AUGUST / 2014

MOvable scaffolding systems
cast in situ
The Movable Support Systems
The most common movable support system in utilization are:

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The ones used on the construction of continuous prestressed
concrete decks by the cantilever method.
The ones used on the construction of continuos prestressed
concrete decks, but casting from 1/5 of the span to the 1/5 of the
next span.

In the first case we named our machines as Form Traveller FT, while in the
second case we named them as Movable Scaffolding Systems MSS.
Boxh solutions exist in the underslung and overhead versions. i.é; working
under or above the decks.

Table of Contents
Movable Scaffolding System:

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• Underslung solution;………….………….. 3

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• Overhead solution;................................. 14
• Self-launching underslung solution;.......... 20

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• Self-launching overhead solution............ 27

Form Travellers:

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• Overhead solution;………………………. 31

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• Underslung solution…………………….. 38

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MOVABLE SCAFFOLDING SYSTEM
Underslung solution

The MSS is a modern equipment designed to allow in situ casting of
full viaducts and bridges spans, with double beam or box decks cross
sections, built as a prestressed concrete structure. The concept was
developed after appearance of the pre-stressing technology used at the
concrete decks construction, with the goal of increasing productivity,
in the construction of bridges and viaducts, mechanizing some phases
of the construction cycle.


Where to use the
MSS
The Movable Scaffolding
System MSS is used in the
bridges and viaducts full span
cast in situ construction

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The MSS includes: a steel structure, working platforms and ladders,
internal and external formwork and a set of hydraulic systems that
allows to operate the formwork, launch the MSS and transmitte the
reactions to the columns and deck already castel.

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TT cross section deck solution
Solution currently used on road decks for spans up till aprox. 55m (in
between columns center).
The internal formwork is launched together with the MSS main
structure, in a folded position. The opening and closing internal
formwork folding movements is hydraulic operated, moving all panels
together as one set.

Main components:
A- Main girder
B- Noses
C- Suspension gallows
D- Transverse beams
E- Supporting brackets
F- Launching wagons
G- Main cylinders
H- Plataforms and ladders
I- External formwork
J- Internal formwork
L- Counterweight

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11093

Box cross section deck solution
Solution currently used on road and railway decks for spans bigger
than 55m (in between columns center).
The internal formwork doesn’t move together with the MSS main
structure. The opening and closing internal movements are made
hydraulically through an internal formwork transport trolley. The
internal formwork panels are transported one at a time.

Main components:
A- Main girder
B- Noses
C- Suspension gallows
D- Transverse beams
E- Supporting brackets
F- Launching wagons
G- Main cylinders
H- Plataforms and ladders
I- External formwork
J- Internal formwork
L- Counterweight
K- Transport trolley

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Simple and effective!
The demand for simple but
effective solutions has guided
the STRUKTURAS efforts over
all these years.
Construction companies
recognise our efforts by being
able to minimize the labor.


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We try not only to find
enginneering solutions, but
fiding the simpliest!

A little bit of the history of the MSS!
STRUKTURAS was founded in 1991 in the continuity of Olav Opedal AS project, an AKER
group company specialized in mechanical engineering. Engineer Tore Gjolme still active in
STRUKTURAS, developed at Olav Opedal AS the MSS concept, the first equipment was used in
1971 in Norway.

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STRUKTURAS company in recent decades became norwegian leading provider of this type of
equipment, being present in more than 200 projects worldwide.

We strive for creating solutions that exceed the expectations of our customers.

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The STRUKTURAS MSS put the bridge construction in a new era!
The MSS is easily adaptable to cross sections ranging from double T to single box and span lengths from
20m to 70m.

Special design solutions from some of our most challenging projects:


Spliting of the Main structure into three sections ( Front Nose – Main Girder – Rear Nose ) and
design of a unique hinged connection between the parts has made it possible to build
superstructures  with a horizontal radius as small as 200m.


A rebar trolley and portal crane can be integrated onto the MSS system for prefabricated
reinforcement cages.


Placement of concrete pumps and cranes onto the MSS system.

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Special projects require special solutions
The accumulated experience in recent decades has allowed STRUKTURAS meet special
requirements of different projects, developing customized solutions.

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We are also proud to have designed, engineered and delivered the largest ever used MSS's.

Some of our largest MSS’s!

