North Manama Causeway

Prefabrication equipment for prestressed concrete deck built with Dywidag system.

Category: Special Equipment
Activity: Final and Construction design
Period: September 2010 – December 2010
Client: Deal s.r.l.
Value: €950,000.00 (Category IXb)

Metal structures for the load-bearing elements of the formwork for production of precast segments for a concrete deck prestressed.

Metal structures for the load-bearing elements of the formwork for production of precast segments for a concrete deck prestressed.

Design of the structures for the fixed part and the mobile part, retaining towers of the fixed part, trolleys to move the segments.

Design of the structures for the fixed part and the mobile part, retaining towers of the fixed part, trolleys to move the segments.

Design of the metal parts of the formwork for the on-site prefabrication of segments.

Design of the metal parts of the formwork for the on-site prefabrication of segments.

The tools are designed to adapt to three different types of segments:
• Segment at constant height – longitudinal length of 260 cm type S1, S2 (standard) and 280 cm type P4, P4A (with diaphragms)
• Segment with variable height longitudinal length of 260 cm typo S3, S4, S5 (standard) and longitudinal development of 280 cm type P1, P2, P3, P5 (with diaphragms)
• Joint voussoir – longitudinal length of i 195 cm type A1, A2 (with diaphragms)

The tools are designed to adapt to three different types of segments:
• Segment at constant height – longitudinal length of 260 cm type S1, S2 (standard) and 280 cm type P4, P4A (with diaphragms)
• Segment with variable height longitudinal length of 260 cm typo S3, S4, S5 (standard) and longitudinal development of 280 cm type P1, P2, P3, P5 (with diaphragms)
• Joint voussoir – longitudinal length of i 195 cm type A1, A2 (with diaphragms)

16 March 2021

Chek Lap Kok Link

Safety interventions of a launching beam for the passage of typhoons.

Category: Assembly Equipment
Services: Design of safety devices for typhoons
Period: May 2015 – September 2015
Client: Freyssinet Construction Asia

The new connection between the island of Lantau in the Hong Kong archipelago and the artificial island of Check Lap Kok, on which the Hong Kong International Airport is based, is part of the development of the road infrastructure network that branches off to China to the north (Tuen Mun) and to the east (Macao), with works of impressive size that illustrate the ferment of Hong Kong and China.

The new connection between the island of Lantau in the Hong Kong archipelago and the artificial island of Check Lap Kok, on which the Hong Kong International Airport is based, is part of the development of the road infrastructure network that branches off to China to the north (Tuen Mun) and to the east (Macao), with works of impressive size that illustrate the ferment of Hong Kong and China.

Our intervention involved the safety of the assembly equipment of the prestressed reinforced concrete viaducts that connect Tuen Mun along an arm of the sea to the artificial island adjacent to the airport. The area of ​​southern China where the Hong Kong archipelago is located is in fact subject to a long season of typhoons that reach winds above 250 km / h; the equipment in question, specifically the launching car that lays the prefabricated reinforced concrete blocks, had not been appropriately sized given the condition of exposure to the effects of a typhoon and for this reason the construction management of the work had blocked its activities with consequent shutdown of the construction site.

Our intervention involved the safety of the assembly equipment of the prestressed reinforced concrete viaducts that connect Tuen Mun along an arm of the sea to the artificial island adjacent to the airport. The area of ​​southern China where the Hong Kong archipelago is located is in fact subject to a long season of typhoons that reach winds above 250 km / h; the equipment in question, specifically the launching car that lays the prefabricated reinforced concrete blocks, had not been appropriately sized given the condition of exposure to the effects of a typhoon and for this reason the construction management of the work had blocked its activities with consequent shutdown of the construction site.

