VSL_NEWS_1998_2

I S S U E T W O 1 9 9 8

Hung Hom Bypass, Hong Kong

6

14-15

PT of the Sydney

Superdome, the

Australia’s largest venue

Lifting of the Chong Ro

building unusual top structure

2 N ° 2 • 1 9 9 8

E D I T O R I A L

5Val de Rennes, a new

French reference in

cable-stayed bridges

8-13

7

Your specialist

contractor in

Retained Earth

Walls

VSL International Ltd.Bernstrasse 9, 3421 LyssachSwitzerland andVSL Management 41, avenue du Centre78067 St-Quentin-en-YvelinesFrance

Editor: A. Le PivertTel : 33 1 30 12 09 30

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

Regional Editors:P. Bron - Western Europe, Africaand South AmericaTel : 33 1 69 19 43 00

G. Pash - AustraliaTel : 61 2 9484 59 44

H. Wlodkowski - Eastern Europeand Middle EastTel : 41 34 447 99 11

J-P. Trin - AsiaTel : 852 2590 22 22

Coordination:S. AlezrahTel : 33 1 30 12 09 41

Circulation:C. Mancuso-GironTel : 33 1 30 12 09 32

Design:Red LineTel : 33 1 41 14 01 80

Linguistic Consultant:N. HargreavesTel : 01 43 66 88 05

P U B L I S H E D B Y

The Asian crisis: a springboard forinnovations

Periods of crisis often nurture innovations andcreative behaviours that lead to opportunities.Although the slump in the Asian market hasseriously hit the volume of work in theconstruction industry, VSL has the rightorganisation to use this recession as aspringboard to introduce new developmentsfor the future.

Given our technical and marketing expertise inAsia, we have the keys to ensure that our corebusiness activities remain competitive andprofitable. A vital trump card is our willingnessto provide customers with all our skills andknow-how to create solutions for their needs.

Each of our offices in Asia is backed up by VSL’sunique world-wide network. This gives oursubsidiaries access to numerous marketingsources and a wide array of information to helpthem attract new businesses.

Our goals are therefore to stay closer to ourcustomers, listen to their needs, provide themwith ever-greater services, and make full use ofour network to promote new activities.

Our commitment as a specialist sub-contractorto Asia is as strong as ever.

Alain Le Pivert

CEO and Chairman of the Board

Special PT Ground

Slab projects in Australia

H E A V Y L I F T I N G

SPECIAL

H I G H L I G H T S

3N ° 2 • 1 9 9 8

B R I D G E S

- K O R E A -S A N G D A E I I I B R I D G E

box bridge is 4.75 m long. Segmentsare cast in-situ and supported bylightweight formtravellers, which onlyweigh 52 t.VSL’s scope of works covers post-tensioning, re-bar, concreting, supplyand operation of form travellers for thesuperstructure and stress bars for thepiers. This represents 960 t of strands(6-4, 6-7, 6-17, 6-19, 6-20, 6-22) and730 t of ø 38-mm VSL stress bars.Currently 8 of the 14 key segmentshave been completed, and theremaining closures will be finished byApril 1999.

J.K LeeVSL Korea

- S W I T Z E R L A N D -V I A D U C S D E S VA U X

These two parallel bridges are part ofthe N1 motorway near Yverdon inWestern Switzerland, the last major,yet uncompleted link in the Swissmotorway network. Each bridge is 950 m long andconsists of 2 steel beams or a steelbox girder, and a prestressed concretedeck cast in 30-m sections using aformwork traveller. The eastern part ofthe bridge, which crosses a deepvalley, comprises two 130-m spansand is being constructed byincrementally launching the steelboxes downwards (slope 2,1%) fromthe eastern abutment.

VSL's involvement comprises:• prestressing the concrete deck with6-7 coupled cables and 6-4 transversecables in flat PT-Plus ducts;

• prestressing the connectiongirders between the 100-m highmain piers using 5-19 cables;• temporary 5-7 stay cables forstabilising a number of piers duringlaunching operation, including asystem to measure the forces inthese stays;• a combined propulsion andretaining system based on SMU-type strand equipment with a 700 kN thrust and a 1,200 kNretaining capacity.

VSL will complete its works on thisproject before the end of 1998.

