Connaect 2016

THE MAGAZINE OF THE GLOBAL BBR NETWORK OF EXPERTS
Edition 10 | 2016
DURABILITY AS
A DELIVERABLE
BBR technology & expertise
delivers durable infrastructure
ELECTRICALLY
ISOLATED
PT TENDONS
Launch of new BBR technology
GATEWAY TO SOUTH
EASTERN EUROPE
New passenger terminal at Zagreb Airport
OPTIMIZED
BRIDGE
CONSTRUCTION
New guidelines encourage innovation in Norway
VOYAGE OF DISCOVERY
Excellence in BBR stay cable technology
for Polands Rzeszw Bridge
www.bbrnetwork.com
The BBR Network is recognized as the leading group of specialized

engineering contractors in the field of post-tensioning, stay cable and
related construction engineering. The innovation and technical excellence,
brought together in 1944 by its three Swiss founders Antonio Brandestini,
Max Birkenmaier and Mirko Robin Ros continues, more than 70 years
later, in that same ethos and enterprising style.
From its Technical Headquarters and Business Development Centre in
Switzerland, the BBR Network reaches out around the globe and has at its
disposal some of the most talented engineers and technicians, as well as
the very latest internationally approved technology.
THE GLOBAL BBR NETWORK
Within the Global BBR Network, established traditions and strong local
roots are combined with the latest thinking and leading edge technology.
BBR grants each local BBR Network Member access to the latest technical
knowledge and resources and facilitates the exchange of information on
a broad scale and within international partnering alliances. Such global
alliances and co-operations create local competitive advantages in dealing
with, for example, efficient tendering, availability of specialists and
specialized equipment or transfer of technical know-how.
ACTIVITIES OF THE NETWORK
All BBR Network Members are well-respected within their local business
communities and have built strong connections in their respective regions.
They are all structured differently to suit the local market and offer a
variety of construction services, in addition to the traditional core business
of post-tensioning.
BBR TECHNOLOGIES & BRANDS
BBR technologies have been applied to a vast array of different structures
such as bridges, buildings, cryogenic LNG tanks, dams, marine structures,
nuclear power stations, retaining walls, tanks, silos, towers, tunnels,
wastewater treatment plants, water reservoirs and wind farms. The BBRTM
brands and trademarks CONA, BBRV, HiAm, HiEx, DINA, SWIF,
BBR E-Trace and CONNCT are recognized worldwide.
The BBR Network has a track record of excellence and innovative
approaches with thousands of structures built using BBR technologies.
While BBRs history goes back over 70 years, the BBR Network is focused
on constructing the future with professionalism, innovation and the very
latest technology.
BBR VT International Ltd is the Technical Headquarters and Business Development Centre of the BBR
Network located in Switzerland. The shareholders of BBR VT International Ltd are: BBR Holding Ltd
(Switzerland), a subsidiary of the Tectus Group (Switzerland); KB Spennteknikk AS (Norway), BBR Polska
z o.o. (Poland) and KB Vorspann-Technik GmbH (Germany) all three are members of KB Group (Norway);
BBR Pretensados y Tecnicas Especiales PTE, S.L. (Spain), a member of the FCC Group (Spain).
02 CONNCT | EDITION 10
DELIVERING
CERTAINTY
OF OUTCOME
When embarking on any project, the thing that customers most want is certainty of outcome they want to be
sure of getting what they need. The BBR Network is always ready with the latest technology and techniques
and to work closely with the wider professional team on shaping the best and most durable construction solution.
We see more-and-more customers, such as the Norwegian roads authority
in relation to the Gulli Bridge, adopting new procurement methods which
call for value engineered construction. Meanwhile, in Australia the
construction of new post-tensioned water tanks in an extreme climate and
THE MAGAZINE OF THE GLOBAL BBR NETWORK OF EXPERTS
Edition 10 | 2016
with sandy ground conditions brought out the best of the BBR Networks
ability to innovate. It is clear that Members of the BBR Network welcome
DURABILITY AS
A DELIVERABLE
BBR technology & expertise
delivers durable infrastructure
these challenges and are ready to participate with a flexible approach

and the highest level of specialist construction advice.
The Portfolio section contains numerous further examples like the
Tamina and Almonte arch bridges and two massive bridges in Malaysia
where technical excellence and teamwork have combined to deliver great
outcomes for customers. Then there are achievements resulting from
long-term customer relationships based on mutual trust such as the
work in New Zealand for Ports of Auckland Limited. Still other successful
projects arise from the BBR Networks ability to contribute two examples
ELECTRICALLY
ISOLATED
PT TENDONS
Launch of new BBR technology
GATEWAY TO SOUTH
EASTERN EUROPE
New passenger terminal at Zagreb Airport
among many fine projects featured are the Q22 tower in Poland and the
rock anchoring work underway in Croatia. We congratulate BBR Network
OPTIMIZED
BRIDGE
CONSTRUCTION
New guidelines encourage innovation in Norway
VOYAGE OF DISCOVERY
Excellence in BBR stay cable technology
for Polands Rzeszw Bridge
Members teams all over the world for their dedication and skill.
For us, of course, one of the most exciting recent developments is the
securing of a European Technical Assessment (ETA) for the BBR VT CONA
CMI Electrically Isolated Tendon (EIT). While we have launched many new
technologies over the years, CONA CMI EIT represents a major step forward
in providing the industry with a highly advanced and durable system which
www.bbrnetwork.com
can also be monitored you can read about this in the Technology section.
Perhaps the best evidence, certainly over the last ten years, that BBR
technologies and the BBR Network bring the latest and most enduring
solutions can be found in the pages of CONNCT. Like our business, in the
last decade our magazine has grown and evolved while demonstrating the
best technology and techniques on the international market.
Marcel Poser
Chairman, BBR VT International Ltd
Jos Manuel Illescas

Vice Chairman, BBR VT International Ltd
www.bbrnetwork.com 03
CONTENTS
05
TALKING BBR
06 BUSINESS REVIEW
09 SPECIAL FEATURE:
A DECADE OF HIGHLIGHTS
12 CONFERENCE NOTES
14 NEWS HIGHLIGHTS
16 PERSPECTIVE
17
PORTFOLIO
18 IN THE SPOTLIGHT
20 BRIDGES
37 BUILDINGS
54 STAY CABLES
62 SPECIAL APPLICATIONS
70 MRR
79
TECHNOLOGY
80 RESEARCH & DEVELOPMENT
83 TECHNICAL UPDATE
86 TECHNIQUES
88 INSIGHT
91
BBR DIRECTORY
EDITORIAL, SOURCES
AND REFERENCES
EDITORIAL OFFICE
BBR VT International Ltd
Technical Headquarters and Business Development Centre
Switzerland
www.bbrnetwork.com
[email protected]
EDITOR
Jane Sandy
CONTRIBUTING EDITOR
Juan Maier
DESIGNER
Jenny Chillingworth
CONTRIBUTORS
Tie King Bang, Richard Blair, elimir Bodiroga, Norbert Bogensperger, Mark
Bond, Andrew Bray, Antonio Caballero, Aaron Callegari, Yeo Swee Choo, Chang
Chee Cheong, Chok Moi Chun, Yan Mung Chun, Jrg Dniker, Andrew Garton,
Martin Grob, Radwan Hamoshi, George Jacob, Kate Janikowska, Tomasz
Jendernal, Mark Kurtovich, Juan Manuel Linero, Tomislav Lopandic, Bartosz
ukijaniuk, Behzad Manshadi, Valentina Mihajlovic, John Mo, Terry Palmer,
Jan Piekarski, Thomas Richli, Chris Roost, Stig Solbjr, Roger Stables, Cezary
Sternicki, Bong Su-Fah, Vedran Tomac, Goran Tomiic, Sascha Weder, Lee
Chong Whey, Paul Wymer, Janelle Yeo.
PUBLISHER
Every effort is made to ensure that the content of this edition is accurate
but the publisher accepts no responsibility for effects arising there from.
p-ISSN 1664-6606
e-ISSN 1664-6614
BBR VT International Ltd 2016
ACKNOWLEDGEMENTS, SOURCES AND REFERENCES
Front cover image: The Gulli Bridge in Norway was built to endure using
technology and expertise from the BBR Network. Photograph by Byggenytt.
Portfolio section
Optimized bridge construction: en.wikipedia.org
Gateway to South Eastern Europe: en.wikipedia.org, www.routesonline.com
New gateway for Mersey: Wikipedia.en, www.merseygateway.co.uk
UKs largest & most complex project: tfl.gov.uk, www.bbc.co.uk
Anchoring for agriculture: www.voda.hr
Technology section
Bernhard Elsener & Markus Bchler, Quality Control and Monitoring of
electrically isolated post-tensioning tendons in bridges, Eidgenssisches
Departement fr Umwelt, Verkehr, Energie und Kommunikation UVEK,
Bundesamt fr Strassen, 2011.
Bernhard Elsener, Monitoring of electrical isolated post-tensioning tendons,
Tailor Made Concrete Structures-Walraven & Stoelhorst (Eds), Taylor & Francis
Group, London, ISBN 978-0-415-47535-8, 2008.
Tarun R. Naik, F. ASCE, Sustainability of concrete construction, Practice
Periodical on Structural Design and Construction, pp:99-103, ASCE 2008.
Dane Miller, Jeung-Hwan Doh & Tim Peters, Environmental Impact
Assessment of Post Tensioned and Conventional Reinforced Concrete Slab
Design, New Developments in Structural Engineering and Construction,
Yazdani, S and Singh A. (Eds), ISEC-7, Honolulu, 2013.
This paper is manufactured with 15% recycled fibre, FSC certified.
All pulps used are Elemental Chlorine Free (EFC) and the manufacturing mill
is accredited with the ISO14001 standard for environmental management.
Vegetable based inks have been used and 85% of all waste associated with
this product has been recycled.
TALKING BBR
06 DURABILITY AS A DELIVERABLE
BBR VT International CEO Antonio
Caballero presents thoughts on
durability as a deliverable while
reviewing the business
09 A DECADE OF HIGHLIGHTS
on the 10th Anniversary of
CONNCT, Editor Jane Sandy
talks about its history and
some highlights
12 CONFERENCE NOTES
observations on a particularly
lively conference in Bangkok,
by Cesary Sternicki
14 OUT-AND-ABOUT WITH THE
BBR NETWORK
selection of international events,
happenings and news over the
last 12 months
16 PERSPECTIVE
leading specialist construction
engineering consultant, Dr Hermann
Weiher, shares his vision on the
future of construction technology
TALKING BBR
BUSINESS REVIEW
Reflections & outlook from BBR VT Internationals CEO
DURABILITY AS
A DELIVERABLE
Durability is a topic which occupies the minds of many people the world over. Dictionary definitions include the
words able to resist wear or decay well and lasting or enduring. In this context, the period of time during which
the expected performance must be delivered is also a critical factor. BBR VT International Ltds CEO Antonio
Caballero explores these and further aspects of durability with particular relevance to the construction industry.
Some ancient structures for example
Right technology
Fit-for-purpose
from the early Greek, Roman or Egyptian
Durability is key for sustainability a
Although BBRs three founders were
civilizations have shown extraordinary
durable structure will deliver the expected
certainly far-sighted, could it be possible
durability over the centuries. While we
performance over its entire service life
that they foresaw some of todays
may admire and wonder at these
with minimal or no maintenance.
infrastructure challenges as they developed
achievements, nowadays structures are
Monitoring is however required to preserve
their technology back in the 1940s? Right
designed and built under extreme cost
the predictability and, thus, minimize time
from the start, it has been part of our culture
pressure and subjected to strict
taken to react to any maintenance issues
to invest heavily in Research & Development
environmental regulations. Most recently
both of which influence the minimum
to ensure that we can offer the right
and due to environmental challenges
safety standards for users.
construction technology for the application.
new structures must also be more eco-
Although there are no objective ways to
Our R&D process includes thorough
friendly and sustainable.
measure sustainability, it is possible to
independent testing of our technology, not
In the modern era, approaches to
measure and monitor durability. The recently
only to meet current standards but also to
construction have also changed. The
introduced BBR VT CONA CMI Electrically
satisfy our own internal benchmarks which
amount of data to which we all now have
Isolated Tendon system (CONA CMI EIT)
are very often more stringent and have
access has grown exponentially with the
permits the indirect measurement of
been specially developed to ensure that it
continuous development of new
durability of post-tensioning tendons
is fit-for-purpose.
information technologies. We can record,
through the evaluation of electrical
BBR post-tensioning and stay cable
analyze and exploit detailed information
resistivity, allowing verification of the
technologies have a proven track record for
in ways that people just a couple of
integrity of the plastic duct, also whether
durability. For example, both De Molenbrug
generations ago would never have
there has been ingress of water and/or
bridge in the Netherlands and the now iconic
believed possible. Today, infrastructure is
aggressive chlorides all elements which
Sydney Tower in Australia have recently
planned thoroughly it is specified and
contribute to the shortening of the life
had thorough health checks and, even
built to be easily maintained or adapted to
expectancy of the structure. Measurements
after more than 40 years service, the BBR
changed usage. This is where BBR comes
can be made during construction and during
stay cable systems are still delivering the
into the picture.
the service life of the structure which will
expected performance and serviceability.
facilitate early detection of any aggressive

element which may be compromising the
durability of the tendon. You can read more
about CONA CMI EIT from page 80 onwards.
TALKING BBR
TALKING BBR
Quality performance
made impressively detailed presentations
It is a well known fact that a whole chain
on major projects in their countries to their
is only as strong as the weakest link.
spellbound international BBR colleagues.
Therefore ensuring quality in all the
Quality of manufacture is also fundamental
processes involved from design,
to durability and performance this is
production, transport, storage, installation
where our well-established network of
and so on is crucial. Every single process
component manufacturers comes in.
involved in the project and every single
They all have specialized and plentiful
element is important and deserves the
know-how and are regularly audited by
appropriate level of attention to achieve
independent certification bodies.
the right level of quality.
The system of attestation of conformity,
Quality has a direct impact on durability
having been established in our post-
and sustainability of systems and products.
tensioning systems as a part of the CE
Therefore, having a solid, proven and
requirements, is currently in place for all
adaptable quality management system
systems and components not only PT
(QMS) in place is a must. The QMS must
and has become a standard for supply
cover all aspects from factory production
to any part of the world. Basically, we
control right up to installation on site.
commoditized and globalized the
As well as our development and testing
state-of-the-art European standards.
processes, the BBR Factory Control
Naturally, much credit must also go to the
Process (FPC) enables full bi-directional
owners, architects and designers of
traceability of each single component from
structures for their foresight in actively
raw material to project execution. On page
choosing to build using the latest
83, you can read about the latest upgrades
construction technology. By doing so, they
to our well-established internet trading and
are creating more durable structures and
QA platform, BBR E-Trace, which supports
investing not only in strength and durability,
our FPC process.
but also low maintenance, flexibility and

protecting the environment. Of course, in
People & technology
the long term they are saving money too.
Today, the construction industry like
1 De Molenbrug on the River Ijssel in the

Netherlands and the iconic Sydney Tower
in Australia respectively feature BBR HiAm
parallel wire and BBR DINA stay cables
and the BBR technology has been proven
to be functioning well, even after over 40
years service.
most other industries has developed
Asset management
to a high level of specialization among all
Just as we humans seek medical check-ups
stakeholders and therefore a high level
and preventative medicines from our health
of atomization. Thus, another important
professionals, a structure also needs some
factor is continuous training and fluent
monitoring, control and occasionally some
communication between all the
treatment or repairs to achieve its
stakeholders the producers who
planned service life. Of course, the owners
manufacture the systems, the designers
are the main party in this and must work
who need to specify the right system,
together with specialists from our Network
PT specialist who must have the right
who will provide the right technical
knowledge and so forth.
assistance and deliver the most optimal
Correct installation including appropriate
solution for the continued healthy and safe
grouting procedures is crucial to the
operation of their structural assets.
long-term reliable performance of BBR
Durability is part of the value judgment that
technology and this is why we also invest
people make when they purchase something
heavily in education, training and
the value lies in the characteristics of the
knowledge exchange. Engineers and
item and its purpose. At BBR, our business
managers within the BBR Network are
has always been about listening to what
great networkers and theres nothing that
customers want and delivering the best
they enjoy more than sharing experiences
technical support and solutions for
visiting each others sites, over the
structural resilience our approach is as
telephone or a quiet drink. The pride with
sustainable as the structures created with
which they view their work is always evident
our technology.
for example, at our recent training session
Dr. Antonio Caballero
in Amsterdam, BBR Network Members
TALKING BBR
TENTH ANNIVERSARY OF CONNCT MAGAZINE

Charting ten years of BBR Network achievements
A DECADE OF
HIGHLIGHTS
The BBR Networks annual magazine CONNCT is celebrating its tenth birthday this
year. BBR HQ has invited Jane Sandy, the magazines editor, to share the background to
how this now long-running magazine came about and some reflections about the culture
and achievements of the BBR Network, as shown through the pages of CONNCT
containing reports about over 600 projects over the past ten years.
TALKING BBR
STAY
CABLES
BRIDGES
LEGENDARY BBR STAY CABLE TECHNOLOGY
Staying power
ince the early days of post-tensioning, BBR Stay

Cable Technology has been recognised as the
most advanced and most reliable system on the
market. BBR is not only the godfather and inventor
of high fatigue resistant wire stay cables, but has also
pioneered, invented and constructed the worlds first
project using modern parallel strand stay cables and has
invented and successfully applied the worlds first
carbon stay cables.
CONNCT has been a ten year-long

adventure which has metaphorically taken
me around the world to explore some of the
Today, BBR Stay Cable Technology can

be used for the following applications:
most exciting construction engineering
achievements anyone could imagine.

Not only this, I have enjoyed some excellent
company along the way there is nothing
I
finer than working with people at the top of

their game in this case the PT Specialists
have been

built in rapidly increasing numbers
since 1950 and have been found to
be especially economical for medium
to long-span bridges from 100 to
1000m, where technical and
economic arguments dictate this
solution. For smaller bridges, other
parameters may be decisive for the
choice of a cable stayed solution
such as reduced depth of deck,
construction methodology and
aesthetics. BBR Stay Cable Technology
is the ideal choice for the cables.
have been used
since ancient times and nowadays
suspension bridges with spans close
to 2000m have been built. BBR

Technology can be used for the main
suspension cables as well as for the
hangers.
of grandstands, stadiums,
aircraft hangars and other lightweight
wide-span structures are an ideal
application for BBR Stay Cable
Technology.

for communication facilities,
chimneys and antennas, as well as
wind power stations can be
stabilised using BBR Stay Cable
Technology.
R&D & QUALITY ASSURANCE

Extensive research, testing and
development efforts place BBR at the
forefront in the field of post-tensioning
and stay cable applications. BBR also
In 1971, the Olympic Stadium in Munich, Germany with its cable supported membrane
roof structure hosted the Games in 1972. Until 2005, the stadium was home to
Bayern Munich FC, one of the world's premier soccer clubs and record title holder in
Germany. The 488 stay cables are comprised of parallel strands, with which BBR
pioneered the usage of High Amplitude fatigue resistant strand stay cables. Photos: Kevin
Lazarz
within the BBR Network. Over the past

decade, I have also found myself sharing
their passion for a challenge and the small
In 1961, the first bridge to be built using parallel wire cables was the pedestrian Schillersteg Bridge across the Schillerstrasse in Stuttgart, Germany.
offers a variety of solutions to counter cable

vibration such as the BBR Square Damper and
cable surface treatments. To assure the highest
quality product, all of the system components are
subjected to the most stringent testing and
Quality Assurance procedures, based on
internationally recognised codes and
recommendations.
SUPERIOR FATIGUE & STATIC

RESISTANCE
For many years, the minimum fatigue test strength
for stay cable systems has been 160N/mm2 (PTI).
More recently, a stress range of 200N/mm2 for
2x106 load cycles in combination with angular
rotations at the anchorages has been adopted
and is now specified by most codes and
recommendations. BBR Stay Cable Technology
had already fulfilled requirements for such fatigue
testing decades before these provisions were
considered to be state-of-the-art!

Standard BBR Wire Cables are composed of 7mm diameter wires of low
relaxation grade, with a minimum guaranteed ultimate tensile stress of 1670 or
1770N/mm2. Typically, the wire bundle is galvanized and covered with a thick-walled
UV-resistant HDPE pipe, and the voids in the pipe are filled with a flexible
corrosion protection compound.

Today, standard BBR Strand Cables are composed of galvanized, waxed and PEcoated 0.62" (15.7mm) strands of low relaxation grade, with a minimum
guaranteed ultimate tensile stress of 1770N/mm2 or 1860N/mm2 inside a UVResistant HDPE Stay Pipe.

The BBR Carbon Stay Cables consist of CFRP (Carbon Fibre Reinforced Polymer)
wires of 5mm diameter covered with thick-walled UV-resistant HDPE pipe.
DECADES AHEAD
Whereas many cable suppliers built their first
major cable supported structure in the late 1970s
and early 1980s, BBR Stay Cable Technology was
used for the first time in the late 1950s and, since
those days, BBR Stay Cable Technology has been
applied to over 300 major structures around the
world including the breathtaking Tatara Bridge in
Japan, which has the longest main span to have
been constructed in the 20th Century.
G
The Strchenbrcke in Wintherthur, Switzerland

crossing the major east-west axis of the Swiss
Federal Railway Network was the world's first
bridge to be constructed using carbon stay cable
technology.
selection of highlights shown here have

34 CONNCT
CONNCT 35
been particularly inspiring.
2007
The first edition of CONNCT, back in 2007, carried a memorable article reflecting on BBRs achievement in the
development of stay cable technology. They were the first to use wire stay cables in 1958, the first to use strand stay
cables 10 years later and the first to use carbon stay cables in 1994. This article is memorable because, through
subsequent editions of the magazine, we can see this same pioneering approach being applied to the development
of still further technology and many projects.
SPORTS ARENA, DZ, POLAND
BUILDINGS
roof ring, there is a huge gutter

made of prefabricated concrete
elements permanently fixed to
the ring structure. The box is
strengthened with cross-walls every
eight meters, where steel roof
girders are supported on the ring.
Ring of confidence
The City of dz Office had
decided to build a new 10,000-seat
sporting and entertainment venue
within the complex of one of the
citys sports clubs dzki Klub
Sportowy. The arena is adjacent to
the existing football stadium which
is home to the former Polish
football league champions.
8*:;8:767The box-shaped concrete structure

of the ring is post tensioned with
28 BBR CONA 1906 internal
tendons (72 t of strands) and 88
BBR CONA 706 external tendons
(12 t of strands).
The internal tendons spaced
equally on the cross-section of the
ring, with seven tendons in one
section take horizontal forces
from main loads (dead loads), while
external tendons placed in
appropriate numbers wherever
needed, as dictated by the bending
moments diagram take bending
moments from excess loads.
Because the ring is so very long, it
is divided into four quarters
resulting in an internal tendon
length of around 120 m. The
internal tendons are anchored in
four specially designed anchor
blocks inside the ring. The external
tendons are anchored in cross-walls
the longest tendon was some
25 m long.
8*:;20(07!
The round sports hall has a
concrete structure with a steel roof
and steel cover wall. The arena level
is approximately six meters below
the surrounding ground level. The
hall is surrounded with a type of
moat, over which there are bridges
leading to the entrances. Inside, will
be the main arena plus all the usual
facilities and a full size basketball
court.
The roof of this huge arena is
supported by a post-tensioned
concrete ring an icon of modern
engineering techniques, constructed
by BBR Polska.
8*:;2:3907!;--8:'
The bearing system involved the installation of 64
elastomeric bearings and 16 specially designed
steel directional slide bearings. The system has a
set of five bearings on each column four
elastomeric slide bearings and one steel guided
slide bearing. The elastomeric bearings transfer
vertical load from the ring to the column, allowing
movement in all directions. Meanwhile, the steel
guided bearings take horizontal forces and allow
radial movement blocking forces from any other
direction to prevent unequal deformation of the
ring.
The ring structure was concreted in stages first
the bottom slab, then side walls, next cross-walls
and lastly, the top slab. Strands were pushed into
ducts after the concreting process was finished.
BBR POLSKA COMPLETED THE

WORK WITH A HIGH STANDARD
OF PROFESSIONALISM AND TO A
HIGH TECHNICAL STANDARD ....
.08;6$;;6$$0.:
8*:;8;-::7.:
to stress all internal tendons from both ends. This

all resulted in much time and effort being spent
on moving and preparing the stressing sets and
operations.
The stressing sequence of the external tendons
was also developed so that equal stressing force
was applied to the structure.
All the work inside the ring box was carried out
by hand it was not possible to use a crane as
there were no openings in the top of the ring
structure and cross-walls precluded the use of a
small crane to operate inside the ring box.
The post-tensioning sequence assumed that first

all internal tendons were tensioned. Then, we
started tensioning all external tendons. The round
shape of the structure meant that it was
extremely important to apply stressing force
equally around the perimeter, as well as on the
cross-section of the ring. Therefore, we used two
stressing sets which operated on opposite sides
of the ring.
Due to high values of loss of stressing force
because of friction on curves it was necessary
The 25 m span post tensioned beam supports a

floor slab. The development of a basketball court
meant that a few columns were replaced with
hangers attached to the beam originally these
were support only to the girders for the arena
seating. The high loads and low acceptable
deflection indicated that a PT beam was the only
solution. The beam was post tensioned with six
BBR VT CONA CMI 1206 tendons (3 t of strands).
8*:;2:3'
This extremely demanding posttensioning task was finished in May

2008 two weeks ahead of
schedule. This superb result is due
largely to the excellent working
relationships which developed
between the BBR Polska team and
the main contractor.
Investor satisfaction is a priority for
us and the reference letter
received from our client, the City
of dz Office, was a great reward
for our efforts. This was the first
time that BBR Polska had executed
such a challenging and unusual
stressing operation we are
looking forward to post-tensioning
another stadium soon!
G
BUILDINGS
229;1", the BBR Network member in Poland has

completed an extraordinary post-tensioning task. Site Engineer,
M. Sc. Bartosz ukijaniuk explains how a massive post-tensioned
roof ring needed to support the dome-shaped roof of the new
sports arena in dz was constructed.
$,/";;$+)#54"
354&,;,54,
14,500 m2
354&,;1#4 385,000 m3
354&,;5,+#"
70 m
354&,; 4+) /
36 m
14;511;+,4/45
140 m
%4+) /;1;511;"/5#/#54
1,500 t
911;5+&); 4+) /
3.7 m (inner 2.5 m)
911;5+&);+/
4.7 m (inner 3.2 m)
911;5+&);4&)/ 440 m
8*:;290:$
Our brief was to evaluate the
detailed design for tendon layout
and the bearing system for the roof
ring, as well as for carrying out the
work which included delivery of
stressing system components, plus
the complex post-tensioning of the
roof ring and delivery and
installation of the bearings. In
addition, we undertook further
complex works for a posttensioned beam.
TEAM & TECHNOLOGY

6%7:9 City of dz Office
.67893.869 Skanska S.A.
:-0!7:9 ATJ Archikekci / KiP Sp. z o.o.
8:.*76(6!
BBR CONA internal
BBR CONA external
BBR VT CONA CMI internal
229;7:8%69;':'2:9
BBR Polska Sp. z o.o. (Poland)
8*:;907!
The roof support ring rests on 16
concrete columns (spaced every
26 m) at around 15 m above arena
level. It is a massive concrete
structure which, in cross-section, is
a concrete box shaped like a
leaning rectangle with 0.5 m thick
walls. On the outer side of the
CONNCT
CONNCT
CONNCT
LANDMARK STRUCTURES
SYDNEY TOWER, AUSTRALIA
lmost 30 years after it was opened, Robert Freedman of BBR

Network member .50%#5%0617.354'3 reflects on the construction
and enduring qualities of the Sydney Tower which now stands
together with the Sydney Opera House and the legendary Sydney Harbour
Bridge as one of the famous city center landmarks.
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new heights
Originally constructed as the defining architectural
feature of the Centrepoint retail and commercial
development, the tower is now Sydneys tallest
structure. The 309 m high tower was opened in
August 1981 as a communications tower and
tourist facility. Like its neighbor across the Tasman
Sea in Auckland, the Sydney Tower is a focal point
for all who live in or visit the city
of five levels accommodating two

revolving restaurants and two
observation decks.
The steel shaft is 6.75 m overall
diameter and consists of 28
columns spaced equally around its
perimeter.
)&.&"7+,7.
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The 56 stay cables are formed into

a hyperboloid of revolution in
mathematics, a hyperboloid is a
quadric, a type of surface in three
dimensions in two groups, each
of 28 straight cables. The cables
are anchored to the roof of the
building in a circle of 37.2 m
diameter. From here, the BBR
cables each made up of 235
galvanized wires of 7 mm diameter
rise through an intermediate
coupling point at 90 m, tangentially
to a neck connector on the shaft
140 m above the roof. The cables,
which lead from here to the turret
anchorage at 184 m, each comprise
55 wires of 7 mm diameter. In
plan, the cables appear similar to
spokes of a huge bicycle wheel
this arrangement assists in resisting
torsional moments on the tower.
The cables were manufactured in
Structural Systems Melbourne
factory and transported to site on
timber drums for uncoiling and
.+)7) !,.

