warren - eastlink super t bridges

8/10/2019 Warren - Eastlink Super T Bridges

1/23


2/23

Hyder Consulting Pty Ltd3

Introduction

EastLink: largest urban infrastructure project in Australia

$2.5 billion, 45 km toll road project

PB and Hyder Joint Venture

71 of 84 bridges in original scope

Currently under construction


Introduction contd

45 km toll road from Mitcham to Frankston


3/23


Introduction contd

71 Bridges over 5 regions


Precast Planning

Standard Precast Units

Super-T to AS5100 profile


4/23


Detailed Design


1800mm Deep Super-T Beams

Can span up to 38m long and weigh over 80 tonnes

Reduced the number of spans required for each bridge


Precast Planning


Precast Pier

& Crosshead Construction

close to movingtraffic

Reduce site costs


5/23


Precast Planning


Barrier Unit


Precast Planning


Wingwalls and Fenderwalls


6/23


Precast Planning


Noise WallPanels


Detailed Design

D&C Contract O&M Contract

Concessionaire

Southern & Eastern

Integrated Transport

Authority (SEITA)

ConnectEast

Independent Review (IR)

SKM/Maunsell/Davis

Langdon

Environmental ManagementRepresentative

Financier EngineerURS/Evans & Peck

Thiess John Holland

(TJH)Transfield Services

(TSL)

Proof Engineer/

Construction Verifier

SMEC/KBR

Independent Quality

Auditor

Tolling

SICE ConstructionDesign

Parsons Brinckerhoff

Hyder JV

Wood Marsh

UGR

Connell Wagner

Road Safety

Auditor

Design

Consultant

Review Process:


7/23


Detailed Design

Standardised approach used in design

Details of connections of precast critical to design

Lifting of precast incorporated in design

Inclusion of Urban Design features

Safety in design was considered

Value Engineering process continued duringdetailed design


Detailed Design

Super T beams

PBHyder designed58 Super-T bridges


8/23


Detailed Design

Super T beam Design involved:

Standardising Super-T beam sizes toensure 24 hour turn around inproduction

Allowing for long periods of storagebefore erection

Using integral abutments for bridgesgiving greater tolerance during erection


Detailed Design

Super T beam Design


9/23


Detailed Design

Precast Segmental Pier Design


Detailed Design

Detailing incorporating Urban Design features

Pier constructionwith falsework

Precast Segmental Pier Design


10/23


Detailed Design

Precast Wing Walls

Wingwall Lifted into place

Abutment beam poured

Insitu concrete fenderwall pouredconnecting to wingwall


Detailed Design

Barriers

Designed for Highand MediumContainment Levels

(High 1000 kN) Connection using

stitch joint to deckand pin joint forcontinutiy

Incorporating UrbanDesign patterning


11/23


Detailed Design

Precast Components designed using 3D CAD


Detailed Design

Precast Components designed using 3D CAD


12/23


Precast Facility

Site selected in Morwell

with following benefits: Using an established

Plant (Di Fabro)

Availability of Labour

Close to concrete supplierand other resources

Established TransportRoutes to Eastlink


Precast Facility

Steel Super-TMoulds

Fabricated inChina

750 2 beamcapacity mould





13/23


Flat Beds for Wingwalls & Fenderwalls

Precast Facility


Precast Facility

Standard Precast Pier Mould


14/23


Precast Facility

Barrier moulds designed for

upside down casting


Precast Production

Super-T Beams

Radiant Heat curing

24 Hour turn-around

Double stacking


15/23


Precast Production

Barriers

Standard lengthsto maximiseoutput

Developing aPin ConnectionDetail


Precast Production

Noise Walls

Post & Panel Wall units castvertically in Battery Moulds

Rock Face template for cantilever walls


16/23


Construction

Transportation

Super-T beams:

87 tonnes

40 m long

Transport studyundertaken


Construction

Lifting

500 tonne crane

Snow Whitepurchasedspecifically for project


17/23


Construction

Lifting

Flexibility in lifting(end to - end)


Construction

Installation

Placement &Levelling

Connected byStitch Joints,BoltedConnections orStressed anchors


18/23


Additional Structures

Other Precast Elements include:

Noise walls

Precast soil wall facing

Humedeck units

Culverts and Pits


EastLink Bridges 17 EastLink bridges over local roads

EastLink over Railway Parade

38m spans, 1800mm deep Super-T beams


19/23


EastLink Bridges

16 EastLink bridges over waterways

Bored piles and columns at pier


EastLink BridgesMonash Interchange 3rd largest interchange in Southern Hemisphere

Nine bridges

Aerial view ofinterchange

Under construction

EastLink N/B Entry Ramp

128m, 4 span Trouser Leg

bifurcation for multiple access


20/23


21/23


Construction Progress(cont.)




22/23






23/23


TJH / PBHyder

Thank You

warren - eastlink super t bridges

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