OUR PASSION FOR INNOVATION AND THE IMPLEMENTATION Deal Magazine

OF A PROACTIVE RESEARCH AND DEVELOPMENT POLICY TOGETHER WITH

CONTINUOUS TRAINING OF OUR TECHNICAL STAFF ALLOW US
TO KEEP PACE WITH OUR PARTNERS AND CUSTOMERS EXPECTATIONS

DEALMAG 2
 / DEALMAG 2 / 2017 / INDEX

02 DEAL SOLUTIONS THAT MAKE 22 RIYADH METRO PROJECT 44 DOHAS NEW CONNECTING
THE DIFFERENCE / Saudi Arabia HIGHWAY VIADUCT
/ Qatar
04 DEAL ALL AROUND
45 HONG KONG-ZHUHAI-MACAO
BRIDGE
06 GRAN MANGLAR VIADUCT / China
/ Colombia
46 AL SEWYRAH BRIDGE
/ Iraq

48 THE LIANTANG PROJECT

28 WADI HANIFA BRIDGE / China
/ Saudi Arabia
49 HANGZHOU BAY BRIDGE PROJECT
30 JAMAL ABDUL NASSER STREET / China
/ Kuwait
10 MANHATTAN WEST 50 THE GREAT NORTH ROAD
DEVELOPMENT INTERCHANGE
/ USA / New Zeland

34 KUALA LUMPUR MRT

/ Malaysia

14 THREE MAJOR CABLE-STAYED 36 ULU JELAI HYDRO-ELECTRIC 52 M4 WIDENING

BRIDGES IN NORTH AMERICA POWER STATION / Australia
/ Canada / USA / Malaysia
53 SYDNEY METRO
16 LESNER BRIDGE REPLACEMENT 38 MRT SYSTEM FOR / Australia
/ USA HO CHI MINH CITY
/ Vietnam
54 TAJUNG PRIOK ROAD
18 THE EVERGREEN LINE PROJECT / Indonesia
/ USA 40 DOHA METRO
/ Qatar
55 VIADUCT CONSTRUCTION
20 MOSES WHEELER BRIDGE FOR RENNES METRO
RECONSTRUCTION / France
/ USA
56 SPECIAL EQUIPMENT
21 ROUTE DU LITTORAL HIGHWAY
/ La Reunion Island

Edited by Graphic Design Printed in Italy by

DEALMAG Deal Advertising Dept. Polystudio.net Grache GFP

+39 0432 607900 Photographs

[email protected] Archivio Deal
 DEAL
SOLUTIONS
THAT MAKE
THE
DIFFERENCE
We continue our mission to adapt
to the new needs and requirements
arising from changes in technology
and clients expectations

2 DEAL MAG
 he continued and significant increase in Deals

T revenue in recent years - despite the global

financial crisis - confirms the high quality
and focused positioning of both our equipment
and our services. Our passion for innovation and
the implementation of a proactive research and
development policy together with continuous training
of our technical staff allow us to keep pace with our
partners and customers expectations.
Acquisition of Tensa gave Deal the ability to complete
the range of products and services offered to its clients.
Im proud to report that more and more customers
are looking at Deal not only as an equipment supplier
but also as a long-term partner with whom to develop
innovative solutions.
Furthermore, the increasingly frequent involvement
of Deal in permanent structural design, as well as
in the provision of technical assistance during the
construction phase, allows us to provide a fully
integrated package that ensures the most efficient,
reliable and economic solutions.
Im privileged to present in this publication a selection
of the more challenging and innovative projects around
the world that Deal has been involved in.
Deal continues its mission to adapt to the new needs
and requirements arising from changes in technology
and clients expectations.