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RING ROAD-Thailand; Span 67,5m; deck weigh 67,5ton/m; deck width 30,5m

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GERALD DESMOND BRIDGE, Long Beach USA; Span 70,1m; Deck weight 47,0ton/m;
Deck width 24,6m (currently in manufacture)

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Typical MSS cycle

Hydraulic Systems
Operations such as opening / launching of internal
formwork, lift and lower the MSS between the
concreting and launching positions, side shift and
longitudinal launching to the next span, are
preformed by different hydraulic systems powered
by electricity.

-Lower the system after prestressing is installed
-Side shift boxh MSS halves
-Launch boxh MSS halves to the next span
-Close boxh MSS halves
-Lift the MSS to the concreting position (close the
internal formwork if the cross section is a TT one. If
the cross section is a box then the internal formwork
will be launched to the next span just after rebar cage of
the boxtom slab and webs is installed.)
-Concreting
-Relocate supporting bracket front rear column to the
front column

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View of the boxtom slab and webs
rebar partial instalation. Internal
formwork still awaiting at previous
span.

View from the internal formwork
front panel towards the new span
to be built. Assembling stage of
the boxtom slab and web rebar at
the new span.

Internal formwork rolling wagon
starting the rails transport

Rails instalation on top of precast
concrete blocks

Installing rebar cage deck
elements using a mobile crane

Transport of an internal formwork
panel using the rolling wagon
hydraulic operated

Arrival of the panel do its opening
and fixation position

General view of the internal
formwork and its transport rolling
wagon.

Detail of the diaphragm opening
above column alignement to
permit to pass with the internal
formwork panel and its transport
rolling wagon

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Launching wagon detail

External formwork and rails

Temporary suspension of the 1st
supporting bracket awaiting fot the
2nd supporting bracket of the pair

View from the MSS rear

View from the MSS front

Deck TT cross section without
concrete diaphragms

Overview showing two MSS’s

Internal formwork of a TT deck
cross section

MSS during launching process

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Overview of an MSS

Detail of the formwork plywood
fixation

Internal formwork folding
cylinders

Supporting brackets installed of
columns

Rear suspension

Launching wagon

Front nose

Front support

Suspension gallows

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The cambering
adjustment

STRUKTURAS developed a
simple system of adjustable
mechanical screw jacks and
adjustable struts that serve
boxh do allow transverse
adjustment due to the deck
transverse slope and
cambering adjustment to
compensate for the elastic
deformation of the MSS due
to the span casting.

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Movable scaffolding system
overhead solution

Like the Underslung MSS, the Overhead MSS is a modern
equipment designed to allow cast in situ prestressed TT or box
section full span concrete decks, in bridges or viaducts.
The main diference between the two MSS underslung and overhead
systems lies in the position of the main structure in relation to the
concrete deck.

The MSS is generally
composed by: a steel
structure, working platforms
and ladders, internal and
external formworks and a set
of hydraulic systems which
allow to operate the
formworks, lauch the MSS in
between different spans and
transmit the forces to the
columns and decks already
concreted.

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In the Overhead MSS the main structure is placed above the
concrete deck and the formwork is suspended while at the
Underslung MSS the main structure is placed under the concrete
deck and the formwork is supported on it.

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Suspended Formworks
The Overhead MSS is supported on top of columns and the formwork
panels are suspended by threaded bars of high strength.After
prestressing is installed the formwork panels are open using chain
hoists, winches or hydraulic cylinders, leaving the panels suspended
from the hangers.

Main components:
A- Main girder
B- Noses
C- Rear support
D- Transversal beams
E- Main supports
F- Launching wagons
G- Main cylinders
H- Working platforms and ladders
I- External formwork
J- Internal formwork
K-Hangers
L- Boxtom platform

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The special solutions

The Overhead can be designed to
special utilization where the columns
are too short, or where necessary to
ensure free heights as in railways,
roads or navigation channels
crossings.
In these cases the formwork can be
designed to open horizontally like in
a drawer rather than rotate arround
the hangers.
Boxh Underslung and Overhead
MSS solution can be made
symmetrical, meaning that they can
be used to cast the spans in boxh
directions without having to reverse
the MSS.

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Special front support using concrete
prefab legs.