When it opened in September 1981, Sydney
Tower was the fourth tallest building in the world.
Before the tower was built, the maximum
allowable height of a Sydney building was 279 m
to allow for the harbours flying boats that were
popular before the modern jet era.
The maximum allowable height was lifted to
305 m with the approval of Sydney Tower. Sydney
Tower still sets the height limit for Sydney
buildings today.
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CONNCT
2009
Architectural freedom is one of the great
things that BBR technologies provide and
even encourage making the infrastructure
we use more functional as well as attractive.
In CONNCT 2010, the work of BBR Polska
on the Lodz Arena which required a
post-tensioned ring beam to support the
domed roof is a splendid example of what
can be achieved.
The cost of building Sydney Tower was A$ 36

million one third the cost of the Sydney Opera
House a huge amount at the time.
Construction of the Centrepoint Tower now
officially known as the Sydney Tower began in
1975. Its unique supporting net structure,
composed of BBR DINA stay cables, sets it apart
from the crowd.
This project involved the erection of a steel tower
which rose 230 m above the roof of the 12-level
office building in the centre of Sydney, Australia. Its
shaft is stayed by a system of BBR parallel-wire
prestressing cables. The tower is topped by a turret
installation. Stressing was carried out in two

stages at night to reduce the transversing effects
of the sun on the cables during daylight hours.
The weathered effect on the structure is caused
by special alloying elements which react with the
air to form a dense tight oxide film to protect the
steel from corrosion. The appearance, texture and
maturity of the weathered steels patina depends
upon three primary natural factors time, the
degree of exposure and atmospheric
environment. With time, the oxide coating
changes from a rusty red-orange to a dark
purple-brown.
Since it opened, Sydney Tower has welcomed
more than 17 million visitors or four times the
population of Sydney!
+,7 !+&)+,7&+",..7)!!,",
One of the citys annual highlights is The Sydney
Tower Run-Up a staggering 1504-step
endurance race up the stairs of the Sydneys
highest building Sydney Tower. All ages and
types of people take part in this now wellestablished event in the Sydney calendar
The 2008 Tower Run-Up, held in support of The
Heart Foundation, marked the 16th time that
the event had been held and 290 competitors
lined up to take the challenge. The winner
completed the challenge in just seven minutes
49 seconds. Both he and the fastest female
runner have won the opportunity to take their
step-scaling skills to the US with the major prize
of return airfares to New York to take part in
the annual race up the stairs of the 86-storey
Empire State Building in 2009.
G
CONNCT
2009
This article from CONNCT 2009 about construction
of the Sydney Tower using BBR DINA stay cables as the
unique supporting net structure, is a particular favorite.
Not only did it require innovation during its construction
some 40 years ago, but also quite recent engineering
inspection revealed that the BBR technology is still
performing well today.
TALKING BBR
PORTFOLIO STAY CABLES
2013
The feature in CONNCT 2013 about the Danube Bridge 2
now the New Europe Bridge over the River Danube between
Bulgaria and Romania stands out from the crowd. It was a very
interesting and comprehensive account of how Spanish BBR
Network Member, BBR PTE installed 208 BBR HiAm CONA
stay cables, using the then new BBR HiEx CONA Saddles, as
well as BBR VT CONA CMI post-tensioning.
DANUBE BRIDGE 2, VIDIN-CALAFAT, BULGARIA & ROMANIA

Major post-tensioning and stay cable bridge construction featuring first use of BBR HiEx CONA Saddles
WALTZING
OVER THE
DANUBE
The BBR Network construction team working on the new Vidin-Calafat

Bridge has performed a finely-tuned sequence of maneuvers, worthy of any
grand ball, to deliver an innovative and massive project. Also known as
Danube Bridge 2, the new structure is a road and railway bridge connecting
the cities of Calafat and Vidin in Romania and Bulgaria respectively and is
the second bridge spanning the River Danube between these two countries.
It forms part of the IV Pan-European Corridor that will allow direct motorway
access between Dresden in Germany and Turkeys largest city, Istanbul.
Diana Cobos, Project Manager on site from BBR PTE the Spanish-based
BBR Network Member describes this marathon of a project.
The Vidin-Calafat Bridge has three distinct
one of 124m and one of 115m all of which
components a low level rail Approach
are sustained by stay cables.
Viaduct with 40m long spans on the
Each of these distinct components involved
Bulgarian river bank, a single-cell box girder
specific construction methods and their
bridge over the Main Navigation Channel
own special technical challenges. For an
and a viaduct over the Non-Navigable
overall impression of the scale of project,
Channel. The latter is 612m long and has
it might help to know that we have installed
eight spans, of which all but the first are
2,100t of BBR VT CONA CMI tendons
80m long. The Main Navigation Channel
most of them 31 strands plus 65,000km
bridge has five spans three spans of 180m,
of plastic duct and 208 stay cables.
Compelling event
The compelling event that drove production
of the first issue of CONNCT was the
massive investment that BBR VT
1
International was making in developing the
range of all-new BBR VT CONA CMX

2014
This article from the 2014 edition of CONNCT shows another example of how BBR Network Members overcome the
trickiest of construction challenges. The Keppel Viaduct in Singapore was being extended, yet traffic flows on this vital
route were maintained while construction work was in progress. To accommodate the project needs, among other
measures the BBR team scheduled night-working and just-in-time material deliveries because of the site constraints.
PORTFOLIO BRIDGES
PORTFOLIO BRIDGES
post-tensioning technology and securing

European Technical Approval for each new
system. With this, also came a change in
BBRs business model and the BBR
Network was born. The mission, then as now,
was to communicate news, deliver technical
KEPPEL VIADUCT, SINGAPORE

Carriageway widening
...the live traffic
information and share achievements on an
environment and
limitations imposed
UNCLOGGING
THE BOTTLENECK
by existing structures
and construction a
The Keppel Viaduct was constructed as part
Post-tensioned extension
of the Ayer Rajah Expressway (AYE) from
To accommodate the widening of deck
1983 to 1988. At that time, it was the longest
slabs at both ends of the viaduct, the
vehicular viaduct in Singapore measuring
design proposes an extension of the
2.2km in length and a crucial traffic
existing crossbeam, such that additional
corridor for east-west commuters as it
prestressed precast beams can then be
The Keppel Viaduct an awkward bottleneck on Singapores Ayer Rajah Expressway is being
connects the East Coast Park Expressway
launched upon the new extended structure.
upgraded from a dual three lane carriageway to a dual four lane carriageway. Singapore-based
(ECP) and AYE. Both the ECP and AYE had
For this, a combination of utilizing two
BBR Construction Systems Project Manager, Tan Yeow Koon describes the projects history and
explains how existing site conditions make both the design and construction a major challenge.
international scale with CONNCT
made both the design
been upgraded over the years into major
existing spare PT ducts and installation of
dual four or five lane expressways, whereas
new PT bars was proposed.
the Keppel Viaduct was still only carrying a
To allow the existing crossbeams to carry
dual three lane carriageway. So, when the
the extra loads, new secondary crossbeams
Land Transport Authority (LTA) finalized the
are to be constructed immediately beneath
plan to re-route the ECP-AYE connection
four of the existing eight beams. The new
with a new expressway the Marina Coastal
crossbeams are 25m in length, with a
Expressway (MCE) a study was carried
cantilevered arm of 9m. For this element
out to look into the bottleneck caused by the
of the work, a total of 10 post-tensioning
Keppel Viaduct. While the LTAs objective to
tendons have been proposed, each having
upgrade the dual three lane carriageway into
38 strands of 12.9mm diameter and each
a dual four lane carriageway looked simple
tendon will ultimately have to be stressed
on paper, the live traffic environment and
to 5,320kN.
major challenge.
magazine as a cornerstone of that strategy.

Incidentally, the unusual name of the
magazine was chosen to reflect one of BBRs
best known brands CONA and also the
1 Singapores Keppel Viaduct, once celebrated

for being the longest in the country, had
become a bottleneck on the busy east-west
commuter route.
2 Site conditions and constraints dictated the
use of a T-shaped cantilevered steel truss
tower, designed in modular segments, for
construction of the crossbeams.
3 The completed crossbeams of the Keppel
Viaduct, extended to accommodate an
additional three or four longitudinal beams,
alongside the eight currently existing beams.
concept of connecting with people.
limitations imposed by existing structures

made both the design and construction a
major challenge.
Global venture
Design concept
Singapore Piling & Civil Engineering
(SPACE), one of our sister companies
within BBR Holdings Limited, was awarded
My involvement began in August 2006 when
the design and build contract by the LTA in

February 2011. SPACE drafted in an equally
well-established consultant on vehicular
bridge design YWL Engineering and the
an email from BBR VT Internationals then
first task on hand was to finalize the design

concept for the major upgrading works.
The existing crossbeams are to be extended
to accommodate an additional three or
Chief Technical Officer, Marcel Poser,
four longitudinal beams, alongside the

eight currently existing beams. To achieve
this, the designer proposed an additional
crossbeam, extension to the existing
crossbeam, new columns sandwiching
arrived in my inbox. In true BBR style, even
the existing one, plus the pile-cap resting

above the existing pile-cap with new
foundation pipes. With this design concept,
the proposed structure will be able to
this was a global collaboration my work
accommodate additional longitudinal

beams and the structural capacity of the
1
viaduct will be enhanced.
had been recommended by an engineer

from Structural Systems (now SRG Limited)
PORTFOLIO BRIDGES
PORTFOLIO BRIDGES
in Australia, David Pash, with whom I had

worked while he was based in the UK. So, to
MRT STATIONS, PACKAGE S2, MALAYSIA

Precast crosshead construction
cut a long story short, with the help of BBR
PLATFORMS
FOR STATIONS
Network Members, the first edition of

CONNCT was created.
Construction of the first MRT line from Sungai Buloh to Kajang is currently
making good progress. Chang Chee Cheong from BBR Construction
Systems (Malaysia) offers a detailed account of how, over a busy main road,
post-tensioned precast segmental crossheads are being constructed and
Record for the future
installed for three stations on the new line.

We were appointed by Naim Engineering
Structure configuration
the nominated subcontractor for the
Each station comprises nine crossheads,
stations on the route to provide our
located in the center of the road over
specialist post-tensioning expertise for
which the rail line is being constructed.
constructing the 27 precast crossheads for
Five crossheads are being created from
the three stations within Package S2. The
the viaduct piers while the other four are
piers supporting the light rail viaduct also
being built between two viaduct crossheads.
provide the main supports crossheads
There is a 6m long cast in-situ pier segment
for the stations. While work on the viaduct
and from this, three pairs of cantilevering
continues by launching gantry above, the
precast segments are erected using the
stations below are being constructed
balanced cantilever method. The segment
concurrently to ensure readiness for track
lengths of 2.48 + 4.05 + 4.13m give a total
and equipment installation.
crosshead length of 27.3m. We are match
Since then and alongside countless other

things, CONNCT has provided the entire
BBR Network with an archive a record of
casting the segments off-site.
global achievements on which everyone
Construction of in-situ pier & first

segment pair
Post-tensioning tendon ducts are fixed on
can draw to illustrate specific experience or
profiling bar supports in the pier segment.

After casting, construction of the pier above
continues to completion and erection of the
viaduct spans by launching gantry follows,
while station works are in progress below.
track record. Like any ten year old, in many
At night, the first pair of precast segments

is erected on heavy duty scaffolds using
a mobile crane. Each segment weighing
40t is supported by four levelling and
ways CONNCT is only just beginning to
alignment jacks. A stitching gap of 175mm

is allowed to handle the difference in shear
keys between the cast in-situ segment and
the precast segment. After stitching
take its place in the world with the
concrete has gained transfer strength, the

tendons in the first pair of segments are
stressed then the heavy duty scaffolds
are removed.
support and input from the BBR Network,

2
2015
The BBR Network's expertize in building overhead precast segmental viaducts for railways is shown to best advantage
by this article from the 2015 edition. It describes a well-organized approach towards producing the infrastructure for
stations on a new MRT line in Malaysia and the team's ability to work with other members of the wider construction
team on the project ensuring that the program is maintained.
we can be sure it will continue to grow and

develop. It has been an honor to share the
BBR journey and I look forward to further
travels with the BBR Network in the future,
through CONNCT.
www.bbrnetwork.com
11
TALKING BBR
ANNUAL BBR GLOBAL CONFERENCE, BANGKOK, THAILAND

Technical updates, networking and knowledge exchange
CONFERENCE NOTES
At the time he attended the 2015 BBR Annual Global Conference, Cezary Sternicki, now BBR HQs Head of Product
Development, had not formally joined the company. As a non-BBR family member, he explains how it was an
excellent occasion to get to know the people in advance and to begin the integration process.
While my background is in the construction
International, there followed briefings on
and civil engineering industry, the size
recent developments in Asia-Pacific
and reach of the BBR Network around the
(Thomas Richli), new technologies (Behzad
world came as a surprise. Equally
Manshadi), supply chain (Josef Lamprecht)
surprising was the discovery that just a
and marketing (Juan Maier). In the second
few people from BBR HQ were responsible
part of these sessions, it became crystal
for organizing the whole of this highly
clear to me what it is that makes the BBR
successful international event.
Network unique. All BBR Network Members

are independent business units that can
1 BBR Network delegates at the 2015 Annual

BBR Global Conference in Bangkok, Thailand.
2 Knowledge sharing was fostered in
unconventional surroundings including
a tuk-tuk race through Bangkok and
exploration of Chao Phraya River canals
on long-tailed speedboats.
3 From the technical sessions, the uniqueness
of the BBR Networks business model
became clear.
4 Captains of the winning team and runners-up
at the BBR Charity Golf Tournament shake
hands. John Mo (left) who led his team to
victory thanks John Taraldsen (right) whose
team came a close second, while Thomas
Richli (center) congratulates them both on
some excellent play.
5 Following the conference, Antonio Caballero
and Thomas Richli visited the Santisuk
Foundation with presents for the children
and donations raised through the BBR Charity
Golf Tournament.
Traditional start
freely adjust to local market requirements
The conference started with the traditional
to best meet their clients expectations.
Charity Golf Tournament. This event offered
Hence, many of them are either highly
a great opportunity for BBR Network
specialized in niche construction areas or
Members to catch up with old friends and
embrace larger portions of the value chain
partners, as well as also enjoying the game
and execute general works in construction.
and supporting those in need. The beneficiary
It was valuable to learn that BBR Global
of this years fund-raising was the Santisuk
Conferences are not only about the heavy
Foundation a non-government organization
stuff and technology related topics they
that helps children from the slums of
also promote the improvement of wider
Bangkok and surrounding area.
business issues. For example, we had a

chance to participate in the workshop led
Conference themes
by Professor Narayanan from the National
Before arriving at the conference, the BBR
University of Singapore about Decision
Networks extraordinary business model
Making for Leaders. Working in small teams
was explained to me, but I only truly
on the tasks, unrelated to daily civil
understood its meaning during the technical
engineering topics, was a good opportunity
sessions. After a warm welcome from
to learn about the BBR Network from a
Antonio Caballero, the CEO of BBR VT
different perspective.
TALKING BBR
Unforgettable experience
The BBR Annual Global Conference is an
unforgettable experience in outstanding

locations, with exceptional people sharing
extraordinary experiences and approaches
Exacting agenda, relaxed evenings
to life and many, many interesting
During the day the agenda was exact to the
conversations. All of this generates some
minute and according to business etiquette,
magnetism around the BBR Network,
meanwhile the evenings had a much more
which attracts unique people to join the
relaxed atmosphere. The latter fostered
organization and stay. This magnetism
knowledge and experience sharing in
must be strong, as there are Members who
unconventional circumstances for
have been within the BBR family for more
instance, during a James-Bond-like tuk-tuk
than 50 years and their uniqueness was
BEST ARTICLE AWARD
race through the streets of Bangkok or
certainly in evidence on the last evening
Winner: KB Vorspann-Technik (Austria)
exploration of Chao Phraya River canals on
during the informal speeches and antics in
long-tail speedboats.
the hotel bar!
2015 BBR AWARD WINNERS

BBR NETWORK PROJECT OF THE YEAR
Station platforms and curved bridge for

MRT & LRT Projects, Malaysia executed
by BBR Construction Services (Malaysia)
Title: Fast turnaround for retail

customers (Shopping center
developments, Austria)
Runner up: SRG Limited (Australia)
Title: Hitting the ground running
(Paradise Dam, Australia)
Highly commended: NASA Structural
Systems LLC & Structural Systems
Middle East
Title: Bridges for reasons & seasons
(Bridges in Bahrain, Dubai & Oman)
BEST PHOTOGRAPHY AWARD
Winner: BBR Contech (New Zealand)

Title: Ground floor achievements
(Retail, distribution & dairy industry
floor slabs, New Zealand)
Runner up: Spnnteknik AB (Sweden)
Title: Strong roots (Arjang & Tanum
Wind Park projects, Sweden)
Highly commended: BBR Construction
Services (Malaysia)
Title: Fast turnaround for retail
customers (IOI City Mall, Selangor,
Malaysia)
5
TALKING BBR
NEWS HIGHLIGHTS
Events, celebrations and latest news
OUT-AND-ABOUT WITH
THE BBR NETWORK
In some respects, the essence of BBR technology is about creating links or
bonds and staying connected. Likewise, BBR Network activities during the
past year have mostly been focused on reaching out to various audiences
and strengthening connections.
1 The team from BBR Network Member Marwan

Alkurdi & Partners pose for a photograph in
their exhibition booth at the International
Conference and Exhibition of Mass
Construction (IEOMC) in Amman, Jordan.
2 Jrg Dniker talks with a delegate in the
BBR and Stahlton booth at the 2015 IABSE
Conference in Geneva.
3 In October 2015, BBR HQ moved into its new
offices which, or course, features floor slabs
post-tensioned with the BBR VT CONA CMF
flat system.
4 BBR HQs Juan Maier and Behzad Manshadi
at the BBR Network exhibition booth at
the Multi-Span Large Bridge Conference
in Portugal.
5 The new BBR Project Finder has been
launched, bringing detailed information about
1,000+ projects to your desktop and can be
accessed from the BBR Network website.
6 Voon Yok-Lin of BBR Malaysia makes the first
cut in the companys massive 21st Birthday
cake during celebrations in Kuala Lumpur.
International conferences
Roadshow down under
The BBR Network was represented at
New Zealands major cities Auckland,
four major conferences during 2015. The
Wellington and Christchurch were locations
International Conference and Exhibition
for BBR Contechs road show in July.
of Mass Construction (IEOMC) in Amman,
BBR VT International supported the local
Jordan was held in June and BBR Network
team in their promotional activities with
Member Marwan Alkurdi & Partners had
leading design consultants and construction
an exhibition booth.
companies. Presentations included BBRs
In May, BBR Philippines sponsored the
capabilities, latest post-tensioning range
17th ASEP-IABSE International Convention
with its unique benefits, and experience
in Manilla where Chee-Cheong Chang
in bridge temporary works. Some 60
from BBR CS Malaysia and Thomas Richli
engineers attended the sessions.
from BBR HQ submitted and presented a

technical paper about efficient bridge
Coming of age for BBR Malaysia
construction techniques. BBR also placed
On 12th April 2015, BBR Malaysia celebrated
an exhibition booth at the Multi-Span
their 21st Anniversary at a large function at
Large Bridge Conference in Porto, Portugal
Sunway Pyramid Resort Hotel attended by
which was attended by over 400 delegates
staff and guests. During the evening, 49
from around the world from both academia
long-serving staff with a total of 645 years
and industry.
service between them were recognized
Meanwhile, in September, BBR and
with special awards. To complete the
Stahlton hosted a booth at the 2015
formal celebrations, Managing Director
International Association for Bridge and
Voon Yok-Lin was invited to cut a giant
Structural Engineering (IABSE) Conference
birthday cake and festivities continued late
in Geneva.
into the night.
TALKING BBR
New BBR HQ
Social media
BBR Project Finder
In the middle of October, BBR VT
In response to the changing trends of how
The new BBR Project Finder has been
International opened the doors to its new
companies interact and engage with their
launched and brings detailed information
offices and moved in. The BBR HQ team
most valued customers, staff and
about 1,000+ projects from within the
is now operating from purpose-built
professional associates, BBR has now
massive BBR portfolio to within easy
modern accommodation and happy in
established a social media presence. The
reach. The Project Finder can be accessed
the knowledge that there are floor slabs
BBR Network is now on Facebook, LinkedIn,
from the BBR Network website, by clicking
post-tensioned with the BBR VT CONA CMF
Google+ and YouTube. Also, BBR news is
on the Project Finder tab, or directly at
flat system both above and below them!
now available through an RSS Feed from the
pf.bbrnetwork.com.
The completion of this new office block
BBR Network website by subscribing to
Information in this valuable reference
which houses sister company Proceq too,
our newsfeed, you will ensure that you are
database may be viewed using a series of
also completes a significant investment by
always up to date with our latest news and
simple selection tools and resulting data on
major shareholder Tectus AG.
announcements. All media can be accessed
individual projects is also cross-referenced
from links at the footer of our website.
to articles in CONNCT magazine and

external sources. Once your selection is
www.bbrnetwork.com
made, you can even download a handy

reference list in pdf format.
More-and-more project details are being
added on a continuous basis and, over
coming months, we will be extending the
functionality of the Project Finder with a
number of new features.
TALKING BBR
PERSPECTIVE
Development in bridge construction technology
EVOLUTIONARY
STRENGTH
Dr.-Ing. Dipl.-Kfm. Hermann Weiher is the founder and owner of Munich-based consulting engineering firm matrics
engineering GmbH and his specialist area of expertize is bridges. Having completed a doctoral degree in the field
of prestressed concrete, his work has included several years as research assistant with the Chair of Concrete
Construction at TU Munich. Meanwhile, Dr. Weiher is an active member of several national and international
committees within fib and IABSE. For this edition of CONNCT, he shares his views on how bridge construction
technology is evolving even within an environment surrounded by regulatory requirements.
The world of construction today is largely
Recently, in the USA in Florida we
bridges, as the complete structure will be
controlled by regulations and guidelines
have seen a governmental shift in bridge
strengthened by its application. There are
aimed at ensuring a structure is built safely
construction technology towards external
relatively few regulations in this area, so
and in a way which ensures its effective
post-tensioning using strands protected
perhaps we will see some innovation here
performance in line with design and service
with grease or wax and now the industry
over coming years.
objectives. This means there has to be a
is trying to adapt. There was a similar
The next step is going to come with the
high degree of conformity in the
situation in Germany in the 1990s when
arrival of extradosed bridges these are
technologies applied to allow comparisons
the government moved away from
very popular in the Japanese market, which
to be made by purchasers.
installing post-tensioning in the webs
was the first to adopt this type of bridge
because of difficulties with concrete
construction. It is an ideal method for
Regulatory developments
placement and also issues with corrosion.
dealing with special span lengths and the
It was in Germany, back in the 1950s, that
Thus, innovation is largely driven by
shape of valleys. These projects literally
work began on developing a new code for
governments who like to have a choice of
play to the strengths of post-tensioning
post-tensioned bridges the first of these
suppliers offering broadly similar
prestressing steel is very strong compared
was DIN 4227 which was published in
technologies and systems. In this
to ordinary steel and the anchorage delivers
October 1953. Obviously, this was early in
environment, companies are not prepared
95% of the strength of the post-tensioning
the industrys experience of post-tensioning
to risk creating an entirely new technology
tendon. Of course, corrosion protection in
and therefore it is not surprising that the
and bearing the financial and administrative
this situation is crucial.
code underwent much revision as bridge
burdens this implies without guaranteed
The advent of ultra high performance
construction continued. By the 1980s, we
returns on their investment.
concrete may also be a game changer.