Alessandro Rovera
DEAL CEO

DEAL MAG 3
DEAL STRATEGIES

DEAL ALL AROUND

Talking with Gilberto Dreas,
Deal Engineering Department Director

ow were Deals Engineering Ser- 3. Construction engineering

H vices born and what makes Deal

different from other engineering
companies in development of such ser-
vices?
In addition to detailed design, a wide
set of engineering activities is required
to enable construction managers to
perform in a safe and timely manner.
Construction efficiency is the prima-
To understand how Deals engineer- ry goal for Deal in developing construc-
ing services department was created, tion engineering services. Thats why
we need to take a step back in time and Deals project engineers have under-
start from the 80s, when a new divi- gone training on construction sites
sion, specialized in bridges and viaduct around the world and speak the same
construction, began to develop with- language as contractor teams.
in Rizzani de Ecchers technical office.
A few years later, in 1994, this division Could you highlight the last success-
became a full-scale company named ful projects for Deals engineering depart-
Deal which concentrated exclusively on ment?
provision of specialized equipment for
construction of bridges and viaducts. Yes, among the projects of recent years,
Soon, however, it was clear to all that I would like to highlight these two in
Deal could not just act as a supplier. particular:
The market needed a partner, capa-
ble of developing design which took The first is the Gran Manglar Viaduct
into account not only convention- project, in Cartagena de Indias, Colom-
al demands, but, above all, work con- bia. Initially, when we started work-
structability. ing with Consorcio de Diseos Costera,
This is how the Engineering Depart- which is responsible for implementing
ment was born. this project, the task was envisaged as
a traditional construction which would
Which engineering services does Deal involve invasive interventions into the
offer? lagoon area.
Based on the experience of designing
Deals engineering services can be according to clients specifications but and building pile-driving equipment
grouped into three major categories: offers value engineering solutions to for the Washington Bypass project,
help reduce life cycle costs, improve Deal has proposed a similar but revised
1. Tender and concept design quality and reduce environmental im- solution, taking into account the spe-
Particularly for design&build projects, pacts. cific characteristics of the site first of
Deal can assist the tenderers by pro- all, the high seismicity of the region.
viding design concepts for specialized 2. Detailed design The concept design for this technolog-
works, developing construction meth- To produce an efficient and buildable ical solution, delivered together with a
odology and schedules, preparing ten- design, constraints imposed by con- cost budget, has been approved, result-
der submittals and coordinating the struction methodology should be con- ing in a very limited environmental
activities of other specialist designers sidered, as well as project specific impact.
involved, in order to develop together design criteria. Deals long-term expe- Under the agreement between Rizza-
the most suitable design and technical rience in precast and erection of pre- ni de Eccher Colombia and Consor-
solutions. stressed concrete structures adds sig- cio de Diseos Costera, Deal has been
When Deal is involved in post-tender nificant value to development of any responsible for implementing detailed
stages, it not only executes the works part of the design package. design, construction engineering, and

4 DEAL MAG
 DEAL STRATEGIES

construction sequences, by identify- struction of similar works and intro- used the span-by-span method to erect
ing specific solutions for this proj- duced a series of optimizations in the a section which included 52-m-long
ect, among which: 1) seismic isolation structural concept which have allowed spans with a U-shaped cross-section.
to reduce stress and 2) introduction of significant cost savings for the client. The work involved creating a continu-
joints in the piles, due to continuous After the award of the project to the RLR ous deck unit, composed of four spans
geological conditions that require lon- JV, Deal has been entrusted with the with lengths of: 34m + 52m + 52m +
ger piles. detailed design and construction engi- 30m. This was a first for this kind of
neering of all decks, and, at this stage, structure, and Deal had to push the lim-
The second project is Doha Metro - all optimizations, proposed at the ten- its both in the span-by-span method-
Red Line North, Elevated and at-grade, der stage, were put into practice. Con- ology and for the erection equipment,
in which Deal was engaged, as early as sequently, prefabrication and launch- in order to achieve this challenging
from the tender stage, in the study of ing of decks were completed without goal. The innovative solution has also
the structural solution. any problems and ahead of the sched- secured / gained cost benefits, com-
At this phase, Deal has applied the ule. Furthermore, in November 2016, a pared to employment of the tradition-
experience gained in design and con- new record was set on this project: Deal al balanced cantilever method

DEAL MAG 5
CARTAGENA /COLOMBIA / AMERICAS

GRAN MANGLAR VIADUCT

CONSTRUCTION
OF COLOMBIAS LONGEST
BRIDGE

Use of an alternative construction method has overcome site

challenges and brought considerable benefits in the construction
of a major viaduct across environmentally sensitive wetlands

olombias National Infrastruc-

C ture Agency ANI is building

a 146km motorway to link the
cities of Cartagena and Baranquilla. The
goal is twofold: firstly, a wish to devel-
op the Caribbean Coast into the most
important logistics route in the country
and, secondly, to facilitate better traf-
fic flow, guaranteeing easy journeys for
both tourists and locals.
Consorcio de Diseos Costera entered
into a design, build and finance con-
tract with ANI for the scheme, which
is officially called Proyecto Cartage-
na-Barranquilla y circunvalar de la
prosperidad.
Only two out of 10 groups that took part
in the prequalification process submit-
ted a tender in 2013 for the challenging
design, construction and maintenance
of the highway. The contract required
the route to pass through marshland that
had already been seriously damaged by
infrastructure that obstructed the water
flow towards the Caribbean Sea. The
marshland has now been restored and
has become a nature reserve.

