VSL News 1996 N°1 - STRUCTURAL TECHNOLOGIES … organisation has long-standing and rich post-tensioning expertise, unmatched technical capabilities as well as unique network of local

E D I T O R I A L

A new layout fora new approachThe Specialist Contractor concept waslaunched to ensure that VSL’s offerwould continue to meet increasinglyexacting market requirements andanticipate future clients demands.

A New ApproachOur organisation has long-standingand rich post-tensioning expertise,unmatched technical capabilities as wellas unique network of local affiliatesthat combine the strengh of a world-class specialist with the responsivenessof locally based partners. As a SpecialistContractor, VSL provides all-inclusivepackages that include upstream designand construction planning, the supplyof high quality post-tensionning systemsand the downstream management ofon-site operations.This new approach of post-tensioningfocuses on projects and processes. It isour way of ensuring that our clients are provided with the best value-for-money services available on the market.

A New LayoutAs VSL’s main communications tool, VSLNews should reflect this stae-of-the-artapproach. The new layout has been de-signed to clearly represent VSl’s far-reaching Specialist Contractor capabilities.Readers will rapidly see that these go farbeyond simply supplying post-tensioningmaterials. VSL News has been redesignedto show how VSL adds value by havingan all-encompassing project approach toclient requirements. Finally, our purposeis to highlight the advantages offered byVSL’s unique network of companies andthe important role played by theirproximity to local markets.We wanted to make it interesting and informative. We hope you enjoy reading it.

Michel MaîtreCEO and

Chairman of the Board

VSL involvement inthe first modernbridge in Vietnam

H I G H L I G H T S

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Post-tensioning andlaunching of the

world’s longest incre- . . . . . . . . . . . . .mentally launched bridge

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...7 The first applica-

tion of PT-Plus inSingapore

Lifting theskybridge of

the world highesttowers

VSL launchesthe most cost

effectivestate-of-the-art PT slab

system in the world

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P U B L I S H E D B YVSL International Ltd.Bernstrasse 9, 3421 Lyssach,SwitzerlandandVSL Management41, avenue du Centre78067 St-Quentin-en-YvelinesFrance

Editor : M. MAITRETel : 33 1 30 12 09 30

Technical Editor : H. R. GANZTel : 33 1 30 12 09 30

Regional Editors :P. BRON - WesternEurope,Africa and Middle EastTel : 33 1 69 19 43 00

G. PASH - South East AsiaTel : 61 2 484 59 44

A. PAYNE - North AmericaTel : 1 919 781 6272

J. SINDEL - Eastern Europe andMiddle East - Tel : 41 34 47 93 21

J-P. TRIN - North East AsiaTel : 852 2590 22 22

Coordination :P. RENARDTel : 33 130 12 09 41

Circulation :C. SICATel : 33 1 30 12 09 32

Conception :Red LineTel : 33 1 41 14 01 80

Linguistic Consultant :N. HARGREAVESTel : 33 1 43 66 88 05

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I N T E R V I E W

PIERRE BRONREGIONAL MANAGER OF VSL’S OPERATING UNIT 5

Mr. Bron could youbriefly explain OU5’s

purpose ?OU5 stands for Operating

Unit number 5. It is the fifth ofVSL’s five Operating Units.With its responsibility for marke-ting and management in WesternEurope, Africa and SouthAmerica, it covers the largest ofthe OU territories.

What is OU5’s role within theVSL Group ?The role of the OU is to offer itsclient's service packages, clearlydefined working methods andscope of works. It also providesa high level of responsivenessand flexibility to adapt to specificlocal situations. The OU is res-ponsible for supplying neededlocal resources where theyexceed the capacities of a VSLaffiliate. Lastly, it is to coordina-te strategies of Profit Centres.

What added value does OU 5offer its clients ?By providing backup to local VSLaffiIiates OU 5 adds value in fourways :Firstly by offering technical sup-port. Thanks to VSL‘s EuropeanTechnical Center, we can offer our clients the experience, knowhow and technical expertise an excellent team of post-ten-sioning specialists.The second type of backup takesthe form of providing construc-tion methods and managing siteoperations. Here at OU 5, webelieve that a well plannedconstruction, schedule which isthen implemented by our specia-lized Project Managers repre-sents the best way to makeconsiderablesavings in the costof labour and materials whilstretaining optimum quality levels.The third way is by optimizingthe allocation of resources. Bycoordinating strategies andconsolidating the resources of anumber of local affiliates, OU 5 isable to provide local clients with

the capacities of a world-class contractor whilst retaining thelightweight structure needed to beefficient, flexible and economic.Fourth way is the guarantee tohave VSL’s quality products and the proven working methods thatunderline our reputation as aninternational PT specialist.

What ambitions do you havefor OU 5 ?Our goal is to adapt our organi-zation to work even more effi-ciently as a specialist contractor,increase our presence in thosecountries where we have no per-manent representative, improvethe quality of the services weoffer and extend our scope ofworks to include VSL’s completerange of capabilities.

How do you intend going aboutthis ?For clients in countries where weare permanently represented byour Profit Centers, we will provideservices that, apart from providinghigh quality equipment and materials,will also offer alternative designsolutions, a PT consultancy serviceand on-site operational manage-ment.In territories covered by a Ii-cense, we shall focus on large ortechnically complex projectswhere our know-how can offer aspecific added value. We recentlyset up a “Special Projects” teamthat includes our best technical

and marketing specialists to pro-vide services that extend beyond the scope of our licensee.