Erich Möschlerand Fabrice Vouilloz

VSL Switzer land

Located in Hoengsung County, theSang Dae III bridge will cross oversteep mountain valleys to widen theexisting dual lane YongdongExpressway into a double dual laneexpressway serving the easterncoastal city of Kangreung.To cross the deep valley and improve

the existing winding road, thesuperstructure is being built using thefree cantilever method over the highlevel piers, the tallest of which rise upto a height of 92 m.Total length is 705 m (65 m + 5 x 115 m+65m and each segment of this7- span continious precast concrete

4 N ° 2 • 1 9 9 8

B R I D G E S

- SWITZERLAND -R E P A I R I N G T H E

T E U F E L S B R Ü C K E

- S PA I N -O R E S U N D L I N K

This 40-year-old arch bridge is part ofthe access to the Gotthard pass inCentral Switzerland. While the elegantmain arch is still in good condition,the actual bridge deck has sufferedfrom the progressive influence of saltcorrosion. It was therefore decided toreplace it. This was done in two stages so that one lane wouldremain constantly open to traffic.

The new deck is constructed fromprecast concrete elements weighingup to 40 t and measuring 10.40 m by4.40 m. Since no heavy duty cranecould be installed at this location,VSL designed and provided a specialtravelling gantry. This latter isequipped with VSL's hydraulicequipment to move the concreteelements into their final position.Suspended from the gantry, theelements were transported up to 90 m from the upper bridge end totheir place of installation. Hydraulicjacks were used to precisely positionthe elements before lowering. Thisoperation was immediately followedby longitudinal post-tensioning usingone-strand cables.The custom-made equipmentworked remarkably well. Theelements were successfully placedand stressed within a very tightprogramme and to the client's fullsatisfaction.

René RuprechtVSL Switzer land

The decks of the viaduct approachesfor the Oresund Link are beingconstructed in the DOSA offshoreplant, located in Southern Spain.A total of 49-composite spans, each150 m long and 30 m wide, will beprecast and delivered to the site.

Construct ing the viaduct

approaches for the Oresund l ink

VSL is in charge of the transversalpost-tensioning for the concreteslab. A 4/0.6’’ tendon is installedand stressed every 0.80 m, using a4/0.6’’ flat anchor in the live endand a VSL H-type anchorage in thedead end.The flat duct is manufactured inCTT Stronghold’s factory inBarcelona and shipped in 11-mpieces. The two parts of the flatduct are connected in the yard bymeans of a steel coupler and athermofuse element.12-m long by 30-m wide rebars &tendons assemblies are re-liftedand placed in position on top of thesteel frames. Once a complete spanis pre-assembled and installed, theconcrete is poured and thenstressed using VSL twin jacks.A total of 12,500 live and deadanchorages, 250,000 m of flat ductand 1,100 t of strands will beinstalled.The job started in spring 1997 andwill be completed by the end ofspring 1999.

Enrique AlonsoCTT Stronghold

B R I D G E S

5N ° 2 • 1 9 9 8

- F R A N C E -VA L D E R E N N E S ,

S T A Y C A B L E B R I D G E

In order to cope with the increasingtraffic of the city of Rennes (WesternFrance), a master plan introduced tocreate a new people mover railwayline. With an overall length of 9,400 m,the Val de Rennes project consists of15 stations, over 7,500 m ofunderground tunnels and trenches and1,025 m of viaducts. Among these, a460-m long double deck viaduct and acable-stayed bridge (the VAL) will becompleted by the end of 1998.

On the 26 November 1998, in thepresence of the Hong Kong Secretaryof Works and the Main Contractor(Maeda/Chun Wo Joint Venture)executives, VSL erected the lastsegment for the Hung HomInterchange.

This event marks the substantialcompletion of the erection works, partof an overall VSL package thatincluded precast geometry control,formwork design, bearings, expansionjoints and post tensioning (1,200 t).

The erection of the 1643 segmentswas carried out in one of the mostheavily congested areas of Hong Kongand utilised a launching girder andheavy capacity cranes. Due to the factthat the works often cross busy roadsand rail corridors, much of theerection work was carried out undersevere time restrictions (a few hoursper night).