6 DEAL MAG
 GRAN MANGLAR VIADUCT

The call for tenders required construc- ly by access from the section that had
tion input for the 5.4km-long viaduct, been already built. A twin set of special-
5.4km-long viaduct which was categorised as a cast-in-si- ly designed launching trusses had been
Top-down construction tu balanced cantilever bridge. The con- deployed in North Carolina to drive the
struction method for this type of bridge precast piles, complete the setting of
method enabling has two major issues. From an environ- the precast pier caps and then launch
construction of the whole mental point of view, installation of the and place the precast girders in record
viaduct, including foundation elements themselves pres- time. The system reached an impres-
ents challenges and there was also a sive monthly production rate of five
foundations, with access social issue as the delivery of the proj- spans - typically 36m long - with mini-
only needed from ect would have prevented local people mal impact on the wetlands below.
the section that has from continuing their fishing activities. Adopting a similar solution for the
The main contractor had to demon- project in Colombia was dramatical-
already been built strate that it could solve these issues. ly different from the original proposal
Solutions to Rizzani de Eccher and Deal present- and resolves all of the project require-
environmental, social, ed an ingenious solution that led to the ments and issues:
team winning the tender as the proj-
programme and cost ects exclusive, strategic partner. Environmental it avoids the need
challenges The innovative top-down construc- for dredging, concrete slabs and the
tion method is extremely high-tech but construction of access roads, which
requires only a minimum amount of otherwise would have damaged the
manpower and operations. The meth- environment for years;
od had already been developed by Deal
and used on the Washington Bypass Social - despite the construction
project (North Carolina, USA), where works, the local population can contin-
it enabled the construction of the whole ue using the wetlands for fishing and
viaduct, including foundations, entire- agriculture;

DEAL MAG 7
GRAN MANGLAR VIADUCT
CONSTRUCTION
OF COLOMBIAS LONGEST
BRIDGE

Programme - the use of precasting

and industrial processes on the project
allows the main contractor to keep in
line with the scheduled delivery times;

Costs - Rizzani de Eccher is able to

deliver lower costs than the original
tender estimates, thanks to high-quali-
ty value engineering and the input from
the many companies of the de Eccher
Group involved in the process

The innovative
top-down
construction method
is extremely high-tech
but requires only
a minimum amount
of manpower
and operations

8 DEAL MAG
PROJECT TEAM DEAL SUPPLIED Precast moulds:
beam mould for girder 37m long
Client: Agencia Nacional Design: pile mould for pile 42m long
de Infraestructura Final design of superstructure pile mould for pile 36m long
Contractor: MHC and substructure. pile mould for pile 24m long
and MECO Consortium Launching equipment: long line pile cap mould
Sub-contractor: 2 launching girders 3 pile moulds bulkhead
Rizzani de Eccher for driving piles and beam erection. Engineering services:
Sucursal Colombia Precast yard equipment: Support for precast yard logistics
Designer: Deal 2 gantry cranes 10t and design
2 gantry cranes 25t Temporary works design
2 straddle carriers 55t Geometry control
Erection sequences
Temporary structure pile driving

DEAL MAG 9
10 DEAL MAG
NEW YORK CITY / USA / AMERICAS

MANHATTAN WEST
DEVELOPMENT
Placing a deck over live railway tracks
in the city that never sleeps

Bridge construction technology Jersey Precast, a local fabricator located

has been used in an innovative in New Jersey where labour rates are An unprecedented
application to create a large plaza significantly cheaper than Manhattan precast solution
above busy rail lines in Manhattan for integration into its plant. Creation of a 10,200sqm
The length of the spans combined with segmental post-tensioned
the level of segmentation required platform
highly accurate geometry control. The Launching of 16 adjacent
scarcity of buildable land in large number of segments derived from bridges to make the