What about those countrieswhere OU5 is not represented ?We are looking at projects on acase-by-case basis.Our structures are organized insuch a way that we can rapidlymobilize human, material andtechnical ressources to meet allopportunities that present themselves.

What are the results so far ?A large number of importantcontracts have been signed andcompleted : the world’s largestfloating concrete barge - then’Kossa barge, strengthening theOléron bridge in France,reinforcing and lifting the Kingston bridhe in Scotland andthe construction in joint ventureof the New Tagus bridge inPortugal.As far as increasing our presenceis concerned, we have created asubsidiary in Chile to promotebusiness in South America.In columbia, we have signed apre-stressing and soil anchorcontract for the PescaderoBridge.

What about OU5’s scope of works ?We are proud to offer all VSLcapabilities : Post-tensioning(which is naturally present as a core business), Heavy Lifting,Retained Earth Walls, StayCables, Offshore Structures,Storage Structures as well asrepair and maintenance ofconcrete civil structures.In addition to VSL traditional scopeof works, we also offer specific PTapplications such as Autofoncage -a state-of-the-art concept thatallow the boring of railway under-passes in record time.Let me conclude this interviewon our main asset : Quality. Ouraim is to be certified IS0 9001by year 1997.

VSL NEWS 3N ° 1 . 1 9 9 6

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4 N ° 1 . 1 9 9 6 VSL NEWS

- FRANCE -R O G E R V I L L E V I A D U C T, N O R M A N D Y

609 TONNES OF PT INSTALLED IN JUST 8 MONTHS

The spans are fixed to the piers andarticulations placed at mid-span(every three spans) permitting thedeck to move thanks to mobile steelbeams installed on sliding bearingsinside the box girders.

Each precast segment has a constantheight of 3.7 m and a maximumweight of 103 tonnes. A pair of sym-metrical segments are alternativelyplaced at each deck using a 140 mlong launching girder.

The segments are prestressed withinternal PT (EC 6-19 tendons) at pla-cing stage and then with external PT(ED 6-18 and 6-19 tendons) once thespans have been completed

The 609-tonne strands used for thepost-tensioning works were installedwithin eight months, with teams work-ing two to three shifts per day overthe last four months.

Jean Claude BARBIEROperating Unit 5 Western Europe

The 680-m long Rogerville Viaduct liesalong the route of the A 29 motorwaywhich will link the towns of Le Havre,Amiens, and Saint Quentin.

The viaduct has two parallel decksmade of precast segments. The deckshave a constant 5 m level difference

between each deck, a 4% slope and acurve following a 3,000 m radius.

The viaduct, built by Bouygues, covers10 spans (43.4 m, 68.8 m, 6 x 76.0 m,68.6 m and 43.3 m) and bears on twoabutments and nine V-shaped piersthat have been vertically pre-stressedusing EC 6-19 tendons. The maximumpier height is 42.5 m. The legs of thesmallest V-shaped piers are prestres-sed with EC 6-19 tendons and bracedby a cross wall while the highest piersare braced by a cross beam.

- VIETNAM -P H U L U O N G B R I D G E ,

H A N O ITHE FIRST MODERN VIETNAMESE BRIDGE

TO USE WESTERN TECHNOLOGY

The Phu Luong Bridge is one of thelargest river crossings along the routeof Highway No. 5. This is currently thebusiest road in Vietnam, linking Hanoito the port of Haiphong. The newbridge, scheduled to be opened inmid-1997, will replace the existingmulti-purpose steel bridge which car-ries a one-way vehicle traffic and therailway line. The twin two-lane bridgeis being constructed using the balan-ced cantilever method with mainspans of 65m + 102m + 102m + 65 m,an 11 m wide deck and a depthvarying from 6 m to 2.5 m.

The contract is being carried out withtwo companies forming part of theMinistry of Transport andCommunication : TransportEngineering Design Inc. (TEDI) andConstruction Co. No. 12 (CC12). It isthe first modern bridge in Vietnam tobe constructed using Western techno-logy. VSL’s scope of works involvesdesigning the superstructure andformtraveller, supplying post-tensio-ning materials including strand andstressbar systems, as well as bearingsand expansion joints. It also includessupplying the form traveller and pro-viding construction engineering andmanagement services as well as trai-ning of TEDI and CC12 engineers andtransferring technological know-how.

This bridge is the first project in Asiato use CS anchorages. Construction ofthe superstructure began in July 1995and is scheduled for completion by theend of 1996. This is made possibleusing the fast track methods intro-duced by VSL which provide a 7 daycompletion period per pair of segments.

The site was visited by the PrimeMinister of Vietnam, H.E. Mr. Vo VanKiet on 23 December 1995. He praisedthe project as being one of the mostsuccessful cooperative venturesbetween a foreign firm and local com-panies.

Siah Chee SengVSL Vietnam R.O

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VSL NEWS 5N ° 1 . 1 9 9 6

- INDONESIA -K . S . T U B U N F LY O V E R ,

J A K A R TATHE WORLD’S LONGEST INCREMENTALLY

LAUNCHED BRIDGE.

of 24 cast segments, each 22 m longare required for the two boxes.Because of the short distance be-tween the bridge and the castingyard, a temporary pier is required toovercome the problem of hogging atthe casting yard segment.

