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AUGUST / 2014
AUGUST / 2014

MOvable scaffolding systems

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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.

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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: ! ! • Underslung solution;………….………… 3 ! •
Table of Contents Movable Scaffolding System: ! ! • Underslung solution;………….………… 3 ! •
Table of Contents Movable Scaffolding System: ! ! • Underslung solution;………….………… 3 ! •
Table of Contents Movable Scaffolding System: ! ! • Underslung solution;………….………… 3 ! •

Table of Contents

Movable Scaffolding System:

! ! • Underslung solution;………….………… 3 ! • Overhead solution; 14 ! • Self-launching
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• Underslung solution;………….…………
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• Overhead solution;
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• Self-launching underslung solution;
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• Self-launching overhead solution
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Form Travellers:
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Overhead solution;………………………. 31

Underslung solution……………………

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MOVABLE SCAFFOLDING SYSTEM Underslung solution The MSS is a modern equipment designed to allow in

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.

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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.

Where to use the MSS

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

the bridges and viaducts full span cast in situ construction 3 ! SCAFFOLDING SYSTEMS & LAUNCHING
the bridges and viaducts full span cast in situ construction 3 ! SCAFFOLDING SYSTEMS & LAUNCHING

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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.

hydraulic operated, moving all panels together as one set. Main component s: A- Main girder B-

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

I- External formwork J- Internal formwork L- Counterweight 4 ! SCAFFOLDING SYSTEMS & LAUNCHING GANTRIES FOR
I- External formwork J- Internal formwork L- Counterweight 4 ! SCAFFOLDING SYSTEMS & LAUNCHING GANTRIES FOR

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11093
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.

The internal formwork panels are transported one at a time. Main component s: A- Main girder

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

J- Internal formwork L- Counterweight K- Transport trolley 5 ! SCAFFOLDING SYSTEMS & LAUNCHING GANTRIES FOR
J- Internal formwork L- Counterweight K- Transport trolley 5 ! SCAFFOLDING SYSTEMS & LAUNCHING GANTRIES FOR

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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!

to find enginneering solutions, but fiding the simpliest! A little bit of the history of the
to find enginneering solutions, but fiding the simpliest! A little bit of the history of the
to find enginneering solutions, but fiding the simpliest! A little bit of the history of the

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.

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

solutions that exceed the expectations of our customers. 6 ! SCAFFOLDING SYSTEMS & LAUNCHING GANTRIES FOR

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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.

Placement of concrete pumps and cranes onto the MSS system. 7 ! SCAFFOLDING SYSTEMS & LAUNCHING
Placement of concrete pumps and cranes onto the MSS system. 7 ! SCAFFOLDING SYSTEMS & LAUNCHING
Placement of concrete pumps and cranes onto the MSS system. 7 ! SCAFFOLDING SYSTEMS & LAUNCHING
Placement of concrete pumps and cranes onto the MSS system. 7 ! SCAFFOLDING SYSTEMS & LAUNCHING
Placement of concrete pumps and cranes onto the MSS system. 7 ! SCAFFOLDING SYSTEMS & LAUNCHING

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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)

47,0ton/m; Deck width 24,6m (currently in manufacture) 8 ! SCAFFOLDING SYSTEMS & LAUNCHING GANTRIES FOR
47,0ton/m; Deck width 24,6m (currently in manufacture) 8 ! SCAFFOLDING SYSTEMS & LAUNCHING GANTRIES FOR
47,0ton/m; Deck width 24,6m (currently in manufacture) 8 ! SCAFFOLDING SYSTEMS & LAUNCHING GANTRIES FOR
47,0ton/m; Deck width 24,6m (currently in manufacture) 8 ! SCAFFOLDING SYSTEMS & LAUNCHING GANTRIES FOR
47,0ton/m; Deck width 24,6m (currently in manufacture) 8 ! SCAFFOLDING SYSTEMS & LAUNCHING GANTRIES FOR
47,0ton/m; Deck width 24,6m (currently in manufacture) 8 ! SCAFFOLDING SYSTEMS & LAUNCHING GANTRIES FOR

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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.