Jean-Yves MondonVSL Hong Kong

- H O N G K O N G -H U N G H O M B Y P A S S : E R E C T I O N O F T H E

L A S T S E G M E N T

The Main Contractor -a joint venturebetween Quille (leader) and GTB-chose VSL to supply and install thelongitudinal post-tensioning (120 t ofVSLE 6-12 system) for the double deckviaduct and the stays (10 t of 200 SSIsystem) for the cable-stayed bridge. The VAL viaduct stay cables have ahigh degree of corrosion protection.Each strand is galvanised, waxed andtightly PE sheathed. In addition, theentire strand bundle is protected by athick walled HDPE pipeDue to the fact that works had to becarried out without interrupting trafficunderneath the bridge, the staycables were pre-assembled and liftedto their final position by a specialcableway. The pre-assemblingincludes the fabrication of the freelength of the stay, formed by thestand bundle and the HDPE, and

Lif t ing of the stays by a

special cableway

Cab les anchored above the deck

connecting the free length to both thedeck and the pylon anchor. The staysconsist of 4-, 12-, and 19-0,6” strands.The design of the 200 SSI system gavethe flexibility to prefabricate the stayanchors in a workshop and deliverthem as a single component on site.For aesthetic reasons the cables wereanchored above rather than belowthe deck. To allow for the narrowspace for stressing the cables in theanchorage zones, a special reducingcoupler was designed to permit theuse of smaller jacks.Thanks to these innovations both inthe technical design and theinstallation method, the VAL shouldbecome a new French reference incable-stayed bridges.

Bertrand RothVSL France

6 N ° 2 • 1 9 9 8

B U I L D I N G S / H E A V Y L I F T I N G

The Sydney SuperDome, whencompleted in September 1999, will beAustralia’s largest indoor venue, witha seating capacity over 20,000 and atotal floor area of 61,000 m2.

During the 2000 Games it will hostbasketball and gymnastics andprovide Sydney with the country’sbest and most versatile indoorentertainment and sporting facility.

Designed and build by Millennium, asubsidiary of Abigroup Limited inconjunction with Obayashi Corporation.The designers are Cox RichardsonArchitects in association with Devinede Flon Yaeger, a US based sportsarchitecture firm, and the consultingstructural engineers are TaylorThomson Whitting.

One of the unique features of theSydney SuperDome is that it has oneof the largest rooftop solar powerstations in the world, providing 70 kW.

- A U S T R A L I A -S Y D N E Y S U P E R D O M E

Post-tensioning of Australia’s largest venue

Millennium is also responsible for theconstruction of the on-site carparklocated adjacent to the SydneySuperDome which, with a capacity ofapproximately 3,500 cars, will becomethe biggest multi-level carpark inAustralia.

VSL provided the post-tensioningservices for both the SydneySuperDome and multi-level carpark tothe structures contractor, De Martinand Gasparini. A total over 500 t of theVSL 12.7-mm Slab system wereinstalled. VSL completed itsinvolvement at the SuperDome during

August 1998 and finished its works onthe carpark at the end of October 1998.VSL’s scope of works coveredapproximately 90,000 m2 of slab &band beams for the carpark and thestressing of the radial bands on thefour Concourse levels for theSydney SuperDome.

Ross LoakimVSL Austral ia

CARPARK NOT INCLUDED IN THIS DEVELOPMENT APPLICATION

7N ° 2 • 1 9 9 8

B U I L D I N G S / H E A V Y L I F T I N G

- S PA I N -EL TRIANGULO DE ORO

El “Triangulo de Oro” is a 6-storeybuilding located in one of the mostimportant commercial areas inBarcelona. The solution adopted bythe consultant for most of the floorswas PT slabs using unbondedmonostrand tendons - a method veryseldom used in Spain.

The tendons were cut, prefabricatedand labelled in CTT Stronghold’sfactory, and then delivered to site.VSL was in charge of the technicalassistance on site and carried out thetendon stressing using singlemonostrand jacks.

Enrique AlonsoCTT Stronghold

- K O R E A -L I F T I N G T H E C H O N G R O B U I L D I N G T O P S T R U C T U R E

VSL Switzerland and VSL Korea successfully joinedtheir skills to clinch the contract with SamsungCorporation for lifting this unusual structure.

The upper structure which houses a restaurant andexhibition galleries is formed by a triangular-shapedsteel truss with curved 60-m long legs which weighsover 3,400 t. The upper structure was erected on topof the Chong Ro Insurance Building and then liftedthrough 30 m by means of 16 SLU-330 strand units,mounted on the three circular building cores. To comply with stringent tolerances requirements,the lifting was controlled using a laser system.