The final 65 m span represents aworld record for an incrementallylaunched bridge.

Since the terms of the contract specifythat railway traffic must not bedisrupted, it was not possible to use atemporary pier between the bridgeand the casting yard. As a result, thebridge has a 46 m launching nose.

The post-tensioning uses VSL 5-19tendons and couplers: Additional lon-gitudinal tendons required for thelive load were installed after comple-tion of the launching. The construc-tion of the deck began in October1995 and completion is expected byMay 1996.

Johannes HimawanVSL Indonesia

A difficult design brief faced VSL’spost-tensioning and launching the K.S.Indonesian engineers when they wereTubun Flyover bridge. Not only will itawarded the contract in 1995 forcross the Jakarta Flood Control Canaland Dass overthe city’s lar-gest railwayjunction, buthigh voltagepower linesoverhead aswell. Once com-pleted, theflyover willconnect thedistricts ofJalan Tubun andJalan KebonSirih in centralJakarta. Trafficwill be divertedto the westernpart of the City, thus bypassing thecrowded Tanah Abang market.

P T Wijaya Karya, the general contrac-tor, stated there was to be no distur-bance to the railway system, thatheadroom had to be kept to a mini-mum IO.45 m metres and that a mini-mum distance had to be kept over-

tions, thelogical solu-tion was tolaunch thebridge incre-mentally.One of the end spans tothis five-spanbridge is cur-ved to mini-mise the dis-turbance tosurroundingbuildings.Spans are 45,55, 65, 55 and45 m long.

head for the power lines. This meantthat the bridge could only be 3.6 mhigh. To comply with all these restric-

VSL TC Europe designed the super-structure and VSL TCAA - based inSingapore - designed the temporarystructure.

The bridge consists of two identicalbox girders, each 8.5 m wide and 3.6m high. A casting yard was installedon the site of the end span. A total

- THAILAND -T H E P A - M O K B R I D G E

CONSTRUCTION OF THE FIRST SPAN HAS BEEN COMPLETED

Our scope of works covers the post-tensioning and erection of high gir-ders. The first span was erected by agantry crane designed and operatedby VSL. The other spans will be erec-ted using a self-launching truss, alsodesigned and operated by VSL.

VSL’s contract will be completed inSeptember 1996. Final project comple-tion is scheduled for November 1996.

Gaysorn LertmongkonnamVSL Thailand

Construction of the first span on thePa-Mok Bridge has been completedand work is underway on the assem-bly of the launching truss for the ins-tallation of the second span.

The bridge is being constructed acrossthe Chao Phraya River, located in Pa-Mok, Aung Thong Province, 100 km tothe north of Bangkok. It will beassembled from seven spans of post-tensioned high girders. A total of 91beams are required, each 50 m inlength and weighing 120 tonnes.The Highways Department is both thedesigner and the client.

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6 N ° 1 . 1 9 9 6 VSL NEWS

- HONG KONG -L E E G A R D E N R E D E V E L O P M E N T

VSL CLIMBFORM SYSTEM IN A HONK KONG SKYSCRAPER

- VIETNAM -S A I G O N T O W E R

VSL CONTRIBUTES TO FAST TRACK BUILDING CONSTRUCTION IN VIETNAM

The use of post-tensioning and a flyingtableform for the Saigon Tower projectin Ho Chi Minh City earmarked thebirth of fast track constructionbuildings in Vietnam.Approached by Transfield Constructionof Australia, the design and buildingcontractor, VSL made an alternativepost-tensioning proposal in 1994which showed savings in bothmaterials and time. To provide anadded value, VSL, together with AlumaFormwork Systems, proposed a light-weight aluminium formwork system toimprove overall constructibility andreduce work time.With spans of 11 m and 8.3 m, each1,000 m2 level took an average of 6 to7 days days to complete. This repre-sent a record for fast construction in

Vietnam. The 15 storey project has aground floor area of 15,000 m2 for useas office space. VSL’s scope of workincluded the design for the floors andformwork, supply of PT materials aswell as and formwork and site super-vision.Being the first alternative PT proposalin Vietnam, this project has launchedthe idea of cost and time savings formany other projects currently on thedrawing board and has once againreaffirmed VSL’s position as the mar-ket leader in value added engineeringand services.

Siah Chee SengVSL Vietnam R.O.

Hong Kong’s unrelenting pace ofbuilding construction recently led tothe replacement of the historic LeeGarden Hotel by yet another skyscraper.Main Contractor for the project - AokiCorporation - was successful in itstender for the construction of the 50floor office building with an aggressivebid based on the use of the VSLClimbform System for the substantialcore wall.

The building is steel framed and has alarge volume of structural steelcolumns and beams cast into theheavily reinforced core wall. Becausethe core was on the critical path, theclient wanted a guaranteed four dayfloor-to-floor cycle time.

The shape of the core is a truncatedtriangle with wing walls which drop

off at varying floorheights. This, and alarge reduction in thewall thickness, led thedesign team to adoptan unusual but ultima-tely successful adapta-tion of the standardClimbform Systemwhich was dismantledin April this yearwithin the target pro-gramme.