So far, we have only seen it used for
had quite conservative building codes and

these were further consolidated with the
New applications
single pilot projects or fairly short span
arrival of Eurocodes.
We have, however, seen a change in the
prefabricated bridges.
This has led, certainly in Europe, to a
type of project for which post-tensioning
Post-tensioning improves a bridge
reluctance to innovate the necessary
technology is used. Rehabilitation and
structurally and we certainly never
bureaucracy, testing regimes and costs
strengthening of existing structures with
expect to see the failure under service of
required to secure approvals make this an
post-tensioning has become more common
a post-tensioned bridge, especially if it is
unattractive proposition for many
especially where traffic loads are now
a continuous girder system with high
companies. So, how have construction
greater than originally envisaged and there
redundancy. The bottom line is that
technology providers set about
is perhaps some age-related deterioration.
post-tensioning was a great invention
differentiating themselves?
It is worth mentioning that not every bridge
and, with modern advances in both
can be strengthened using the same method
anchorages and corrosion protection
Government-led change
and, indeed, sometimes strengthening is
which have partly been driven by mass
Progressively, they have worked to improve
not the best solution. Meanwhile, external
application markets, for example, slabs
their systems with anchorages and
post-tensioning is the most common and
or wind turbines the systems are now
corrosion protection being key factors.
best solution for strengthening concrete
really efficient.
PORTFOLIO
18 IN THE SPOTLIGHT
BBR Adrias CEO, Zelimir Bodiroga,
reflects on the companys enviable
20 year track record
BRIDGES
20 SPANNING THE GORGE
with arch closure at the Tamina
Bridge, a precision approach was
needed to dismantle temporary
stay cables, as PT work for the
bridge deck began
BUILDINGS
37 GATEWAY TO SOUTH
EASTERN EUROPE
the new passenger terminal at
Zagreb Airport is taking shape with
the help of some 37,000m2 of slabs
post-tensioned with BBR technology
STAY CABLES
54 VOYAGE OF DISCOVERY
taking a tour of Rzeszw Bridge
reveals exciting moments and
technological achievement
SPECIAL APPLICATIONS
62 INNOVATIVE WATER
TANK SOLUTION
two-way PT concrete panels for
water containment to meet
ground conditions in challenging
environment
MRR
70 COASTAL COMMERCE
PROTECTING THE ASSETS
in a relationship stretching back
20 years, BBR Contech has
ensured that Aucklands vital port
facilities have received quality
repair and remediation
www.bbrnetwork.com
17
IN THE SPOTLIGHT BBR
IN THE SPOTLIGHT
BBR Adria celebrates 20th anniversary
TWO DECADES
OF EXCELLENCE
1
In 2016, BBR Network Member BBR Adria will be celebrating the 20th anniversary of its foundation. We asked
the companys CEO, elimir Bodiroga, to reflect on the companys heritage and engineering achievements.
Today, BBR Adria is a leading construction
BBR HQ, in collaboration with Zurich
Slovenia, Bosnia and Herzegovina,
engineering contractor specializing in
structural engineering design firm CEPAS
Montenegro and other countries of former
post-tensioning operations for buildings
Plan AG, provided an alternative design for
Yugoslavia. Most work has been carried
and bridges, as well as providing remedial
arch erection. This included form travelers
out in our home market, Croatia, although
and marine construction engineering
and featured BBRV stay and back stay
there have been many projects in the other
services. The company is building on the
cables, as well as two temporary steel
territories we cover.
tradition of BBR post-tensioning in the
pylons to stabilize the arch during
region which stretches back over 40 years
construction. Construction also involved
Our first million m2
with more than 15,000t of high value
ground anchors and girders prestressed
Since our foundation, we have installed
strands and tendons used in the
with BBR technology.
post-tensioning for approaching 150
construction of bridges, viaducts,
The wider professional team on the
bridges or viaducts and many buildings,
overpasses, industrial facilities, tanks,
scheme included Conex of Zagreb and
as well as providing ground anchors for
sports halls and other buildings.
also Dr Jure Radic, then a Professor, who
some 70 projects and post-tensioning for
One of our most senior engineers, Zdenko
has more recently played a key role in the
several marina schemes.
Mesek now retired had over 45 years
design of the new Terminal at Zagreb
The companys biggest achievement during
of working with post-tensioning technology.
Airport (see page 37). It was towards the
recent years has been the introduction of
I always remember that he once told me
end of the Maslenica project that BBR
post-tensioning for buildings in the Balkan
that the quality and reliability of BBR
Conex d.d. was formed and the company
region. When I first joined BBR Adria, back
post-tensioning was simply the best and
was owned jointly by BBR HQ and Conex.
in 2004, the company was just starting
if a project was to feature post-tensioning,
Our birthday was actually on 26th October
work on its first such project a large car
then it should be BBR.
1996 and we immediately set up
park at Brnik Airport, near Ljubljana,
headquarters in Zagreb. Since then, the
Slovenia. Numerous projects of various
Company roots
companys name has changed to BBR Adria
sizes then followed and now this core
Construction of the Maslenica Bridge,
and several years later a management
activity represents up to 75% of our
which carries the A1 highway across the
buyout was agreed which has set the firm
turnover not including traditional bridge
Maslenica Straits to the north of Zadar,
on a new and dynamic course for the future.
post-tensioning. In material terms, we
marked a turning point in the history of
Now, BBR Adria has 30 permanent
have completed about a million square
BBR in Croatia.
employees and is active in Croatia, Serbia,
meters of post-tensioned slabs.
IN THE SPOTLIGHT BBR
1 A major business landmark for BBR in Croatia

developed from the project to construct the
Maslenica Bridge.
2 Zagrebs 100m Strojarska Towers
development includes the second tallest
structure in Zagreb and incorporated
BBR VT CONA CMM post-tensioning for the
floor slabs.
3 In 2003, during the restoration works at
Pulas Roman Amphitheater in Croatia, BBR
Adria post-tensioned the roof of what is now
the olive museum, which lies beneath the
arena, with the BBR CONA compact system.
Photograph released into the public domain
by Orlovic via Wikimedia Commons.
4 Re-opened in 2005, the Sloboda Bridge over
the River Danube in Novi Sad, Serbia features
BBR CONA stay cables. The original 1981
bridge had BBR HiAm stay cables, but was
destroyed in NATO airstrikes in 1999. The
bridge is believed to be the only stay cable
bridge in the world to have been built twice.
5 The unique design of the Ptuj Bridge over
the River Drava in Slovenia featured BBR VT
CONA CMI and CME, internal and external,
post-tensioning tendons.
6 Our specialist construction technology and
expertise was required for the realization of
the Zagreb Arena, including post-tensioning
the 86 precast lamellas each 42m high
with the BBR VT CONA CMI internal system
which form the buildings distinctive exterior.
Public recognition
presents. Thinking about this challenging
After just ten years of working with BBR
project again today, I still get goose-bumps
technology and growing our business in the
and for sure, I will be talking about it
region, we were honored by a special award.
almost every day for the next 20 years!
We were presented with a First Croatian
That same year, we enjoyed a very fine
Kuna Award for our efforts in 2006-2007.
co-operation with our colleagues from
The award, from the Institute for Business
fellow BBR Network Member KB Vorspann-
Intelligence, recognized BBR Adrias position
Technik on the Ptuj Bridge project in
in the top 1% of best Croatian companies.
Slovenia. More recent history can be seen
Since then, we have carried out work on
through the pages of CONNCT, which
some of the regions highest profile
have featured our work on the Strojarska
projects. In 2008, we were awarded a major
Towers project as well as articles in this
contract for specialist construction services
edition about the new Passenger Terminal
for the Zagreb Arena. It was a question of
at Zagreb Airport, the Brije

ce Viaduct in
honor for us to achieve the tight program
Sarajevo, Project Ive Mikaca Varadin and
because the eyes of the whole of Croatia
our geotechnical rock anchoring project
were on us, watching and hoping we could
for a pumping station at Bi Bosut.
complete the work in time for the World
The excellent reputation we now enjoy is
Handball Championships. We worked
a direct result of the dedication of every
16-hour days to install the distinctive
member of the BBR Adria team. Their
lamellas our team members took it in
continuous attention to detail enables us
turns to work outside in the wind, snow and
to provide excellence in every aspect of
freezing temperatures. I also remember
customer service and this will be the key
how we finished on 23rd December and
to our continued success in the future.
then ran to the stores for family Christmas
PORTFOLIO BRIDGES
PORTFOLIO BRIDGES
TAMINA BRIDGE, CANTON ST GALLEN, SWITZERLAND

Arch closure & start of deck post-tensioning work
SPANNING
THE GORGE
An exciting new arch bridge has been under construction

in the Swiss Canton of St Gallen, as reported in CONNCT
2015 (page 26), and there will soon be a road connection for
the first time between the communities of Pffers and Valens
set high above the stunning Tamina Gorge. Two BBR Network
Members have been contributing leading edge technology
and expertise to the realization of this breathtaking project.
Norbert Bogensperger of KB VT (Austria) and Sascha Weder
of Stahlton (Switzerland), have joined forces to deliver an
update to the story.
PORTFOLIO BRIDGES
It was an operation
requiring the handling of
24-strand stay cables up
to 152m long and weighing
around 185t in total.
A landmark event has taken place on the
As you may recall, we worked with the main
Tamina Bridge site since the last edition
contractor on alternative concepts which
of CONNCT arch closure was
have benefited both the program and
FACTS & FIGURES
achieved on 28th March 2015. This means
budget, as well as general buildability.
Deck length 417m
that the final segment forming the arch
These included using our temporary
Number of piers 5
beneath the bridge deck has been placed.
stay cables just once instead of twice,
Height of piers up to 55m
There was, of course, a major celebration
designing the post-tensioning so that less
Arch length 265 m
as the final concrete hopper, suspended
reinforcement was needed and there were
Number of segments 55
(for free cantilever arch construction)
from a crane, flew across the gorge to
less horizontal forces in the abutments.
pour its consignment of concrete. We all
As well as making deck construction cheaper
took a moment to reflect on our
with normal falsework than with free
achievement, the teamwork which had
cantilevering, it is estimated this alternative
led to this point and to think about the
design will lead to the bridge opening taking
work still ahead of us.
place earlier than originally scheduled.
Segment length 5m
Segments launched from Pffers
side 32
Segments launched from Valens
side 23
PORTFOLIO BRIDGES
Temporary stay cables

The arch springs across the gorge from
There were three
two massive abutments and, during
main steps to our
construction, was supported from the up

to 100m high temporary pylons by stay
strategy for this
cables 31 pairs on the arch side and
operation firstly
24 pairs on the back span, a total of 110

stay cables.
The KB VT team, working with members
of the main contractors team, installed
safety, then delivering

the technical solution
the cables at the rate of up to four per week
and finally speed.
on both sides of the gorge simultaneously.

It was an operation requiring the handling
of 24-strand stay cables up to 152m long
and weighing around 185t in total.
The stay cables were fed into position
1 The temporary stay cables were
deconstructed in stages.
2 The upper stressing platform in early 2015,
amid a snowy landscape.
3 Special Y-shaped tendons were developed
for the project by KB VT from the BBR VT
CONA CMX system to fit spacing
requirements in the girder-walls of the arch.
4 Stay cables at the second stage of the
temporary pylon on the Valens side of the
gorge.
5 In March 2015, the final segment was
concreted. Here, the concrete hopper,
delivered by crane to the center of the arch,
is being emptied.
Photographs 1, 2, 4 & 5 courtesy of
Tiefbauamt St Gallen.
using a double winch fixed in the middle of
Stressing
the cross-beams with guide rollers in all
Back and main cables were stressed
directions, it was like a kind of endless rope
simultaneously in small stages. This
hauling system. For stressing operations,
enabled us to have permanent control of
we also used two 7,000kN jacks for the
the pylon position and deflection.
main cables and ten 3,500kN lifting jacks
Deflection limits for the pylons had been
for back span cables.
clearly defined and were strictly observed,
As well as being prepared with several
with real-time adjustments made to the
methods of installation to allow maximum
stressing procedure dependent upon
flexibility, we also had robust safety plans
measured deflections.
and procedures to protect our workers
Our final stressing operation was carried
during materials handling and while
out to ensure the arch position was aligned
working generally on such an exposed site.
correctly to receive the next segment.

PORTFOLIO BRIDGES
Deconstruction of stay cables

When construction of the arch had been
completed, we carried out an equally
complex series of actions to remove the
stay cables.
There were three main steps to our
strategy for this operation firstly safety,
then delivering the technical solution and
finally speed.
We released the cables on the main span
using specially adapted monojacks, with
additional wedging for safety reasons.
The back span cables were deconstructed
using lifting jacks or monojacks. Again the
operation was carried out simultaneously
on both pylons with the maximum
difference at any one time being one pair
of stay cables. We adopted releasing
sequences similar to the original stressing
sequences to avoid asymmetric loading
of the now completed arch.
Cables were bundled near the couplers,
cut and then released with the winch

down the arch. Removal of the cables was
carried out according to cable length.
While this was a challenging stage of this
Shorter ones were simply removed by
wonderful project, we recognized that a
crane, while the medium sized cables
complex solution such as this can only be
were bundled, hung on the crane using
delivered if there is mutual trust between
special clamps then lifted and cut at the
all parties. Early involvement in the project
point they exited the cross beam. The
was essential and we learned that there
longest cables were handled similarly,
are no perfect ready-made concepts
but cut a second time at a lower platform
developing them is a live process requiring
for safety reasons leaving around 50m
both engineering skills, innovation and
of cable to be removed later. Dismantling
flexibility. Together, STRABAG, Hltschi
the stay cables took about a week per
& Schurter (now Meichtry & Widmer) and
cross-beam level with two weeks for the
KB VT formed a strong team of solutions-
upper level.
oriented people.
6 Work from the stressing platforms was

undertaken in all types of weather.
7 The falsework structure for bridge deck
construction at the top of the arch.
8 Concrete is delivered to the center of the
bridge by crane and placed by the
construction team.
Photographs 7 & 8 courtesy of Tiefbauamt
St Gallen.
PORTFOLIO BRIDGES
ALMONTE VIADUCT, CACERES, SPAIN

Arch bridge constructed with temporary stay cables
Bridge superstructure
Once the arch had been closed after the
final segment pour, the main contractor
began building a falsework structure to
create the superstructure for the bridge
deck, while also constructing the three
arch supports.
As the KB VT crew were leaving the site,
WORLD RECORD
ARCH BRIDGE
the team from BBR Network Member

Stahlton began the installation of post-
With the placing of the final arch
The 96m viaduct crosses the
tensioning for the bridge deck which is
keystone in August last year,
Alcantara-Garrovillas reservoir and will
being constructed above the arch. The

deck is of a continuous box girder form
Spains Almonte Bridge claimed
carry the AVE high speed railway from

Madrid to Extremadura. The 996m long
and supported at 35-55m intervals.
its place in the list of world records
Almonte Viaduct is the most prominent
Stahltons work on post-tensioning the
for having the longest span for an
structure on this section of high speed
individual sections began in August. We
arched high speed railway bridge.
railway line. The viaduct is divided into
are using the BBR VT CONA CMI internal

1506 and 1906 systems and the number
Like Switzerlands Tamina Bridge,
three distinct parts two access roads

and one central section, the latter
of tendons placed in the box section
temporary stay cables were also
includes the Almonte Bridge, a 384m
varies between four and eight per side,
used here to support construction
span concrete arch bridge.
depending on the span length.
of the arch and Spanish BBR
For the construction of the arch, a total
Starting at the center of the bridge, deck

construction is proceeding towards the
Network Member, BBR PTE has
of 208 BBR HiAm CONA 5506 and 3706

stay cables were used as temporary
abutments in both directions at the
now completed the stay cable
supports while the arch segments were
same time. Our work also includes post-
dismantling process.
being cast in sequence. With the
tensioning for the approach bridges on
concreting of the final segment, the arch
both sides of the gorge.
became self-supporting and the stay
In total, we will be using around 180t of
cables were progressively and carefully
prestressing steel for the BBR VT CONA
TEAM & TECHNOLOGY
CMI internal tendons, some 140
Owner ADIF
Main contractor FCC Construccin
S.A + Conduril
Technology BBR HiAm CONA stay
BBR Network Member BBR PTE, S.L.
(Spain)
anchorages and around 8km of BBR VT

Plastic Duct to ensure added durability
and robustness in this location which is
exposed to the elements.
destressed before being dismantled.
The completed Tamina Bridge is

scheduled to open to traffic in 2017,
forming the first ever direct connection
across the Tamina Gorge between the
Alpine villages of Pffers and Valens.
TEAM & TECHNOLOGY

Owner Tiefbauamt Kanton St. Gallen
Main contractor STRABAG Erni
Meisterbau JV
Structural design Leonhard, Andr
und Partner
Alternative design Hltschi & Schurter
(now Meichtry & Widmer Dipl. Ing ETH/SIA
AG) (arch alternative for JV)
Technology BBR VT CONA CMI internal,
BBR VT Plastic Duct
BBR Network Member Temporary stay
cables: KB Vorspann-Technik GmbH
(Austria), Post-tensioning: Stahlton AG
(Switzerland)
PORTFOLIO BRIDGES
BATANG SADONG BRIDGE, SARAWAK, MALAYSIA

Ten span balanced cantilever construction
LONGEST MULTIPLE
SPAN BALANCED
CANTILEVER BRIDGE
The 1.48km long Batang Sadong
Bong Su-Fah, BBR Malaysias
Deflection control
Bridge will be the longest multiple
Construction Manager, together with
The levels of the bridge top and bottom
Chief Prestressing Engineer George
are taken at the following times:
Jacob, outline the balanced cantilever
after advancing form travelers to set
span balanced cantilever bridge

in Malaysia. When completed in
method using form travelers and the
2016, it will stimulate the growth
necessary deflection control procedures
of a new township, Sadong Jaya
being used to ensure the as-built levels
and also link the townships of
of the bridge achieve the design levels.
the levels for next segment

after concreting of both left and right
segments
after stressing of tendons.
The deflections are calculated, plotted on
Simunjan and Sebuyau in
Construction cycle
a graph and then compared with the
Sarawak. BBR Malaysia has been
This massive bridge has nine piers with
theoretical values. If the difference is
engaged by the main contractor
10 spans in a configuration of 75 + 140
significant, the level for the next segment
+ 150 + 175 + 200 + 200 + 175 + 150 +
to be cast is adjusted to bring the deflection
140 + 75m. The bridge has a deck width
into line with the theoretical values.
balanced cantilever piers which
of 11.24m and will carry two traffic lanes
Measurements must be taken early in the
are on bearings, while they
in both directions. The box girder depth
morning shortly after dawn so that
construct the remaining piers. In
is 10.5m at piers, reducing to 3.6m at
temperature gradients on the bridge deck are
midspan. We are working on two piers
minimized. As the top deck slab is exposed
simultaneously with two pairs of form
to the sun, it gets warmer compared to the
construction engineering services
travelers. The typical cycle time to
cooler, concealed deck slab thus, the bridge
for all the piers.
construct a pair of left and right segments
deck levels change during the day. The
is 12 days.
starting point for the leveling is at the axis of
to construct the four challenging
addition, BBR Malaysia is providing
the piers, which forms the reference datum.
PORTFOLIO BRIDGES
1 BBR Malaysia is providing specialist

construction engineering services for the
1.48km long Batang Sadong Bridge which,
when completed, will be the longest multiple
span balanced cantilever bridge in Malaysia.
2 The BBR Malaysia team working on the
Batang Sadong Bridge celebrate completion
of another pair of balanced cantilever
segments. Typical cycle time to construct
a pair of left and right segments is 12 days.
TEAM & TECHNOLOGY

Owner Government of Malaysia
Main contractor KACC Construction
Sdn Bhd
Designer J.H.L Konsult Sdn. Bhd.
Works contractor PPK Sdn Bhd / BBRCS
(M) Sdn Bhd
Technology BBR CONA internal
BBR Network Member BBR Construction
Systems (M) Sdn Bhd (Malaysia)
2
Closure segment
TYPICAL SEGMENT PAIR CONSTRUCTION CYCLE
After completion of the cantilevers, a gap

of two meters remains between the end
of two opposite cantilevers this is to
allow space for tendon stressing with
multi-jacks. One form traveler is removed
and re-erected on another pier. The
second form traveler is launched forward
to connect to the other cantilever to
serve as formwork for the closure pour.
Stitching beams are installed to secure
the two ends of the cantilever from
differential movement during concreting
of the closure segment. The levels of the
two ends are checked.
If the difference is significant more than
30mm the stiff stitching beams are used
to reduce the difference in level. Vertical
prestress bars are stressed with hollow
jacks to pull the ends of the cantilevers up
or down. Alternatively, kentledge concrete
blocks might be placed on top of the deck
to press the cantilever down.
When the concrete strength achieves
40MPa, the bottom and top continuity
tendons are stressed. Finally, the form
traveler is removed and reinstalled on
another pier.
Balanced cantilever cast insitu
construction using form travelers is not a
fast method but it is an efficient way to
build long span bridges over deep and
wide rivers. Materials, including concrete,
can be delivered by barges directly to the
piers. Also, as form travelers can be
reused, construction costs are reduced.
Day 1 Day 2
After completion of cantilever tendons, left and right form travelers are advanced outwards from
the pier to construct the next pair of segments. The levels of the form travelers are adjusted upwards
to the required precamber level in anticipation of the downward deflection during concreting of the
segment. Also considered in the precamber value is the effect of post-tensioning of the cantilever
tendons causing the cantilevers to deflect upwards, but these magnitudes are relatively small
compared to the deflection due to weight of concrete segments.
Calculation of the theoretical deflection takes into account the different creep and modulus of
elasticity of the segments which are cast at different times.
Day 2 Day 4
The installation of the reinforcement usually begins on the lighter segment to minimize the out of
balance moment on the pier. After fixing the bottom and web reinforcement, the bottom tendon
ducts and anchorages are installed.
Day 4 Day 7
Works are carried out on the top slab soffit and outer web formwork. Next comes the fixing of top
slab reinforcement and tendon ducts and top cantilever anchorages.
Day 7 Day 9
Closing of the inner side formwork is completed and tie rods are secured to contain the high pressure
during concreting.
Both segments are cast with Grade 50 concrete, on the same day, using cranes secured on barges in
a near balanced cantilever way. This is done by alternating the concreting between the left and right
segments in several stages. The bottom slab of the lighter segment is concreted first, followed by the
bottom slab of the heavier segment, and then back to the lighter segment to concrete the webs and
then repeating the same on the heavier segment. Then followed by concreting the lighter segments
top slab and finally the top slab of the heavier segment.
Day 9 Day 11
After 24 hours, the web formworks are rotated to detach from the cast concrete surface and kept
moist for concrete curing. Meanwhile, strands are threaded into the empty ducts and anchor heads
are fixed in preparation for stressing.
Day 11 Day 12
When the concrete has achieved the required concrete transfer strength of 40MPa, the cantilever
tendons are stressed. Upon completion of stressing, the form travelers are launched to the next
segment position. Two 750t jacks are used to stress a pair of 3106 tendons or 2206 tendons.
The 2206 tendons can also be stressed with 500t jacks.
PORTFOLIO BRIDGES
GULLI BRIDGE, NORWAY

Incrementally launched river bridge
OPTIMIZED BRIDGE
CONSTRUCTION
Gulli Bridge is part of the new highway between Oslo and Stockholm.
The new 741m long bridge crosses Norways longest river, the Glomma,
and at the eastern end of the bridge is the city of Kongsvinger home
of Norwegian BBR Network Member, KB Spennteknikk. Stig Solbjr,
Technical Manager, describes the bridges setting, how it was
designed under new guidelines and constructed to be durable.
PORTFOLIO BRIDGES
1 The 741m long Gulli Bridge, part of the new

Oslo-Stockholm highway, crosses the River
Glomma close to Norwegian BBR Network
Member KB Spennteknikks head office in
Kongsvinger. Photograph by Byggenytt.
2 Aerial view of the completed Gulli Bridge
where the team supplied, installed and
stressed 19,000m of BBR VT CONA CMI PT
tendons and supplied purpose-made TOBE
pot bearings for installation after the
incremental launching operation. Photograph
by Jon Ivar Shus.
3 The value engineering exercise resulted in the
selection of incremental launching as the
bridge building method. Photograph courtesy
of Grzegorz Gucwa, Skanska.
3
At 621km long and with a drainage basin
Optimized bridge design
The bridge has 32 precast concrete
covering 13% of the country, the Glomma
The Gulli Bridge was designed under new
elements with a unit length of 25m all
or Glma is Norways longest and
guidelines set out by the Norwegian
built in the production plant, a temporary
largest river. It runs from Lake Aursund
Road Department. Value engineering
factory created on site, on the northern
near Rros in Sr-Trndelag and ends when
workshops were held between the selected
side of the river and incrementally
it flows into the Oslofjord at Fredrikstad.
contractor and client to find an optimized
launched in two week cycles.
Major tributaries include the Vorma river,
solution for the construction project with
We supplied, installed and stressed
which runs from Lake Mjsa Norways
respect to program and budget. The cost
19,000m of BBR VT CONA CMI 1206
largest lake and joins the Glomma at Nes.
savings are then shared between the client
post-tensioning tendons and assisted the
This is a particularly significant connection
and contractor.
main contractor with personnel for the
because the River Lgen ends in Lake
From this value engineering exercise, came
incremental launching. We also supplied
Mjsa where drainage waters from the
a proposal by the contractor to use the
32 purpose-made TOBE FR-4 pot
large Gudbrandsdal valley collect and
incremental launching method a common
bearings that were installed after the
thereby, via the Vorma, the River Glommas
choice in European countries other than
incremental launching process and two
flow is significantly increased.
Norway for the bridges construction.
ETIC EJF 500 expansion joints one at
Historically, the Glomma has been a major
each end of the bridge, produced by the
transportation route famous for once
French BBR Network Member.
being Norways leading log floating river as
Bridge design
it flows through some of the richest forest
The collaboration between the owner and
districts. Over the years, the combination
contractor resulted in a slight change in
of raw materials, water power and easy
the curvature of the bridge and extended
transport has fostered development of
spans from 40 to 50m, which reduced
TEAM & TECHNOLOGY
industry along the Glomma. Some of the
the number of columns. The River
countrys largest manufacturing and
Glomma has a high water flow and difficult
processing installations are found
ground conditions due to spring flooding.
around the rivers mouth, where supplies
In addition, the incremental launching
of timber and hydropower have been
method simplified the crossing of the
supported by excellent port facilities.
railway, which passes under the bridge.
Owner Statens Vegvesen

Main contractor Skanska Norge AS
Consultant Dr. Ing. Aas Jakobsen
Technology BBR VT CONA CMI internal,
bearing, expansion joint
BBR Network Member KB Spennteknikk
AS (Norway)
PORTFOLIO BRIDGES
MERSEY GATEWAY BRIDGE, RUNCORN-WIDNES, CHESHIRE, ENGLAND

BBR post-tensioning for bridge deck
NEW GATEWAY
FOR MERSEY
A second road crossing over the River Mersey in North West England has been a long
held aspiration for many and now the new bridge is taking shape. Roger Stables, of
BBR Network Member Structural Systems (UK) Limited, tells the story of the bridges
history and his companys role in the construction project.
1 Artists impression of the completed

Mersey Gateway Bridge between Runcorn
and Widnes.
2 Aerial view of bridge construction site with
completed trestle bridge and showing all
three cofferdam sites, as well as the Silver
Jubilee Bridge in background.
3 Aerial view of the north cofferdam where
excavation for a pylon base is underway.
Photographs 1, 2 & 3 courtesy of
www.merseygateway.co.uk.
The River Mersey flows for some 70 miles
on the southern side, around 1.5km to
from its source near the town of Stockport
the east of the Silver Jubilee Bridge.
to the city of Liverpool before flowing into
More than just forging a connection and
the Irish Sea. On its journey, the river
easing congestion, it is hoped that the
narrows between Runcorn and Widnes,
bridge will be a catalyst for regeneration
in the Borough of Halton, and it was here
and new and inward investment in the
that the Silver Jubilee Bridge was first
local area and north west as a whole.
opened in 1961. As the only vehicular
The Merseylink Consortium consisting
crossing of the Mersey in the Halton area,
of sponsors Macquarie Capital (Australia),
and with the increase in road traffic over
FCC Construccin S.A. (Spain) and BBGI
the last 50+ years, the road bridge and
was selected as preferred bidder for
local highway network has been under
the project in June 2013 and will be
severe pressure despite bridge widening
responsible for the design, building,
and strengthening work in the 1970s.
financing and operation of the bridge for
Now, a major new six-lane toll bridge is
30 years. Financial close was achieved in
under construction between Widnes on
2014 and construction work began on
the northern bank of the river and Runcorn
7th May the same year.
PORTFOLIO BRIDGES
This particular design

was chosen as it
maximizes benefits
for users and the local
community while
minimizing impact on
the environment.
Construction methodology
Three cofferdams were built in the river
to allow excavation for the bases of the
bridge pylons. Meanwhile, a temporary
trestle bridge was built to allow access
to the site.
Span-by-span construction of the main
bridge deck began in autumn 2015. The
team is using Europes longest Movable
Scaffolding System (MSS) which
measures 157m long and weighs in at
around 1,700t. Named Trinity to reflect
the unusual three pylon design and the
three companies within the Merseylink
Civil Contractors Joint Venture Kier
Infrastructure and Overseas Limited,
Samsung C&T ECUK Limited and FCC
Construccin S.A. the MSS is capable
of casting spans up to 70m long.