Overview of the Overhead MSS

Formwork opening

Supports installed on top of transverse
steel beams anchored to the columns

Formwork panels at open position during
launching

Installing steel brackets at short columns
to support transverse steel beams

View of the external formwork

View of the internal formwork

Upper part of the main support and
launching wagon used at launching and
side shift

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Detail of the launching cylinder

Main support and access ladder

Rail and winch used to open and close
formwork panels

Internal formwork

External formwork

View in the launching formwork
direction

Transverse beams

Temporary support behind the abutment

Detail of the winch used to open and
close the formwork panels

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Pros and cons
In general terms we can refer the following
pros and cons of the Overhead MSS when
compared to the Underslung solutions;

Pros:

Usually easier to assemble behind
the abutment except in the cases
where the ground elevation behind
abutment allows the undrslung
MSS to be assembled unrestricted.

Usually easier to move from one
deck to the paralel one, unless the
ground elevation behind the
abutment makes it possible to lauch
the Underslung MSS till behind the
abutment and then perform at this
working area the operation in
question.
Cons:

Requires to leave more blockouts at
the concrete decks which are used
to suspend the formworks.

The horizontal reaction forces
transmited to the columns are larger
than at the Underslung MSS since
this one is made by two halves and
launching one half at a time
alternately transmits a smaller
reaction force.

In particular at the box section
decks the pre-assembled rebar cage
is more dificult installed inside the
external formwork than at the
underslung MSS.

When there are two parallel decks
and we are building at the second
one, it is not easy to take advantage
of placing a mobile crane on the
first deck, because the overhead
main structure of the MSS hinders
or prevents placement of the rebar
cages inside the formwork.

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SELFLaunching MOVABLE
SCAFFOLDING SYSTEMS
Underslung selflaunching solution

Where to use the
SMSS?
The SMSS is used to cast in
loco full span concrete decks,
in bridges and viaducts being
especially suitable for use on
water or where the columns
are to high.

The SMSS can relocate the supporting brackets from one column to
the next without the need for cranes being by this very fact to
operate on water or in situations of very high columns.

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Main components:

SMSS main feature
The SMSS is equipped with a supporting bracket transport device
eliminating the use of cranes to perform this operation.

A- Main girder
B- Rear nose
C- Suspension gallows/ roling
support
D- Transverse beams
E- Supporting brackets
F- Launcging wagons
G- Main cylinders
H- Working platforms and ladders
I- External formwork
J- Internal formwork
K- Transport trolley

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SMSS advantages

No need to use crane to
relocate the supporting
brackets from one column
to the next.

Easy to use on the water or
with very high columns.

Typical SMSS cycle for a box cross section deck
-Lower the SMSS after the prestressing is installed
-Transfer the load reaction from the suspension gallows/rolling gallowes support to the launching
device
-Side shift both SMSS halves
-Launch both SMSS halves to the next span
-Launch the suspension gallows/rolling support
-Close both SMSS halves
-Lift the SMSS to the concreting position
-While the rebar cage are installed the two supporting brackets pairs are transported to the next
columns, using the existing device located at the main girders and front nose
-Move the internal formwork to its position on the SMSS as soos as the rebar cage installation of the
bottom slab and webs is finished.
-Concreting

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Suspension gallows hydraulic cylinder
detail

View of the external formwork and
internal formwork rolling wagon rails

Suspension gallows, internal formwork
and rails

Internal formwork and rails detail

Front nose

Casting 1st span

SMSS launching stage

External formwork

Installing rebar

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Transverse beams and bottom slab
formwork

Front nose support

Rear view before relocate the supporting
brackets

Relocating the supporting brackets

Detail of the rear nose

Top view of the rar nose

Installing front nose

Installing front nose

Installing front nose

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Front nose and supporting brackets

Front nose support at column

Rear supporting bracket before to be
moved to the next column

Front nose and supporting brackets

Launching device and access

External formwork

Pre-assembling of the internal formwork
rolling wagon together with one panel

Pre-assembling of one internal formwork
panel

Hinge detail in between front nose and
main girder

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The main girders of
our MSS’s and
SMSS’s
Strukturas optimized over all
these years and the many
dozens of projects, the main
girder design that equips all of
our MSS’s and SMSS’s
whether underslung or
overhead.

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Selflaunching movable scaffold
systems
oVERHEAD SOLUTION: SELFLAUNCHING

The Overhead MSS also exist as a selflaunching version, i é; the
main supports are relocated by a winch device included on the
equipment instead to use a crane.