Stuart PearsonVSL Hong Kong

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VSL NEWS 7N ° 1 . 1 9 9 6

- MALAYSIA -K O TA M A S A I W AT E R R E S E R V O I R S , J O H O R E B H A R U

VSL - A SPECIALIST STORAGE STRUCTURE CONTRACTOR.More than 24,000 houses are plannedin a new multi-billion development forthe fast-growing Malaysian state ofJohore. VSL has been invited to submita proposal for the design and construc-tion of two service reservoirs to formpart of this development. Total sched-uled construction time for the reservoirsis 14 months, with a June 1996 startdate. This project will be carried out ona turnkey basis and the scope of VSL’s

- JAPAN -T A K A H A M A P U M P I N G S TAT I O N , T O K Y O

VSL GROUND ANCHORS USED TO DRIVE DOWN A MASSIVE CAISSON

works includes the design andconstruction of the 8 and 2 million gal-lon (36 and 9 million litres) waterreservoirs and the pumping station,including commissioning of the pumpsand laying of associated pipework.

The construction method uses full heightprecast prestressed concrete segmentsfor the wall and cast-in-place concretefor the base slab, ring footing and roof.

The 8 million gallon reservoir is madeof 46 precast standard wall panels and4 precast buttress panels. The base slaband the dome roof are in reinforcedconcrete. The pumping station will bedesigned and built by a specialist sub-contractor appointed by VSL.

Chong Chee KenVSL Malaysia

- SINGAPORE -K R A N J I S E WA G E T R E AT M E N T W O R K S - P H A S E I I I

THE FIRST APPLICATION OF PT-PLUS IN SINGAPORE

VSL’s involvement in the KranjiSewage Treatment Works includes thedesign and construction of three egg-shaped digesters and the constructionof two gas holder tanks and onesludge storage tank.

The engineers, Binnie & Partners,approached VSL for the preliminary designand structural sizing of the digestersprior to tendering. Each digester, with a7,760 m3 tank capacity, is 36.5 m highand has an internal diameter of 21.9 m.Wall thicknesses vary from 459 mm to707 mm and the foundations includeforty 1.2 m dia. bored piles.

This is the first application of the PT-Plus system in Singapore. The verticaldigester tendons have twenty EC 5-18tendons, while the horizontal tendonsare made of 25-18 and 25-12 strands.The sludge storage tank and gas hol-der tanks are also post-tensionedusing EC 5-7 type horizontal tendonsand 5” monostrand vertical tendons.Site works are on schedule and theGeneral Contractor, Hyundai Engineering& Construction Co Ltd, is keeping upwith the construction programme.

Patrick WOOVSL Singapore

An underground concrete shaft jointingthe pipelines and the pumping stationwas cast. VSL used a drive downcaisson method to construct the shaftfrom which the two pipeline tunnelroutes will be bored.To provide the 3,000-tonne pressureneeded to drive down the caisson, tenE6-17 ground anchors were laid outaround it and ten sets of VSL 500-tonne lifting gear (stroke 350 mm)were needed. A distinctive feature ofthis project was that the operationwas fully automated. The shaft has a23 m external dia., a 47.8 m depthand a 1.8 m wall thickness.

Susuke SAKATAVSL Japan

To improve water supply to theNortheast of Tokyo, two large water

pipelines totalling 45.5 km have beenlaid to connect two rivers and a lake.

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8 N ° 1 . 1 9 9 6 VSL NEWS

- GERMANY -T H E N E W B I C Y C L E I N B E R L I N

AN ALTERNATIVE DESIGN FOR TENSION MEMBERS

- AUSTRALIA -C R O W N C A S I N O P R O J E C T, M E L B O U R N E

THE PROJECT IS NEARING COMPLETION.

The Crown Casino is nearing comple-tion with the first stage due to beopened in November 1996.

to 30 m and depths from 6 m to 9 m.� Hotel Floor Slabs. Includes 40 levelsof band beams and slab bonded post-tensioned tendons.

Warwick CopelandVSL Asutralia

This new stadium will be equippedwith a 250 m long oval race track andseating capacity for 10,000 specta-tors.

French architect, Dominique Perrault,won the competition for the design ofthe stadium. The structural designwas by Arup GmbH of Berlin. The steelroof was built and erected by KruppStahlbau GmbH. The 142 m diameterroof is constructed of 48 radial gir-ders, an inner ring beam, an outerring beam and 48 tension members.

The tension members provided for inthe initial design used 160 mm dia.solid core mild steel sections with220 mm diameter end forks and steelbolts. This solution was judged to bequestionable by the building authori-ties and was rejected by KruppStahlbau GmbH as the rigid steelmembers offered no flexibility in theadjustment of construction tolerances.This led to VSL’s alternative design forthe tension members being adopted.

This design is based on VSL’s staycable system. Each tension memberincludes twenty-two 0.6” mono-strands, a fixed end anchorage and an

The casino structure consists of twobasement and four podium levels pro-viding 3,000 car park spaces, and300,000 m2 of generalfloor area incorporatinggaming tables, showroomand function facilities,night-clubs, restaurantsand family entertainment.

