EL MAYOR PUENTE DE NORUEGA: Hardangerbrua

CONSTRUCTION SCHEDULE

The Hardanger Bridge

• The Hardanger bridge project was approved (by the parliament) in February 2006, and shall be completed in the spring of 2013

Pylons Viaducts

260 mill kr 50 mill kr

Anchorages

150 mill kr

Cables and hangers

420 mill kr

Steel box girder

450 mill kr

Membrane and asphalt Total NOK

20 mill kr 1350 mill kr

Approach roads

400 mill kr

Client´s costs

300 mill kr

Total cost NOK

2300 mill kr

• Design and planning period 2 years (March 2006 - May 2008) • Construction of tunnels and approach roads, construction period February 2009 - December 2010, completion spring 2013 • Construction of bridge, about 3.5 years, commenced august 2009, completion spring 2013 • Pylons and anchorages, 1.5 years • Cables and hangers, about 1 year • Installation of steel box girder and completion work, about 1 year • Steel box girder and elements for cables to be produced in workshops in parallel with towers and anchorages, production time about 2 years

HARDANGER BRIDGE T E C H N I C A L B RO C H U R E

ENGLISH

grafisk.senter@vegvesen.no 0094-07

COSTS

Galvanised cable wires

ANCHORAGE UNIT

Anchors strand of 528 wires

SPLAY SADDLE

,8 m

20

ANCHORAGE BLOCK

A

0,5 m

3 0,25 m

TOWER ADJUSTMENT 0m

Pullback cable

PEH tube Injected cement mortar

Wrapping of reinforced tape

Before spinning of the cable, the towers are pulled back about 0,5 m at the top. As the steel box girders are fitted, the pullback cable is slackened and the towers go to their natural vertical position.

SPLAY CHAMBER

▲

Section A-A

2

Wrapping of galvanised wire

600 mm

1

CABLE STRAND 19 strands each from 528 galvanised 5.3 mm wires. In all 10,032 wires.

Breaking load of the cable 342,000 kN.

THE CABLE

UPPER HANGER CLAMP

STRAND SHOE A

UPPER SOCKET

▲

38 prestressing strands, tension in strand 5,235 kN

PRESTRESSING STRAND

Section A-A

200 mm 38 strands per splay chamber

Bu

A

▲

Vallavik

Galvanised wires

1m

Zinc casting Cast steel

,

27

ANCHORAGE CHAMBER ANCHORAGE PLATE

A

▲

s

ct

Formwork: 3,400 X 2 m2 = 6,800 m2 , walls and roof

15 m

Statsraad Lehmkuhl

fa

CABLE ANCHORAGE

172 m

1310 m

172 m

Concrete: 2,000 m3 B45 SV-40 Concrete: 4,000 m3 B35 low heat concrete in anchorage block and plate Reinforcement: 1,000 tonnes Prestressing steel: 33,600 MNm Bore hole 200 mm: 4,400 metres

HANGER CABLE

Borehole liner: 5,080 metres

s

1.5 tonnes

ANCHORAGE BAR

STEEL BOX GIRDER LOWER SOCKET LOWER HANGER CLAMP

The anchorage plates in the splay chamber are connected to the concrete slab in the anchorage chamber via 76 prestressing cables. The prestressing cables lie inside plastic tubing that is installed through bore holes in the rock.

1,8 m

ANCHORAGE PLATE

Transverse bulkhead every four metres

TENSION CABLE

14.500 mm

Vehicle-proof steel parapets are fitted on both sides of the bridge, as well as a intermediate parapet between the roadway and the foot and cycle path.

4.500 mm

4.500 mm

3.250 mm

The bridge is carried by cables and hangers.

The cable consists of galvanised steel wires. It is assembled by pulling each wire on a spinning wheel that is drawn on an aerial cableway. Two or four wires are put in place out on each trip across the strands. The wires are gathered into 19 strands, each consisting of 528 wires. All the strands are then compacted into a circular cross section by use of a hydraulic press.

The hanger clamps are then fitted, and the cable is wrapped with a soft galvanised wire that protects it and helps it maintain its shape. On the outside of the wrapping wire, a reinforced tape is applied to protect against moisture and rain.

Even though the strands of the cable are compressed together, the cable still contains about 20% air. The cables are dehumidified by dry air injection.