Post-tensioning technology
Specialist companies BBR PTE S.L.,
Structural Systems (UK) Ltd and VSL
TEAM & TECHNOLOGY

DBFO Merseylink Limited
Main contractor Merseylink Civil
Contractors Joint Venture: Kier
Infrastructure and Overseas Limited,
Samsung C&T ECUK Limited and FCC
Construccin S.A.
Structural designers Merseylink Design
Joint Venture: Flint & Neill, Aecom, Eptisa
and Fhecor
Technology BBR VT CONA CMI internal
BBR Network Member Structural
Systems (UK) Limited & BBR PTE (Spain)
Bridge design
Systems (UK) Ltd have formed a joint
The Mersey Gateway Bridge is of a cable-
venture known as BSV Mersey JV in
stayed design, similar to the Second
order to offer the Mersey Gateway project
Severn Crossing Bridge but with three
with what we believe to be the most highly
pylons instead of two. The outer two pylons
skilled and optimized specialist service
will be 110m (north) and 125m high (south),
within our field an approach considered
while the central pylon will be shorter, at
essential for such a high profile and
80m high. The bridge will have a river span
technically challenging project.
of 1km and, with the approach viaducts
When completed in 2017, the new bridge
on either side, will have a total length of
will carry three traffic lanes across the
2.13km. This particular design was chosen
River Mersey in each direction and link
as it maximizes benefits for users and the
Runcorns Central Expressway with main
local community while minimizing impact
highways to the M62 motorway and
on the environment.
towards Liverpool.
PORTFOLIO BRIDGES
VIADUCT, SARAJEVO, BOSNIA AND HERZEGOVINA

BRIJECE
New road bridge relieves traffic in capital city
DETOUR AROUND
SARAJEVO
At around 720m long, the Brijece Viaduct is a key component of the 10km
Sarajevo Bypass scheme which will reduce traffic congestion in the city
center and connect the city with the A1 highway. The viaduct is located on
the 4km approach road which connects the Bypass to Sarajevo. Tomislav
Lopandic of BBR Adria, describes his companys work on the project.
1 The 720m long, 11-span Brijece Viaduct is

a key component of the 10km Sarajevo
Bypass scheme which will reduce traffic
congestion in the city center and connect
the city with the A1 highway.
2 The viaduct was post-tensioned in stages
using BBR VT CONA CMI internal tendons
consisting of 14 x 15.7mm diameter strands.
PORTFOLIO BRIDGES
Post-tensioning & stressing

We post-tensioned the viaduct in stages
using BBR VT CONA CMI internal tendons
consisting of 14 x 15.7mm diameter strands.
The BBR Adria team carried out tendon
stressing four days after casting the deck
or after the C35/45 concrete had
achieved a minimum of 70% of its design
strength. The higher concrete strength
permitted the use of less local anti-bursting
reinforcement, thus reducing congestion.
The tendons were each stressed to a
force of 2,856kN. Around 653t of
1,860MPa prestressing steel was installed
in the viaduct.
Timescales & completion
The first phase of construction started
towards the end of 2013 and was
completed in early 2014. In this period we
executed 10 slabs. With the selection of a
new main contractor in April 2015, the

second phase of construction began and
a further 42 slabs had been constructed
by the time it finished in October 2015.
Completion of the Brije
ce Viaduct will
not only improve traffic conditions on
Construction of the Sarajevo Bypass was
other access roads around Sarajevo, but
divided into three sections and the Brijece
also offer motorists a faster and more
Viaduct is in Lot 2 which covers the stretch
comfortable journey.
from Butila junction to Brijece. After the
For BBR Adria, the Brijece Viaduct project
new road crosses the Brijece Viaduct, it
has been an exceptional logistical and
splits into two one road goes to Stup and
technological success even in the face
the other to Rajlovac.
of a short program and involving the

execution of up to four separate slabs at
Project overview
the same time. Installation, tensioning and
The viaduct is designed for speeds of up to
grouting were performed by one engineer
100km/h and is 11.75m wide which allows
and three BBR specialists. This project has
two 3.5m wide lanes and a 2.5m wide
clearly demonstrated the experience and
emergency lane, along with other features.
resourcefulness that the BBR Adria team
In all, we have been working on six separate
is able to bring to every new project.
structural elements for this viaduct which

crosses the roundabout at Brijece, the
M13 road and a dual track railway line.
The viaduct has 11 spans, supported at
between 28 and 35m intervals, and was
built in two separate packages. Package 1
has two independent carriageways carried
on bridges, the left carriageway is 360m
long and the right is 363m. It also features
access and exit ramps which have two
3.5m wide lanes and are each 125m long.
Package 2, consists of two 359m long
parallel structures. All structures were built
in stages the main viaduct in 11 stages
and the ramps in four. In total, 1,691m of
road has been created for the project.
TEAM & TECHNOLOGY

Owner JP CESTE BiH Federation
Main contractor GP GP d.d.
Designers Ipsa Institut, Trasa d.o.o.
BBR Network Member BBR Adria d.o.o.
(Croatia)
PORTFOLIO BRIDGES
BATANG SEMARIANG BRIDGE, SARAWAK, MALAYSIA

High capacity self-advancing beam launcher saves on program & budget
SELF-ADVANCING
TO SUCCESS
The Batang Semariang Bridge
The overall bridge length is 300m and
of tendons and then launching the U-shape
project was initiated by the state
consists of eight equal spans of 37.5m
beam to the designated span using mobile
each, crossing over the Semariang River.
cranes. After this, the deck slab would be
The bridge is designed as a continuous
cast and finished with second stage
of a new route to link Petrajaya
span structure with expansion joints only
stressing works. The purpose of this was
the new state government
at the two abutments. The 14.5m wide
to reduce the launching weight and thus
administration hub to Kuching,
deck accommodates two traffic lanes in
avoid the costs, time and risks involved in
each direction. Each span comprises
using high capacity mobile cranes and
three prestressed box shaped beams
heavy temporary bridge access. In this
Project Manager Chok Moi Chun
with each precast beam weighing 170t.
region, 40m long precast beams are
and Assistant Technical Manager
Based on our good track record and
commonly used and typically they weigh
Tie King Bang describe how the
construction engineering experience, we
100-130t and only rarely as much as 170t.
were awarded the whole bridge package
The improved approach we adopted
from piling, precasting of beams,
involves use of a beam launcher with
changed to enable fast and
post-tensioning, beam launching to
capacity to launch 40m long precast beams
cost-effective construction of
completion of the bridge superstructure.
weighing up to 180t. With the high lifting
government of Sarawak as part
capital of Sarawak. BBR Malaysias
construction methodology was
capacity of the beam launcher, thanks to
this new multi-span river bridge.
Optimized construction methodology
the triangular truss system, the box shaped
The original construction method involved
beams could be cast in full section and
casting the U-section of the box-shaped
stressed to the required force in just one
beam only, followed by partial stressing
stage at the casting yard.
PORTFOLIO BRIDGES
Tendon configuration
Bridge sub-structure
level adjustment and transverse shifting of
Six BBR CONA internal bonded tendons
Each bridge pier is supported by three
the beam launcher. It also has an additional
are installed in each post-tensioned precast
1.2m diameter vertical bored piles and two
feature which enables beam lifting using a
box girder beam. As the re-engineered box
0.75m diameter raked bored piles for lateral
single triangular truss. This is useful when
section has a higher moment of inertia and
stability. The three vertical piles continue
the need arises to deliver the outer beam
stiffness, all the tendons can be stressed
above the pile cap to form the vertical
towards the end of a crosshead without
to the required design force in one stage
piers which support the crosshead. The
extending the transverse rail or having
with a 500t capacity multijack before the
crosshead supports the three boxed beams
additional temporary support.
beam is delivered to the beam launcher.
and was also designed to handle the
After launching the three beams, the end
temporary loads from the beam launching
Construction cycle & program
and intermediate diaphragm beams and
operation. The span-by-span construction
The construction cycle for each span is
side stitching of the deck slab are
method means that the offset point of
approximately one month and can be divided
constructed. A pair of BBR CONA internal
applied load from the launching works
into three main stages self-advancing of
tendons in each diaphragm beam is
and one side span are unavoidable. The
beam launcher, beam launching works and
stressed before the deck is completed and
crosshead is designed to resist torsion
in-situ construction works. Self-advancing
stable, then the beam launcher advances
force at every pier support. Also, the
of the beam launcher and launching of three
to the next span.
axial and bending capacity of the high
precast box girder beams takes seven days.
piers were analyzed and checked based
In-situ construction, involving construction
on eccentric load from the launching
of diaphragm beam and deck slab stitch,
works. The beam seating area on the
requires approximately three weeks the
crosshead is enlarged to reduce localized
beam launcher then advances to the next
compressive stress on the concrete.
span. The overall construction program
1 The bridge pier crossheads support the

three boxed beams and were also
designed to handle temporary loads from
beam launching operations.
2 BBR Malaysias alternative construction
proposal for the Batang Semariang Bridge
involved using a beam launcher to handle
the 40m long precast beams which weigh
up to 180t.
for this bridge is 15 months. Six months

Self-advancing beam launcher
program time was allocated for piling
Our existing beam launcher was upgraded
works up to substructure level and eight
the 140t winches were replaced with a
months for launching works and in-situ
180t system and the launcher was equipped
construction of the bridge superstructure.
with the facility to advance to the next span
Construction time and costs are greatly
by its own self-advancing mechanism. The
reduced by using a self-advancing high
TEAM & TECHNOLOGY
beam launcher is 72m long for cantilevering
capacity beam launcher for multiple span
Owner Government of Malaysia

Main contractor Zecon Dredging Sdn Bhd
Designer J.K. Bersatu Sdn. Bhd.
Bridge subcontractor BBR CS (M) Sdn Bhd
Systems (M) Sdn Bhd (Malaysia)
to the front pier and is comprised of double
bridge construction. As it is self-advancing,
trusses, each truss is divided into six equal
mobile cranes are not needed to shift the
modules connected with high tensile bars.
beam launcher. With the high load capacity
It has two main support legs and three
of the beam launcher, heavier beams can
auxiliary support legs attached to hydraulic
be launched and tendon stressing reduced
jacks and a motorized trolley system for
to one stage instead of two.
PORTFOLIO BRIDGES
PROJECT IN PICTURES
Rail Bridge, Otaio River, New Zealand
GOING WITH THE FLOW

A new rail bridge in New Zealand is expected to perform for more
than 100 years and for that some credit must go to the CONA CMX
post-tensioning range of solutions.
The 126m bridge spans the Otaio River in
BBR Contech supplied, installed, stressed
the South Canterbury region of New
and grouted 12 post-tensioned BBR VT
Zealands South Island. As reported in
CONA CMI 0906 multi-strand tendons into
CONNCT 2015, it replaces a steel and
each unit.
timber structure built more than a century
The process took around four months and
ago that, according to rail infrastructure
the new NZ$5 million bridge opened for
manager KiwiRail, was no longer economical
business soon afterwards. Its new location,
to repair.
which is better aligned with the rivers
TEAM & TECHNOLOGY
The new bridge, which is located about six
channels, should help to prevent future
Owner KiwiRail
Main contractor McConnell Dowell
Constructors
Structural engineer Novare Design
BBR Network Member BBR Contech
(New Zealand)
meters downstream of the old one, is
damage during major floods.
constructed of concrete beams and
Nothing remains of the old Otaio rail bridge
columns and nine spans of 14m-long precast
today, but thats progress for you. Instead,
concrete deck units. Working with main
the new bridge is conveying freight to places
contractor McConnell Dowell Constructors
north and south and, all going well, will
and engineering specialist Novare Design,
carry on doing so for another century.
PORTFOLIO BUILDINGS
NEW PASSENGER TERMINAL, INTERNATIONAL AIRPORT ZAGREB, CROATIA

Post-tensioned floor slabs as alternative design proposal
GATEWAY TO SOUTH
EASTERN EUROPE
Zagrebs Pleso Airport first opened in 1962 and both the runway and passenger terminal
were extended significantly in the 1970s. However, since the turn of the century, the
number of passengers passing through has doubled to around 2.5 million per year. While
recent expansion of the existing terminal has eased pressure on facilities, work on the
construction of a second passenger terminal capable of handling 5 million passengers
annually is now underway. Goran Tomii
c of BBR Adria reports on the project.
PORTFOLIO BUILDINGS
An international competition was held to
The project is funded by French
find the best design for the new terminal and
consortium ZAIC consisting of Aroport
the proposal put forward by a consortium
de Paris and Btiment International
of Croatian architects including IGH d.d.
Airport who were awarded the
(Civil Engineering Institute of Croatia) and
concession by the Croatian government
architects Velimir Neidhardt, Branko Kincl
to build the new passenger terminal
and Jure Radi

c was declared the winning
and manage the airport for 30 years.
solution. Their undulating form for the
The design and build contract was let to
building was inspired by the local landscape
the Meunarodna Zrac

na Luka Zagreb
and reflects the shape of the mountainous
and Bouygues Btiment International
backdrop of the city.
Joint Venture.
1 To increase capacity at Zagreb's Pleso

Airport, a second passenger terminal
capable of handling five million passengers
annually is now under construction.
2 By April 2015, work had begun on installation
of the frame for the undulating roof form
and was well-advanced by the end of June.
3 The south, east and west faades are
designed as flat aluminum curtain walls with
structural glazing.
4 The new passenger terminal at Pleso Airport
in Zagreb begins to take shape.
4
PORTFOLIO BUILDINGS
The structure was

initially designed to be of
prefabricated concrete
construction, however,
following a proposal by
the contractor, it was
rapidly redesigned to
be of monolithic posttensioned construction.
Design & layout

The new passenger terminal is a four level
building comprising a rectangular main
section and extending into two asymmetrical
wings the western for international
departures and arrivals, the eastern for
domestic traffic. Lower levels will be used
for arrivals and the upper for departures.
On the northern faade, there are eight
passenger boarding bridges connecting
with 16 departure gates inside the building.
The structural frame of the building
consists of circular reinforced concrete
columns, post-tensioned concrete beams
and slabs, plus four reinforced concrete
communications cores.
Above the concrete structure is a rippling
steel space frame which links the roof of
the main building and passenger boarding
bridges with the northern faade. The
south, east and west faades are designed
as flat aluminum curtain walls with
structural glazing. The roof is partially
glazed and partially covered with the very
latest in aluminum cladding.
Construction overview
The total area of the corrugated steel roof
is 25,000m2, while three concrete floors
not including the ground slab have an
area of about 45,000m2. The central
section of the terminal building has a
footprint of 130 x 136m and there are
no expansion joints due to the layout of
seismic walls located near the very ends
of the ground plan.
The structure was initially designed to be
of prefabricated concrete construction,
however, following a proposal by the
contractor, it was rapidly redesigned to be
of monolithic post-tensioned construction.
PORTFOLIO BUILDINGS
Ceilings & floors
The beams here measure 1,600 x 550mm
The horizontal ceiling structure was
and between them is an 180mm thick slab.
resolved to be of monolithic post-tensioned
Beams in the upper level floors sit on a
construction. All three levels of ceiling
14.4 x 14.4m column grid. They extend in
panels have longitudinal and transverse
both directions and are 3,000mm wide by
pouring strips. These pouring strips reduce
550mm deep, with a 250mm thick infill slab.
the surface area of the first phase of
Larger openings that interrupt the
construction on sections up to 60-70m long.
continuity of these beams are resolved with
FACTS & FIGURES
The predominant grid sizes are 7.2 x 14.4m
reinforcement at the edge of the openings,
37,000m2 post-tensioned slabs
for the ground floor and 14.4 x 14.4m for
so that loads are transferred to the adjacent
8,000m2 reinforced concrete slabs
first and second floors.
beams. One exception is where the pillars
25,000m2 roof
Post-tensioned slabs were designed as
of the top floor are offset from the main
280t BBR VT CONA CMM tendons
shallow, wide beams. The first floor slab has
axis and, here, their forces are taken by
beams running in the longer 14.4m direction.
3,000 x 850mm reinforced beams.
5,000t reinforcement bar
PORTFOLIO BUILDINGS
5 The roof is partially glazed and partially

covered with the very latest in aluminum
cladding.
6 A total of 280t of steel prestressing strand
was used for the BBR VT CONA CMM
monostrand tendons.
7 Post-tensioned slabs were designed as
shallow, wide beams and, as pictured here,
for the first and second floors, arranged on
a 14.4m x 14.4m grid.
8 By October 2014, work on site had reached
a peak and BBR Adria was installing
post-tensioning for several slabs at the
same time.
Post-tensioning
We used around 280t of BBR VT CONA
CMM tendons with strand of 150mm2
cross-sectional area and 1,860MPa
characteristic tensile strength. There were
many benefits offered to the project by
this BBR technology including factory
provided corrosion protection, speed and
ease of laying, larger tendon eccentricity
and small friction losses which allowed
prestressing of the larger 60-70m sections.
Proportionately, more tendons are
grouped in the reinforced beams, while
fewer tendons pass through the slabs at
equal distances. In the beams, the tendons
are profiled using a parabolic curve. The

radius of curvature of the tendons above
the columns is R = 4m, which gives an
optimal minimum breaking load (MBL).
For the 180 and 250mm thick slabs, outside
of beam zones, we adopted the free tendon
Completion of new terminal
layout which significantly simplifies and
Construction work began in summer 2014
accelerates installation. By request of the
and concrete construction was completed
investor, the tendons in the 3,000 x 550mm
in February/March 2015. The BBR Adria
beams near columns have been grouped in
team has finished its tasks, but work
such a way that, if necessary at some stage
continues around the site on the external
in the future, four 400 x 400mm openings
building envelope, roads to connect the
could be created without having to cut or
new facility to the existing road network
interfere with the PT tendons. Due to their
and, finally, there will be a testing and
high stiffness, some seismic walls will
commissioning phase. We are all looking
subsequently be made monolithic with the
forward with great excitement to late
slab and, until then, will rely on temporary
2016, when the new passenger terminal is
short columns.
scheduled to open for business.
TEAM & TECHNOLOGY

Investor International Airport Zagreb
Architects IGH dd (Civil Engineering
Institute of Croatia), Velimir Neidhardt,
Branco Kincl and Jure Radic
Main contractor KAMGRAD d.o.o.
Structural designers Dr.sc. Jure Radic,
Milan Crnogorac, Predrag Presecki
(PT slabs)
Technology BBR VT CONA CMM
monostrand
(Croatia)
PORTFOLIO BUILDINGS
WIRI INLAND PORT, AUCKLAND, NEW ZEALAND

Post-tensioned slabs for cold storage
CONNECTING
SEA & LAND
When you have a port management company as a client, you would quite
naturally expect to work by the sea. Not so in New Zealand, where BBR
Contechs long-standing partnership with Ports of Auckland Ltd (POAL)
and concrete floor specialist Conslab extended in 2015 to an inland project
and a port of a very different kind.
Originally established around 2005, the Wiri
productive uses for valuable real estate
Inland Port is a 15-hectare freight handling
formerly used to store empty containers.
hub located in South Auckland. It is about
The Wiri Inland Port has proved a great
25km from the seaport, but crucially close
investment, says Pete Algie, Asset
to two key state highways and the North
Manager for POAL. When the rail siding
Islands main trunk railway line.
opened in 2010 we ran four trains a week

between the seaport and the hub, today
Ground-breaking service
we run 21 and are looking to increase that
The hub exploits these attributes to
number further.
provide a ground-breaking service for

exporters and importers of containerized
goods the ability to drop off and pick

up their containers without having to
negotiate the often congested Auckland
motorways to get to and from the
central-city seaport. They can use road
and rail to transport their containers in or
out of the hub, while the containers are
moved between the seaport and the hub
via a dedicated rail siding, usually at night
and during the weekends.
Completing the process, the hub offers
all the e-commerce and border clearance
services available at the seaport, which
means containers can be unsealed and
their goods dispatched directly to points
north and south.
The benefits of this innovative approach
are significant a dramatic reduction in
the number of central city truck trips
and therefore reduced carbon emissions
and traffic delays for other road users
a more convenient drop-off and pick-up
location for cargo owners, a more efficient
supply chain, less cargo handling and an
opportunity for POAL to find more
2
PORTFOLIO BUILDINGS
It was no easy task, with a

tightly constrained site and
a single entry point making
access a challenge for all
the contractors involved.
New cold store development

The latest development at the hub and
the reason for the BBR Contech project
is an 11,800m2 cold store which is capable
of handling around 20,000 pallets of
frozen goods.
Working with Conslab and main contractor
Ebert Construction, BBR Contech installed
post-tensioning into four slabs for the cold
store between June and August 2015 two
were 175mm thick and two were 190mm,
the latter was required to hold heavy-duty
pallet racking. It was no easy task, with a
tightly constrained site and a single entry
point making access a challenge for all the
contractors involved.
The work was complicated by the fact
that the foundation for the slab was a layer
of polystyrene insulation, says Terry
Palmer, BBR Contech Project Manager.
There was no choice but to pump the
concrete through hoses from the outside to
avoid damaging the insulation and the PT
ducts. It was extremely labor intensive!
Pete Algie says that, while the Wiri Inland
Port project was very different from BBR
Contechs typical seaport work for POAL
(see page 70), the two stories demonstrate
the range of services that BBR Contech
performs across the POAL asset base.
1 The latest development at Wiri Inland

Port required construction of four
post-tensioned slabs.
2 Two post-tensioned slabs were 175mm
thick and two were 190mm the latter
has been designed to support heavy duty
pallet racking.
3 Construction of the post-tensioned slabs
was complicated as the foundation for the
slab was a layer of polystyrene, so concrete
was pumped from the outside to avoid
damage to the insulation and PT ducts.
TEAM & TECHNOLOGY

Owner Ports of Auckland Ltd
Main contractor Ebert Construction
Concrete flooring specialist Conslab
Technology BBR CONA flat
(New Zealand)
PORTFOLIO BUILDINGS
PROJECT HIGHLIGHTS
Post-tensioned slab solutions for buildings
GLOBAL APPEAL & VALUE

TEAM & TECHNOLOGY
1 Developer VMD PROMET d.o.o.
Main contractor TEAM d.d.

Designers Kreimir Tarnik,
Predrag Presecki & Goran Tomiic
(PT slabs)
monostrand
BBR Network Member BBR Adria
d.o.o.
The advantages of post-tensioned ground and floor slabs, as well as

transfer floor plates, is being recognized all around the world. The benefits
whether concerning aesthetics and practicalities, or time and cost are
being delivered by BBR Network Members whose skill is also acknowledged
by their regular customers.
2 Owner Knowledge Vision Sdn Bhd
Main contractor Pembinaan Yuen

Seng Sdn Bhd
BBR Network Member BBR
Construction Systems (M) Sdn Bhd
(Malaysia)
3 Owner Government of Western
Australia
Design & build contractor John
Holland Pty Ltd
Technology BBR VT CONA CMI
internal
BBR Network Member SRG Limited
(Australia)
4 Owner Sistema Plastics
Main contractor Haydn & Rollett

Concrete flooring specialist Conslab
(New Zealand)
5 Owner Government of Western
Australia
Main contractor City Busport
Alliance (Perth Transport Authority,
Brookfield Multiplex and BG&E)
internal
(Australia)
6 Developer Halter AG
Main contractor Feldmann Bau AG +

Estermann AG
Consulting engineer Suisseplan
Ingenieure AG
internal
BBR Network Member Stahlton AG
(Switzerland)
1 Project Graharova, Zagreb, Croatia.