In addition, a five star hotelrises forty floors abovestreet level with an empha-sis on suite-style accom-modation.VSL has contributed specialist exper-tise to three areas of the job, namely,Vertical Lift Core, Transfer Beams, andHotel Floor Slabs.� Vertical Core: The Core is stressed

satisfactorily matched the theoreticalcalculated values.

This project represents a goodexample of the value VSL can addthanks to its technical expertise,innovative ideas and high qualitypost-tensioning systems.

Johann KolleggerVSL Germany

adjustable stressing anchorage with aring nut. Each individual tensionmember was accurately tightenedusing hydraulic jacks.

The stressing of the tension memberstook place in December 1995 andJanuary 1996. Following the removalof the central support tower inFebruary 1996, the force in certaintension members was remeasured and

Beams. Stressing is carriedout incrementally using126, 96 and 75 m lengthVSL 5-19 type tendons.� Transfer Beams (7) arelocated four storeys abovethe main hotel entranceand atrium. They supportthe hotel structure. Eachbeam is 1 m wide, withspans ranging from 21 m

to accommodate eccentric floorloadings on the external cores causedby their interaction with the Transfer

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VSL NEWS9N ° 1 . 1 9 9 6

- AUSTRALIA -S Y D N E Y C A S I N O P R O J E C T, N E W S O U T H W A L E S

VSL ‘S CONTRIBUTION TO NSW‘SMOST PRESTIGOUS CONSTRUCTION PROJECT

The Sydney Casino project, at an esti-mated value of AU$575 million(US$435 million) is currently NewSouth Wales’ largest and most presti-gious commercial construction project.The Developer of the project is SydneyHarbour Casino Properties Pty Ltd,and the General Contractor isLeighton Contractors Pty Ltd.

For ease of control, Leighton havesplit the site into a number of sepa-rable packages including hotel, apart-ments and theatres. VSL were suc-cessful in negotiating post-tensioning(PT) contracts to cover all areas of theproject, one of only three or fourcontractors to do so.

The project is being constructed on afast track programme with construc-tion following very closely behind thedesign by Consulting Engineers OveArup and Partners. Consequently, ourPT contract was awarded on the basisof a schedule of rates per tonne ofstrand installed. The project will use atotal of 950 tonnes of PT over an areaof 150,000m2 with a completion dateof May 1996.

The structure, covering a site area ofapproximately 35,000 m2, includes afive level basement carpark, maincasino floor and three levels of familyentertainment. Above the Podium

- USA -THE RITZ-CARLTON HOTEL AND SAN JUAN CASINO, PUERTO-RICO

VSL OPTIMUM DESIGN SAVES OWNER CONSTRUCTION DOLLARS

levels are two 12 level tower blocks,one for the hotel, the other for theapartment accommodation. These

construction phase. This expertisespeeds up preparation of the placingdrawings and allows us to solveconstruction related problems quickly,whenever they occur, without causingdelays.

VSL (your Project Partner) often has aclose relationship with the Engineer(and therefore with the Owner) fromthe start of a project. It is VSL’s expe-rience, technical ability and capacityto perform at a higher level of valuewhich make it stand out from thecompetition.

Phil AranaVSL Corp. - Florida, USA

The Miami office of the VSLCorporation continues to serveOwners and Engineers by providing ahigh level of value-added engineeringservices that result in real construc-tion savings. VSL’s early involvementin a project results in a more efficientdesign - the right slab thickness forthe spans and loads, compatibilitywith available slab forming systems,and establishing the fastest possibleconstruction cycles.

The Engineer of Record for The Ritz-Carlton Hotel worked together withVSL Engineers to fine tune the floorlayout, balancing architectural,mechanical, structural and construc-tion requirements.

VSL is able to bring our specificexpertise to this and other projects byrecognising and simplifying post-tensioning details to prevent themfrom becoming problems during the

tower blocks are not stressed due totheir irregular S-shape.Commencing in January 1995, VSLinstalled 104 permanent groundanchors to the perimeter diaphragmwall. The anchors ranged in size from6-3 to 6-10 and took approximatelyfour months to complete. An interest-ing element of the construction is thetransfer slab at level 5 which includesapproximately 86 tonnes of multistrandtendons with a large percentage using55 strand tendons.

John Davie - VSL Australia

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- GERMANY -K A I S E R S A A L M O N U M E N T I N B E R L I N

COMPUTER CONTROLLED PRECISION HEAVY LIFTING

As Ziiblin had already successfullyworked with VSL’s Heavy Lifting spe-cialists, we were invited to define alifting concept. VSL’s lifting schemeconsisted of jacking up the 1,300tonne building using VSL strand Iift-ing units. 13 SLU-330 type units wereused to form 11 lifting points, nineoutside and two inside the building.The hydraulic pump scheme and thecomputerised control system usinglaser technology were both designedby VSL to maintain the level and avoidexcessive deformation.

The scope of VSL’s works included thedesign, supply, assembly and operationof the lifting and control equipment.After five days of assembly work, theKaisersaal was raised off the groundon 29 February and lifted the follow-ing morning without major interrup-tions over a distance of 2.40 m inabout two hours.

This very demanding project was anexcellent occasion for VSL HeavyLifting to prove its know-how andreliability.

Erich Miischlerand Ernst Schneider

VSL Switzerland

Sony is building its European head-quarters on the site of the neo-Baroque Kaisersaal building, adjacentto the luxury war-damaged HotelEsplanade on the Potsdamer-Platz inBerlin.