The steel box girder include rails to carry the external maintenance vehicle. The external maintenance vehicle is 20,9 metres wide and weighs about 8 tonnes.

Inside the steel box girder a small transport vehicle that can carry two persons is installed.

Section B-B

The cable is spun of galvanised steel wires with a diameter of 5.3 mm. The cable wire has a tensile strength of 1,570 MPa. There are 130 hangers in total. The length varies from 2.04 m to 127.6 m. The five shortest hangers are made as one piece of cast steel. The hanger cables are made from locked coil cable, consisting of seven layers of wires, of which the outer three are Z-shaped wires. Hangers are connected to the cable and to the steel box girder with 160 mm bolts.

CABLE AND HANGERS

The air inside the steel box girder is dehumidified and the outside of the box girder, except for the carriageway, is spray-galvanized and painted with three coats of paint.

The splay chambers are designed in such a way that only the top of the chamber is visible. At Vallavik the splay chambers will be constructed inside the mountain. Here only the front wall will be visible.

The anchorage chamber inside the mountain is 15 metres deep and about 40 metres long.

The access to the anchorage chambers goes trough 150 - 200 metres of access tunnels.

CABLE AND HANGERS

The sections are transported by boat to the construction site. Each section is lifted into position and fastened to the hangers. The middle section is installed first. Assembly then works symmetrically out from the centre. The end section is lifted into position before the last sections are installed.

STRAND SHOE

Locked coil cable 70 mm Breaking load 4,500 kN

ct

The beam that carries the road consist of a steel box. The total length when all the box sections have been welded together is 1,308 metres. The steel box girder is produced in 15 metre lengths that are joined together into 60 metre sections. There is a transverse bulkhead every four metres.

Cable wires in strand shoe

B

B

fa

The actual cable anchorage inside the splay chamber consists of 76 anchorage units. Each anchorage units consists of one plate, two bars and one strand shoe.

m

▲

BRIDGE DECK / STEEL BOX GIRDER

CABLE ANCHORAGE The cable anchorage consists of splay chamber and anchorage chamber. On each side of the fjord there are two splay chambers and one anchorage chamber.

The suspension cable for the bridge is anchored in the splay chambers. The cable is supported on a splay saddle where it is split into 19 single strands. Each of these strands are fixed to a strand shoe. The strand shoe is installed on two huge bars that are embedded in the concrete foundation of the splay chamber.

20

▲

STEEL BOX GIRDER Rail for maintenance vehicle

Guide vanes for wind stabilisation

Then the hangers, that consist of a cable with a cast steel sockets at each end, are fitted. The hanger cable is anchored into the sockets by a conically shaped zinc block cast around the spread-out cable wires.

+ 201,5 m

CAST STEEL SADDLE SADDLE HOUSING

14,5 m + 185,0 m

PYLON SADDLE 4,5 m

•

SUSPENSION CABLE

fa ct

BRIDGE TOWERS

s

Pylon foundation: 10 x 12(15) m basal area, height 6 m

Wall thickness of tower columns: 600 mm, at cross beams up to 800 mm

200,5 m

•

Pylon columns: 8.6 x 7.0 m at base, 4.5 x 4.5 m at top

PYLON COLUMN

Foundations: 4 foundations, 3,600 m3 concrete, B 35 low heat concrete, 330 tonnes reinforcement 2 Pylons including cross beams and saddle housing: 10,400 m3 concrete, B45 SV-40, reinforcement 2,150 tonnes

+ 99,82 m

4 Concrete foundations for saddles: 112 m3 concrete B55 SV-40 •

CROSS BEAM

PYLON The bridge pylon consists of two concrete columns joined by three cross beams. Each pylon is supported by two concrete foundations. The pylon columns are rectangular. All outside corners are rounded. The pylon columns are constructed in 4-metre climbing sections, 44 sections in each column. The pylons are constructed by using climbing formwork.

CLIMBING SECTION

+ 46,6 m

Nidaros Cathedral

+ 9,0 m Vallavik

The statue «Monolitten»

On top of the tower columns the suspension cables are supported by saddles. They are surrounded by a concrete housing that is designed to protect the cables and saddles.

CLIMBING SECTION

Inside one of the pylon columns there is a lift, inside the other there are stairs.

6 m + 1,0 m Bu 10 m

21,14 m

SCHEMATIC DRAWING OF PYLON CONSTRUCTION