Typical MSS cycle

-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

supporting bracket front rear column to the front column 9 ! SCAFFOLDING SYSTEMS & LAUNCHING GANTRIES
supporting bracket front rear column to the front column 9 ! SCAFFOLDING SYSTEMS & LAUNCHING GANTRIES
supporting bracket front rear column to the front column 9 ! SCAFFOLDING SYSTEMS & LAUNCHING GANTRIES
supporting bracket front rear column to the front column 9 ! SCAFFOLDING SYSTEMS & LAUNCHING GANTRIES
supporting bracket front rear column to the front column 9 ! SCAFFOLDING SYSTEMS & LAUNCHING GANTRIES

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

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

Internal formwork still awaiting at previous span. Rails instalation on top of precast concrete blocks View

Rails instalation on top of precast concrete blocks

span. Rails instalation on top of precast concrete blocks View from the internal formwork front panel

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.

stage of the boxtom slab and web rebar at the new span. Installing rebar cage deck

Installing rebar cage deck elements using a mobile crane

Installing rebar cage deck elements using a mobile crane Internal formwork rolling wagon starting the rails

Internal formwork rolling wagon starting the rails transport

Internal formwork rolling wagon starting the rails transport Transport of an internal formwork panel using the

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

formwork panel using the rolling wagon hydraulic operated Arrival of the panel do its opening and

Arrival of the panel do its opening and fixation position

Arrival of the panel do its opening and fixation position General view of the internal formwork

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

of the internal formwork and its transport rolling wagon. Detail of the diaphragm opening above column

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

the internal formwork panel and its transport rolling wagon 10 ! SCAFFOLDING SYSTEMS & LAUNCHING GANTRIES

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Launching wagon detail View from the MSS rear Overview showing two MSS’s External formwork and

Launching wagon detail

Launching wagon detail View from the MSS rear Overview showing two MSS’s External formwork and rails

View from the MSS rear

Launching wagon detail View from the MSS rear Overview showing two MSS’s External formwork and rails

Overview showing two MSS’s

detail View from the MSS rear Overview showing two MSS’s External formwork and rails View from

External formwork and rails

Overview showing two MSS’s External formwork and rails View from the MSS front Internal formwork of

View from the MSS front

MSS’s External formwork and rails View from the MSS front Internal formwork of a TT deck

Internal formwork of a TT deck cross section

the MSS front Internal formwork of a TT deck cross section Temporary suspension of the 1st

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

bracket awaiting fot the 2nd supporting bracket of the pair Deck TT cross section without concrete

Deck TT cross section without concrete diaphragms

the pair Deck TT cross section without concrete diaphragms MSS during launching process 11 ! SCAFFOLDING

MSS during launching process

without concrete diaphragms MSS during launching process 11 ! SCAFFOLDING SYSTEMS & LAUNCHING GANTRIES FOR

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Overview of an MSS Supporting brackets installed of columns Front nose Detail of the formwork

Overview of an MSS

Overview of an MSS Supporting brackets installed of columns Front nose Detail of the formwork plywood

Supporting brackets installed of columns

Overview of an MSS Supporting brackets installed of columns Front nose Detail of the formwork plywood

Front nose

an MSS Supporting brackets installed of columns Front nose Detail of the formwork plywood fixation Rear

Detail of the formwork plywood fixation

columns Front nose Detail of the formwork plywood fixation Rear suspension Front support Internal formwork folding

Rear suspension

nose Detail of the formwork plywood fixation Rear suspension Front support Internal formwork folding cylinders Launching

Front support

the formwork plywood fixation Rear suspension Front support Internal formwork folding cylinders Launching wagon

Internal formwork folding cylinders

suspension Front support Internal formwork folding cylinders Launching wagon Suspension gallows 12 ! SCAFFOLDING SYSTEMS

Launching wagon

support Internal formwork folding cylinders Launching wagon Suspension gallows 12 ! SCAFFOLDING SYSTEMS & LAUNCHING

Suspension gallows

folding cylinders Launching wagon Suspension gallows 12 ! SCAFFOLDING SYSTEMS & LAUNCHING GANTRIES FOR

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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.

the elastic deformation of the MSS due to the span casting. 13 ! SCAFFOLDING SYSTEMS &
the elastic deformation of the MSS due to the span casting. 13 ! SCAFFOLDING SYSTEMS &
the elastic deformation of the MSS due to the span casting. 13 ! SCAFFOLDING SYSTEMS &
the elastic deformation of the MSS due to the span casting. 13 ! SCAFFOLDING SYSTEMS &
the elastic deformation of the MSS due to the span casting. 13 ! SCAFFOLDING SYSTEMS &
the elastic deformation of the MSS due to the span casting. 13 ! SCAFFOLDING SYSTEMS &

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Movable scaffolding system overhead solution Like the Underslung MSS, the Overhead MSS is a modern

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.