To preserve these historical monu-ments, the city council required thatSony integrate them into its buildingcomplex. However, because theKaisersaal was also blocking theconstruction of an important road, ithad to be relocated bv 75 m.

Sony entrusted general contractor Ed.Ztiblin AG with the relocation works.This consisted in strengthening the

fairly fragile two-storey building (14 x17 m in plan) and underpinning itwith a grid of massive post-tensionedbeams, Once the building had beenlifted, sliding tracks could be exten-ded underneath and the buildingmoved.

- FRANCE -N U C L E A R P O W E R

P L A N T M A I N T E N A N C EREPLACING THE CLOSURE HEAD

IN A NUCLEAR REACTOR

Part of the EDF (Electricité de France -the government-owned French utilitycompany) maintenance system forFrench nuclear sites includes removingand replacing the closure heads in1,300 MW nuclear power plants.

The scope of VSL’s works involveslifting the closure head (100 tonnes)from ground to 27 m using a trolleyplaced on beams fitted with a SLU 120handling jack at 36 m, then slidingthe trolley and its load over a distanceof approximately 7 m to the entranceof the building.

The replacement closure head is thenattached to the trolley at 27 m andslid into the plant to replace theremoved head.

The reverse operation is scheduled totake place two weeks later to removethe old closure head.

The handling equipment has been soldto EDF and is exclusively used for thisreplacement operation in the powerplant. EDF is in charge of storing theequipment and VSL is responsible forsupervising the operations and main-tenance.

Jean-Claude PeslierVSL France

▲▲ Control room:the nerve centreof the lifting operation

▲▲ Shop-testing the liftingequipment (partial view)

Lifting the closure headWeight : 100 tonnes

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VSL NEWS11N ° 1 . 1 9 9 6

- CHILE -ESCONDIDA COPPER MINE

LIFTING THE ROOF OF ONE OF THE WORLD’S LARGEST MINES

VSL was engaged as the specialistcontractor to lift more than 4,200tonnes of steel roof structure andconveyor for the Escondida CopperMine in northern Chile. VSL’s contractfor engineering and execution of thelifting operations was critical to thesuccess of this fast-paced project.

VSL was selected by the owner - MineraEscondida Limitida - and the construc-tion manager - Fluor Daniel - becauseof its technically superior solution, itsability to respond rapidly to the needsof the project, and the confidence ofthe construction manager and ownerthat VSL could perform the workwithout interruption to ongoing miningoperations. Through extensive engineer-ing and close co-ordination with theclient, construction manager and gene-ral contractor, the project was complet-ed in less than a year, despite thedifficult site conditions and severalchanges in the scope of the project

- MALAYSIA -PERTRONAS TOWERS, KUALA LUMPUR

LIFTING THE SKYBRIDGE LINKING THE WORLD’S HIGHEST TOWERS

The 20,000 mz steel roof structurewas lifted in eight separate opera-tions. The heaviest roof section andauxiliary lifting structures weighedover 620 tonnes. The lifting systemwas designed for zone 4 earthquakeloading (UBC) and to withstand thedaily blasting at the open pit mine.Close co-operation between VSLCorporation in the United States andVSL Sistemas Especiales deConstruction S.A. in Chile resulted in

The Skybridge project consists of asteel/concrete two storey glass sidedwalkway spanning between the world’stwo tallest buildings which stand at450 m. It links the twin towers atlevels 41 and 42. The V-shaped legssupporting the bridge at its centrerepresent a distinctive feature of theskybridge project. These legs aremounted upon a spherical bearing atlevel 29 on each of the towers and riseat 63 degrees towards the bridge centre.

In addition, the client - Samsung (M)Sdn Bhd - specified that eight liftingtendons were to be used to lift theCentral section. To further complicatethe lift, there was a stringent toleranceon allowable deflections to protectthe glass cladding.

a successful project for the client.The engineering of the heavy liftingtowers, tower guys and roof supporttrusses; the choice of the methods;the provision of equipment as well asspecialists for operating the equip-ment were provided by VSLCorporation. On-site labour and localengineering were provided by VSLSistemas.

Construction manager, Frank Arcese,said “We are very happy with thework of VSL....If we ever have anotherproject like this, we will definitelyinvite VSL to be involved.“

Keith W. JacobsonVSL Corp. - USA

andAndrés Avendano

VSL Sistemas - Chile

The scope of works of VSL was thelifting of the skybridge using apiece-by-piece method. The opera-tion was carried out by VSLSingapore Heavy Lifting Department,in co-operation with theAsia/Australasia VSL Technical Centrefor the temporary works design andwith local support from VSL Malaysia.

The small working area and timeconstraints meant that the four compo-nents had to be lifted from eccentric posi-tions. The degree of manipulation requiredto move these components in plan, orien-tation and vertically involved an intricatesequence of controlled moves.

The VSL proposal provided the MainContractor - Samsung/Kukdong/Jasatera JV - and the owner - KualaLumpur City Centre Bhd - with a signi-ficant saving in cost, time and risk.

David TraynerVSL Singapore

The works proceeded successfullydespite the persistent efforts ofthe elements with strong winds,

torrential rain and electricalstorms (including lightningtrikes).

