided for incremental launching construction on 46m spans. As freelance consultant, my duties included analysis of construction means & methods and advanced preliminary design of the deck launch set (launch nose, self-reacting casting cell with transverse pre-tensioning systems for 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 freelance consultant, my duties included preliminary and final design of 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 included five 3-span single-track PC bridges. As freelance consultant, my duties included the design of 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 included two adjacent PC bridges with 43m spans to be incrementally launched on steep uphill gradient. As freelance consultant, my duties included analysis of construction means & methods and the advanced preliminary design of the deck launch set (launch nose, casting cell for two-phase casting, synchronized friction launchers on the abutment and a 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 use of 4 custom-designed MSS for 40m spans. As freelance consultant, my duties included the advanced preliminary design and structural analysis of a modular system of 690t covered underslung MSS with short main girders and self-repositioning pier brackets designed for cage prefabrication behind the abutment and weekly cycles.
  • Codelfa (1999-2000). Tiziano Bridge, Alessandria, Italy. The pre-award 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 half of the deck over permanent piers and abutments, incremental launching construction of the second half of the deck, and connecting the two box-girders with a cast-in-place central curb. Four temporary piers halved the launch spans to save post-tensioning. As freelance consultant, my duties included preliminary and final design of the deck launch set (launch nose, temporary piers, thrust systems, lock devices, skidding shoes and pier brackets for side shifting, long-line casting bed for 10m segments, mobile 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 included three PC bridges (530m, 470m and 270m, respectively) built by incremental launching on steep downhill grade. As freelance consultant, my duties included analysis of construction means & methods and the advanced preliminary design of three deck launch sets (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 concrete stays and a 280m main span required replacement of the roll bearings of the central 40m closure span. As freelance consultant, my duties included preliminary and final design of the span lifting equipment for bearing replacement and deck realignment.
  • Siforms (1998). Helland Bridge, Hellandsas, Norway. Client: Selmer. The pre-award design of two adjacent 600m PC bridges provided for incremental launching construction on 70m spans. As freelance consultant, my duties included analysis of construction means & methods and the advanced preliminary design of a common deck launch set 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 launch 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 use of a custom-designed MSS for 45m spans. As freelance consultant, my duties included the advanced preliminary design and structural analysis of a 720t covered underslung MSS with short main girders and self-repositioning pier brackets designed 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 freelance consultant, my duties included analysis of construction means & methods and the advanced preliminary design of the deck launch set (launch nose, synchronized friction launchers on the abutment and a cable-stayed pier, casting cell for two-phase casting, rear 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. Client: Soares da Costa. As freelance consultant, my duties included analysis of construction means & methods and the advanced preliminary design of three configurations of thrust systems and a full deck launch set (launch nose, casting cell for two-phase casting, and casting yard geometry and foundations).
  • Tensacciai (1997). Ribeira das Insuas Bridge, Portugal. This project included two adjacent PC bridges built by incremental launching; total deck surface 22.900m². Client: Soares da Costa. As freelance consultant, my duties included analysis of construction means & methods and the advanced preliminary design of a common deck launch set for the two bridges (two launch noses, re-deployable friction launchers with hydraulic clamps, two adjacent casting cells for simultaneous launch of the two decks, and geometry and foundations of the casting yard).
  • Tensacciai (1997). Val Benoit Bridge, Belgium. This project included 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 freelance consultant, my duties included analysis of construction means & methods and the advanced preliminary design of the deck launch set (launch nose, thrust systems, casting cell for two-phase casting, and casting yard geometry and foundations) as well as of the permanent steel pylon.
  • DEAL (1997). Petra Tou Romiou Viaduct, Limassol-Paphos Highway, Cyprus. The project included two adjacent PC bridges to be launched incrementally on tall piers; total deck surface 8.800m². As freelance consultant, my duties included analysis of construction means & methods and the advanced preliminary design of a common deck launch set for the two bridges (two launch noses, re-deployable friction launchers with hydraulic clamps, two adjacent casting cells for simultaneous launch of the two decks, and geometry and foundations of the casting yard).
  • Bonatti (1994). Palizzi Cable-Stayed Light-Rail-Transit (LRT) Bridge, Milan, Italy. A 160m dual-track cable-stayed LRT 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 the firm’s technical director, my duties included the advanced preliminary design of the deck launch set (launch nose, rear thrust systems, casting cell, two temporary cable-stayed piers, and casting yard geometry and foundations).
  • 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 the firm’s technical director, my duties included the advanced preliminary design of the launch set of the Serio River Bridge (launch nose, axial friction launcher, hydraulic casting cell for two-phase casting, modular inner forms, rear rebar jig, gantry crane and lifting beam for prefabricated cages and inner forms, and casting yard geometry and foundations), 7 ground-falsework assemblies for PC overpasses, and the self-centering paved platform for the roadway tunnel.
  • Bonatti (1993). Palizzi Bridges, Milan, Italy. Two adjacent 95m three-span PC bridges were incrementally launched over six electrified railroads with the help of a central temporary cable-stayed pier. As the firm’s technical director, my duties included the advanced preliminary design of two deck launch sets (launch nose, rear thrust systems, wood casting cell for two-phase casting, modular inner forms, temporary cable-stayed pier, and casting yard geometry and foundations).
  • Bonatti (1991). Avellino Road Interchange, Avellino, Italy. The project included 4600m² of cut-and-cover tunnels built with full-depth precast slab panels. As the firm’s technical director, my duties included the advanced preliminary design of self-propelled hydraulic support towers for 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 firm’s expert of bridge launching, my duties included the advanced preliminary design of the deck launch set (launch nose, friction launchers, casting cell for one-phase casting, self-extracting inner 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 firm’s expert of bridge launching, my duties included the advanced preliminary design of the deck launch set (launch nose, friction launchers, casting cell for one-phase casting, self-extracting inner tunnel form, rear rebar jig, portal crane and lifting beam for half-span cages, and casting yard geometry and foundations).
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