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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.

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.

the forces to the columns and decks already concreted. 14 ! SCAFFOLDING SYSTEMS & LAUNCHING GANTRIES
the forces to the columns and decks already concreted. 14 ! SCAFFOLDING SYSTEMS & LAUNCHING GANTRIES

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Suspended Formworks

Main components:

The Overhead MSS is supported on top of columns and the formwork panels are suspended
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.
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.

in box h directions without having to reverse the MSS. 16 ! SCAFFOLDING SYSTEMS & LAUNCHING
in box h directions without having to reverse the MSS. 16 ! SCAFFOLDING SYSTEMS & LAUNCHING
in box h directions without having to reverse the MSS. 16 ! SCAFFOLDING SYSTEMS & LAUNCHING
in box h directions without having to reverse the MSS. 16 ! SCAFFOLDING SYSTEMS & LAUNCHING
in box h directions without having to reverse the MSS. 16 ! SCAFFOLDING SYSTEMS & LAUNCHING

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Special front support using concrete prefab legs. Overview of the Overhead MSS Formwork opening Supports

Special front support using concrete prefab legs.

Special front support using concrete prefab legs. Overview of the Overhead MSS Formwork opening Supports installed

Overview of the Overhead MSS

using concrete prefab legs. Overview of the Overhead MSS Formwork opening Supports installed on top of

Formwork opening

prefab legs. Overview of the Overhead MSS Formwork opening Supports installed on top of transverse steel

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

on top of transverse steel beams anchored to the columns Formwork panels at open position during

Formwork panels at open position during launching

columns Formwork panels at open position during launching Installing steel brackets at short columns to support

Installing steel brackets at short columns to support transverse steel beams

brackets at short columns to support transverse steel beams View of the external formwork View of

View of the external formwork

support transverse steel beams View of the external formwork View of the internal formwork Upper part

View of the internal formwork

View of the external formwork View of the internal formwork Upper part of the main support

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

support and launching wagon used at launching and side shift 17 ! SCAFFOLDING SYSTEMS & LAUNCHING

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Detail of the launching cylinder Internal formwork Transverse beams Main support and access ladder External

Detail of the launching cylinder

Detail of the launching cylinder Internal formwork Transverse beams Main support and access ladder External formwork

Internal formwork

Detail of the launching cylinder Internal formwork Transverse beams Main support and access ladder External formwork

Transverse beams

of the launching cylinder Internal formwork Transverse beams Main support and access ladder External formwork Temporary

Main support and access ladder

formwork Transverse beams Main support and access ladder External formwork Temporary support behind the abutment Rail

External formwork

beams Main support and access ladder External formwork Temporary support behind the abutment Rail and winch

Temporary support behind the abutment

External formwork Temporary support behind the abutment Rail and winch used to open and close formwork

Rail and winch used to open and close formwork panels

Rail and winch used to open and close formwork panels View in the launching formwork direction

View in the launching formwork direction

formwork panels View in the launching formwork direction Detail of the winch used to open and

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

of the winch used to open and close the formwork panels 18 ! SCAFFOLDING SYSTEMS &

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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.

prevents placement of the rebar cages inside the formwork. 19 ! SCAFFOLDING SYSTEMS & LAUNCHING GANTRIES
prevents placement of the rebar cages inside the formwork. 19 ! SCAFFOLDING SYSTEMS & LAUNCHING GANTRIES
prevents placement of the rebar cages inside the formwork. 19 ! SCAFFOLDING SYSTEMS & LAUNCHING GANTRIES
prevents placement of the rebar cages inside the formwork. 19 ! SCAFFOLDING SYSTEMS & LAUNCHING GANTRIES
prevents placement of the rebar cages inside the formwork. 19 ! SCAFFOLDING SYSTEMS & LAUNCHING GANTRIES

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SELFLaunching MOVABLE SCAFFOLDING SYSTEMS Underslung selflaunching solution The SMSS can relocate the supporting

SELFLaunching MOVABLE SCAFFOLDING SYSTEMS

Underslung selflaunching solution

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.