A NYC meant that the citys lead-

ing real estate developer was in
search of a creative solution to maxi-
the need to limit the size of each one to
56t to allow for transportation through
Manhattan. As a result, the maximum
platform
Installation of 2,400t
precast/post-tensioned
mise use of the limited space available length for a typical segment was only segmental beams
on a prime development site. 1.93m and the pier segments were as Adoption of a PT ratio
Brookfield Office Properties, own- short as 1.27m. three times higher than for
er and developer of the Manhattan There were between 37 and 39 seg- standard bridge applications
West Project, needed to close a large ments per beam, which meant that Construction above 15 live
gap above the busy railway tracks in even a slight deviation on the horizontal rail lines
the middle of the 7-million-sq-ft site. plane would have caused a major prob- Use of a launching girder
The solution came from observing the lem. The geometry control system pro- with a 3,600t lifting capacity
bridge construction industry and using vided by Deal and precise management Remote connection of the
high-tech bridge erection machinery to of the moulds allowed the subcontrac- lifting girder to engineers
create a deck over the lines. tor to achieve excellent accuracy in the and technicians in Italy
The result is the Manhattan West Plat- alignment.
form, a 10,200sqm segmental post-ten- Cycle efficiency for the segment pre-
sioned deck made up of 16 adjacent fabrication was maximised by Deals
bridges, each with a length of 73m. It provision of three short-line moulds
covers a record 73m x 146m gap over for the typical segments, a mould for
15 live rail tracks that transport about pier segments and an adjustable short-
800,000 people per day, in and out of line mould able to cast segments with a
Penn Station. variable web thickness.
Spanning the gap required extensive A straddle carrier supplied by Deal ser-
engineering work, which resulted in viced the staging area in Manhattan and
a custom-built launching gantry (LG) was used to off-load the segments that
being used to position the 2,400t pre- were brought in at night and place them
cast/post-tensioned segmental beams in their temporary storage locations.
above the live rail lines and their elec- The segments had to be double-stacked
trified power systems. These beams to maximise storage capacity.
now support a public plaza and a park- Two factors in particular contributed
ing area between two high-rise build- to the success of the Manhattan West
ings. Project:
Precasting was an essential part of the
project but these activities were not The skills of the deck engineer,
carried out in downtown Manhattan. McNary Bergeron, which designed
Instead, the moulds were provided to a precast concrete beam that could