The project
Problem solving

To unblock the impasse created and avoid the heavy economic repercussions, the client requested the presence on site of one of our managers, called to assist in the re-inspection of the launching wagon in the exceptional scenario of the typhoon and to study the devices for putting safely on the batteries of the equipment. We have therefore produced the necessary documentation to illustrate the suitability of the equipment built and the project documentation necessary to build the temporary safety devices, allowing our client to quickly obtain authorization for the resumption of work by the validation body of the Hong Kong authorities.
We also provided assistance to the construction site during the production and installation phases of these devices, carrying out checks and modifications to the devices in real time due to the changing logistical needs of the construction site.

16 March 2021

Temporary pier for the launch of the Ihsaniye viaduct

Detailed design of two temporary piers for the launch of the Ihsanye Bridge.

Category: Special Equipment
Services: Detailed Design
Period: July 2017 – December 2017
Client: Freyssinet International & Cie
Amount: 300’000 €

The incremental launch of the Ihnsaniye Bridge in Turkey needed the construction of two temporary piers to allow the crossing of the span with a maximum span of 80m (typical span around 50m). The bridge has two specular and independent decks with a CAP box section approximately 21m wide.

The incremental launch of the Ihnsaniye Bridge in Turkey needed the construction of two temporary piers to allow the crossing of the span with a maximum span of 80m (typical span around 50m). The bridge has two specular and independent decks with a CAP box section approximately 21m wide.

The temporary piers are about 15 m high and consist of 4 double T columns linked together by a reticular structure. At the top, two high-inertia beams support the sliding sleds and the lifting cylinders and, in turn, rest on diagonal elements that carry the load on the columns, placed at a reduced distance between the centers with respect to the supports.

The temporary piers are about 15 m high and consist of 4 double T columns linked together by a reticular structure. At the top, two high-inertia beams support the sliding sleds and the lifting cylinders and, in turn, rest on diagonal elements that carry the load on the columns, placed at a reduced distance between the centers with respect to the supports.

The whole system is designed to minimize the deformations under the reaction transferred from the bridge because the prestressed concrete deck is very rigid and therefore extremely sensitive to differential settlements.

The whole system is designed to minimize the deformations under the reaction transferred from the bridge because the prestressed concrete deck is very rigid and therefore extremely sensitive to differential settlements.

16 March 2021

Transport structure of the toroidal magnets for the nuclear fusion project “ITER”

Detailed and construction design of the steel transport structure.

Category: Special Equipment
Services: Detailed and Construction Design
Period: July 2017 – December 2017
Client: OMBA – ASG Superconductors
Amount: approx. €300,000

A toroidal magnetic field was realised for the international nuclear fusion project “ITER” to ensure the confinement of nuclear plasma. Each of the 10 magnets to be produced consists of a bundle of superconducting cables (total length 5.5km and weight 120t) inserted in a metallic case, with a total weight of 300 tons and a size of 9x16m.

A toroidal magnetic field was realised for the international nuclear fusion project “ITER” to ensure the confinement of nuclear plasma. Each of the 10 magnets to be produced consists of a bundle of superconducting cables (total length 5.5km and weight 120t) inserted in a metallic case, with a total weight of 300 tons and a size of 9x16m.

For transporting the magnet, a special support structure has been developed to guarantee both diffuse rigid support and shock protection.

For transporting the magnet, a special support structure has been developed to guarantee both diffuse rigid support and shock protection.

The structure is made up of two double longitudinal and transverse walls that create a safe envelope; between the coupled walls, made with solid web I-beams, there is a series of saddles supported by secondary beams connected to the walls.

The structure is made up of two double longitudinal and transverse walls that create a safe envelope; between the coupled walls, made with solid web I-beams, there is a series of saddles supported by secondary beams connected to the walls.

In addition, the load-bearing structure was designed according to the different assembly and transport phases: the main walls are made up of two superimposed I sections that can therefore be dismantled into an upper part and a lower part. The structure can also be divided into smaller segments, to allow a “standard” transportation of the framework which must return to the workshop several times.