The main lift took place at the end of June 1998. The structure was then fixed at its final level. The 30-m free gap between the building and theupper structure adds an unusual touch to Seoul'sskyline

Walter Al thausVSL Switzer land

8 N ° 2 • 1 9 9 8

R E T A I N E D E A R T H

A highly effective soilstabilisation system

The system is technically provenand highly reliable. It usesgalvanised steel mesh to reinforcethe soil mass. Alternating layers ofreinforcing mesh and backfill arebuilt up over the height of thestructure, creating a particularystable composite material withexcellent load-bearingcharacteristics.The major advantages presented bythe VSL reinforcement panel wereconfirmed by testing prior to beingpatented. Its use of crossbars,mobilising the soil thrust, providesthe whole panel with an adherencethat is far greater than that offeredby competing frictional systems. As a result, it provides:• reduced requirements for thequality and execution of the backfill;• a constant and reliable seismicresistance as, unlike the frictionsystem, the soil bearing capacityrestores itself;• reduced reinforcement depth andthus smaller quantities of oftencostly backfill.

VSL Retained Earth System isextremely economical to design andconstruct. The system simply consistsof three components -reinforcingmesh, precast facing panels andbackfill material- and this simplicityallows construction to proceed easilyand rapidly.

A full-services approachVSL's approach to a Retained Earthproject is tailored to meet the client’sspecific needs. Services range fromthe supply of all Retained Earthcomponents and technical supportto the design and construction of acomplete turnkey project.

SPECIAL

VSL has continued to develop a broad range of innovativeconstruction systems. VSL Retained Earth, a mechanicallystabilised earth (MSE) system, is one of these innovative solutions.This composite soil reinforcing system uses welded wire mesh toimprove the shear and compressive strength of an earth backfill.Over two million square meters of VSL Retained Earth walls arecurrently in service world-wide for highway projects, bridgeabutments, material storage facilities and other grade separationstructures. From the United States to Europe, VSL’s Retained Earthsystem has proven its performance and economy in hundreds ofsuccessful projects. Anumber of these references are developed inthis magazine.

An exceptional range ofarchitectural finishes

VSL Retained Earth is designed toprovide unlimited possibilities forarchitectural finishes that fully takeenvironmental issues intoconsiderations. VSL provides anextensive variety of panel sizes,textures, shapes, relief effects andcolours able to meet all aestheticrequirements. For example, localmaterials are used in theproduction of the precast facingpanels to blend with thesurrounding environment.

Of all existing MSE systems, VSL'smesh reinforcement principle providesthe greatest soil-to-reinforcementinteraction and pull-out resistance,ensuring a high level of stability, precisealignment and reliable performance.

Facing panels are

avai lab le in a wide

range of shapes,

sur face textures and

colours

Facing panels areavailable in a widerange of shapes,surface texturesand colours

9N ° 2 • 1 9 9 8

The Chilean contractor Brotecawarded VSL a contract for theconstruction of 6,200 m2 ofmechanically stabilised walls - thefirst Retained Earth Walls ever builtin Chile - as part of a roadconstructionprogramme in Concepción, a townlocated 60 km south of Santiago.

The Eje Prat Road project includes theaccess ramp and an embankmentbetween two new bridges for whicheight walls were needed - the longestbeing 210-m, and 10-m high.

VSL designed the walls, manufacturedthe hexagonal panels and supervisedtheir installation on-site.

Because of the project’s location in alevel 3 seismic area, the wallswere required to sustain a seismicacceleration of 0.4 g.To enhance the aesthetics of the walls,a third of the panels featured a raised-relief design while others incorporateda curved terrace layout which allowedthe structure to harmoniously blendinto the landscape.

Apart from their attractive aesthetics,hexagonal panels were chosen to

- C H I L E -E J E P R A T R O A D W A L L S I N C O N C E P C I Ó N

R E T A I N E D E A R T HSPECIAL

A rapid and easy construction system The construction of a Retained EarthStructure is extremely straightforward:

1 • Precast ing the panels on si te orin a precast yard

3 • Instal l ing the panels one-by-one

4 • Placing the reinforcing mesh

4 • Connecting the mesh with theloop clevis thanks to a dowel bar

5 • Placing and compacting the backfill

2 • Placing

the panels

using a

standard

crane

VSL’s firstRetained

Earth Walls in Chile

simplify the construction of walls withdifferent layout curves. Special angle panels were used forparticularly tight curves.

In addition to the savings generatedand its attractive appearance, theuse of the VSL Retained Earthsystem proved to be fully adapted tothe bad soil condition that existedon site.