DEAL MAG 11
MANHATTAN WEST sioning, the lowering system was con- PROJECT TEAM
DEVELOPMENT nected to the pier segments by means of Project: 9th Avenue
eight threaded bars and then the span Development - Manhattan West
was moved to the second-stage area Platform
where the remaining 10 PT cables were Client: Brookfield Properties
tensioned and the final grouting was Designer: McNary Bergeron &
carried out before erecting the span in Associates
its final position. Design and build general
contractor: Rizzani de Eccher
The LG was connected remotely to (USA) Ltd.
engineers and technicians in Italy
who monitored its functionality and DEAL SUPPLIED
accommodate 100t of post-tensioning ensured that all sensors and indicators Launching equipment
strands inside; were working properly. After the first Design and fabrication of:
The ability of Deal to manufacture two beams were set in place, the TPP Launching gantry for span
a high-tech LG with the capacity for was removed and the assembly bed was fabrication and span launching
smooth placement of the 16 beams. relocated over spans 3 and 4 and used Segment transporter on rails to
The LG was essentially a gantry able to as the stage from which subsequent feed the launching equipment
move sideways on rails; its main com- beams were assembled. with segments
ponents were a winch and a lower- The PT ratio for this project the weight Straddle carrier on tyres for the
ing system. It was made from 1,100t of of the steel PT strand per square metre segment storage area
steel with a capacity to lift 3,600t and of deck area - is three times higher than Mobile stressing platform
featured a 90t winch for handling the for standard bridge construction appli- Precast segment moulds
individual segments before they were cations. Design and fabrication of:
joined with epoxy and post-tension- 3 short-line moulds for typical
ing to create a single giant beam. Every Each beam required 100t of post-ten- segments
component was designed and manu- sioning supplied by Tensa, a subsidi- 1 short-line variable mould for
factured in Italy and the LG was bro- ary of Deal, using 20 tendons with 37 transition segments
ken down into more than 90 containers strands and 14 with 31 strands. 1 pier segment mould
to allow transportation by sea to New Preliminary assessment of anchorage 1 segment manipulator
York. performance was through dedicated 1 special trolley to transport
The assembly process for the deck tests carried out in the Structural Lab- segments to storage
was very similar to that of a sequen- oratory of the University of Padua in
tial span-by-span bridge. The key dif- Italy. All the types of anchorages used TENSA SUPPLIED
ference was that a single platform was on the project (37MTAI15, 31MTAI15, Post-tensioning system
being built so there was no need for a 9MTAI15) underwent load transfer Supply of 320 complete tendons
gantry that could launch segments from testing under the schemes design con- made up of 37 strands together
pier to pier. Instead, the equipment ditions, including the correct concrete with anchorages of type
moved sideways to place one complete strength (9,500psi) and the anchorage 37MTAI15
bridge span adjacent to the next. spacing at the end segments Supply of 212 complete tendons
made up of 31 strands together
with anchorages of type
CONSTRUCTION 31MTAI15
SEQUENCE Supply of 72 complete tendons
made up of 9 strands together
The first activity on site was the instal- with anchorages of type
lation of a steel temporary protection 9MTAI15
platform (TPP) over the rail lines. This Total quantity of 0.6steel
served the dual purpose of protecting strand: 1,600t
the railways and providing an assembly Installation equipment
bed - the beam factory- from where Multi-strand stressing jacks
the LG could be assembled and beam complete with hydraulic pumps
numbers 3 and 4 could be set into place. for use with 37-strand tendons
The whole operation was designed to Multi-strand stressing jacks
minimise the time needed for PT bar complete with hydraulic pumps
tensioning and for the completion of for use with 31-strand tendons
the connections. The winch picked up Multi-strand stressing jacks
each segment using a C-hook and car- complete with hydraulic pumps
ried it into place on top of adjustable for use with 9-strand tendons
screw jacks, over the two steel I-girders Strand threading machines
that made up the assembly bed. Epoxy Grouting pumps
was then applied to the joints and the
first-stage tendons (24 cables) were Technical assistance on site
connected with temporary PT bars and and engineering services
tensioned. After the first-stage ten-

12 DEAL MAG
 DEAL STRATEGIES

A CONTRACTOR WHO OVERSEES

FULL-CYCLE DEVELOPMENT
OF INNOVATIVE CONTRUCTION
EQUIPMENT

the principal players of our industry cast cap and pre-cast beams, reducing
and have worked on signature projects, the damage to environment to nearly
such as: the Oakland Bay Bridge in San nothing, as direct site access was pro-
Francisco, Port Mann Bridge in Van- vided only from the top. This resulted
couver, Palmetto Interchange in Mia- in a winning bid and an extremely suc-
mi, Central Artery in Boston, the Dal- cessful and profitable project.
las High-Five Interchange, and many Over the years, Deal has dominated
more! the North American market due to one
primary difference over our competi-
Starting from the design of the casting tors: we were contractors before beco-
yards, we have gone all the way to the full ming equipment suppliers, and this
supply of custom-designed equipment, background is paramount in enabling
including technical assistance, to help us to understand the entirety of issues
manage such equipment and projects. at hand and in finding the right solu-
A prime example of innovation is the tion that addresses such problems in
Talking with creation of the Pile Driver which was the safest and most practical manner,
used to construct the seven-mile-long giving us a distinct advantage.
Riccardo Castracani, Washington Bypass bridge, completely Our past period of over 20 years has
Deal Business in top down, by driving piles out in can- been a great success and has given us
tilever using an overhead truss, then the tools to continuously deliver safety
Development, USA using the same truss to erect the pre- and efficiency

eals North American presen-

D ce started over 20 years ago with

the supply of a balanced can-
tilever launching gantry, on one of the
most prestigious projects at that time
the Confederation Bridge to Prince
Edward Island in Canada and conti-
nues to date, solidifying its presence
and becoming, in essence, the comple-
te solution, from a means and methods
point of view, to complex pre-cast seg-
mental bridge projects.
Our scope has gradually grown from
supply of existing equipment to the
full-cycle development of innovative
equipment solutions, influencing, at
times, the actual design of bridges and
bringing winning solutions to the table
for our clients.
We have had the privilege of develo-
ping long-lasting relationships with