In addition, the load-bearing structure was designed according to the different assembly and transport phases: the main walls are made up of two superimposed I sections that can therefore be dismantled into an upper part and a lower part. The structure can also be divided into smaller segments, to allow a “standard” transportation of the framework which must return to the workshop several times.

16 March 2021

Montreal Metro

Metallic equipment for the prefabrication of SCC viaduct segments.

Category: Special Equipment
Services: Detailed Design
Period: May 2018 – December 2018
Client: Deal s.r.l.

Design of the metal structures constituting the movement and formwork support elements for the prefabrication of the elementary segments of a reinforced concrete deck made with the “short line” system.

Design of the metal structures constituting the movement and formwork support elements for the prefabrication of the elementary segments of a reinforced concrete deck made with the “short line” system.

Design of metal structures constituting the fixed and mobile head,fixed head support towers, segment moving wagons. Design of sheet metal formwork structures and rigging and stripping equipment.

Design of metal structures constituting the fixed and mobile head,fixed head support towers, segment moving wagons. Design of sheet metal formwork structures and rigging and stripping equipment.

The equipment designed was used to manufacture different types of segments:
• Viaduct M194 – Typical segment and piles – Width 9.3 m, height 2.60 m, length variable from 3.05 to 3.70 m.
• Viaduct M195 – Section and typical pile – Width 9.3m, height 2.95m, length variable from 2.8 to 3.75m.

The equipment designed was used to manufacture different types of segments:
• Viaduct M194 – Typical segment and piles – Width 9.3 m, height 2.60 m, length variable from 3.05 to 3.70 m.
• Viaduct M195 – Section and typical pile – Width 9.3m, height 2.95m, length variable from 2.8 to 3.75m.

16 March 2021

Riyadh Metro Design Line 3

Segment prefabrication tools of the road deck for the “Station” viaducts.

Category: Special Equipment
Activity: Final and Construction Design
Period: January 2015 – June 2015
Client: Deal s.r.l.
Value: approximately €800,000.00 (Category IXb)

Metal structures for the load-bearing elements of the formwork for the production of precast segments for a prestressed concrete deck with spans of 21 and 26 m.

Metal structures for the load-bearing elements of the formwork for the production of precast segments for a prestressed concrete deck with spans of 21 and 26 m.

Design of the metal structures of the prefabrication tools (fixed part and mobile part), of the trolleys for the movement of the segments. Steel formwork design.

Design of the metal structures of the prefabrication tools (fixed part and mobile part), of the trolleys for the movement of the segments. Steel formwork design.

The tools are designed to adapt to two different types of segments:
• Typical segment
• Segment on pier

The tools are designed to adapt to two different types of segments:
• Typical segment
• Segment on pier

16 March 2021

Ponte Braila assembly equipment

Detailed design of assembly equipment and checks during the transport and lifting phase of elementary bridge segments.

Category: Special Equipment
Services: Detailed Design
Period: March 2019 – August 2019
Client: Fincantieri Infrastrutture S.p.a.

The Danube Bridge at Braila is a suspension bridge with a total length of 1974.30m with 3 spans including a central span of 1120m.

The Danube Bridge at Braila is a suspension bridge with a total length of 1974.30m with 3 spans including a central span of 1120m.

The deck has a typical width of about 40m but varies moving longitudinally and consists of a box made of an external orthotropic plate stiffened by trussed diaphragms.

The deck has a typical width of about 40m but varies moving longitudinally and consists of a box made of an external orthotropic plate stiffened by trussed diaphragms.

The design included the structural analysis of the segments of the bridge box (dimensions approximately 30x40m) during the storage and assembly phase and the design of the supports, their layout and the necessary reinforcements.

The design included the structural analysis of the segments of the bridge box (dimensions approximately 30x40m) during the storage and assembly phase and the design of the supports, their layout and the necessary reinforcements.

The temporary metal connections of the diaphragm of the mast to the mast itself were also studied. Its section consist of a reinforced concrete box of 6.75x3m with a wall 60cm-thick and a length of approximately 20m.