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.

suitable for use on water or where the columns are to high. ! 20 SCAFFOLDING SYSTEMS
suitable for use on water or where the columns are to high. ! 20 SCAFFOLDING SYSTEMS

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Main components:

SMSS main feature The SMSS is equipped with a supporting bracket transport device eliminating the
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.

• Easy to use on the water or with very high columns. Typical SMSS cycle for
• Easy to use on the water or with very high columns. Typical SMSS cycle for
• Easy to use on the water or with very high columns. Typical SMSS cycle for

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

of the bottom slab and webs is finished. -Concreting ! 22 SCAFFOLDING SYSTEMS & LAUNCHING GANTRIES

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Suspension gallows hydraulic cylinder detail Internal formwork and rails detail SMSS launching stage View of

Suspension gallows hydraulic cylinder detail

Suspension gallows hydraulic cylinder detail Internal formwork and rails detail SMSS launching stage View of the

Internal formwork and rails detail

hydraulic cylinder detail Internal formwork and rails detail SMSS launching stage View of the external formwork

SMSS launching stage

Internal formwork and rails detail SMSS launching stage View of the external formwork and internal formwork

View of the external formwork and internal formwork rolling wagon rails

external formwork and internal formwork rolling wagon rails Front nose External formwork Suspension gallows, internal

Front nose

and internal formwork rolling wagon rails Front nose External formwork Suspension gallows, internal formwork and

External formwork

formwork rolling wagon rails Front nose External formwork Suspension gallows, internal formwork and rails Casting 1st

Suspension gallows, internal formwork and rails

formwork Suspension gallows, internal formwork and rails Casting 1st span Installing rebar ! 23 SCAFFOLDING SYSTEMS

Casting 1st span

gallows, internal formwork and rails Casting 1st span Installing rebar ! 23 SCAFFOLDING SYSTEMS & LAUNCHING

Installing rebar

formwork and rails Casting 1st span Installing rebar ! 23 SCAFFOLDING SYSTEMS & LAUNCHING GANTRIES FOR

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Transverse beams and bottom slab formwork Relocating the supporting brackets I n s t a

Transverse beams and bottom slab formwork

Transverse beams and bottom slab formwork Relocating the supporting brackets I n s t a l

Relocating the supporting brackets

and bottom slab formwork Relocating the supporting brackets I n s t a l l i

Installing front nose

I n s t a l l i n g f r o n t n

Front nose support

l i n g f r o n t n o s e Front nose support

Detail of the rear nose

t n o s e Front nose support Detail of the rear nose Installing front nose

Installing front nose

nose support Detail of the rear nose Installing front nose Rear view before relocate the supporting

Rear view before relocate the supporting brackets

front nose Rear view before relocate the supporting brackets Top view of the rar nose Installing

Top view of the rar nose

relocate the supporting brackets Top view of the rar nose Installing front nose 24 ! SCAFFOLDING

Installing front nose

brackets Top view of the rar nose Installing front nose 24 ! SCAFFOLDING SYSTEMS & LAUNCHING

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Front nose and supporting brackets Front nose and supporting brackets Pre-assembling of the internal formwork

Front nose and supporting brackets

Front nose and supporting brackets Front nose and supporting brackets Pre-assembling of the internal formwork rolling

Front nose and supporting brackets

and supporting brackets Front nose and supporting brackets Pre-assembling of the internal formwork rolling wagon

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

the internal formwork rolling wagon together with one panel Front nose support at column Launching device

Front nose support at column

wagon together with one panel Front nose support at column Launching device and access Pre-assembling of

Launching device and access

Front nose support at column Launching device and access Pre-assembling of one internal formwork panel Rear

Pre-assembling of one internal formwork panel

and access Pre-assembling of one internal formwork panel Rear supporting bracket before to be moved to

Rear supporting bracket before to be moved to the next column

supporting bracket before to be moved to the next column External formwork Hinge detail in between