With the invaluable assistance of VSLHeavy Lifting team from Switzerlandand a modification to their new laser

levelling system, it was thus possibleto monitor and fully control thislifting operation.

P T S Y S T E M S

12 N ° 1 . 1 9 9 6 VSL NEWS

- STAY CABLE -T E S T S

2 MILLION LOAD CYCLES AT 160 MPA FOR THREE PERFECT VSL CABLE TESTS

- SLAB SYSTEM -V S L L A B + T M

THE COST-EFFECTIVE STATE-OF-THE-ART

PT SLAB SYSTEM

The stay cable specimens tested werefor 6-24, 6-44, and 6-63 strandcables. Testing, which was carried outin Chicago, was in accordance withthe Post-Tensioning Institute’s recom-mendations for Stay Cable Design,Testing and Installation. After suc-cessfully undergoing 2 million loadcycles at 160 MPa stress range, each

As Building Owners havebecome more sophisti-cated, demands for-construction qualityand durability haverisen. In its constantsearch to improvethe science ofpost-tensioning,VSL is pleasedto offer its newVSLAB”” System,a two strand groutedtendon.

specimen was subject to static ultimateloading. All three specimens easilypassed the test requirements.

These three results show that VSL’s200 SSI and 200 Monostrand(Grouted) stay cable systems, both ofwhich use greased and sheathedmonostrands, have very high fatigueresistance and excellent anchorageefficiency.

Manufacturing and installation of theFoss Waterway Bridge stay cables willcommence in May 1996.

Duncan LAPSLEYVSL Technical Centre - USA

VSL has recentlv completed testingthree full sized stay cable specimens,this being part of the contract requi-rements for the Foss Waterway cablestayed Bridge in the State ofWashington, USA. On this contract,VSL Corporation will supply and installthe VSL 200 Monostrand stay cablesystem (with grouted free length).

The VSLAB”” (pronounced V-SLAB)System offers many features previous-ly unavailable in commercial post-tensioning. Lying at the heart of theVSLAB’” System are two grouted slabstrands that provide a higher perfor-mance level. Each of the two strands isplaced within a corrosion-resistantpolypropylene duct. Positive duct-to-anchorage connections provide full

strand encapsulation, leavingno partial strand lengths exposed

to the surrounding concrete. Strandencapsulation is maintained, even atslab construction joints, by the incor-poration of the innovative VSLAB’”System details.

To meet its commitment to providethe highest quality system, VSL offersa complete package. This begins withthe production of components. VSLhas set up a Quality Assurance Plan toensure that all production problemsare resolved prior to field use. VSLengineering ensures that all compo-

nents are compa-tible and designedto maintain tole-

rances during nor-mal field handling. To

guarantee in-place quality,the VSLAB”” System is installed,stressed and groutedby VSL crews.

By specifying theVSLAB”” System, the Owner has themost cost-effective state-of-the-artpost-tensioned slab system in theworld.

Dan FalconerVSL Corp. - USA

P T S Y S T E M S

The metal pylon head is supported bytwo cylindrical concrete legs and rises60 m over the deck which is a 240 mlong, 7.3 m wide single carriageway.The deck is supported by 28 stays.Seven groups of two parallel stayssupport a 133 m long main span andseven groups of two parallel stayssupport the smaller 64.5 m long span.

The scope of VSL’sworks was the designand installation of the200 SSI System. VSLwas selected by thegeneral contractor onthe technical perfor-mance of the system.Close co-operation be-tween the EuropeanTechnical Centre andthe Western EuropeOperating Unit led tothe commercial successof the operation.The multi-layer conception of the 200SSI system guarantees optimal corro-sion protection. The strands, greasedand covered with a tightly-extruded PEsheath, are guided from anchor head to anchor head by individual PE tubes.Finally, an outer PE pipe protects thebundle formed by the guide tubes.

The main feature of the 200 SSI concept is its ease of installation.Having positioned the preassembled

empty stay pipe, the strands are indi-vidually pushed through the anchorhead. This system also allows for non-destructive inspection and even thereplacement of strands during thestructure’s service life.

An international site team wasbrought together to ensure the suc-cess of the 200 SSI. The installation

works and stressing of the stay cableswere completed in a record-breakingeight weeks. This feat highlights theadvantages of the system: possibilityof preassembly, lightness of staypipes and use of a single strand ins-tallation system.

Adrian GNAEGIWestern Europe Operating Unit 5

VSL NEWS 13N ° 1 . 1 9 9 6

- STAY CABLE -R I V E R L E V E N B R I D G E , S C O T L A N D

AN APPLICATION OF VSL STAY CABLES WITH SINGLE STRAND INSTALLATION (200 SSI)

The River Leven Bridge links the LeslieRoundabout to the SouthfieldRoundabout in Glenrothes, 30 milesnorth of Edinburgh in Scotland. Thebridge is situated in a park area andcrosses 17 m above the water level ofthe River Leven.