Andrès AvendañoVSL Especiales de Construcción S.A.

The Eje Prat wal l completed

10 N ° 2 • 1 9 9 8

The Queensland Government hasrecently awarded to Bielby Holdingsthe construction works for the BrownsPlains Road/Mt. Lindsay HighwayInterchange. The project is located just20 km south of Brisbane in a high-density suburban area with major retaildevelopments adjacent to the site.Once completed, the project will form aseries of grade separated intersections,with seven VSLRetained Earth Walls fora total area of 5,900 m2.

VSL was awarded the contact to designand supply the Retained Earth Wallsbased on a 2-m x 1-m panel modulewith in-line horizontal and verticaljoints. The conforming arrangementpresented difficulties for wallinstallation. Therefore, VSL’s successfulalternative using a 2-m x 2-m panelwith a false joint provided a workablesolution and consistency with thearchitectural requirements.

Additional architectural featuresinclude up to three individual bandsfrom top of wall consisting of off formfinish (1% peach colour in off-whitecement), light sand blast (1% peachcolour in off-white cement) and lightsand blast (2% peach colour in off-white cement).

Thanks to the larger panels and simplererection method, VSL have providedthe contractor with reduced installationtimes for each wall.

Bary STORYVSL Austral ia

- A U S T R A L I A -PACIFIC MOTORWAY

PROJECT PACKAGE 6

The Pacific Motorway Project, whencompleted, will upgrade the existinghighway between Beenleigh andNerang to an 8-lane motorway. John Holland Construction wasawarded the road and bridge works tothe southern-most section at Nerang,some 70 km south of Brisbane. VSLwas chosen by the main contractorto design and supply Retained EarthWalls to the motorway and a majorintersection at Cayuga Street.

- A U S T R A L I A -B R O W N S P L A I N S R O A D

M T. L I N D S A Y H I G H W A Y I N T E R C H A N G E

R E T A I N E D E A R T HSPECIAL

The Cayuga Street walls weresupplied to the conformingarchitectural requirements of a 1.5-m x 1.5-m panel with a steppedrib pattern finish and representednearly 70% of the total area of wall.All remaining walls were supplied ina smooth hexagonal finish. The totalwall area was over 3,000 m2 with amaximum wall height of 6.5 m.

Bary StoryVSL Austral ia

11N ° 2 • 1 9 9 8

The site is a very large embankmentwith a significant soil volume:5,000,000 m3 for the platforms usedby the complex and 800,000 m3 ofworking soil and support structures.Consequently, the site required greatheights of soil embankments (up to

- P O R T U G A L -L I S B O N F O O D S U P P L Y M A R K E T

M.A.R.L will be Lisbon’s most important food market supplying all

Portugal’s supermarket chains.

20-m height) which had to becontained within RE walls. VSL proposed, with the support of itsconsultant Prof. Mateus de Brito, analternative solution to the initialproject using plastic mesh. This alternative solution consisted of

two superimposed walls supportingthe entire specialised soil project.

As it was necessary to redefine theentire project, VSL designed the walland launched a study on the soilfoundation’s global capacity that ledto the replacing of an important partof the foundations. VSL was also incharge of the drainage system project(particularly complex due to the walllength and height), the selection ofthe backfill material and all the siteco-ordination.

VSL completed its works mid-October1998 and delivered a 4,700-m2

Retained Earth Wall with smooth andraised hexagonal panels to the owner,M.A.R.L. Besides supplying all REmaterials, VSL’s scope of worksincluded the technicalsupervision/assistance and all theassembly work.

Zenobia Quadros-Mart insVSL Sistemas Portugal

Construct ion of MARL’s Retained Earth wal l ,

measuring up to 20-m height .

R E T A I N E D E A R T HSPECIAL

12 N ° 2 • 1 9 9 8

In order to reduce wall thickness andsimplify the construction process,Ferrostal AG (Man Takraft Group)selected VSL to design and supply thematerials as well as supervise theconstruction of three mechanicallystabilised walls: a 12-m high centralwall and two 18-m high side walls.

This project is part of the constructionof a new crushing plant for the world’slargest copper mine, Chuquicamata.This mine is located in a seismic zoneat 3,000 m above sea level in a desertarea.

The VSL proposal provided the Owner(Codelco), the main Contractor(Ferrostal), and the Civil WorksContractor (Delta) with significant costand time savings as well as a moreaesthetic solution.