External formwork

before to be moved to the next column External formwork Hinge detail in between front nose

Hinge detail in between front nose and main girder

formwork Hinge detail in between front nose and main girder ! 25 SCAFFOLDING SYSTEMS & LAUNCHING

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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.

of our MSS’s and SMSS’s whether underslung or overhead. ! 26 SCAFFOLDING SYSTEMS & LAUNCHING GANTRIES
of our MSS’s and SMSS’s whether underslung or overhead. ! 26 SCAFFOLDING SYSTEMS & LAUNCHING GANTRIES
of our MSS’s and SMSS’s whether underslung or overhead. ! 26 SCAFFOLDING SYSTEMS & LAUNCHING GANTRIES
of our MSS’s and SMSS’s whether underslung or overhead. ! 26 SCAFFOLDING SYSTEMS & LAUNCHING GANTRIES
of our MSS’s and SMSS’s whether underslung or overhead. ! 26 SCAFFOLDING SYSTEMS & LAUNCHING GANTRIES
of our MSS’s and SMSS’s whether underslung or overhead. ! 26 SCAFFOLDING SYSTEMS & LAUNCHING GANTRIES
of our MSS’s and SMSS’s whether underslung or overhead. ! 26 SCAFFOLDING SYSTEMS & LAUNCHING GANTRIES

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Selflaunching movable scaffold systems oVERHEAD SOLUTION: SELFLAUNCHING The Overhead MSS also exist as a selflaunching

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.

the use of marine resources usualy whith very high costs. ! 27 SCAFFOLDING SYSTEMS & LAUNCHING
the use of marine resources usualy whith very high costs. ! 27 SCAFFOLDING SYSTEMS & LAUNCHING
the use of marine resources usualy whith very high costs. ! 27 SCAFFOLDING SYSTEMS & LAUNCHING

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Type and amount of supports

Main components:

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

Launching wagon detail

Launching wagon detail Formwork opening Detail of the formwork opening View from the rear Main support

Formwork opening

Launching wagon detail Formwork opening Detail of the formwork opening View from the rear Main support

Detail of the formwork opening

wagon detail Formwork opening Detail of the formwork opening View from the rear Main support and

View from the rear

opening Detail of the formwork opening View from the rear Main support and launching wagon Front

Main support and launching wagon

opening View from the rear Main support and launching wagon Front support relocation Moving upper part

Front support relocation

Main support and launching wagon Front support relocation Moving upper part of front support and launching

Moving upper part of front support and launching wagon

Moving upper part of front support and launching wagon Front support on top of column Front

Front support on top of column

support and launching wagon Front support on top of column Front support 29 ! SCAFFOLDING SYSTEMS

Front support

launching wagon Front support on top of column Front support 29 ! SCAFFOLDING SYSTEMS & LAUNCHING

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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.

specific requirements of each preject and each client. ! 30 SCAFFOLDING SYSTEMS & LAUNCHING GANTRIES FOR
specific requirements of each preject and each client. ! 30 SCAFFOLDING SYSTEMS & LAUNCHING GANTRIES FOR
specific requirements of each preject and each client. ! 30 SCAFFOLDING SYSTEMS & LAUNCHING GANTRIES FOR
specific requirements of each preject and each client. ! 30 SCAFFOLDING SYSTEMS & LAUNCHING GANTRIES FOR
specific requirements of each preject and each client. ! 30 SCAFFOLDING SYSTEMS & LAUNCHING GANTRIES FOR

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Overhead form traveller Cast in situ The Form Traveller is a Temporary support structure supporting

Overhead form traveller

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.