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This equipment able to transport and install the main supports
themselves, is named Selflaunching Movable Scaffolding System
SMSS.

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This SMSS configuration is very usefull when the deck
construction is located above water eliminating the use of
marine resources usualy whith very high costs.

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Type and amount of supports
The type and amount of supports can be ajusted so that the
overall functioning of the SMSS suits the intended deck
construction cycle.

Main components:
A- Main girder
B- Noses
C- Rear support
D- Transverse beams
E- Main supports
F- Launching wagons
G- Main cylinders
H- External formwork
I- Hangers

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Launching wagon detail

Formwork opening

Detail of the formwork opening

View from the rear

Front support relocation

Front support on top of column

Main support and launching wagon

Moving upper part of front support and
launching wagon

Front support

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Tailor made solutions
STRUKTURAS design,
engineer, built and supply also
many tailored solutions,
meeting, specific requirements
of each preject and each
client.

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Where to use the Form
Travellers?
Overhead form traveller
The Form Travellers are used in
the in situ construction of the
concrete prestressed decks by
the cantilever method.

Cast in situ

The Form Traveller is a Temporary support structure supporting
the weigh of the bridge and viaduct deck segments cas in situ
built by the cantilever method from the pierhead to the center of
the span, and generally consisting of the following components:
main steel structure, internal and external formwork for shape in
situ the concrete segment, working platforms and ladders,
anchor system to the previous casted segments and hydraulic
equipment used to launch, level and ajust.

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Form Travellers
Excellent cost-effective solution!
The STRUKTURAS Form Travellers includes a main support structure
equiped with a formwork being completed by several launching and
adjusting hydraulic systems.

MAIN COMPONENTS:
A- Boxtom slab platform
B- Main frame
D- Main cylinder
E- Pull-down cylinder
G- Launching device
H- Main rail
Y- Rear working platform
K- Front beam
L- Rear truss
M- Rear bogie
N- Wind bracing
O- Transverse beams
P- External formwork
R- Internal formwork
T- Lower working platform
U- Upper working
X- Front Bogie

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Only one concept

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Many different applications

The STRUKTURAS Form
Travellers are usually made to max.
5m lenght segments, but may in
special cases be made to measure.
The segment weights typically range
in between 80ton and 550ton

MAIN ADVANTAGES

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Typical weights of the STRUKTURAS Form Travelles

-Easily adjustable to the segment
lenght variations, cross section
height, web thickness, deck width,
can fit almost any deck cross
section.
-Reduced weight, saving prestressing
in the deck construction phase.
-Easy to transport
-Easy to assemble
-Reduced deformations
-Easy to ajust to the curves

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- 120 ton
- 180 ton
- 220 ton
- 300 ton
- 450 ton
- 550 ton

Steel components
segment – 32 ton de steel
segment – 43 ton de steel
segment – 50 ton de steel
segment – 68 ton de steel
segment – 96 ton de steel
segment – 105 ton de steel

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Wooden components

- 10 ton of
- 15 ton of
- 18 ton of
- 25 ton of
- 35 ton of
- 40 ton of

wood
wood
wood
wood
wood
wood

The weights above are per Form Traveller and must be multiplied by 2 for the pair.
The approximate weights listed above are based on deck standart cross sections, with up to 18m wide
and 5m segment lenght.
The wooden beams can be partially replaced by aluminiym beams.
The wooden weights also include the film faced plywood.

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ASSEMBLING OF THE FORM TRAVELLERS ON THE PIERHEAD

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NON SYMMETRICAL ASSEMBLY

ASSEMBLING WITH CROSS-SUPPORT
The cross-support is an auxiliary structure specially design to permit completion of
the two Form Travellers assembling, on top of the pier head of reduced
dimensions.

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The use of the cross-support alows to build the pierhead segment as short as
possible, leading to savings on the formwork, since it need not be installed with big
brackets cantilevering from the columns external surface.

As an alternative to the use of the
cross-support on the pierhead the
STRUKTURAS Form Travellers can
also be installed in a non symetricall
assembly

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After first segment is casted at one site
of the pierhead first Form Traveller is
launched allowing free space required
for the installation of the second Form
Traveller.