- C H I L E -C H U Q U I C A M A T A M I N E C R U S H I N G P L A N T

VSL RetainedEarth Walls

for the world’slargest

copper mine

Designed to last 15 years in a0,3 g seismic zone, the walls alsohave to resist the circulation of theheavily loaded mine trucks driving asclose as one meter from the panels.

Given the height of the walls and theneed to deal with heavy loads, specialreinforced panels and heavy meshwere necessary. System componentswere supplied from United States, andthe galvanised mesh as well as thepanels were manufactured locally. Toreduce costs, the backfill materialcame from one of the crushing plants,

and was compacted under strictsupervision. In addition, given the shortservice life of the structure and the dryenvironment (desert), the system wastailored-design and was subject to lessstringent corrosion specifications.

The design was flexible enough toallow last minute modifications to thedimensions of the walls.Manufacturing the panels close to thejob site provided additional flexibilityand reactivity to all requiredmodifications

Andrès AvendañoVSL Especiales de Construcción S.A.

Chuquicamata RE wal ls

designed to last 15 years

in a 0.3 g seismic zone

R E T A I N E D E A R T HSPECIAL

13N ° 2 • 1 9 9 8

Valentin wallsLocated at Valentin, North of Besançon(Eastern France), two interchangeshave been constructed, to easetraffic movement through this mainaccess and transit road.

Six retaining walls, originally intendedto be in reinforced concrete on deep-seated foundations, were alternatelyerected using VSoL by the successfultenderer G.T.F.C., a Bouyguessubsidiary operating in this region.

- F R A N C E -VA L E N T I N A N D P O N T C H A R R A W A L L S

These two projects were carried out with “ VSoL”,

the name used for VSL’s soil reinforcement

technique in France.

embankment, allowed for a 15% costreduction for the backfill whencompared with competing reinforcedsoil systems.

On completion, the saving totalledas much as 40% of the originalproject budget.

Pontcharra wallsIn order to divert the traffic crossingthe town of Pontcharra (SouthernFrance), a bypass is currently underconstruction between two roads.

Two retaining walls are to be built bythe main contractor D.T.P.Terrassements, a Bouyguessubsidiary, to meet the needs of thenarrow space available for thejunction of the two roads.

These 3-m high walls are alternatelycast in-situ using VSoL concreteand cover a surface area of 900 m2.

These walls, topping at 6 m for asurface area of 1,800 m2, weredesigned so that their facings exactlymatched the pattern chosen by thearchitect. No less than 80 differenttypes of precast concrete panels wererequired to satisfy this demand.

Thanks to VSoL’s shorterreinforcements, the reinforced soil

Each wall segment is a single panelwith a partial raised relief andsansdblasted finish that perfectly follows the line of the road profile.The works started in November 1998 and will becompleted in Spring 1999.

Raphaël LuVSL France

R E T A I N E D E A R T HSPECIAL

Approximate Scale

14 N ° 2 • 1 9 9 8

Y O U R L O C A L C O N S T R U C T I O N P A R T N E R S

- V S L I N A U S T R A L I A -A P T G R O U N D S L A B S S P E C I A L I S T

VSL has over the last two and ahalf years carried out thedesign and installation of theVSL mono strand system inalmost 300,000 m2 of slab onground in Australia.

In Australia, VSL’s approach hasbeen to work closely with all partiesin developing and installing anengineered solution tailored toparticular needs of each projects.

Key aspects considered by VSL include:• minimisation of slab joints to reduce ongoingmaintenance costs;• sub-base design to optimise slab and sub-base cost for individual site conditions;• concrete properties to maximise durabilityand strength while minimising the combinedcost of the concrete and post -tensioning;• pour size to provide a slab that hasbuildability characteristics that match localcapabilities;• design detailing to match project specificrequirements such as a range of jointingtreatments depending on usage and tendonpositioning to suit fixed racking layouts, etc.

The benefits of VSL post-tensioned slabs on groundhave provided developers,users, and builders withadvantages in a wide rangeof applications over otherfloor slab systems. Projectssuch as wineries, storage,and distribution centres, aircraft hangars, water tankbases, freezer stores andtransport facilities have alladopted post-tensionedground floor slabs.