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.

of the concrete prestressed decks by the cantilever method. ! 31 SCAFFOLDING SYSTEMS & LAUNCHING GANTRIES
of the concrete prestressed decks by the cantilever method. ! 31 SCAFFOLDING SYSTEMS & LAUNCHING GANTRIES

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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

T- Lower working platform U- Upper working X- Front Bogie ! 32 SCAFFOLDING SYSTEMS & LAUNCHING
T- Lower working platform U- Upper working X- Front Bogie ! 32 SCAFFOLDING SYSTEMS & LAUNCHING
T- Lower working platform U- Upper working X- Front Bogie ! 32 SCAFFOLDING SYSTEMS & LAUNCHING

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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

segment weights typically range in between 80ton and 550ton MAIN ADVANTAGES -Easily adjustable to the segment
segment weights typically range in between 80ton and 550ton MAIN ADVANTAGES -Easily adjustable to the segment
segment weights typically range in between 80ton and 550ton MAIN ADVANTAGES -Easily adjustable to the segment

MAIN ADVANTAGES

-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

Typical weights of the STRUKTURAS Form Travelles

Steel components

Wooden components

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120 ton segment – 32 ton de steel

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10 ton of wood

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180 ton segment – 43 ton de steel

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15 ton of wood

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220 ton segment – 50 ton de steel

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18 ton of wood

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300 ton segment – 68 ton de steel

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25 ton of wood

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450 ton segment – 96 ton de steel

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35 ton of wood

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550 ton segment – 105 ton de steel

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40 ton of 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.

The wooden weights also include the film faced plywood. ! 33 SCAFFOLDING SYSTEMS & LAUNCHING GANTRIES

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

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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.

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

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.

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.

required for the installation of the second Form Traveller. ! 34 SCAFFOLDING SYSTEMS & LAUNCHING GANTRIES
required for the installation of the second Form Traveller. ! 34 SCAFFOLDING SYSTEMS & LAUNCHING GANTRIES
required for the installation of the second Form Traveller. ! 34 SCAFFOLDING SYSTEMS & LAUNCHING GANTRIES
required for the installation of the second Form Traveller. ! 34 SCAFFOLDING SYSTEMS & LAUNCHING GANTRIES
required for the installation of the second Form Traveller. ! 34 SCAFFOLDING SYSTEMS & LAUNCHING GANTRIES
required for the installation of the second Form Traveller. ! 34 SCAFFOLDING SYSTEMS & LAUNCHING GANTRIES
required for the installation of the second Form Traveller. ! 34 SCAFFOLDING SYSTEMS & LAUNCHING GANTRIES
required for the installation of the second Form Traveller. ! 34 SCAFFOLDING SYSTEMS & LAUNCHING GANTRIES
required for the installation of the second Form Traveller. ! 34 SCAFFOLDING SYSTEMS & LAUNCHING GANTRIES
required for the installation of the second Form Traveller. ! 34 SCAFFOLDING SYSTEMS & LAUNCHING GANTRIES
required for the installation of the second Form Traveller. ! 34 SCAFFOLDING SYSTEMS & LAUNCHING GANTRIES
required for the installation of the second Form Traveller. ! 34 SCAFFOLDING SYSTEMS & LAUNCHING GANTRIES
! 34
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for the installation of the second Form Traveller. ! 34 SCAFFOLDING SYSTEMS & LAUNCHING GANTRIES FOR
for the installation of the second Form Traveller. ! 34 SCAFFOLDING SYSTEMS & LAUNCHING GANTRIES FOR
for the installation of the second Form Traveller. ! 34 SCAFFOLDING SYSTEMS & LAUNCHING GANTRIES FOR
for the installation of the second Form Traveller. ! 34 SCAFFOLDING SYSTEMS & LAUNCHING GANTRIES FOR
for the installation of the second Form Traveller. ! 34 SCAFFOLDING SYSTEMS & LAUNCHING GANTRIES FOR
for the installation of the second Form Traveller. ! 34 SCAFFOLDING SYSTEMS & LAUNCHING GANTRIES FOR

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

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Corgo Segment weight 264 ton Segment length 6,00m Deck width 28m Pre cast concrete structs

Corgo

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

weight 264 ton Segment length 6,00m Deck width 28m Pre cast concrete structs outsite of the

Pre cast concrete structs outsite of the deck

width 28m Pre cast concrete structs outsite of the deck Form Traveller overview and transversal diaphragms

Form Traveller overview and transversal diaphragms existing at every two segments

and transversal diaphragms existing at every two segments Form Travellers arriving to the closing segment Form

Form Travellers arriving to the closing segment

two segments Form Travellers arriving to the closing segment Form Traveller overview showing detail of the

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

detail of the precast concrete struts outside of the deck Aerial view of the Form Traveller

Aerial view of the Form Traveller main structure

of the deck Aerial view of the Form Traveller main structure Form Traveller main structure Constantine

Form Traveller main structure

Form Traveller main structure Form Traveller main structure Constantine Segment weight 170 ton Segment lenght 3,50m

Constantine

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

weight 170 ton Segment lenght 3,50m Deck width 30m Transversal diaphragm details close to the pierhead.