200 SSI Anchor Head

M A R K E T I N G

14 N ° 1 . 1 9 9 6 VSL NEWS

E J E P R AT R O A D W A L L , C O N C E P C I O N , C H I L EOUR FIRST RETAINED EARTH WALL IN CHILE

The office building for Chile’sTelephone Company (CTC) will be thetallest in the middle of Santiago’sdowntown section. With 33 storeys, itcovers approximately 60,000 m’. Itshould be noted that the building islocated in a zone 4 seismic area.The post-tensioning alternative offeredby VSL was the only solution that metthe building’s height criteria, theowner’s column-free space require-

ment and the tight budget. The flexi-bility of the VSL post-tensioning sys-tem meant that CTC’s demanding spe-cifications could be met. The closeworking relations between the pro-ject’s engineers (Lagos & Contreras),the contractor (Inela-Agroman) andthe VSL design team resulted in ahighly successful project.

Celso VillaVSL Sistemas - Chile

After casting an eye around for projectsto develop the Retained Earth Wall sys-tem (REW) in Chile, VSL SistemasEspeciales de Construccion S.A. wasawarded a contract for the execution ofa REW project for 6,200 m2 of plainfacing panels by the Chilean contrac-tor, Brotec, in August 1994.

The Eje Prat Road project inConcepcion, a town in southern Chile,includes ramp structures and anembankment between two new bridgeswith eight back-to-back retainedearth walls. The longest wall is 210 mlong and 10 m high.

Because the project is located in azone 4 seismic area and for aestheticreasons, 30% of the panels have a rai-sed finish. The REW between thebridges includes a terrace with a cur-ved lower wall. The distribution ofraised finish panels and the curvedlayout was chosen by the client, thePublic Department of Transportation.

The REW system provided significantsavings in cost and time as well asbeing a practical solution given theunfavourable soil characteristics.

Andres AvendanoVSL Sistemas - Chile

▼ General view of wall n°2

VSL DEVELOPS ITS PRESENCE IN SOUTH AMERICA

C T C B U I L D I N G, S A N T I A G O , C H I L EVSL PT ALTERNATIVE WAS THE ONLY SUITABLE

SOLUTION FOR THIS HIGH RISE BUILDING

M A R K E T I N G

VSL NEWS15N ° 1 . 1 9 9 6

VSL MOVESINTO NEW ZEALAND

AFTER THE AUCKLAND SKY TOWER,VSL SIGNS THE QUAY WEST PROJECT

Following the successful introductionof VSL Climbform into New Zealandvia the award of the Auckland SkyTower Project to VSL NSW, VSL is nowmaking inroads into the precastconcrete-dominated New Zealandbuilding industry.

Post-tensioning has been used predom-inantly in Civil Engineering structuresin New Zealand (e.g. bridges, wharvesetc.). However, the building industryhas been heavily geared to precastconcrete construction systems.

The Quay West project, being built byCivil & Civic for Mirvac Developments(NZ) Pty Ltd has been awarded to VSLon a design and construct basis. TheConsulting Engineers are MurrayJacobs Limited. The project is a presti-gious 33 levels apartment building,

VSL’S UNIQUE REPAIR/RETROFIT EXPERTISEGEORGETOWN UNIVERSITY LAW CENTRE,

WASHINGTON, D.C.

28 of which are post-tensioned. Ourcontract involves some 100 tonnes ofstrand and approximately 20,000 m2of stressed floor.

Our marketing efforts are obviouslypaying off as we have also beenawarded our second New ZealandClimbform Contract - the MountStreet Student Accommodation pro-ject for Fletcher Construction Pty Ltd.Although only 16 floors, and not ofthe same scale as Sky Tower, it isalways pleasing to receive repeatcustom.

We look forward to providing moreinnovative construction solutions inNew Zealand.

Michael BrownVSL Australia

Increasingly, VSL’s services are beingsought as a specialist repair/retrofitcontractor for routine cable repairs aswell as for major restoration works toexisting structures. VSL has recentlycompleted a project that highlightsour unique capabilities in this area.

Georgetown University in Washington,D.C. is undertaking an expansion of itsLaw Centre. A new structural steelbuilding is being constructed on top ofan existing three-level post-tensionedparking garage. VSL was contracted byWhiting Turner, the constructionmanager, to carry out the followingworks related to the repair and selectivedemolition of the parking garage:� Provide more than 80 openings in

the post-tensioned slabs for steelcolumn penetrations.

��Provide 12 openings in the post-tensioned mat foundation to allow forpenetration of new piles and pile caps.

��Provide two new elevator openingsin the post-tensioned slabs.

��Re-anchor unbonded tendons at theedge of all new openings.

��Provide a structural surveillance ofthe parking structure to assist theconstruction manager in his evalua-tion of the garage.

��Provide various concrete and PTrepairs to beams, slabs and atconstruction joints.

As the Georgetown University projectdemonstrates, VSL can provide abroad scope of services onrepair/retrofit projects.In addition to the capabilities listedabove, VSL has developed expertise inthe following specialties:��Conventional reinforced concrete

repairs��Precast refurbishment��Fabrication and installation of

structural steel elements for repairs��Shotcreting��Slab waterproofing/membranes

Because of these unique capabilities,we have developed close relationshipswith consultants, property managers,and contractors who have an ongoingneed for these services. VSL’s worksclosely with the client to providestructural surveys, budget pricinginformation, and a broad scope ofrepair services.

Our highly-skilled technical staff,from engineers to field technicians,provide the highest quality and mostinnovative solutions to our clientsneeds.

Don Kline - VSL Corp.Washington DC - USA

Sky Tower - Auckland

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