FCL TRANSPORT,MELBOURNEFCL, a major, national transportationand container handling groupneeded torelocate theiroperations as a

result of the Melbourne City LinkProject.Their modern purpose-built facility isnow nearing completion in theMelbourne port side area of Footscray.All floors and pavements weredesigned by VSL as post-tensioned toaccommodate a range of loadingrequirements including:• container stacking (4 boxes high,

100 t stacks)• operating container handling

forklifts (96 t axle load)• empty container storage and

maintenance building• warehouse racking storage (6 t

post loads)

Slab thicknesses ranged from 300 thickto 160 thick and were designed to suitthe poor “Coode Island Silt” subgradematerial present across the site.The largest single slab pour was2,800 m2, requiring some 826 m3 ofconcrete. A total area of 39,000 m2 ofslab was required.In addition to the slabs, all the newbuilding foundations were designedby VSL, as post-tensioned achievingsignificant construction savings overconventional deep piled foundations.

The design of all pavements andfootings needed to allow for likelylong term differential settlements,characteristic of the local subgrade.

FCL Transport faci l i ty:

si te pavements plan

FCL Transport new faci l i ty

96t axle Forklift

100t Container

Empty Container

Warehouse Racking

Maintenance Building

0 50m

15N ° 2 • 1 9 9 8

Y O U R L O C A L C O N S T R U C T I O N P A R T N E R S

Big W, Monarto S.A. Warehousing 34,200 m2

Bridgestone, Salisbury S.A. * Warehousing 15,000 m2

Australia Post, Dandenong. Vic. * Letter Facility 27,100 m2

GMH, Dandenong Vic. * National Spare Parts 51,200 m2

QP2, Campbellfield Vic. Distribution 22,400 m2

BTR Foundry, S.A. * Manufacturing Facility 7,900 m2

FCL, Footscray. Vic. Transport Facility 40,000 m2

UMT Tas. * Cool & Freezer Store 17,000 m2

RAAF, Edinburgh S.A. Hangar 3,200 m2

Tubemakers, Somerton Vic. * Distribution Centre 7,500 m2

S.A. Water, Riverland S.A. * Water Tanks Bases 8,200 m2

Woolworths, Pooraka S.A. Distribution Centre 40,000 m2

CRT Bulk Handling, Altona Vic. * Transport Facility 53,500 m2

Bandiana, Albury NSW * Active Distribution22,000 m2

Southcorp Winery S.A. Winery Storage* Design by VSL.

GMH NATIONAL SPAREPARTS WAREHOUSE,DANDENONGThe project comprises of 51,200 m2 ofpost-tensioned slab on grade floor asan overlay over existing concretepavements associated with formermanufacturing buildings on this site.A 135-mm thick slab was proposed byVSL to fit within a 150-175 availableconstruction depth.

Other projects carried out over the last 2 years are:

26 No. 1900 m2 pours are required andwhen completed provide awarehousing floor with joints typically65 m apart in either direction.

UMT Freezer store

Slab edge detai l

UMT COLDSTORE,TASMANIAThis prominent project at Spreyton, inTasmania, comprises of a separatewarehouse and a cool store/freezerbuilding.A total of 17,000 m2 of post-tensioned slabs were designedand stressed by VSL.Load efficient, high durability, highcrack control post-tensioned slabswere selected by the builderHansen & Yuncken for this “Designand Construct” project.Of particular interest is the adoption

Armoured expansion joint detai l ,

typical ly incorporated in slab on

ground projects.

of twin layers of post-tensioned slabsto the freezer areas where the P.T. wearing slab was constructed overa thick polystyrene insulating layerover a lower post-tensioned base slab.The adoption of this floor slabarrangement is believed to be a firstfor Australia and was found bydetailed structural analysis to havesignificant load capacity in addition toits thermal efficiency.

Being a food related facility, a durable,crack-free post-tensioned floor systemwith minimum joints provided qualityand cost effectiveness that met UMT’srequirements.

UMT coldstore

VSL has gained the confidence of designers, builders and facility operatorsin developing slab designs and installing post-tensioning in slabs on groundthroughout southern Australia.

Peter Bannerman & Frank Fi l ipponeVSL Austral ia

General Motors Helden warehouse

Cover p la te to s tee langle one s ide on ly

Stee l angle whi thanchor bars CFW to back

140

150120

Post-tensionedWearing Slab

Post-tensionedBase Slab

Polystryene

Perimeter mesh(1 m wide)

Heat distribution pipe systeme(bellow and bedding), withinfilling leyer

Your solution networkHEADQUARTERS

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