The temporary metal connections of the diaphragm of the mast to the mast itself were also studied. Its section consist of a reinforced concrete box of 6.75x3m with a wall 60cm-thick and a length of approximately 20m.

16 March 2021

Ferro Berica

Design of the steel support structure of a concrete runway.

Category: Revamping of existing structures
Services: Final Design
Period: July 2020 – August 2020
Client: Ferro Berica

The design of the metal structures supporting the existing runway of an overhead crane was carried out in the Ferro Berica factory in Vicenza, following the appearance of severe cracks and detachments of concrete parts of the BAP beam that supports the crane track within a specific span of the plant.

The design of the metal structures supporting the existing runway of an overhead crane was carried out in the Ferro Berica factory in Vicenza, following the appearance of severe cracks and detachments of concrete parts of the BAP beam that supports the crane track within a specific span of the plant.

The metal load-bearing structure was designed with a metal crosspiece consisting of a box section supported by two vertical columns arranged at a slight inclination.

The metal load-bearing structure was designed with a metal crosspiece consisting of a box section supported by two vertical columns arranged at a slight inclination.

A layer of non-shrink mortar was also interposed between the upper edge of the steel frame and the bottom edge of the damaged PRC beam to restore the damaged concrete cover, guaranteeing the contact between the two structural elements and allowing the metal frame to get charged when the overhead crane passes.

A layer of non-shrink mortar was also interposed between the upper edge of the steel frame and the bottom edge of the damaged PRC beam to restore the damaged concrete cover, guaranteeing the contact between the two structural elements and allowing the metal frame to get charged when the overhead crane passes.

15 March 2021

Reinforcement of the existing tower of the Bulacan Pre-Heater concrete plant

Reinforcement of the steel beam named 4F_04

Category: Revamping of existing structures
Services: Specialist counseling
Period: May 2018 – June 2018
Customer: Freyssinet

The job was part of the study of the reinforcement of the existing preheating tower and the definition of reinforcing solutions, in order to adapt to a series of new loads expected on the structure. The object of this work is the reinforcement of the beam named 4F_04, located on the 4th floor.

The job was part of the study of the reinforcement of the existing preheating tower and the definition of reinforcing solutions, in order to adapt to a series of new loads expected on the structure. The object of this work is the reinforcement of the beam named 4F_04, located on the 4th floor.

The current section of the 4F_04 beam is a symmetrical I-section with a height of 2520 mm, a bottom and top flange of 400×45 and a web thickness of 20 mm, in S235 steel.
This section is enhanced by:
– a T welded to the lower flange of dimensions: h = 500mm, flange 400×50, web 20mm
– longitudinal rectangular-shaped stiffeners 250×20 at a distance of 700mm and 1400mm from the upper face of the beam.

The current section of the 4F_04 beam is a symmetrical I-section with a height of 2520 mm, a bottom and top flange of 400×45 and a web thickness of 20 mm, in S235 steel.
This section is enhanced by:
– a T welded to the lower flange of dimensions: h = 500mm, flange 400×50, web 20mm
– longitudinal rectangular-shaped stiffeners 250×20 at a distance of 700mm and 1400mm from the upper face of the beam.

15 March 2021

Hangars for the Aferpi Steelworks

Design of metal structures for the hangars of a steelworks.

Category: Revamping of existing structures
Services: Final Design
Period: October 2016 – January 2017
Client: Aferpi

As part of the redevelopment and improvement project of the AFERPI steelworks in Piombino, the structures of the existing hangars of the old ingot mill were rechecked following the loads imposed by the new production cycles and the new regulations.
The hangars have a static scheme of a moment-resisting frame with a trussed beam in the transverse direction, while in the longitudinal direction the structure is braced. The main truss is made of angular profiles and bolted joints. The spans of the hangars vary between 30 and 45m; the welded I-section posts are placed at a distance of 20m with false trusses at a distance of 5m and longitudinal beams of the roof.

15 March 2021