2 Almyra Residence, Bandar Putri@Bangi
development, Malaysia.
3 Perth Childrens Hospital, Perth,
Western Australia.
4 Sistema Plastics Warehouse, New Zealand.
5 Perth Busport, Perth, Western Australia.
6 Mall of Switzerland, Ebikon, Switzerland.
2 Advantages for all

BBR Malaysias Yan Mung Chung designed
1 Maximizing space with PT
the 1.5m thick post-tensioned transfer floor,
Following the Strojarska Towers project,
using BBR CONA internal tendons, for the
VMD Promet and BBR Adria, have continued
Almyra Residence four 30-storey tower
their successful cooperation for the Project
blocks over a common podium car park, part
Grahorova scheme, also in Zagreb, Croatia.
of the Bandar Putri@Bangi development,
The building consists of two underground
south of Kuala Lumpur. The PT transfer floor
garages and four to six upper business and
offers a reduced structural depth and
residential floors. The underground structure
aesthetic flat slab soffit, as well as reducing
is square shaped, while the upper part
formwork, props and backprop costs and
consists of an L-shaped residential/business
construction program, compared with the
area and square shaped retail space.
originally planned 1.8m deep reinforced
The 4,500m2 foundation slab and the
concrete beams. It is no wonder that
underground garage ceilings were post-
structures designed with post-tensioned flat
tensioned. The ceiling of the retail space has
slabs are increasingly common in this region.
also been constructed as a post-tensioned
A two stage casting was adopted whereby
slab. BBR VT CONA CMM monostrand
one layer of concrete was cast and first
technology was installed on the project.
tendons stressed to support the weight of
The large spans of up to 17.5m mean
the second stage concrete. For columns
there are fewer columns in the garages, so
with shear loads, drop caps up to 600mm
maneuvering is much easier and the retail
deep were used to increase the punching
area is more spacious.
shear capacity.
PORTFOLIO BUILDINGS
We believe in surrounding ourselves with competent,

trusted partners. These guys [Conslab & BBR Contech]
have consistently delivered in terms of performance
and value and they meet and often exceed our
expectations. The longevity of our partnership reflects
this theyre the experts at what they do and are as
committed as we are to maintaining a healthy and
5 Top down construction

Australian BBR Network Member SRG was
rewarding relationship.
contracted to provide the post-tensioning
Kim Barrett, Managing Director, Haydn & Rollett, New Zealand
to the roof slab and entry portals of the

new underground Perth Busport, part of
the Perth City Link Project. Top down
construction was chosen because of the
sites close proximity to the recently
completed rail tunnel and because it
does not require extensive formwork.
Prior to excavation beneath to create the
main concourse, the 800mm thick roof
slab was constructed on the ground. It
covers an area of approximately 213 x 46m
with no movement joints and is designed to
support future multi-storey buildings above.
The project involved placing 9,000m3 of
concrete and 1,500t of rebar. The
post-tensioning works included installation
4 Cementing a relationship
Over the past 15 years, New Zealands
BBR Contech has formed a great working
of BBR VT CONA CMI post-tensioning

tendons which were up to 46m long and
required 150t of steel prestressing strand.
relationship with concrete flooring

specialist Conslab and, through Conslab,
property developer and builder Haydn &
Rollett. This relationship has led to some
27 post-tensioned flooring projects
together, covering an area of 280,000m2.
In 2015, a commission for a 45,000m2
3 Major & complex work
The Perth Childrens Hospital will replace
post-tensioned slab for a factory and
the existing Princess Margaret Hospital
through the 300,000m2 mark for this
for children, built over 100 years ago.
partnership and took BBR Contechs
SRG was contracted to install 220t of
total tally of PT slab projects to more than
6 Largest in Switzerland
prestressing strands in the post-tensioned
two million square meters!
With 46,000m2 of retail space and around
beams for 120,000m2 of suspended floors
This most recent project was the largest
140 shops, Mall of Switzerland in Ebikon is
over nine storeys. Works also included
ever undertaken for the New Zealand-based
set to become the largest shopping
supply and installation, sealing and
manufacturing company, Sistema Plastics.
destination in central Switzerland. An
grouting of almost 3,000m of temporary
The flooring project involved 14 pours to
adjoining car park with 1,600 spaces is also
movement joints across the project.
create a 170mm thick, 300m x 150m
under construction. In addition, 12 cinema
The project was broken into four main work
structure comprising coupled slabs with
screens, a hotel and apartments are
areas and was serviced by five tower cranes.
two permanent movement joints in the
planned for the site. BBR Network Member
The complex nature of the project and space
longest direction. It required more than
Stahlton is using the BBR VT CONA CMI
constraints on site created many challenges
200t of 15.2mm strand a massive
internal system, with both fixed and
throughout construction including
investment that will ensure a strong,
movable anchors, to provide post-tensioned
just-in-time material deliveries, craneage
robust surface for both vehicle traffic and
beams and floor slabs for the shopping
coordination and coordination between
a very high-spec automated racking
center and one-way post-tensioned floor
construction zones and other trades.
system that is the largest in New Zealand.
slabs for the car park.
distribution center in Auckland, broke
PORTFOLIO BUILDINGS
IVE MIKACA, VARADIN, CROATIA

Transfer plate construction for diversity of building use
PRACTICAL SOLUTION
FOR MULTI-FUNCTIONAL
BUILDINGS
In modern buildings designed for residential and commercial use, the
vertical axis of the walls and columns must often allow three different uses
of the structure. Firstly, there is an underground garage, next a business
area mostly placed on ground floor and thirdly, several residential floors.
Goran Tomii
c of BBR Adria describes the solution his company has been
successfully providing for such buildings in Croatia.
The key was to
To deliver all of these three different
The ground and first floor slabs were
have the transfer
functions in one building, we have found
built with larger spans of up to 12m and
that the construction of a transfer plate
then the upper residential floors were
plate on the first floor
is an effective and practical solution.
constructed above them. The key was to
to accept the upper
At Ive Mikaca, the transfer plate is a
have the transfer plate on the first floor
slab consisting of shallow beams
to accept the upper walls and columns
walls and columns
(2,400 x 700mm) in both directions and
as vertical loads. So, the first floor acts
as vertical loads.
a slab thickness of 220mm between
like a foundation slab for the upper floors.
them. Seismic resistance was achieved
The tendons in the transfer plate were
with two staircase and lift cores and
stressed in several phases these
faade frames made of a rigid beams
followed construction of each upper floor.
and columns the Vierendeel system.
PORTFOLIO BUILDINGS
BARANGAROO DEVELOPMENT, SYDNEY, AUSTRALIA

Progress report from citys largest construction project
MASSIVE
WATERFRONT
REGENERATION
It was back in 2011 that we constructed
Barangaroo is the largest construction
drawing, installation, stressing and
the first building in this way in Varadin,
project in Sydney since the turn of the
grouting. SRG also undertook post-
Croatia. Since then, we have delivered
millennium a 22-hectare harbor-front
tensioning works for the Napoleon
four similar building projects for the same
urban renewal project that involves the
Bridge that spans across Sussex Street.
customer. Around 20t of BBR VT CONA
complete transformation of the western
SRGs civil engineering team also
CMM tendons were embedded in each
edge of Sydneys CBD. The site involves
completed the stressing of beams used
building each of which feature floor
three areas Barangaroo Reserve,
for the Barangaroo Reserve cultural
areas of 800m2.
Central Barangaroo and Barangaroo
space. This project involved the
There are many benefits of this kind of
South. When finished, the former
construction of a land bridge supporting
construction. It is possible to have
container port will be transformed into
a park, complete with bicycle paths,
bearing walls outside of the apartments,
a mix of office and residential towers,
walking tracks, retaining walls, water
giving future potential buyers or clients
plus recreational spaces such as public
mains, trees and grassed areas over the
freedom to arrange the rooms as they
waterfront walks and parks.
top of a large 17m high 18,000m2 open
wish. Also, the underground parking
SRG has worked alongside Lendlease,
floor space.
garages have fewer walls and columns,
the developer and main contractor for
so maneuvering vehicles is much easier
Barangaroo South and the main
and sight-lines clearer.
contractor for the Barangaroo Reserve,
After these four projects in Varadin, a
as the five year program of works has
new investor has decided to build the first
progressed. SRG's role has focused on
building with a transfer plate in Cakovec
the post-tensioning works, including
not far from Varadin. This project is still
three multi-storey towers and additional
in progress and, here, we decided to go a
slabs, entailing close to 2,500t of 15.2mm
step further and prestress a foundation
steel prestressing strand.
plate to reduce slab thickness.
In the last year, SRG has completed

substantial post-tensioning works on the
commercial office towers and apartments
at Barangaroo South, including shop
TEAM & TECHNOLOGY

Developer Lendlease (Barangaroo
South), Barangaroo Delivery Authority
(Headland Park), Transport for NSW
(Wynard Walk)
Main contractor Lendlease (Barangaroo
South & Headland Park), Thiess
Contractors (Wynard Walk)
Subcontractor Ward Civil (Wynard Walk),
Baulderstone (Headland Park)
Technology BBR CONA flat, MRR range,
PT bar
(Australia)
1 The BBR Adria team is seen here working on

the post-tensioned foundation slab for a new
building. After recognizing the benefits of
post-tensioned transfer plates in nearby
Varadin, the new investor decided to
commission the first building in Cakovec to
feature a transfer plate.
2 The Ive Mikaca scheme is the latest in a
series of multifunctional buildings
constructed with a transfer plate.
TEAM & TECHNOLOGY

Developer Marlex Invest d.o.o.
Designers Miljenko Kovac, Predrag
Presecki (PT slabs)
Main contractor Megrad 3B d.o.o.
monostrand
(Croatia)
PORTFOLIO BUILDINGS
POST-TENSIONED FLOORS, NEW ZEALAND

350,000m2 of PT floors delivered in 14-year relationship with international commercial property specialist
LONG-TERM
PARTNERSHIP
FOR QUALITY
Some might call it a match made in heaven, but the BBR Networks more pragmatically minded
post-tensioning specialists in New Zealand simply call it a successful partnership. Theres certainly
proof in the numbers in a 14-year long working relationship, BBR Contech has designed and
installed BBR post-tensioning for 46 floors for commercial property specialist Goodman. Together,
they have created an impressive total of 350,000m2 of post-tensioned floors equating to around
50 rugby pitches this is a significant achievement in anyones terms.
The post-tensioned floors, ranging in size

from 2,000m2 to 30,000m2, have been
installed in five business parks in Auckland,
all owned and managed by Goodman
Property Trust an NZX listed entity which
has a NZ$2.2 billion property portfolio
and around a million square meters of
rentable space in business parks, industrial
estates, office parks and warehouse and
distribution centers.
Goodmans success reflects its focus on
owning, managing and developing only
premium-quality properties in New
Zealands main distribution centers of
Auckland and Christchurch. All of its assets
offer modern, highly functional spaces for
a range of customer uses and many
provide on-site facilities, such as gyms,
cafs, banks and childcare services.
Located close to major arterial routes and
city centers, they have attracted around
250 customers including global brands
such as DHL, BMW, Toll and Woolworths
and are delivering enviably high
occupancy and retention rates. A number
have also won awards for their architectural
merit, environmental sustainability and
investment performance.
1
PORTFOLIO BUILDINGS
Post-tensioned
flooring is definitely
my first choice where
its an appropriate
option and Id
certainly recommend
it to others.
Peter Yendell, Infrastructure Manager, Goodman
Insistence on PT floors
effectively throughout their lifecycles, as
Goodman has specified PT floors for
this ultimately improves their long-term
about half of its total property portfolio.
environmental and financial performance.
According to Peter Yendell, Goodmans
PT floors offer a number of advantages
Infrastructure Manager, the companys
over the alternatives. For a start, they're
decision to use the technique reflects its
stronger so they can handle heavier loads,
commitment to long-term investments
and they have a total absence of joints,
and insistence on quality at every stage of
which reduces the risk of cracking and
the construction process.
avoids joint degradation. They also have a
We operate in a competitive market where
more attractive appearance, are easier to
our ability to attract and retain high-caliber
maintain and have longer lifespans and
customers depends on the quality of our
they provide us with flexibility for fit-outs,
properties, he says. We strongly believe
which is vital in meeting our customers
in building well and managing our assets
specific operational needs.
1 BBR Contechs regular customer, Goodman,

owns, manages and develops premium
quality properties for a range of clients
including global brands such as BMW.
2 The award winning Ford Building in the
Highbrook Business Park incorporates a
post-tensioned concrete floor system
providing largely column-free interior space
with minimal structural depth.
3 At East Tamakis Highbrook Business Park,
BBR Contech installed a 30,000m2 slab
for Goodman tenant DHL Excel.
4 Kmarts principal distribution hub on the
M20 estate in Manukau City where, since
2008, BBR Contechs post-tensioned floors
have provided effective solutions for the
construction of 11 separate facilities.
5 Fliway one of New Zealands largest
logistics providers has its Auckland branch
office at Westney Industry Park where BBR
Contech has installed post-tensioned floors
for 10 of the parks buildings.
PORTFOLIO BUILDINGS
14 years of performance
The BBR Contech-Goodman partnership
began in 2002 at The Gate, a premium
industrial estate in Penrose. Working with
head contractor Haydn and Rollett, Allied
Concrete and concrete floor specialists
Conslab, the BBR Contech team designed
and installed eight PT slabs in four years,
with floor areas ranging from 2,000m2 to
10,000m2 and totaling 36,000m2.
In the 10 years since then, the team has
applied its post-tensioning expertise to:
Goodmans flagship property, the
world-class Highbrook Business Park,
which is situated on 150 hectares of
landscaped grounds and parkland in East
Tamaki. Between 2006 and 2014 BBR
Contech installed the PT for 21 floors
covering a total 172,700m2 the largest
being a 30,000m2 slab in 2007 for
Goodman tenant DHL Exel. The estate

continues to be actively developed, with a
further 42.6 hectares of land still available.
M20 Business Park, which offers more
than 100,000m2 of warehouse and office
space in the heart of Manukau City.
BBR Contech installed PT for 8,000m2
of flooring for tenant James Halstead
Flooring in 2008 and has since installed
a further 43,000m2 in 10 more buildings,
the most recent in 2015. At the M20
estate, post-tensioned floors have been
an effective way of designing and building
over a combination of hard and soft pile
raft systems, allowing the elimination of
pile caps and ground beams.
Savill Link, a warehouse estate for both
medium and heavy industrial uses, in
which BBR Contech installed PT for
26,400m2 of flooring one slab of
6,400m2 and the other 20,000m2 in
2011 and 2013.

Westney Industry Park, a premium
industrial space located next to Auckland
International Airport, whose occupants
include Cotton On, DSL, DHL, Fliway,
Linfox Logistics and Supply Chain
International perspective
Solutions. BBR Contech worked on the
Goodmans commitment to excellence and
site between 2006 and 2008, installing
its extensive customer base expose it to
PT for 57,700m2 of flooring in 10 of the
trends and developments on a global scale.
parks 16 buildings.
Peter says that New Zealand appears to
Asked why he keeps coming back to BBR
use post-tensioned flooring to a far greater
Contech, Peter says: As a company that
degree than do Goodmans counterparts
specializes in designing and installing
around the world.
post-tensioned floors, they offer very
This may be because of customer
sound engineering solutions that meet
specifications, personal preferences and
our customers needs. They work in close
engineering and cost considerations, but it
partnership with concrete floor specialist
still surprises me, he says. Post-tensioned
Conslab and our numerous building teams
flooring is definitely my first choice where
to consistently deliver a quality product
its an appropriate option and Id certainly
that meets our budget.
recommend it to others.
TEAM & TECHNOLOGY

Owner Goodman Property Trust
(New Zealand)
PORTFOLIO BUILDINGS
GUOCO TOWER, SINGAPORE

Progress report on high rise PT construction project
REACHING FOR THE SKIES

Guoco Tower located on top of the
The Tanjong Pagar Development is a
The post-tensioned beams are 700mm
Tanjong Pagar MRT Station, at the
mixed scheme comprising a six storey
deep and vary in width from 1,000mm to
podium and two towers of 20 and 64
3,000mm. The deep deck system
storeys respectively. The 64-storey tower
comprises 1.2mm thick steel sheets formed
Peck Seah Street will be Singapores
will house 38 floors of Grade A office
into tapered ribs of 250mm deep and
tallest building when completed.
space and 26 floors of residential
100-190mm wide at 600mm spacing, with
Singapore-based BBR Construction
apartments, while the 20-storey tower
a 150 to 180mm thick structural topping.
will be a 200-room hotel.
There is a seven meter maximum clear span
The structural system used for the tower
between beams. The slab was analyzed and
progress report of work on this
consists of one way post-tensioned
checked as a plate to mobilize the torsional
spectacular project.
beams with deep deck system slabs.
stiffness of the beams and columns.
junction of Choo Guan Street and
Systems provide a photographic
1 The Guoco Tower takes shape as part of

Singapores Tanjong Pagar mixed
development.
2 View of a typical deep deck slab, at the Guoco
Tower site, where there is a maximum clear
span of seven meters between beams.
TEAM & TECHNOLOGY

Developer Guocoland Limited
Architect Skidmore, Owings & Merrill
LLP (SOM)
C&S consultant Arup (Singapore) Pte. Ltd
Main contractor Samsung C&T
Corporation
Systems Pte. Ltd. (Singapore)
2
PORTFOLIO BUILDINGS
Q22, WARSAW, POLAND

PT slabs for high rise building
CHANGING THE
WARSAW SKYLINE
For the last two years,
BBR Polska has been delivering
specialist post-tensioning
technology and know-how for
the construction of one of the
tallest high-rise buildings in
Warsaw. Bartosz ukijaniuk,
BBR Polskas Design Team &
Works Manager, tells of the
companys role in the
realization of the 155m high
office building, known as Q22.
The building is being constructed on
the site of a former hotel which was
demolished to make way for new offices.
With an address in the heart of Warsaws
business district and vision of providing
first class office space, this has been
an extremely prestigious building project
right from the design stage, through
project management and site
supervision, onto the execution of the
various elements. It would be no
surprise, therefore, to learn that only
top class specialists were invited to join
the project.
Building layout
The building has five underground levels
and 42 storeys above ground, 39 of
which are post-tensioned. The first 16
above ground levels form an 84m x 30m
podium from which the 26-storey
tower pentagonal on plan, 55 x 30m
begins to rise. The total slab area is
around 58,800m2 and the whole building
will offer some 50,000m2 of office
space and also house many amenities
including restaurants, fitness area and
lockers for cyclists.
1
PORTFOLIO BUILDINGS
Post-tensioning
Construction phases & schedule
There were uneven spans between columns
Construction of the building was divided
and walls, thus some areas of the slabs
into two phases. Firstly, the tower part was
were heavily post-tensioned, some areas
constructed, then secondly, when the tower
only have tendons in column strips and
reached level 20, work on the podium
some have no post-tensioning at all. We
section began.
used the BBR VT CONA CMF system for
The construction schedule was extremely
all the slabs. In addition, a few edge beams
tight. Each whole level including walls,
were post-tensioned with 1206 BBR VT
columns and slabs was constructed in
CONA CMI tendons due to long spans
five days.
and deflection limitations.
Such a challenging time schedule fostered
The slabs were designed, by Buro Happold
good cooperation between all teams
engineers, to be post-tensioned with flat
involved in the execution process. The
bonded tendons. Our design scope was to
very detailed planning of the construction
deliver the detailed tendon layout. Close
sequence, carried out by the highly skilled
cooperation between the design parties
and experienced frame contractor
BBR Polska, gp-projekt and Buro Happold
engineers, was extremely important.
resulted in an excellent performance on
Despite the challenges, the construction
site. At this point, it is also important to
process went smoothly.
mention that the detailed designs for
The realization of our part of the project
post-tensioning and mild reinforcement
took about ten months. During this time we
were coordinated along with other detailed
installed 153t of stressing steel in almost
elements such as faade fixing design,
2,000 tendons and for the grouting, we
design of the mounting for the temporary
used almost 55t of cement.
wind shields (structures needed during the
For the BBR Polska team, it was a fantastic
lifting process) and other temporary and
experience to work on such a project and
permanent structural and finishing items.
a great opportunity to demonstrate the

advantages that PT technology brings to
the construction of high-rise buildings.
Working in the confined space of a single
slab pour, together with mild reinforcement
fixers and under time pressure where the
1 The extremely prestigious Q22 project will

provide first class office space in Warsaws
business district.
2 With very tight schedules, the project fostered
good cooperation by all teams involved.
Photograph courtesy of gp-projekt sp. z o.o.
3 Inspection of one of the completed levels
each of which including walls, columns
and slabs was constructed in five days.
Photography courtesy of Micha Stefanowicz.
complete installation of tendons for one

slab pour took only one day, was a challenge
which we overcame with great success.
We hope that our experience, in terms of
both execution and design, will be called
upon in the future to benefit other high-rise
buildings that will be constructed in Poland.
For the BBR Polska

team, it was a fantastic
experience to work on
such a project and a
great opportunity to
demonstrate the
advantages that PT
technology brings to
the construction of
high-rise buildings.
TEAM & TECHNOLOGY

Developer & general contractor Echo
Investment S.A.
Architect Kurylowicz & Associates
Sp. z o.o.
Structural design (inc PT) Buro Happold
Polska Sp z o.o.
PT detailed design gp-projekt sp. z o.o.
& BBR Polska Sp. z o.o.
Frame contractor Modzelewski & Rodek
Sp. z o.o.
Project management & supervision
Gleeds Polska Sp. z o.o.
Technology BBR VT CONA CMF flat,
BBR Network Member BBR Polska
Sp. z o.o. (Poland)
RZESZW BRIDGE, RZESZW, POLAND

Speedy stay cable installation
VOYAGE OF
DISCOVERY
By the time Kate Janikowska, Press Officer of BBR Polska, arrived at the
Rzeszw Bridge site with her camera, the team had already installed
the last stay cable and the official opening of the bridge was rapidly
approaching. She thought that there would be nothing new to photograph,
but her visit soon became an exciting voyage of discovery.
It was relatively late when I reached the

construction site late in the day and
towards the end of the construction phase,
the last stay cable had already been
installed. There was a certain stillness
about the place and the site looked quiet
compared to the hectic earlier days of
the project.
This was a shock, so I checked the date.
Had the appointment really been made
for today? The site was definitely the
right one this was the only thing I could
be sure of, as I had spotted Rzeszws
massive new landmark from way off in
the distance.
The security guard explained that most
teams had already left the site and
would be back tomorrow, only the BBR
team was still there they would work
until at least 7pm, but they were all inside
the pylon.
After texting my hosts and a short wait at
the barrier, BBR Polskas Chief Engineer
Master Builder Tomasz Borsz appeared,
waving and hurrying towards me. On
hearing my concerns about the apparent
lack of anything significant being underway,
Tomasz set out to prove just how exciting
the project still was even at this
1
advanced stage so close to completion.
Significant moment
which belongs to Rzeszw Power Plant
As we stood beside the new bridge deck,
and it also had to be crossed without
Tomasz pointed to the gap between the
using piers. Thus a cable-stayed bridge,
deck and its temporary supports. The
with a 107.2m high pylon, was considered
bridge was now suspended by the stay
the perfect solution.
cables. This meant that the 64 BBR HiAm
For all these reasons, Rzeszw now has a
CONA stay cables were fully installed and
landmark bridge and the contractor has
doing their job as intended.
had the opportunity to design and

construct a cable-stayed structure, a
Cable-stayed solution
solution normally only chosen for crossing
It really was 30 years ago that the northern
the major Vistula or Odra rivers, as Poland
inner by-pass of the city had first been
has no dramatic topographical features.
envisaged, as a response to predictions

that Rzeszw city center would soon need
relief from traffic congestion. It was
planned that West-East transit traffic was
to be transferred to the new bypass.
Rzeszw is the biggest city in south east
Poland and, since 1999, has been the
capital of Podkarpackie Voivodeship.
At first, the large size of the bridge seemed
surprising, as was the decision to erect a
cable-stayed structure over a watercourse
only several meters wide but the bridge
spans more than just the Wisok river.
One of the design requirements was to
reduce the number of piers, both in the
river and on the flood plain, as the area is
protected under the Natura 2000
environmental scheme. Next, there is a
water reservoir adjacent to the river,
1 BBR Polskas Chief Engineer Tomasz Borsz

hosted many visits to the site, as well as
leading the stay cable installation team.
2 Rzeszw Bridge at night, just after the official
opening ceremony. Photograph courtesy of
Porr Polska Infrastructure SA / press material.
3 Late in the afternoon, the Rzeszw Bridge
site looked still and silent, as most of the
BBR Polska team were at work on top of or
inside the pylon.
4 A significant moment the stay cables were
now carrying the weight of the bridge.
5 The completed bridge pile heads of the
temporary supports are still visible in the river
beneath and awaiting dismantling and the
concrete base rings filling with underwater
concrete by divers. Photograph courtesy of
Porr Polska Infrastructure SA / press material.
The bottom of the power plant water

reservoir is covered with an HDPE liner
which had to be cut each time a pile was
to be driven, thus avoiding uncontrolled
tears in the liner.
So, for each pile, a diver would jump into
the water, cut the liner, then the pile was
driven to the exact co-ordinates and
covered with a prefabricated collar made
of HDPE lining material. Next, the collar
had to be pressed with a concrete ring
and filled with aggregate. When the
temporary supports are dismantled, the
piles will be cut and the rings will be filled
with concrete poured under water.
Exciting trip upwards
Next, Tomasz escorted me to the top of
the pylon so that I could examine more
closely one of the places in which our
4
team had been working.