Transversal diaphragm details close to the pierhead.

30m Transversal diaphragm details close to the pierhead. 35 ! SCAFFOLDING SYSTEMS & LAUNCHING GANTRIES FOR

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Mondego Segment weight 225 ton Segment length 5,00m Deck width 18,2m Main frame and rear

Mondego

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

weight 225 ton Segment length 5,00m Deck width 18,2m Main frame and rear bogie view General

Main frame and rear bogie view

5,00m Deck width 18,2m Main frame and rear bogie view General view of the cros support

General view of the cros support assembling

rear bogie view General view of the cros support assembling Rebar and blockouts for anchoring Salamanca

Rebar and blockouts for anchoring

cros support assembling Rebar and blockouts for anchoring Salamanca Segment weight 100 ton Segment length 4,10m

Salamanca

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

weight 100 ton Segment length 4,10m Deck width 11,30m Main frame and rear bogie view Form

Main frame and rear bogie view

4,10m Deck width 11,30m Main frame and rear bogie view Form Traveller boxtom view Cross-support side

Form Traveller boxtom view

Main frame and rear bogie view Form Traveller boxtom view Cross-support side view Form Traveller lateral

Cross-support side view

view Form Traveller boxtom view Cross-support side view Form Traveller lateral view safety sets ! 36

Form Traveller lateral view safety sets

side view Form Traveller lateral view safety sets ! 36 SCAFFOLDING SYSTEMS & LAUNCHING GANTRIES FOR

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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

is open, and Form Travell is launched to the next segment ! In most cases the

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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.

concrete quality and techniques for assessing its strenght. ! 37 SCAFFOLDING SYSTEMS & LAUNCHING GANTRIES FOR
concrete quality and techniques for assessing its strenght. ! 37 SCAFFOLDING SYSTEMS & LAUNCHING GANTRIES FOR
concrete quality and techniques for assessing its strenght. ! 37 SCAFFOLDING SYSTEMS & LAUNCHING GANTRIES FOR
concrete quality and techniques for assessing its strenght. ! 37 SCAFFOLDING SYSTEMS & LAUNCHING GANTRIES FOR

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

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Form travellers Underslung solution The Underslung Form Traveller, as the Overhead one, is a temporary

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.

and hydraulic equipment used to launch, level and ajust. ! 38 SCAFFOLDING SYSTEMS & LAUNCHING GANTRIES
and hydraulic equipment used to launch, level and ajust. ! 38 SCAFFOLDING SYSTEMS & LAUNCHING GANTRIES

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

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The formwork surfaces in contact with the concrete can be wood, film faced plywood, metal

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.

metal sheet or plastic plate, depending on the number of reuses envisaged and the concrete architectural

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.

with the main structure of the overhead Form Travellers. ! 39 SCAFFOLDING SYSTEMS & LAUNCHING GANTRIES

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

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AN ALTERNATIVE SOLUTION

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

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Ask us, we have the solution!

Form Travellers. ! ! Ask us, we have the solution! Special solutions: ! • The Underslung
Form Travellers. ! ! Ask us, we have the solution! Special solutions: ! • The Underslung
Form Travellers. ! ! Ask us, we have the solution! Special solutions: ! • The Underslung

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.

can be tailor made to different types of rebar cages. ! 40 SCAFFOLDING SYSTEMS & LAUNCHING

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Our services include: -tender stage quotation preparation -design, fabrication, delivery and technicall assistance to the
Our services include: -tender stage quotation preparation -design, fabrication, delivery and technicall assistance to the
Our services include: -tender stage quotation preparation -design, fabrication, delivery and technicall assistance to the

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

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Ask for out reference list!

conditions of the original ! Ask for out reference list! CLARKSGATE 5, N - 3970 LANGESUND

CLARKSGATE 5, N - 3970 LANGESUND NORUEGA

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ar@strukturas.com.pt

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