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Corgo
Form Travellers arriving to the closing
segment

Segment weight 264 ton
Segment length 6,00m
Deck width 28m

Form Traveller main structure

Constantine
Pre cast concrete structs outsite of the
deck

Form Traveller overview showing detail
of the precast concrete struts outside of
the deck

Segment weight 170 ton
Segment lenght 3,50m
Deck width 30m

Form Traveller overview and transversal
diaphragms existing at every two
segments

Aerial view of the Form Traveller main
structure

Transversal diaphragm details close to
the pierhead.

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Mondego
Segment weight 225 ton
Segment length 5,00m
Deck width 18,2m

Rebar and blockouts for anchoring

Form Traveller boxtom view

Salamanca
Main frame and rear bogie view

Segment weight 100 ton
Segment length 4,10m
Deck width 11,30m

Cross-support side view

General view of the cros support
assembling

Main frame and rear bogie view

Form Traveller lateral view safety sets

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Cycle General Description
In a very general terms a Form
Traveller utilization cycle consists
of the following operations:

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-Form Traveller is launched
together or not with the internal
formwork, to its position at the
new segment.
-External formwork is ajusted
and fixed
-The rebar at boxtom slab and
webs is installed
-The internal formwork is
launched or in case that has
already been launched together
with the Form Traveller, it is just
closed
-Segment is casted
-Main rail is launched and
anchored
-Asa the concrete attained the
required strength
-The formwork is open, and
Form Travell is launched to the
next segment

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In most cases the execution cycle
of a pair of segments is weekly.

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There are even cases where 5 to 7
segment pairs are builted in one
month!

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The minimization of the
construction cycles depends on
the segment geometry, the rebar
design, the concrete quality and
techniques for assessing its
strenght.

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Form travellers
Underslung solution

The Underslung Form Traveller, as the Overhead
one, is a temporary support structure supporting
the weigh of the bridge and viaduct deck segments
cast in situ built by the cantilever method from the
pierhead to the center of the span, and generally
consisting of the following components: main steel
structure, internal and external formwork for shape
in situ the concrete segment, working platforms
and ladders, anchor system to the previous casted
segments and hydraulic equipment used to launch,
level and ajust.

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The formwork surfaces in contact with the concrete can be
wood, film faced plywood, metal sheet or plastic plate,
depending on the number of reuses envisaged and the concrete
architectural requirements.

Where to use the
Form Travellers?

The Form Travellers are
used in the in situ
construction of the
concrete prestressed decks
by the cantilever method.

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These Form Travellers are
especially suitable to cast
concrete arches or cable
stayed build decks, in the
cases where the stay is in
conflict with the main
structure of the overhead
Form Travellers.

!39
SCAFFOLDING SYSTEMS & LAUNCHING GANTRIES FOR CONCRETE BRIDGES-BRIDGE ENGINEERING CONSULTANTS

www.strukturas.com

!

AN ALTERNATIVE SOLUTION

The STRUKTURAS Underslung
Form Travellers are an excellent
alternative to the classical
Overhead Form Travellers.

!
!

Ask us, we have the solution!

Special solutions:

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The Underslung Form Traveller can be adapted to diferent types of bridges, such as arches and
stayed decks, leaving the free space to install the temporary or final stays, as to create the conditions
to make an easy launch backwards to the initial assembling position.
In cases where the rebar cage is pre-assembled, the STRUKTURAS Underslung Form Traveller is
the perfect choice. The external formwork of this type of Form Traveller is suspended below leaving
free space for instaling the rebar cage.
Pre-assembled rebar cage transport system. These systems can be tailor made to different types of
rebar cages.

!40

!

SCAFFOLDING SYSTEMS & LAUNCHING GANTRIES FOR CONCRETE BRIDGES-BRIDGE ENGINEERING CONSULTANTS

www.strukturas.com

!

Contact us!
Our services include:
-tender stage quotation preparation
-design, fabrication, delivery and technicall assistance to the new equipment
-rebuilt design regarding existing equipments delivered by us, for use in different conditions of the original

!

Ask for out reference list!
Consulte o nosso parceiro na sua área geográfica:

Eng. Aquilino Raimundo
Cel +351 932 255 374
Tel +351 243 701 460
ar@strukturas.com.pt

CLARKSGATE 5, N - 3970 LANGESUND

NORUEGA

!

ar@strukturas.com.pt

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