The pylon, shaped like an inverted tuning
fork, is essentially a reinforced concrete
structure with a box cross-section,
strengthened with steel inserts located at
The 64 stay cables,
Fancy footwork
the upper stay cable anchorages. The 64
The new bridge has five spans (30 + 30 + 30
stay cables, arranged in four sets of 16
arranged in four
+ 150 + 240m). There are six piers two of
cables each, spread from the pylon in two
sets of 16 cables
which are abutments, three others tie-down
planes like a fan.
the back span and the last one is the pylon.
The live end anchorages in the pylon are
each, spread from
The structure was incrementally launched,
spaced every 1.7m, while the passive
the pylon in two
so there were 22 temporary supports
anchorages are at 12m intervals in the
11 on each side of the bridge and these
deck between the carriageway and the
planes like a fan.
required some really fancy footwork.
lanes for pedestrians and cyclists.
View from the top
appreciation of the work scope and fast
The view from the top of the pylon was
program, it is easy to understand why
simply stunning. However, the view down
Tomasz Borsz believes that Bilfinger
inside the pylon was even more impressive.
Infrastructure should receive a special
There were around five stepladders leading
award for their excellent site organization.
downwards and I could just make out the
It may look simple, commented Zygmunt
high visibility safety vests and helmets of
Dereszkiewicz, Bilfinger Infrastructures
the BBR team working way below us. The
bridge works manager, but actually, the
reason that the site looked empty is that
achievement is a direct result of BBR
most members of the BBR team were
Polskas experience and ability to
inside the pylon and therefore not visible.
cooperate in extreme conditions as each
It was hard to imagine that, just a few
structure is different. They are a perfectly
months before, steel fixers and concrete
organized team, said Konrad Przymorski,
placers were working above the heads of
also from Bilfinger Infrastructure, but its
the BBR team.
really great that the cables have now been
Also, some of the crew were working inside
installed because when they were laid out
the deck where they were injecting the
on the deck you couldnt walk or drive on it,
anchorages with resin and installing end
he added with a smile.
protection caps both procedures are
Experience is certainly an important factor.
for corrosion protection. This site, like
Our team has applied BBR stay cable
many similar projects, has two extreme
technology to several dozen structures
environmental conditions the wind at
most frequently between 30 and 120m
of the anchor zone a steel pipe to carry
the top is fearsome while inside the deck,
high, all with long cables and a large
the cable and an anti-vandal pipe.
it is incredibly hot.
number of strands. While the stay cables
Having never seen it before, I consulted
Progress has been really breathtaking
in Bydgoszcz, our previous stay cable
Tomasz Borsz who explained that
the whole project, along with the access
project, have a significant cross-section
measurements would be taken during a
roads, was completed in less than two
from 72 to 109 strands the largest
structural monitoring phase. The results
years. Stay cable installation was carried
stays in Rzeszw have 114 strands.
of the monitoring will form the basis for
out at a cracking pace by the 16-man BBR
On closer inspection of the BBR HiAm
establishing damping parameters and
Polska team who finished their work in just
CONA stay cable pipes which feature
then the most optimal BBR damping
nine weeks.
helical ribs as a primary countermeasure
device will be selected. It is currently
The safe, comprehensive and effective
against cable vibration I noticed
envisaged that BBR Viscous Dampers
scheduling of numerous phases, trades
something interesting. There was space
will be installed in half of the stay cables.
and workers has been an outstanding
to install a damping device. The damper
We will await with great interest to see
feature of this project. Now having an
housing is located between the bottom
what decisions are made.
Special visitors
Trade secrets
Once inside the site office, I was shown
My musings were suddenly interrupted
some photographs among them, pictures
when I hit my leg on something hard under
of Messrs Voon, King and Seven from
the table. It was a box and just as I was
BBR Malaysia on site, here in Rzeszw.
about to look inside, Tomasz warned me
Tomasz described how stay cable
Dont touch! Thats the Chief Engineers
specialists are always curious about the
Stay Cable Tool Box. Then, he relaxed a
approach to cable installation techniques
little: Well, OK you can have a look, but
taken by teams worldwide. While it may
no photographs inside are our specialist
seem that installation is carried out in
tools. In the box, I saw some tiny wedges
exactly the same way for every project, in
Tomasz would not let me take one and
fact no two structures are identical.
something that looked like pliers. Thats
There had been other guests too. Dr Behzad
enough, said Tomasz abruptly, Im taking
Manshadi from BBR VT International Ltd
the box with me.
came to observe the installation and
Thus, my exploration was over when
performance of the BBR CONA HiAm
Tomasz left the office with his precious
system. Also, Gnter Damoser of KB
box and, incidentally, my coffee as well.
Vorspann-Technik GmbH had also been
It was clearly time for me to leave and
on site several years earlier, he had
reflect on how the devil is always in the
hosted Tomasz at his Sava Bridge
detail. This project has not just been about
construction site in Belgrade and this was
the huge stay cables, kilometers of strand
a return invitation. The two engineers had
and tons of steel, but also about taking
a brainstorming session about the most
care of the small details which, to the
effective technological solutions on their
casual observer, are hard to see in the
respective projects.
shadow of the imposing 107m high pylon.
6 The stunning view downwards from the top

of the pylon.
7 Right to left: Messrs Voon, King and Seven
from BBR Malaysia taking a well-earned
break after helping the BBR Polska team
with cable installation during their visit to the
Rzeszw Bridge site.
8 The BBR Polska team assembles at the top
of the pylon, ready to go home at the end of
the day.
TEAM & TECHNOLOGY

Owner Gmina Miasto Rzeszw
Architect Promost Consulting
Designer Mosty Gdansk
Main contractor Porr Polska
Infrastructure (formerly Bilfinger
Infrastructure)
Technology BBR HiAm CONA stay
BBR Network Member BBR Polska
Sp. z o.o. (Poland)
ELIZABETH QUAY PEDESTRIAN BRIDGE, PERTH, AUSTRALIA

Hanger installation & heavy lifting
ARCHITECTURAL
HIGHLIGHT ON
THE WATERFRONT
The BBR Network Member in Australia, SRG, has played a crucial role in the construction of the iconic
centerpiece feature, of Perths exciting new Elizabeth Quay development a double arch pedestrian
and cyclist bridge. Richard Blair of SRG provides an overview of the project.
Elizabeth Quay is a major Western

Australian development project currently
under construction in Perths central
business district being delivered by the
State Government. Located on the north
shore of the Swan River, the Elizabeth
Quay development is a A$2.6 billion
project designed to revitalize Perth and
embrace one of citys best natural assets.
The project is a significant development
for the city and will feature a stunning
inlet connected by 1.5km of continuous
boardwalks and promenades, delivering
great public leisure spaces, new hotel and
short stay accommodation and
contemporary inner city living opportunities.
Landmark bridge
Working together with Decmil and Hawkins
Civil under the DASSH Joint-Venture, we
were contracted by Leighton Broad to
bring the unique double arch bridge design
to life, through technical engineering and
construction work.
The 20m high double arch, cable-stayed
suspension bridge is the first of its kind
in Perth. In line with Australias many
renowned port and waterfront icons,
the Elizabeth Quay bridge will create a
striking architectural feature for the
future precinct and the city, connecting
the ferry terminal and Williams Landing to
the new Island.
1
Lifting experience
SRGs expertise in innovative structural
engineering and detailed civil infrastructure
HENDON PARK FOOTBRIDGE, AUCKLAND, NEW ZEALAND

PT expertise for pedestrian and cycling bridge
has been integral to bringing the ambitious

architectural design to reality. The bridge
has been under construction since early
2014 and, last year, the massive 86t arches
were constructed and lifted into place.
Due to the size and shape of the arches,
lifting and erecting each structure was no
easy feat, the boom radius did not allow
the arch lift to be completed in a single
operation. A 275t crawler crane and
hydraulically adjustable intermediate prop
were utilized to support the arch at a lower
level before tracking the crane back to
STRIKING
SIMPLICITY
complete the lift. This complex process

was made possible through the expertise
If there were a competition for the most beautiful bridge in New
and hard work of a number of skilled
Zealand, the list of contenders would be a long one but the latest kid
structural and civil engineers, structural

steel fabricators and site operatives.
on the block could very well steal every prize going.
Hangers
The team at BBR Contech are thrilled to
arctic white, will curve through space,
Our extensive experience with
be part of the 320m-long Hendon Park
connecting to a sculpted arch via a
cable-stayed structures saw the in-house
Footbridge project, a key element in the
complex cable configuration that forms
design and operation of the bespoke
largest and most ambitious road scheme
a hyperbolic paraboloid.
cable stressing assemblies, with a pair
ever undertaken in New Zealand. Called
BBR Contech has supplied PT bars for
of 30t center hole jacks applying the
the Waterview Connection, the NZ
two massive concrete abutments that
loads to enable pin engagement.
Transport Agency's NZ$1.4 billion project
will take the load of the main arch bridge.
A total of 16 hangers tie the arches and
will provide the final link in a 48km
It has also supplied all 39 steel hanger
bridge deck together. Each span
motorway ring route around Auckland city
bars helping to create a bridge that
comprises a mix of 25, 30 and 35mm
easing congestion on state highways
will be loved, lingered on and talked
diameter hangers in varying lengths to
elsewhere in the network, enabling better
about for many years to come.
best suit the load case at each location.
connections for motorists and improving
Having completed the main structural
links to the citys northern and southern
elements of the bridge, the next steps in
neighbors.
TEAM & TECHNOLOGY
the project will see the deck and
The simple, elegant and utterly beautiful
architectural finishes installed ahead of
pedestrian and cycling bridge was designed
the opening to the public.
by Beca and Warren & Mahoney Architects
For SRG, it has been a privilege to be
and is being built by the Well-Connected
involved in this significant development
Alliance. Its ten span concrete deck with a
for the city of Perth and to deliver this
central 80m span over SH-20, finished in
Developer NZ Transport Agency

Architect Warren & Mahoney
Designer Beca
Main contractor Well-Connected Alliance
Technology PT bars, steel hangers
(New Zealand)
important component of the project for

Leighton Broad.
1 One of the two massive 86t arches being

lifted into place for Perths new double arch
cable-stayed suspension bridge.
TEAM & TECHNOLOGY

Owner Metropolitan Redevelopment
Authority
Architect ARUP
Designer ARUP
Main contractor Leighton Broad
Technology Heavy lifting, hangers
(Australia)
PORTFOLIO SPECIAL APPLICATIONS
ONSLOW WATER TANKS, WESTERN AUSTRALIA

Post-tensioned precast panels
INNOVATIVE WATER
TANK SOLUTION
BBR Network Member SRG
recently completed a major
project for Western Australias
Water Corporation to construct
two 5ML water storage tanks
and associated pipelines, in the
town of Onslow, 1,400km north
of Perth, on the Pilbara coast.
The recent development of several large
gas field projects in the vicinity of Onslow
was driving town growth and increased
water demand. The existing town water
supply infrastructure had reached its
capacity and two new water storage tanks
were needed to ensure the township has
sufficient water to meet its current and
future needs.
Innovative bid
A tank design and construct contract was
issued with the option to submit bids for
the construction of either steel or concrete
tanks. SRGs project team submitted a
successful bid to construct concrete tanks
based on an innovative post-tensioned
method. The advantage of using concrete
is that it requires less ongoing maintenance
than steel and lasts up to 100 years.
SRG developed pioneering precast panels,
post-tensioned in two directions, to
overcome any potential cracking in the
precast concrete. The panels were cast in
Perth and then transported to site where
they were stitched together using a
customized concrete mix that responded
to the harsh environmental conditions.
This process ensures the concrete is
kept in compression in both directions.
Should a micro-crack occur in the
concrete, the panels have been designed
to self-seal effectively closing the crack.
1
First in Australia
The contract also required that the tanks,
which weigh 6,000t, be constructed on
sandy ground. Because of the potential for
ground settlement, under the weight of the
tanks, each tank site was pre-loaded with fill
material to self-compact prior to the tanks
being constructed. Specialist settlement
sensors were obtained from the US for this
part of the project, which was the first time
this technology had been used in Australia.
SRG was the principal contractor for this
project and responsible for the full
management of the design, construction,
testing and commissioning of the two
water tanks. This also involved managing
contractors and consultants who were
also on site.
This contract was, however, not without its
environmental challenges. Over the course
of the project there were cyclones and
floods. Nevertheless, the team was able to
overcome these weather events to deliver
a successful outcome on-time for the client
all the while working in the relentlessly
extreme heat of the Pilbara region.
2
I am writing to thank you and the

SRG team for the great work
undertaken in the design and
construction of the two 5 ML water
storage tanks and associated
pipelines at Onslow, WA.
This project has been challenging
given its remote location and
climate. However, these challenges
have been overcome through
detailed planning and organization
SRG has consistently

1 SRG developed pioneering precast panels
which were cast in Perth and transported
to site for erection.
2 The 6,000t tanks had to be constructed
on sandy ground, so each tank site was
pre-loaded with fill to self-compact and
specialist sensors were used for the
first time in Australia to monitor any
potential settlement.
3 Members of SRGs senior management visit
site to review the completed project. Left to
right: David Macgeorge (Managing Director),
Radwan Hamoshi (Project Manager), Kim
Boyd (Regional Manager Construction).
demonstrated its commitment to

managing the existing environmental
TEAM & TECHNOLOGY
Client Water Corporation Western
Australia
Main contractor SRG Ltd
Technology Precast PT panels
BBR Network Member SRG Ltd
(Australia)
conditions and maintaining a safe

worksite during the entire project.
Scott Shand, Project Director, Regional Water Conveyance
BIBOSUT PUMPING STATION, VINKOVCI, CROATIA

Permanent & temporary ground anchors
2
ANCHORING FOR
AGRICULTURE
Several droughts during earlier years of the 21st century have endangered the stability of agricultural
production in Croatia. Now, as part of a national project to improve irrigation and land and water
management, a new pumping station is under construction near Vinkovci, in the Bi-Bosut area
with some expert help from local BBR Network Member, BBR Adria. Goran Tomiic
outlines the
project which involves the regions largest ground anchoring operation in the last five years.
1 The first and second rows of anchors were

installed at an angle of 6 and the third and
fourth line at an angle of 15 spacing was
at 2.5m.
2 Aerial view of the site, showing amelioration
channel, with construction of the pumping
station on its alignment and River Sava in
the background.
TEAM & TECHNOLOGY

Owner Hrvatske vode
Main contractor Eurco d.d.
Designer Institut IGH d.d
Technology BBR VT CONA CMG ground
(Croatia)
The new 16.4 x 20.5m pumping station
Reinforced walls
will provide water for irrigation through
Construction of the pumping station began
the controlled release of water from the
with reinforced concrete retaining walls.
Sava River to raise low water levels in the
The 11m deep construction pit is rectangular
amelioration channel. The station, which
with an area of just over 805m2. It has been
is located in the amelioration channel,
designed and constructed with reinforced
will have a total pumping capacity of
concrete retaining walls featuring four rows
10m3/s using four pumps with a flow
of ground anchors. The walls will also form
rate of 2.5m3/s each and be capable of
part of the pumping station itself. The
pumping to a height of four meters.
function of the retaining walls is three-fold
The 16.4 x 8.8m section of the project
to preserve the stability of the vertical
dealing with drainage takes the form of
excavation of the construction pit, prevent
cascading pools of differing heights.
the hydraulic fracturing of the soil inside
These allow water to overflow towards the
the pit and, finally, as a part of the ongoing
amelioration channel, leaving sediment
construction of the pumping station.
behind while slowing down water flow and
To support these functional requirements,
having the environmentally beneficial
the retaining walls have been designed so
effect of increasing oxygen levels in the
that the four meter entrances are in an
water as it mixes with the air
area of low permeability silty clay which

prevents water seeping through the bottom
of the excavation.
HATAITAI BUS TUNNEL, WELLINGTON, NEW ZEALAND

Ground anchoring and grouting
STRENGTH,
RESILIENCE &
PERFORMANCE
A high-profile project in New Zealands capital city is harnessing
BBR Contechs extensive experience in ground anchoring and grouting.
The Hataitai Bus Tunnel opened in 1907,
To achieve this, the team installed a
providing much-needed access for trams
total of five full-scale proof anchors and
running between Wellington city and the
30 double-corrosion-protected anchors
eastern suburbs of Kilbirnie and Hataitai.
using 32mm and 40mm PT bars. It was
In 1963, electric trolley buses replaced the
a complex process that included water-
trams and, today, buses continue to travel
tests for the drilled anchor boreholes,
Ground anchors
the tunnels 365m length, making about
preliminary grouting and re-drilling,
The BBR VT CONA CMG ground anchors
2,400 journeys a week.
full-scale on-site suitability and pull-out
comprise four strands, each with a
A structural assessment in 2014 revealed
tests and repeated cycles of high-
cross-sectional area of 150mm2 and a
that, while the tunnel was likely to
pressure post-grouting for all the
characteristic tensile strength of 1,860MPa.
withstand a reasonably large earthquake,
ground anchors.
The anchors are founded in layers of sand
the adjacent hillside and old tunnel
Comprehensive project and noise
and gravel of medium or thick compaction
entrances could come down and block
management plans ensured minimal
and stressed to 400kN.
the route.
disruption for bus schedules, passengers,
The first and second rows of anchors
This was the cue for BBR Contech and
local residents and businesses.
were installed at an angle of 6 and the
a six-month project starting in November
third and fourth line at an angle of 15,
2014. Technically demanding owing to
they are spaced 2.5m apart. We installed
the site itself and poor ground conditions
a total of 5,526m of temporary anchors
in places, it included strengthening the
and 2,511m of permanent anchors.
tunnel portals by excavating for and

constructing new vertical buttresses and
Further stages
wing extensions on both sides of each
After the excavation of the foundation
entrance and attaching a new
pit, the base plate and inner walls of the
reinforced-concrete ground beam across
pumping station will then be executed,
the top of each portal.
TEAM & TECHNOLOGY

Owner Wellington City Council
Designer Opus International Consultants
Technology PT bar ground anchor
(New Zealand)
along with the floodgates. To achieve a

monolithic effect for the structure, a
connection needs to be created between
the structure and the inner structure
of the retaining walls. This will be
accomplished by installing fasteners
(dowels) in the retaining walls.
The geotechnical anchors installed in
the northern and southern retaining
walls are permanent corrosion protected
anchors, while those in the western and
eastern walls are temporary and serve
only while the retaining walls are needed
to protect the construction pit. We have
installed a total of 83 permanent and
234 temporary anchors for the project.
SWISS PT INNOVATION
Non-standard applications meet customer needs
LIMITLESS APPLICATIONS
FOR POST-TENSIONING
BBR technology has always
proved flexible and its innovative
use for non-standard applications
1 Railway Bridge Lotto 781 in Bellinzona.
Two short BBRV tendons were installed as
seismic protection.
2 Tendons passing from foundation into the
pier of Railway Bridge Lotto 781.
3 Railway Bridge Lotto 782 in Bellinzona two
short BBRV tendons fix the bridge deck to
the pier.
4 Post-tensioned steel girder for Terminal 2 at
Zurich Airport. The dead end anchorage can
be seen on the left, with the deviation saddle
in the center.
5 The House of Natural Resources, ETH Zurich
provides offices and also serves as a pilot
installation for studying the structural
performance of wood from deciduous trees,
combined with post-tensioning.
6 The House of Natural Resources, ETH Zurich
the laminated beams of each span are
connected to the hardwood columns only
by one post-tensioning tendon which has
been pushed through the central cavity of
the beams thus they are flexurally rigid.
1 Seismic protection for railway viaduct

Near Bellinzona in Switzerland, 15 piers
of a 1,010m long railway viaduct had to
be stabilized by anchoring into the
to meet customer requirements
foundation blocks. The requirements for
is embraced the world over. Jrg
this project were:
Dniker of Swiss-based BBR
tendon length approx. 3.5m
Network Member, Stahlton AG,

reports on several projects from
the past year where his company
has supported engineers in
devising and implementing
tendon force between 5,270 and

8,933kN MBL
tendon must permit for adjustment due
to settlement of -50/+140mm
angular rotation of +/-1.4 degree
tendon must be electrically isolated
On either side of the central guide bearing,
innovative yet practical solutions
Stahlton proposed the use of BBRV wire
to construction challenges using
tendons with 82, 102 or 139 galvanized
BBR post-tensioning systems.
7mm diameter wires encapsulated in thick

walled PE ducts filled with a flexible grout
to protect against corrosion.
4 Wood strong enough for PT

In Switzerland, wood from deciduous trees
is mostly burned, used for heating pellets
or sold abroad. In the opinion of Professor
Andrea Frangi from the Institute of Structural
Engineering at the ETH in Zurich, this is very
uneconomic. He believes it would be more
sustainable, if the hardwood were first to be
used for structural components, after that it
could be processed into chipboard and finally
it still could be burned in high temperature
ovens to provide heating.
Together with his students, he searched for
an optimized use for wood from deciduous
trees, utilizing its good performance and the
higher strength compared to pine. Finally,

on the campus of the ETH Zurich, he
constructed a four storey building The
House of Natural Resources which acts
TEAM & TECHNOLOGY

1 Owner Swiss Federal Railway
represented by AlpTransit San

Gottardo SA
Main contractor Consorzio MPC c/o
Muttoni SA
Designer Consorzio Ingegneri c/o
Brenni engineering SA
Technology BBRV wire
2 Owner Swiss Federal Railway
represented by AlpTransit San

Gottardo SA
Main contractor Consorzio MPC c/o
Muttoni SA
Designer Consorzio Ingegneri c/o
Filipini & Partner SA
Technology BBRV wire
3 Owner Flughafen Zurich AG
Main contractors Baltensperger AG,

Schneider Stahlbau AG
Designer STB Schnyder + Tobler
Technology BBRV wire external
4 Owner Eidgenssische Technische
Hochschule Zurich (ETH)

Main contractor Hring & Co. AG
Designer ETH Zrich, Institut fr
Baustatik und Konstruktion (IBK)
Technology BBR CONA unbonded
2 PT to avoid bearing displacement
as pilot installation and office building at
For the neighboring 443m long railway
the same time. Over its lifetime, it will be
bridge, the starting position was different.
monitored for forces, deformations,
To take up the huge forces of a train braking
vibrations, temperature and humidity.
on the bridge and to avoid displacement at
The two wooden storeys of the house consist
the bearings, the requirements for the PT
of a three dimensional frame structure on a
tendons were:
column grid of 3 x 6.5m without any
tendon length 5.5 to 12.2m
supporting walls. The laminated beams of
tendon force MBL between 1,990 and
each span are connected to the columns
5,270kN, two tendons per pier

tendon type must be exchangeable and
electrically isolated
only by one monostrand post-tensioning

tendon which has been pushed through the
central cavity of the beams (4 x 0.6) thus
We proposed the use of external BBRV wire
they are flexurally rigid. Special anchorages
tendons improved with electrical insulation.
permit for regulation of the tendon force or

the replacement of the load cell. A novelty is
3 Deflection control for load transfer
the composite slab of beech wood panels
Modifications to Zurich Airports Terminal 2
and concrete. The panels act as formwork
required the creation of large new openings
as well as tension elements for the concrete.
for placing escalators. The existing slabs
Machined recesses within the 40mm thick
were a composite construction of steel
beech veneer panels take over the bond and
beams and concrete slabs. Six new steel
shear forces.
beams up to 25m long had to be installed.
The post-tensioning details for this project
Two external post-tensioning tendons
were:
consisting of 52 x 7mm diameter
tendon type unbonded PT tendons
prestressing steel wires each with an MBL
(greased, PE-coated monostrand)
of 3,340kN, allowed deflection control
tendon length 19.85m x 16 tendons
during load transfer from the existing slab
stressing force 700kN (MBL = 1,116kN).
onto the new steel girders.
UNIVERSITY RESEARCH EQUIPMENT, AUCKLAND & CANTERBURY, NEW ZEALAND

Testing facilities realized for two earthquake laboratories
SUPPORTING
ENGINEERING
EXCELLENCE
With around 20,000 earthquakes
The BBR Contech team has a decades-
recorded each year most recently
long connection with this work
In June 2015, the University of Aucklands
educating undergraduates as guest
Centre for Earthquake Engineering Research
lecturers on post-tensioning and concrete
called on BBR Contech to provide specialist
quakes of 2010/11 it is no wonder
durability, supporting a wide range of
grouting services for a shake table in its
that New Zealand is often called
seismic and other research projects
new, fully enclosed test hall part of the
the Shaky Isles. It is equally no
and, of course, providing an extensive
largest seismic testing facility in Australasia.
range of services both to repair
The halls facilities are used for testing
earthquake-damaged structures and to
large-scale structural components and
universities have made a significant
stop the damage happening in the first
assemblies and to simulate earthquake
investment in research on the
place. In 2015, these connections blended
forces, with technology enabling real-time
nature and effects of earthquakes,
nicely into one, with two university-based
views of the test results.
projects that will enable students to test
The shake table is an integral part of these
new theories in practical, hands-on ways.
experiments. Embedded in a pit and
the devastating Christchurch
wonder that the countrys
with the aim of ensuring that
1 Shaking things up in Auckland
buildings can withstand the severest
measuring about 3.6m x 2.4m, it comprises
of quakes and, most importantly,
an 800mm-high concrete plinth with steel
protect the people within them.
mounting points, to which is attached a

large, 65mm-thick steel plate that can
impose earthquake movements when
loaded with a building structure.
BBR Contechs role was to grout the steel
plate in place using vibration resistant epoxy
mortar. While this may sound
straightforward, it actually required three
phases over two days of intense
concentration and incredible attention
to detail to ensure that the plate was
absolutely level, the grout was free of voids
and the plate itself capable of shaking to
international research standards. The team
had only one chance to get it right and of
course they succeeded, overcoming the
dual challenges of a complex under-plate
structure and the need to work quickly to
place the 300 liters of grout within the
working pot life and thus ensure an effective
epoxy bond.
The team also supplied PT bars for another
part of the test hall a 13m wide x 3.7m-high
strong wall and a 13m x 7.5m strong floor.
Together, they enable students to assess

the seismic capabilities of buildings up to
three storeys high, with test assemblies
connected to the wall and floor via fixings
at 500mm centers.
Elsewhere at the University of Auckland,
BBR Contech has continued to support a
PhD students research into the
performance, design and use of FRP
anchors to transfer forces from FRP strips
into or through structural elements. The
aim is to produce a robust design process
for these anchors, so that efficient and
strong FRP solutions can be developed
for structures with complex geometries.
1 The shake table pit showing the concrete

plinth and steel mounting points for the
65mm thick steel plate which will replicate
earthquake movements.
2 The new fully-enclosed test hall takes shape
at the University of Aucklands Centre for
Earthquake Engineering Research.
3 Construction of the University of
Canterburys new structural earthquake
laboratory is underway and due for
completion in March 2016.
4 Facilities at Canterbury will include a
300m2 strong floor and an L shaped
strong wall, both requiring post-tensioning.
TEAM & TECHNOLOGY

1 Owner University of Auckland
Technology Grouting, PT bar

(New Zealand)
2 Owner University of Canterbury
Main contractor Dominion

Constructors
Project manager The Project Office
Structural engineer Aurecon
internal, PT bar
(New Zealand)
2 More walls & floors further south
total length of 28m. The floor and wall
About 1,000km south of Auckland, the
will feature cast-in inserts at 400mm
University of Canterbury is building a
centers to allow test rigs to be attached.
new, multi-million-dollar structural
Working with main contractor Dominion
earthquake laboratory as part of its
Constructors, structural engineering
Canterbury Engineering the Future
firm Aurecon and project manager
program, which includes earthquake
The Project Office, BBR Contech will
repairs, building extensions and new
supply, install, stress and grout 96 PT
buildings for the College of Engineering.
bars and 15 post-tensioning tendons in
The new building will combine flexible
the wall and floor. It is an enormous
learning spaces with room to test
investment more than 3,600 cast
full-scale building systems under a variety
inserts and coupler adaptors are needed
of load conditions. Its facilities will include
for the inserts alone, while the total
a 300m2 strong floor and an L-shaped,
complement being imported for the job
9.2m high, 1.6m thick strong wall with a
weighs about 80t!
PORTFOLIO MRR
PORT OF AUCKLAND, NEW ZEALAND

Repairs for busy maritime facilities
COASTAL COMMERCE
PROTECTING
THE ASSETS
PORTFOLIO MRR
Way back in 1995, New Zealands

BBR Contech completed its first
wharf repair project at the Port
of Auckland. It must have gone
well, because 20 years later the
relationship is as strong as ever
and BBR Contech remains
the repairer of choice for Ports
of Auckland Ltd (POAL) and its
main consultant Beca.
Established in the 1840s, the Port of

Auckland is New Zealand largest and
busiest container and international trade
port, connecting the countrys importers
and exporters with more than 160 ports
in nearly 70 nations. It handles 37% of
New Zealands total seaport trade and
31% of its trade across all ports, including
airports. It is also New Zealands main
port for cruise liners and vehicle imports.
In the past 20 years, BBR Contech has
been involved with repairs to six wharves
associated with POAL operations the
Fergusson container terminal, the
Bledisloe multi-purpose terminal which
includes a third container-ship berth
and the Captain Cook, Freyberg, Jellicoe
and Queens Wharves, which handle
everything from general or breakbulk
cargo to steel, timber, vehicles and dry
and liquid bulk products.
The Port of Auckland operates 24-hoursa-day, seven-days-a-week, so its vital
that we keep it in good condition, says
Pete Algie, Asset Manager for POAL,
which manages the commercial freight
and cruise ship harbor facilities.
Its a constant process of monitoring,
assessment, repair and remediation,
especially given that many of the wharves
are more than 50 years old. Time, tides
and traffic have inevitable effects, and we
need to manage the risks of damage and
corrosion to the decks and the beams
and piles beneath.
www.bbrnetwork.com
71
PORTFOLIO MRR
It was a big project

completed in a
very constrained
environment, but
we managed to
finish four weeks
ahead of schedule.
Twenty years of service

Most of BBR Contechs projects have
involved conventional repair techniques,
such as injecting epoxy resin to prevent
the ingress of sea water to concrete deck
slabs, and using hydro-demolition followed
by applications of dry-spray gunite to

exposed and damaged substructures.
The latter approach has been particularly
common, most notably in 2011 when
BBR Contech repaired the 100-year-old
Unfortunately the substructure was badly
Queens Wharf, the largest job of its type
in need of repair, so we were called in to
ever undertaken in New Zealand.
fix it. That meant removing and reinstating
Queens Wharf was designated party
more than 190m3 of concrete and
central for the 2011 Rugby World Cup,
replacing a significant amount of reinforcing
says Mark Kurtovich, BBR Contechs
bar essentially replacing two-thirds of the
Development Manager. Thousands of
wharfs substructure.
people were expected to gather there to
It was a big project completed in a very
watch the games and enjoy a wide range
constrained environment, but we managed
of concerts and other entertainment, so a
to finish four weeks ahead of schedule. With
number of stakeholders needed assurance
all the other projects going on at the same
that it was structurally safe and sound at
time, that went a long way to easing the
the time and into the future.
pressure on both the wharf and the client.
Aerial view of the busy Port of Auckland.

Photograph courtesy of Ports of
Auckland Ltd.
2 The BBR Contech team carrying out
repairs to the sea wall between Jellicoe
and Freyberg wharves.
3/4 Replacing reinforced concrete on
Freyberg Wharf, named after the former
Governor-General of New Zealand, was a
challenging project.
5 Queens Wharf was ready for its role as
party central during the 2011 Rugby World
Cup, thanks to completion of a massive
structural repair program by BBR Contech.
PORTFOLIO MRR
They also had to

meet our rigorous
health and safety
standards and comply
with our environmental
management policy.
It could have been a
big headache, but
somehow they
made it easy.
Peter Algie, Asset Manager, Ports of Auckland Ltd
The BBR Contech guys had to contend

with huge machines constantly on the
move around the wharves, as well as the
hazards of the marine environment when
working on the substructures not only
the water and the tides, but also the tugs
and other shipping vessels that constantly
come and go.
They also had to meet our rigorous health
and safety standards and comply with our
Other POAL projects have included
environmental management policy. It could
designing, installing and commissioning a
have been a big headache, but somehow
cathodic protection system for the
they made it easy.
Fergusson container terminal in 2000, and

repairing breastworks at Captain Cook Wharf
Highly rated performers
in 2012. Then in 2014 another big project
Pete says this ability to deliver with
came along, this one involving five different
minimal fuss is one of many qualities that
wharves at the same time. It included:
have made BBR Contech a partner of
completing conventional concrete
choice for POAL and Beca. They recognize
repairs to the Queens Wharf breastworks

replacing a 15m2 section of heavily
Owner Ports of Auckland

Structural consultant Beca
Technology MRR range
(New Zealand)
which plans can change at short notice.
reinforced concrete on the deck of
Theyre quick to adapt without complaint,
Freyberg Wharf a complex project
they do a great job in keeping our wharves
given the large amount of steel involved
up to scratch and they leave the sites
and the challenges of working in a busy
clean and tidy. Everyone at the port is very
operational area
happy with BBR Contech great work,
undertaking substructure concrete
TEAM & TECHNOLOGY
that we work in a dynamic environment in
great attitude.
repairs and installing Fabriform under
BBR Contech has more recently helped
Jellicoe Wharf and the Fergusson and
POAL with a diagnostic assessment of the
Bledisloe container terminals. Originally
ports wharf condition. This will contribute
developed by Construction Techniques
to the companys asset management
in the 1960s, Fabriform is made by
strategy and its long-term repair and
pumping highly fluid concrete mix into
remediation strategy.
specially woven fabric envelopes, which
Were keen to look beyond conventional
are pre-positioned in areas vulnerable to
repair techniques which may no longer
erosion, such as seawalls.
meet our needs to alternative approaches
This was a particularly challenging project
such as a greater use of cathodic protection
as it was based in some of the busiest
systems, says Pete. BBR Contechs
parts of the port and therefore a relatively
practical experience will make a valuable
dangerous workplace, says Pete Algie.
contribution to our plans.
PORTFOLIO MRR
HAMMERSMITH FLYOVER, WEST LONDON, ENGLAND

Bearing replacement for major arterial road flyover
UKS LARGEST & MOST

COMPLEX PROJECT
The Hammersmith flyover is an important four lane highway route linking the west with central
London and is used by around 70,000 vehicles each day. When it opened in 1961, it was the first of
its kind and featured the latest in construction engineering. Mark Bond from BBR Network Member
Structural Systems UK tells how, over 50 years later, they have now contributed to its 21st century
makeover with know-how and teamwork, resulting in the successful completion of one of the UKs
largest and most technically complex strengthening projects.
1 Great precision and control was necessary to

lower the new spherical bearings into the pits.
2 The Hammersmith flyover, an important route
linking west and central London takes traffic
over the Hammersmith gyratory system.
Photograph released into the Public Domain
by Patche99z via Wikimedia Commons.
TEAM & TECHNOLOGY

Client Transport for London (TfL)
Main contractor Costain Limited
Lead designer Ramboll Parsons
Brinckerhoff
BBR Network Member Structural
Systems (UK) Limited
We were appointed by main contractor
Specialist works undertaken
Costain during the Early Contractor
We undertook a huge volume of work for
Involvement (ECI) phase in 2014, as
this project including:
part of their contract with Transport for
LVDT movement monitoring at 240
London (TfL) to strengthen and repair
discreet locations, each capable of
the flyover. This involved designing a
recording structural movements down
hydraulic jacking system that was capable
to 0.1mm longitudinally, laterally and
of the lifting the flyover whilst also

supporting the bridge under dynamic
loading during the day when it was under
live traffic conditions a key strategy
for the buildability of the scheme.
in rotation.
Permanent pier strengthening to the
piers made up of 48 high tensile bars
and steel bracketry.
Vertical box beam strengthening with
336 embedded and load tested bars.
Temporary pier strengthening made up
of 240 high tensile bars and individual,
bespoke bearing plates.
Pit wall strengthening consisting of 960
embedded, load tested and stressed
high tensile bars.
Installation and subsequent removal
of 15 temporary bearings, each
weighing 2,100kg.
Removal of existing bearings and
steelwork some 6,000kg at each
pier location.
Installation of 34 permanent bearings,
each weighing up to 2,400kg each.
Design, installation and operation of 12
multipoint, synchronized jacking systems
for the simultaneous control of the
vertical and lateral movement of the
structure. Each of the application jacks
weighed 750kg and was capable of
accommodating 16,000kN.
24 hour/7 day working and monitoring
and, yes, we even had a Merry
Christmas on site.
PORTFOLIO MRR
Structural Systems approach to

engagement and collaboration was
exemplary and they were a pleasure
to work with from the early stages
of developing and agreeing the
conceptual arrangements for
jacking through to the detailed
implementation. The challenges
that we collectively faced were
significant and Structural Systems
were proactive and positive
throughout the process leading to
delivery of a successful solution and
in working to the extremely high levels
of precision required, all within an
extremely demanding programme.
Matthew Collings, Project Director,
Ramboll Parsons Brinckerhoff, Lead Designer
Jacking system
the full bearing replacement process for
Using our specialist experience, we worked
one pier from 43 working days for the
collaboratively with the project team to
first pier, down to just 21 days for the last,
develop bespoke jacking and monitoring
from first lift to final de-jacking onto
systems to minimize risks.
permanent bearings.
The system allowed the flyover to be
Even when the complete program sequence
supported by hydraulic jacks on up to five
was changed by designers mid-way through
The challenge for the project team

was to carry out the works to
strengthen and refurbish the flyover
with minimal effect on the flow of
traffic. This could not have been
achieved without the support and
co-operation throughout the supply
chain, of which Structural Systems
Ltd (SSL) played a significant part.
SSL devised a methodology so that
any works to replace the bearings,
that had an effect on traffic, were
carried out during night-time
possessions of the flyover between
22:30-05:00hrs, which was
implemented without any over-runs
into the morning peak. They also
constantly improved their
methodology to reduce the number
of night-time possessions required.
This was all carried out against a
main programme which was changing
due to the realization of unforeseen
risks, to which SSL worked
proactively with the project team to
the mitigate delays. Overall SSL
have been a critical part of the
delivery of a successful project.
piers at any one time, allowing bearing
the works due to unforeseen bridge
Graham Carter, Transport for London
replacement to be performed
conditions, together, we were able mitigate
simultaneously whilst achieving a precise
the delay. The team achieved every one of
tolerance by accurate monitoring of load/
the clients milestone dates throughout the
levels across pier groups. This feat of
project and achieved practical completion
hydraulic engineering not only enabled the
a month ahead of program.
flyover to remain open during the day, but
We now look forward to taking our creativity
also ensured maximum efficiency during
in designing and delivering a workable
bearing replacement work.
solution to these complex engineering
The SSL UK mobile jacking control unit was
requirements, along with our trusted
custom-built to connect into our bridge
management techniques, forward to our
SSL were asked to deliver a

technically complex sequence of
pier strengthening, jacking and
bearing replacement, safely without
disrupting peak time traffic flows
and all to an accuracy of 0.1mm,
which is exactly what they did
without issue or incident.
monitoring and hydraulic jack system.
next challenge.
Andy Bannister, Project Manager, Costain
Changing the bearings
Engineering skills to appreciate included
Changing the bearings was especially
installing up to 2,400kg bearings to a 0.1mm
tricky, as they were situated within two
accuracy in all planes and in relation to the
meter deep pits which were only fractionally
adjacent bearing, all surveyed and installed
wider than the piers themselves. The
within the two meter deep pit under the
replacements were spherical bearings
bridge. Site congestion was high as the
which were considerably larger than the
continuously re-orientated bridge was
old roller bearings, making their handling
supported by primary hydraulic jacks while
and fitting a complex task in itself.
being monitored by sensors to ascertain the
From each pit, 6,000kg of existing bearings
exact position of the piers and abutments.
and stools were removed and replaced with

7,000kg of temporary works in the form of
Project delivery
temporary bearings, jacks and plate to
The Health and Safety Plans for the lifting
enable the bearing change. Then, 5,000kg
and jacking operations were carefully
of new bearings were installed and all the
coordinated and closely supervised which
temporary works removed.
resulted in no loss-of-time incidents.

We improved project delivery by reducing
PORTFOLIO MRR
MIDTOWN & ROYAL DOMAIN APARTMENTS, MELBOURNE, AUSTRALIA

Faade remediation projects
TAKING THE
LEAD IN FAADE
REMEDIATION
A major project at one of the busiest intersections in Melbourne has recently
been finished, reports Andrew Bray of Australian BBR Network Member
SRG. The project involved completing remedial works to the Midtown
faade, situated on the corner of Bourke and Swanson Streets in the middle
of the citys thriving CBD, for client ISPT.
1
ISPT is one of Australias largest unlisted
1 Stakeholder satisfaction
center of Melbourne most of these
property fund managers with over A$11
The building was fully tenanted at the time,
activities were completed during the night or
billion of funds under management
with a number of high profile businesses
outside of normal working hours, with liaison
through investments in office, retail,
such as banks and telecommunications
required between the City of Melbourne,
industrial and residential properties.
companies continuing to trade as work
Yarra Trams and all essential services
They own high quality property and
was carried out. With many high profile
including the police and fire brigade.
create office and retail spaces that meet
stakeholders, client liaison was crucial in
Thanks to the strong relationships we had
the changing needs of their tenants.
order for the works to run to program, whilst
developed with the numerous stakeholders
Our project was for remediation work to
maintaining unencumbered access to shop
who had an interest in the project including
the seven storey main tower and adjoining
fronts and commercial properties so that
the client ISPT and Melbourne City Council,
two storey building and involved concrete
they could continue with their daily business.
constraints were overcome through intense
and render repairs, brickwork repairs,
With little road access, coverway gantries
logistics planning and weekly meetings
glass window replacement and repairs
were erected over Little Bourke Street and
between all parties involved in the project.
and coating works, as well as a major
along the front faades of Bourke and
roof upgrade to the two storey building.
Swanston Street. Mixed use access
Cohesive project team
The works were deemed necessary after
including swing stage scaffolds, booms,
The cohesive nature of the project team
independent engineering inspections
scissors, rope access and mobile scaffolds
ensured that all matters were discussed
indicated full faade remediation was
were incorporated into the works to enable
transparently with a key focus on ensuring
required to fix spalled concrete and
all traffic road and pedestrian to
that unencumbered access for the works
detached render.
continue to use the building as normal,
to continue were met, whilst abiding by
Remediation projects are always very
whilst maintaining visibility to the site to
the City of Melbourne requirements and
intricate and detailed and Midtown was
ensure that third parties were not deterred
requests for all tenancies to remain
no different. SRG is skilled at managing
from entering businesses and the arcade
operational. In most cases, months of
projects of this nature one of the
area of the building.
planning were necessary given that
reasons why it was a success.
The major challenge for the project was
another major construction site was also
co-ordination with, and communication to,
underway nearby, which meant that traffic
the many stakeholders involved in the
management was required for necessary
project, which also required a myriad of
crane lifts so neither project was delayed.
planning permits and compliance with
This clearly demonstrates our ability to
noise restriction regulations.
take a leadership role and the transparent,
It is significant that SRG coordinated
high-integrity approach we take to all
material delivery and scaffolding to the
our projects.
PORTFOLIO MRR
Excellence Award
The project was completed ahead of
schedule, to budget and to the high
standards clients have come to expect
from SRG. In recognition of the complexity
of the work, we were also awarded the
Australasian Concrete Repair Association
(ACRA) Award for Excellence for Building
and Remediation over A$2M for the
Midtown Faade Project.

As a result of the works carried out at
Midtown, its faade now adds quality to
the appearance of one of the busiest mall
precincts of the city. It was a remarkable
Initially the client wanted to split the
project, undertaken with our usual great
contract into two separate stages to
attention to detail.
minimize the impact on residents,

however, once SRG commenced works
2 Royal Domain Apartments
on site, the feedback from tenants who
Aaron Callegari of SRGs Services
were encouraged by the buildings facelift
Division reports that the team has
and the quality of workmanship being
completed remedial works at the Royal
performed, meant that phase two of the
Domain Apartments on St Kilda Road,
works was brought forward.
also in Melbourne.
In addition to the positive comments
The faade includes many decorative
received from the client and major
architectural mouldings made of polystyrene
stakeholders, the main material supplier
which had become detached from the main
for the project has also praised the
concrete structure. These elements are
outstanding quality and workmanship of
being reattached using stainless steel pins,
our remedial technicians.
as well as a comprehensive patching and
Congratulations to everyone who has
coating system to revitalize the iconic
been involved in this project living up to
buildings faade.
our value of excellence.
1 Work underway on the Midtown faade at

one of Melbournes busiest intersections.
2 Close-up view of the SRG team at work on
remediation of the Midtown faade.
3 Work is almost completed on the facelift at
the Royal Domain Apartments.
TEAM & TECHNOLOGY

1 Client ISPT

(Australia)
2 Client Royal Domain Plaza Owners
Corporation
(Australia)
PORTFOLIO MRR
BARWON RIVER BRIDGE, WINCHELSEA, VICTORIA, AUSTRALIA

Strengthening infrastructure with carbon fiber technology
NEW STRENGTH
FOR BRIDGE
As part of major improvements to the Princes Highway, Andrew Bray
from Australian BBR Network Member SRG, reports that his company
has strengthened a bridge over the Barwon River in Winchelsea,
Victoria with carbon fiber.
2
When a wooden bridge was constructed
In total over 3km of carbon fiber
What is carbon fiber?
over the picturesque Barwon River in the
laminate was required to strengthen
Carbon fiber is an extremely strong
mid 1800s, the town of Winchelsea was
the three spans of the bridge.
and lightweight material consisting of
created and a new gateway to the
crystalline filaments of carbon and is
western districts of Victoria was established.
Construction challenges
Floods swept away the first Barwon Bridge
Challenges of the project included close
in 1849 and a new bluestone bridge was
monitoring of environmental conditions
How does carbon fiber
opened in 1867. During the next century,
to ensure the carbon fiber adhesive
strengthening work?
a second bridge was constructed adjacent
achieved a suitable bond strength and
Carbon fiber strengthening involves
to the bluestone bridge. It is this bridge
some design modifications required at
the external application of carbon fiber
that we have been working on.
the bridge piers.
materials to concrete in order to
All works were completed ahead of
increase the flexural, shear, axial or
Project outline
program and to the satisfaction of the
seismic resistance of a structure.
Strengthening works commenced in
client, VicRoads, and the head
There are other materials with similar
January last year, following the installation
contractor, Cut and Fill. This is a
properties to carbon fiber, including
of a fixed scaffold access system set up
testament to the great work carried out
Kevlar or aramid which can also be
beneath the 61m long bridge to span over
by our crew.
used to strengthen structures.
the Barwon River.
In addition to the vast experience that
These materials are typically referred
SRG was responsible for the provision
SRG has acquired in applying FRP both
to as fiber reinforced polymers (FRP)
of access, supply and installation of
fabric and plate to a host of different
and are available as either a fabric
carbon fiber strengthening and various
structures, our in-house design capability
wrap or as stiff laminate plates.
associated works, including concrete
is available to support the requirements
They are generally applied using a
repair to deteriorated sections of the bridge.
engineers and owners alike.
high strength epoxy resin to bond the
used as a strengthening material.
material to the structure in accordance

with an engineering design.
1 Strengthening work was carried out from a

fixed scaffold access system set up beneath
the 61m long river bridge.
2 Over 3km of carbon fiber laminate was installed
to strengthen three spans of the bridge.
TEAM & TECHNOLOGY

Client VicRoads
Main contractor Cut and Fill
(Australia)
1
TECHNOLOGY
80 RESEARCH & DEVELOPMENT
introducing the BBR VT CONA
CMI Electrically Isolated Tendon
which offers the highest possible
corrosion protection
83 TECHNICAL UPDATE
latest European Technical
Assessments secured for BBR
technologies plus information
about the updated BBR E-Trace
trading & QA platform
86 TECHNIQUES
insight into the installation of the
CONA CMI Electrically Isolated
Tendons provided by Jrg Dniker
of BBR Network Member Stahlton
88 INSIGHT
background to the market for
electrically isolated post-tensioning
tendons and perspective for the
future
TECHNOLOGY
BBR VT CONA CMI ELECTRICALLY ISOLATED TENDON

Most advanced multi-strand post-tensioning system
HIGHEST POSSIBLE
CORROSION
PROTECTION
The European assessed BBR VT CONA CMI Electrically Isolated Tendon (EIT) is the most advanced
multi-strand post-tensioning system with the highest possible level of corrosion protection PL3
as specified in the latest fib recommendations. Dr. Behzad Manshadi, BBR VT Internationals Head
of Research & Development outlines the features and benefits of the system.
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TECHNOLOGY
The ultimate PT system
Anchorage configuration
Key features
Quality control, durability and long-term
The main components in the anchor zone of
High electrical resistance minimizing
monitoring of PT tendons are required.
the CONA CMI EIT system are the protection
Combined with a simple and non-
cap, wedges, anchor head, isolation ring,
destructive method of measuring the
load transfer element (bearing trumplate)
impedance of the tendons makes this
and trumpet. In the anchorage zone, the
the ultimate post-tensioning system for
BBR VT Plastic Duct is connected to the
achieving the highest level of protection
trumpet and the strand bundle is spread
Highest possible protection level (PL3)
PL3.
out towards the anchor head, where each
according to fib recommendation to
The CONA CMI EIT is a multi-strand
strand is individually locked with a CONA
enhance safety and provide superior
post-tensioning system for internally
CMX wedge. Lastly, the protection cap with
bonded applications and provides
the help of the isolation ring encapsulates
excellent performance including
the whole anchor head and wedges. CONA
situations where enhanced safety,
CMI EIT tendons can also be coupled with
corrosion protection, quality control,
the Type H fixed coupler.
durability and long-term monitoring of
Thick corrugated BBR VT Plastic Ducts
post-tensioning tendons are required.
eliminate the ingress of water and

chlorides and anchor head encapsulation
risk of stray currents causing

electro-chemical corrosion of steel
Thick corrugated BBR VT Plastic
Ducts prevent water and chloride
ingress
long term durability

Continuous monitoring of electrical
impedance resulting in early
detection warning system
Standard tendon sizes from 02 to 31
strands. Larger sizes upon request
Optimized for 15.7mm diameter,
1,860MPa strand
Standard sizes
prevents stray currents from causing
The standard tendon sizes range from
electro-chemical corrosion of the
available utilizing an advanced
02 to 31 seven-wire prestressing strands.
prestressing steel. This combined with
proprietary load transfer element for
Both 15.3mm strands with a cross
a simple and continuous method of
very small center spacing & edge
sectional area of 140mm2 and 15.7mm
measuring the impedance of the tendons
strands with a cross-sectional area of
makes CONA CMI EIT the ultimate
150mm2 are possible, whereas the
post-tensioning system for achieving the
maximum characteristic tensile strength
highest level of protection with an early
Fixed couplers for joining tendons
for both strands is 1,860MPa.
detection warning system.
BBR VT Plastic Ducts filled with high
But theres even more the system has

Operation & advantages
been successfully tested in accordance
The CONA CMI EIT is the most compact
with procedures specified by the latest fib
and light-weight system available on the
recommendation (Bulletin 75) and, thus,
market. The tendon force is transferred
the BBR VT CONA CMI EIT range has been
to the concrete using an advanced and
approved for the optional use category
proprietary three-plane load transfer
electrically isolated tendon in accordance
element, allowing for very small center
with EAD 160004-00-301 which
spacing and edge distances at the
supersedes ETAG 013 and in accordance
anchorage. Furthermore, the full post-
with the Swiss guideline Leitfaden fr die
tensioning load can be applied at very
technische Zulassung von Spannsystemen

in der Schweiz.
low concrete strength fcm,0=19/23MPa.
Most compact & light-weight system
distances at anchorages
Application of full post-tensioning
force at very low concrete strengths
performance BBR grout

European Technical Assessment and
CE marking
1 The BBR VT CONA CMI Electrically Isolated

Tendon (EIT) is the most advanced
multi-strand post-tensioning system for
eliminating the ingress of chlorides and
preventing stray currents from causing
electro-chemical corrosion of the steel.
TECHNOLOGY
BBR VT CONA CMI ELECTRICALLY ISOLATED TENDON

Testing of anchorage-duct assembly & BBR VT Plastic Duct system
PUTTING
TECHNOLOGY
TO THE TEST
BBR VT International has a long track record and commitment to testing of
its new technology and techniques before making them available for use
worldwide. The BBR HQ R&D team now share some aspects of their testing
procedures for BBR VT CONA CMI Electrically Isolated Tendons (EIT).
1
EIT performance of BBR VT CONA CMI
Electrical resistance, together with the
anchorage-duct assembly
temperature behavior of the testing
This test was carried on the anchorage-
specimen, were measured and recorded
duct assembly, again in accordance with
over a period of 112 days. The test
fib Bulletin 75: Polymer-duct systems

for internal bonded post-tensioning.
A BBR VT CONA CMI anchorage
consisting of 12 strands of 15.7mm
diameter each, ring wedges, bearing
trumplate, steel ring, anchor head,
trumpet and plastic protection cap
was assembled and connected to a
specimen of ID 75 BBR VT Plastic Duct
using a BBR VT round duct slip-on
coupler. The connection was sealed using
a heat-shrinkable sleeve.
The test specimen was immersed vertically,
for almost four months, inside a container
filled with saturated Ca(OH)2 (calcium
hydroxide) solution. During this time, the
electrical resistance was measured using
an LCR meter between the bar connected
to the bearing trumplate and the electrical
wire connected to the anchor head and
protruding from the protection cap.
The level of electrolyte and quantity of
Ca(OH)2 were continuously monitored
by pH indicator paper and found to be
between 12-13. The temperature of the
testing room was also measured by
thermometer and recorded, together with
each electrical resistance measurement.
procedure fully meets the intent of the
1 These two images show how a fully

assembled specimen BBR VT CONA CMI
anchorage was immersed for almost four
months in a container filled with saturated
Ca(OH)2 solution and electrical resistance
was measured, along with temperature.
2 This graph shows that measured electrical
resistance, over a period of 112 days, of
the BBR VT CONA CMI EIT specimen
considerably exceeded the specified
minimum value of 15kOhm.
3 One meter specimens of three configurations
of all sizes of BBR VT Plastic Duct were
immersed in water for more than 24 hours
and the measured electrical resistance of all
permutations of the duct system exceeded
the specified minimum value of 2,000kOhm.
test specification and the measured

electrical resistance considerably
exceeded the specified minimum value
of 15kOhm during the entire duration of
the test. Thus, the BBR VT CONA CMI EIT
complies with the requirement given by
EAD 160004-00-301 which will replace
ETAG 013 and in accordance with the
Swiss guideline Leitfaden fr die
technische Zulassung von Spannsystemen
in der Schweiz.
50
Electrical Resistance (kOhm)
Temperature (C)
Acceptance Criteria (15kOhm)
3000
40
35
30
300
25
20
30
15
10
5
0
0
0
20
40
60
Time (day)
2
45
80
100
Temperature C
Electrical Resistance (kOhm)
30000
TECHNOLOGY
TECHNICAL UPDATE
BBR E-Trace
UP-TO-DATE TRADING
& QA PLATFORM
The BBR Networks internet-based trading and quality assurance
platform has been updated and enhanced. BBR VT Internationals
Product & Quality Manager, Christian Roost, talks us through the
strategy and changes.
BBR E-Trace our in-house developed
comfortable to operate. Then our
internet-based software links all
programmers invested more than 500
members of the Global BBR Network
working hours in reprogramming the
including BBR PT Specialists, BBR
system to the newest code standards
Component Manufacturers (CMs) and
and yet more programming hours to
ETA Holder, BBR VT International. This
make new features and tools. The
comprehensive e-commerce platform
purpose of the new code was to create
EIT performance of BBR VT Plastic
leads users through the quality process,
a faster and yet robust platform which
Duct system
ensuring that each step through the
can be easily extended for future BBR
The test was carried out on BBR VT plastic
production and supply chain is properly
systems and applications. New features,
duct in accordance with fib Bulletin 75.
documented and recorded. The platform
such as the kit generator, are already
In order to confirm the electrical resistance
facilitates the everyday work of all BBR
established and have been used many
properties of the duct system intended
Network Members and also supports
times, providing a superlative increase
for use with EIT tendons meeting the
effective supply chain management.
of productivity in terms of sourcing to
PL3 criteria, three duct configurations
Essentially, the BBR E-Trace platform
the BBR Network.
were tested the duct alone, duct with
allows us to achieve 100% traceability
The updated BBR E-Trace has been online
connector and duct with connector and
of every single BBR component, as well as
now for six months and feedback has
vents. One test per size was performed
an optimal full Factory Production Control,
been very positive. We are continuously
on all duct sizes and each configuration
both essential to ensure and maintain
working on this trading system to ensure
mentioned above.
the CE marking in BBR systems.
that the platform remains up-to-date.
A one meter specimen was prepared in
After more than five years since the
The team here is looking forward to
each case and the ducts with connectors
launch of BBR E-Trace, it was time to
developing still further new tools and
were sealed using heat-shrinkable sleeves.
update the system and add some new
features to make BBR E-Trace even
A steel rod was concentrically installed
features. First of all, we have changed
more useful for our customers and
into the test specimens and the duct
the design and the navigation to be more
component manufacturers.
specimens were filled with tap water and

thereafter both ends of the specimen
ducts were sealed.
The electrical resistance was measured
while the test specimens were immersed
horizontally for more than 24 hours in a
water tank with their ends sealed against
the walls of basins inserted into the tank.
To achieve this, an LCR meter was used
to record resistance between the bar
which was in contact with water inside
the duct, and the basin that was connected
to the water tank.
The measurements of electrical resistance
for all permutations of the duct system
specimens exceeded the specified
minimum value of 2,000kOhm.
TECHNOLOGY
TECHNICAL UPDATE
New approvals, extensions & renewals
TRIO OF NEW
TECHNICAL
ASSESSMENTS
Over recent months, three new assessments have been secured for technologies within the BBR VT CONA
CMX range. European Technical Assessment for the CONA CMO system has been secured, along with new
assessments for the CONA CMB and CONA CMI systems.
BBR VT CONA CMO onion

The European Technical Assessment, ETA-15/0808, of the
new BBR VT CONA CMO anchorage has been issued. The key
features and benefits of this new multi-strand post-tensioning
system are:
For internally bonded post-tensioned applications particularly
in very thin concrete cross-section such as slabs
Economical solution for fixed-end anchorages
compatible with BBR VT CONA CMF, CONA CMI SP and
BT systems
Standard tendon sizes from 2 to 6 seven-wire prestressing
strands
Optimized for 12.9mm & 15.7mm diameter, 1,860MPa strands
Full stressing at very low concrete strength (fcm,0=21/26MPa)
No anti-bursting or splitting reinforcement required
Equipped with an innovative clip-lock design of the bulb-strand
spacer, increasing productivity during anchorage installation
Very small center spacing and edge distances at anchorages
Compatible with corrugated flat or round tendon duct utilizing
either galvanized steel or plastic material.
1 The new BBR VT CONA CMO Onion

multi-strand anchorage, with a flat array
of onion-bulb strand ends, is designed for
internally post-tensioned applications
particularly suited to use in very thin
concrete cross-sections, such as slabs.
2 The features of the BBR VT CONA CMB
Band system make it ideal for use in the
prestressing of wind towers and also the
strengthening of bridges and tanks.
3 As well as for silos, nuclear power plants,
stadiums and a wide range of other special
applications, the BBR VT CONA CMI
internal system, with its superior cryogenic
performance, is perfect for LNG/LPG
tank applications.
1
TECHNOLOGY
BBR VT CONA CMB band

The BBR VT CONA CMB Band European Technical
Assessment ETA-10/0065 has been issued. The new
assessment is based on the previous CONA CMB European
Technical Approval and has the following key features:
The European Technical Assessment ETA-06/0147 has

been issued for BBR VT CONA CMI, the most up-to-date
For external unbonded post-tensioned applications
and advanced multi-strand post-tensioning technology.
Standard tendon sizes from 1 to 16 seven-wire
Compared to the previous CONA CMI European Technical
prestressing strands
Optimized for 140mm2 & 150mm2, 1,860MPa strands
Approval, this assessment incorporates the following new

key features:
as well as for 165mm2, 1,820MPa compact strands

Consists of bands with 1, 2, or 4 prestressing strands
Offering a high level of corrosion protection, it is widely
used for the prestressing of wind towers, strengthening
of bridges and tanks
Steel prestressing strands are factory provided with a
corrosion protective material and an extruded double or
single HDPE protective sheathing
Tendons with single sheathing and tendons with double
Extending the optional uses of the system:

Tendon for cryogenic applications
Encapsulated tendon
Electrically isolated tendon (see pages 80 & 81)
Introduction of new BBR system grouting accessories:
Grouting & protection caps
Accessories for inlets and outlets
New 2-segment CONA CMX 06 wedge Type Z this
sheathing are each in two configurations:
wedge can be used on the full CONA CMX range of
individual strands connected with webs
post-tensioning systems and is particularly useful in
European Technical Assessment

ETA 06/0147
Unbonded Band Post-tensioning System with 01 to 16 Strands

ETA 15/0808
BBR VT CONA CMB SP
(Type H and Type F) from properly gripping the strand.
Bonded Post-tensioning System with 04 to 31 Strands
A complete series of the latest approvals

along with CAD drawings and technical brochures
is available for download from our website
www.bbrnetwork.com/downloads/approvals.html
the wedge teeth of conventional 3-piece wedges
BBR VT CONA CMI
Full stressing at concrete strength (fcm,0=29/35MPa).
geotechnical applications where soil and mud may clog
Onion Post-tensioning system
individual monostrands without interconnections
BBR VT CONA CMO
(monolithic configuration)

ETA 10/0065
TECHNOLOGY
TECHNIQUES
Enabling monitoring of PT tendons with BBR VT CONA CMI EIT
QUALITY
WITH
CONTROL
BBR HQ and BBR Network
If it can be verified that post-tensioning
available. In Switzerland, the EIT standard is
Member Stahlton AG have
tendons are encapsulated and completely
not only applied to post-tensioning systems,
watertight, it is safe to assume that no
but also to permanent soil or rock anchors.
been working closely
corrosion will occur on the steel strands,
together to extend the
anchor heads and wedges. Taking this a
Responsibilities, purpose & planning
BBR VT CONA CMI system
stage further, if it is possible to monitor this
To fulfil the high requirements for EIT
to EIT standards which will
at any point during the lifecycle of the
tendons, it is essential that the
tendons, meaningful predications can be
responsibilities of all companies involved
made about the health of the post-tensioning.
owner, consulting engineer, supervisors,
from additional features,
Furthermore, reliable electrical isolation
contractors and PT specialist are clearly
such as monitoring
will protect the steel post-tensioning strands
understood and outlined.
of the post-tensioning
from any damage caused by sparking of
From the outset, the purpose that the EIT
any stray current passing through the
tendons are to serve protection against
tendon. The risk of stray currents arises
stray current, performance monitoring or
Swiss BBR Network Member,
mainly when the post-tensioned structure is
fatigue should be specified by the client, as
Stahlton AG, presents some
located near to railway tracks and especially
this will dictate the EIT system specification.
background information and
around installations using direct current
Where there are no national acceptance
(DC), such as rail or tramways.
criteria and tolerable rate of failures
allow customers to benefit
installation. Jrg Dniker of
a pictorial overview of key
available, then the system must be specified
stages in the installation of
Collaborative development based
according to the aim of the EIT tendons
the CONA CMI EIT system.
on experience
and the project prior to execution.
To extend the BBR VT CONA CMI system
Complete wiring installation diagrams
to meet the EIT standard, BBR VT
including the earthing concept and location
International has been working closely
of the measuring control box or boxes
together with Swiss BBR Network Member
should be completed at project design
Stahlton AG because of their long track
stage. All project team members will need
record of working with electrically isolated
to understand the interfaces between the
tendons using both the BBRV wire and
EIT system and their own work elements.
CONA strand systems.
It is also important that a thorough risk
The first bridge executed with EIT tendons
assessment and management process be
by Stahlton was back in 1996. Since then,
agreed by all parties, as effectiveness of an
it has become common in Switzerland to
otherwise high quality EIT installation by a
construct railway and highway bridges, as
PT specialist may be affected by the work
well as other important structures which
of others on the project.
are subject to aggressive environmental
The improved protection level offered by
influences like de-icing salt or stray current,
the BBR VT CONA CMI EIT post-tensioning
using electrically isolated tendons. Or
system is an important milestone on the
sometimes the EIT approach is chosen just
road to achieving more durable and
so the option of monitoring the system is
maintainable structures.
1 Pictured here working with the site team,

Jrg Dniker (top) believes that the improved
protection level offered by the BBR VT CMI
EIT post-tensioning system is an important
milestone on the road to achieving more
durable and maintainable structures.
TECHNOLOGY
STEP-BYSTEP GUIDE
1
BBR VT Plastic Duct is cut to

length, then vents at high and low
points are built in and sealed to the
duct using a heat shrinkable sleeve.
2 Once the ducting and bearing

trumplates have been positioned
and sealed with heat shrinkable
sleeves, the steel strands are
pushed through the duct in the
normal way.
3 The anchor head, wedges and
wedge retaining plate can now
be installed and the electrical
measuring cable, in this case a
25mm2 cross-section wire for
measuring stray current, can be
fixed to the anchor head.
4 A plastic protection cap is placed

over the anchor head to seal it off.
Various strengthened positions
in the cap allow for holes to be
drilled for mounting the grouting
port and cable gland to suit the
local situation. For this particular
construction project, the standard
grout connection has been closed
and sealed with silicone and a
yellow cap, as space limitations
meant that the grout pipe could
not be placed from behind. Thus,
a new hole was drilled in the side
of the cap which is not visible in
4
the picture.
5 Wiring of the tendons to the
measuring box. The location of
the measuring box, along with the
earthing concept and overall
wiring scheme must be planned
well in advance.
6 The connection of the wiring to
the measuring box is the final
stage in installing the BBR VT
CONA CMI Electrically Isolated
Tendon system. Shown here is a
measuring box for four tendons,
plus an earth cable.
TECHNOLOGY
INSIGHT
Construction technology to promote sustainability
MAKING GREENER
FOOTPRINTS
With the benefit of increased knowledge about the way in which we live and our environment, it has
been clear for some years now that taking a sustainable approach is important to our own health
and well-being and that of our planet. Dr. Behzad Manshadi, BBR VT Internationals Head of
Research & Development reviews how key developments in the field of construction technology
have and continue to reduce the environmental impact of the industrys activities.
Environmental
Priorities
Sustainable
Construction
Social
Priorities
Economic
Priorities
Back in 1987, the United National General
is a crucial factor in lowering the structures
Assembly Report of the World Commission
long-term environmental impact.
on Environment and Development,
Optimum corrosion protection of post-
entitled Our Common Future, defined
tensioning tendons to prevent ingress of
sustainable development as development
water and thus chloride induced corrosion
that meets the needs of the present
for high-strength steels has been a critical
without compromising the ability of future
factor in the long-term performance of
generations to meet their own needs.
post-tensioned concrete structures.
Sustainability has been described as at
Meanwhile, practically no non-destructive
the point where economic, social and
techniques are available for monitoring and
environmental priorities converge and this
inspection of these tendons.
applies equally to the construction sector.
In the last two decades, the BBR Network
For our industry, these priorities can be
and indeed the whole industry has
defined as:
adopted a multi-layer approach to corrosion
Economic whole life approach,
protection for new post-tensioning tendons
maintenance & decommissioning
to achieve the required serviceability, safety
and user disruption
and durability.
Social neighbors, users and

construction workers
Environmental minimizing impact,
1 Sustainability has been described as at the

point where economic, social and
environmental priorities converge and this
applies equally to the construction sector.
2 Following the fib recommendation, several
bridges and viaducts for new high-speed
railway lines have been designed and
constructed with simply supported spans
realized with partial or total pre-casting of
the decks.
3 The electrically isolated anchorages permit
easy monitoring and inspection of the tendons
simply by measuring the electrical impedance
between the high-strength steel inside the
ducts and the normal external reinforcement.
Evolution of electrically isolated tendons

At the beginning of the 1990s, a new
CO2 (entire lifetime), reusability
generation of thick-walled corrugated
and recyclability
polymer ducts for bonded internal tendons
The use of post-tensioned concrete offers
was developed and gradually introduced
advantages when measured against all of
onto the market. The main purposes of
these criteria. Post-tensioning originally
these ducts was generally to improve the
developed in the 1940s in response to
performance of the enclosed tendons
materials shortages was the first key
and last on the list of their possibilities
construction technology development on
was to make electrical monitoring of the
the road to greater sustainability.
tendons feasible.
In 2000, based on industry applications
Sustainable post-tensioning
Considerations for the creation of a
sustainable post-tensioned structure must
include both the short and long-term impacts
of the structure. Durability of construction
and actual knowledge, fib Bulletin 7:

Corrugated plastic ducts for internal
bonded post-tensioning was issued as a
non-enforceable guideline for corrugated
plastic ducts.
TECHNOLOGY
The first so-called Electrically Isolated
This guideline recommended a multi-layer
standardizing the direction of EIT technology
Tendons (EIT) were developed in Switzerland
protection approach as design strategy and
has been the new fib recommendation
in the mid-1990s when the post-tensioning
three categories for post-tensioning tendons
industry, Swiss Federal Road Authorities,
in terms of corrosion protection were
Swiss Federal Railways and research
proposed:
institutions jointly worked on the system
Category (a) tendons in traditional
fib Bulletin 75: Polymer-duct systems for

internal bonded post-tensioning which was
published in 2014. Compared to fib Bulletin
7 issued in 2000, this adds extensive
information about material components,
fabrication processes, on-site installation,
as well as testing and approval for the duct
systems. In particular, Chapter 7 and Annex
B provide testing details that can be
considered as a solid basis for European
(EAD 160004-00-301) and Swiss guidelines
for standard evaluation of encapsulating
and EIT performance of the duct system
and anchorage duct assembly.
Electrically isolated tendons are now a
proven system with which to enhance the
durability of structures with post-tensioning
tendons and thus a definite trend towards
large worldwide usage of these tendons
in a sustainable construction manner is
anticipated.
The main factors influencing the success of
electrically isolated tendons are high quality
material and components, along with a
detailed design focused on the critical
aspects, proper testing, the personnel skills
and experience in execution and the respect
of well-established construction procedures.
BBR HQ provides the highest quality
construction technology and is committed
to both testing and training, while the
BBR Network is qualified to advise at the
earliest stages of a project and provide
professional installation of all BBR
technology, including BBR VT CONA CMI
Electrically Isolated Tendons.
components, their design, inspection and

associated monitoring techniques.
The EIT technology used a tight polymer
duct to encapsulate the high-strength steels
and reduce fretting fatigue, grouting that
creates a protective alkaline environment
corrugated steel duct.

Category (b) tendons specifies use
of corrugated polymer ducts for
enhanced protection.
Category (c) tendons must be
electrically isolated.
for the strands and an isolation element to
The guideline gave indications for the choice
electrically isolate the anchor head and
of the tendon category, measuring
wedges from the ground and the rest of the
instructions, limits of the electrical
structure.
resistance and orientation for the
The electrically isolated anchorages permit
interpretation of results.
monitoring and inspection of the tendons
The guideline became the basis for
by measuring the electrical impedance
publishing the fib Bulletin 33: Durability
between the strands and the external
of post-tensioning tendons introducing

worldwide three protection levels (PL).
Electrically isolated tendons fulfill the
requirements of the highest protection
level PL3 according to this fib Bulletin.
normal reinforcement. Monitoring over time

allows the identification of the penetration of
water containing chloride at defects in
the ducts and coupling joints. Thus, for the
first time, a simple and cost-effective early
warning system was available to provide
Present position
alerts as to whether maintenance of
In the last 20 years, an increasing number
post-tensioning tendons was required.
of bridges, flyovers and viaducts have been

constructed mainly in Switzerland with
Swiss guidelines made global
electrically isolated tendons according to
Based on substantial experiences of using
Protection Level 3 (PL3). Similar systems
tendons with thick-walled corrugated ducts
following the fib recommendation have
with or without electrical isolation, a first
recently been applied in Italy for the design
guideline Massnahmen zur Gewhrleistung
and construction of several bridges and
der Dauerhaftigkeit von Spanngliedern in

Kunstbauten was published jointly by the
Swiss Federal Railways (SBB) and the Swiss
Federal Roads Authority (ASTRA) in 2001.
viaducts for new high-speed railway lines

on simply supported spans realized with
partial or total pre-casting of the decks.
The most recent development in
THINKING ALOUD
David Macgeorge, Managing Director of SRG Limited the BBR Network Member for Australia, Hong Kong and the Middle East
explores how harnessing a changing environment leads to business strength
OWNING A
CHANGING
ENVIRONMENT
We often operate under challenging conditions, tight deadlines and in
complex situations. Owning these changing environments and having the
courage to harness challenges is key to defining what a business stands for.
Given the innovative history and track record of BBR, this is something that
fellow BBR Network Members will understand and endorse completely.
Against this backdrop, our Prime Minister
we work in. They are able to combine
has put innovation at the top of his agenda
specialist areas of engineering, outside of
and has recently released a policy that
the standard field of structural engineering,
focuses on start ups, research institutes and
to design solutions that ensure simplicity
the wider economy. Innovation has a place
and affordability. In fact, we have just
at the business table no matter the size of
patented our first new product and it is now
your organization and is vital to success in
being distributed around the world.
times of turbulent market conditions.
Tackling problems that others wont has
In the past year, we have embarked on a
allowed us to grow a business stream and
journey to reshape our business and enable
means were known in the industry as
it to compete successfully in these
innovative problem solvers. Having the
challenging construction and resource
courage to act when problems are brought
market conditions. We took what some
to us continues to deliver dividends for our
might regard as a bold approach and
business and customers.
completely rebranded our business. In
In addition, we have built a strong alliance of
doing this, we sent a clear message to our
partners, business units and team members
investors, market, business partners and
that has ensured our success this year. I
indeed our own staff. Our rebranding has
believe that in difficult environments good
been about moving away from siloed
people and good companies stand up and
business units knowing that we needed to
add value to industry. Central to this is using
harness the power of the group as a whole.
the power of the group and having the
Uniting the company has allowed us to
courage to act.
leverage our combined expertise, skills and
The BBR Network is a powerful group full of
technical excellence and has carved out
innovative and technical minds there is a
niche offerings and services that allow us to
terrific opportunity to further leverage the
continue to succeed and prosper.
power of the group to own and capitalize on
One way in which we have leveraged our
an ever-changing environment. As a
talent is through the formation of a
member of the group since 1961, we look
dedicated team, who create products that
forward to building on the partnership and
solve technical challenges in the industries
owning changing environments together.
BBR DIRECTORY
HEADQUARTERS
Ringstrasse 2
8603 Schwerzenbach-Zurich
Switzerland
Tel +41 44 806 80 60
Fax +41 44 806 80 50
www.bbrnetwork.com
[email protected]
EUROPE
AUSTRIA
KB Vorspann-Technik GmbH
Weitwrth 25
5151 Nussdorf a.H.
Tel +43 6272 407 90
Fax +43 6272 407 90 11
www.kb-vt.com
[email protected]
BOSNIA & HERZEGOVINA
see Croatia
RUSSIA
see Germany
BULGARIA
see Spain
LITHUANIA
see Austria
CROATIA
BBR Adria d.o.o.
Kalinovica 3, 10000 Zagreb
Tel +385 1 3839 220
Fax +385 1 3839 243
www.bbr-adria.com
[email protected]
MONTENEGRO
see Croatia
DENMARK
see Norway
ESTONIA
see Austria
FINLAND
see Norway
FRANCE
ETIC S.A.S.
3 rue de Marly
78 000 Versailles
Tel +33 1 39 50 11 20
Fax +33 1 39 50 11 03
www.etic-sas.fr
[email protected]
GERMANY
KB Vorspann-Technik GmbH
Bahnhofstrasse 108
82166 Grfelfing
Tel +49 89 72 44 969-0
Fax +49 89 72 44 969-12
www.kb-vt.com
[email protected]
NETHERLANDS
Spanstaal Ballast Nedam Infra
Specialiteiten B.V.
Nijverheidstraat 12, 4143 HM Leerdam
Post Address: PO Box 236, 4140 AE Leerdam
Tel +31 345 63 92 00
Fax +31 345 61 91 07
www.infraspecialiteiten.nl
[email protected]
NORWAY
KB Spennteknikk AS
Siva Industrial Estate
Norvald Strands veg 19-21
Postboks 1213, 2206 Kongsvinger
Tel +47 62 81 00 30
Fax +47 62 81 00 55
www.spennteknikk.no
[email protected]
POLAND
BBR Polska Sp. z o.o. (Head Office)
ul. Annopol 14, 03-236 Warszawa
Tel +48 22 811 50 53
Fax +48 22 676 92 31
www.bbr.pl
[email protected]
KOSOVO
see Croatia
BBR Polska Sp. z o.o.

ul. Tarnogorska 214a, 44-105 Gliwice
Tel +48 32 331 47 98
Fax +48 32 330 24 11
www.bbr.pl
[email protected]
LATVIA
see Austria
PORTUGAL
see Spain
LICHTENSTEIN
see Switzerland
ROMANIA
see Spain
SERBIA
see Croatia
SLOVENIA
see Croatia
SPAIN
BBR Pretensados y Tcnicas Especiales, S.L.
Antigua Carretera N-III, Km. 31, 150
28500 Arganda del Rey, Madrid
Tel +34 91 876 09 00
Fax +34 91 876 09 01
www.bbrpte.com
[email protected]
SWEDEN
Spnnteknik AB
Sjngsvgen 7,
192 72 Sollentuna
Tel +46 8 510 678 10
Fax +46 8 510 678 19
www.spannteknik.se
[email protected]
SWITZERLAND
Stahlton AG
Hauptstrasse 131
5070 Frick
Tel +41 44 938 99 00
Fax +41 44 422 11 16
www.stahlton.ch
[email protected]
UKRAINE
see Poland
UNITED KINGDOM
Structural Systems (UK) Ltd
12 Collett Way
Great Western Industrial Estate
Southall, Middlesex, UB2 4SE
Tel +44 20 8843 6500
Fax +44 20 8843 6509
www.structuralsystemsuk.com
[email protected]
BBR DIRECTORY
AFRICA
LESOTHO
see South Africa
SOUTH AFRICA
Structural Systems (Africa)
Group Five House, 9 Country Estate Drive
Waterfall Business Estate
Jukskei View, Johannesburg 2090
Tel +27 10 060 1555
Fax +27 86 616 7482
www.structuralsystemsafrica.com
[email protected]
SWAZILAND
see South Africa
MIDDLE EAST
BAHRAIN
see United Arab Emirates
AMERICAS
EASTERN CANADA
Canadian bbr Inc.
3450 Midland Ave.
Scarborough
Ontario M1V 4V4
Tel +1 416 291 1618
Fax +1 416 291 9960
[email protected]
OMAN
Structural Systems Limited (Oman Branch)
Office A-11, Al Souroh Building
Al Ghala Industrial
PO Box 1946, PC-130
Muscat
Sultanate of Oman
Tel +968 2459 5279
Fax +968 2459 5252
www.bbrstructuralsystems.com
[email protected]
QATAR
see United Arab Emirates
UNITED ARAB EMIRATES

NASA Structural Systems LLC
(Head Office)
Office M 03, Bu Shaqar Building
Garhoud, PO Box 28987
Dubai
Tel +971 4 2522 501
Fax +971 4 2522 502
[email protected]
Structural Systems Middle East LLC
Office 38
Sheikh Abdullah Bin Zayed Al Nahyan
Industrial Area
Musaffah-2, P O Box 126740
Abu Dhabi
Tel +971 2 5554 347
Fax +971 2 5554 348
[email protected]
BBR DIRECTORY
ASIA-PACIFIC
HONG KONG
SRG (Hong Kong)
Office 606
6/F Shun Feng International Centre
182 Queens Road East
Wan Chai
Tel +852 3598 8518
MACAU
see Hong Kong
MALAYSIA
BBR Construction Systems (M) Sdn Bhd
No.17, Jalan Sg. Jeluh 32/191
Kawasan Perindustrian Kemuning, Seksyen 32
40460 Shah Alam
Selangor Darul Ehsan
Tel +60 3 5636 3270
Fax +60 3 5636 3285
www.bbr.com.my
[email protected]
PHILIPPINES
BBR Philippines Corporation
Suite 502, 7 East Capitol Building
No.7 East Capitol Drive
Barangay Kapitolyo
Pasig City, Metro Manila 1603
Tel +632 638 7261
Fax +632 638 7260
[email protected]
SINGAPORE
BBR Construction Systems Pte Ltd
BBR Building
50 Changi South Street I
Singapore 486126
Republic of Singapore
Tel +65 6546 2280
Fax +65 6546 2268
www.bbr.com.sg
[email protected]
THAILAND
see Singapore
VIETNAM
see Singapore
AUSTRALIA
SRG Limited
Level 1, 338 Barker Road
Subiaco WA 6008
Tel +61 8 9267 5400
Fax +61 8 9267 5499
www.srglimited.com.au
[email protected]
SRG Limited
Suite 3, Level 1, 75 Carnarvon Street
Silverwater NSW 2128
Tel +61 2 8767 6200
Fax +61 2 8767 6299
[email protected]
FIJI
see New Zealand
NEW ZEALAND
BBR Contech
15 Kerwyn Ave, East Tamaki
PO Box 51-391
Pakuranga, Auckland 2140
Tel +64 9 274 9259
Fax +64 9 274 5258
www.contech.co.nz
[email protected]
SRG Limited
Unit 1/12 Commerce Circuit
Yatala, Queensland 4207
Tel +61 7 3442 3500
Fax +61 7 3442 3555
[email protected]
BBR Contech
27 Port Road, Seaview
PO Box 30-854
Lower Hutt, Wellington 5040
Tel +64 4 569 1167
Fax +64 4 569 4269
www.contech.co.nz
[email protected]
SRG Limited
112 Munro Street
South Melbourne
Victoria 3205
Tel +61 3 9296 8100
Fax +61 3 9646 7133
[email protected]
BBR Contech
7A Birmingham Drive, Middleton
PO Box 8939
Riccarton, Christchurch 8440
Tel +64 3 339 0426
Fax +64 3 339 0526
www.contech.co.nz
[email protected]
Additional BBR technology licenses have been granted in Europe, Asia-Pacific and Americas for more information, please contact the BBR Headquarters.

Connaect 2016

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THE MAGAZINE OF THE GLOBAL BBR NETWORK OF EXPERTS

The BBR Network is recognized as the leading group of specialized

these challenges and are ready to participate with a flexible approach

Jos Manuel Illescas

Some ancient structures for example

from the early Greek, Roman or Egyptian

Durability is key for sustainability a

Although BBRs three founders were

civilizations have shown extraordinary

durable structure will deliver the expected

certainly far-sighted, could it be possible

durability over the centuries. While we

performance over its entire service life

that they foresaw some of todays

may admire and wonder at these

with minimal or no maintenance.

infrastructure challenges as they developed

achievements, nowadays structures are

Monitoring is however required to preserve

their technology back in the 1940s? Right

designed and built under extreme cost

the predictability and, thus, minimize time

from the start, it has been part of our culture

pressure and subjected to strict

taken to react to any maintenance issues

to invest heavily in Research & Development

environmental regulations. Most recently

both of which influence the minimum

to ensure that we can offer the right

and due to environmental challenges

safety standards for users.

construction technology for the application.

new structures must also be more eco-

Although there are no objective ways to

Our R&D process includes thorough

friendly and sustainable.

measure sustainability, it is possible to

independent testing of our technology, not

In the modern era, approaches to

measure and monitor durability. The recently

only to meet current standards but also to

construction have also changed. The

introduced BBR VT CONA CMI Electrically

satisfy our own internal benchmarks which

amount of data to which we all now have

Isolated Tendon system (CONA CMI EIT)

are very often more stringent and have

access has grown exponentially with the

permits the indirect measurement of

been specially developed to ensure that it

continuous development of new

durability of post-tensioning tendons

information technologies. We can record,

through the evaluation of electrical

BBR post-tensioning and stay cable

analyze and exploit detailed information

resistivity, allowing verification of the

technologies have a proven track record for

in ways that people just a couple of