DEAL MAG 13
VANCOUVER / CANADA LONG BEACH / USA AMERICAS

A single type of advanced technology

to serve three major cable-stayed bridges
in North America

GOLDEN EARS BRIDGE (2007)

PORT MANN BRIDGE
REPLACEMENT (2009)
GERALD DESMOND BRIDGE
REPLACEMENT (ONGOING)

Innovative engineering has allowed of special lifting frames with the same
Provision of equipment Deal to adapt, reuse and develop the characteristics as the previous pair. The
suitable both for erection design of its special lifting frames new project was the replacement of the
of single components and for to suit the requirements of three of old Port Mann Bridge, which had been
erection of an entire steel grid North Americas most significant built in the early 1960s when the popu-
Designed to ensure bridge projects of recent years lation of Metro Vancouver was 800,000
accuracy in the positioning inhabitants. By the time of its replace-
of elements ment, the bridge was supporting traf-
Lifting capacity: he Golden Ears Bridge spans the fic flows of over 800,000 vehicles every
Gerald Desmond 230t, Port Mann
and Golden Ears 100t
Record-breaking width
T Fraser River to connect the com-
munities of Pitt Meadows and
Maple Ridge to Langley, Surrey and
week. The five-lane bridge and adja-
cent highway could not meet the growing
needs of the area and, as a result, there
of 46.7m Gerald Desmond beyond. The combination of the six- was congestion for up to 14 hours per
Equipment lifting stroke: lane bridge and a 14km road network has day. The newly completed Port Mann/
Gerald Desmond 75m, created a quick and convenient link that Highway 1 Improvement Project has now
Port Mann and Golden Ears 60m reduces travel times and regional traffic significantly reduced this congestion
congestion for both residents and busi- and was the largest transportation infra-
nesses. structure project in the history of British
For this project, Deal designed and sup- Columbia.
plied a pair of special lifting frames for The 2km-long bridge is made up of
the erection of the grid of steel elements three key sections: the cable-stayed
and the precast concrete panels for the main crossing of the Fraser River, the
hybrid cable-stayed/extradosed bridge. South approach in Surrey and the North
The equipment was flexible in design approach in Coquitlam.
and was suitable both for erection of an The new ten-lane Port Mann Bridge is
entire steel grid by lifting it from the one of the widest bridges in the world,
ground or, alternatively, for erection of as it is also designed to accommodate
single components, lifting them up from light rail rapid transit in the future.
the back. One of the main characteris- The project also involved the widening
tics of the equipment is its accuracy in of 37km of highway between Vancou-
positioning the elements, which is par- ver to Langley, including 30km of new
ticularly important in the case of bolted lanes for high-occupancy vehicles and
joints. the replacement of nine highway inter-
Two years later, the same equipment changes.
was required for a new project in Cana- In 2016, Deal became involved in the
da, and this time Deal supplied two pairs project to replace the Gerald Desmond

14 DEAL MAG
Bridge. The through-arch bridge in of the equipment are similar to those On the first two projects, a steel frame
Long Beach, California, was built in proven on the two previous projects - called a spider was used to deform
1968 across Cerritos Channel to pro- Golden Ears and Port Mann the new bridge elements that were ready for
vide a link to Terminal Island. The old project has posed real challenges for erection to match the joints with those
bridge has recently been encountering Deals engineers. These have included already assembled, which had been
structural and maintenance problems, the necessity of increasing the capacity deflected by the deck loads.
so the Port Authority decided to replace of the lifting frames from 100t to 230t, A new concept for the spider has
it with a new cable-stayed bridge with the massive dimensions of the bridge been developed for the Gerald Des-
61m of vertical clearance. The new (width of 47.6m), and the equipments mond Bridge project in order to min-
bridge will allow access into the port for required lifting stroke of 75m. In addi- imise the equipment weight, which is
the tallest container ships and will be tion, particular attention has had to be always critical in terms of the struc-
the first long-span cable-stayed bridge dedicated to the shape of the equip- tural capacity. The innovation involves
in California. ments main structure as it cannot be creating the required counter-camber
allowed to interfere with the tempo- of the steel elements by means of a ten-
For the erection of the main spans, Deal rary stabilising structures of the tower sioning system made up of cables and
is suppling two pairs of special lifting cranes used for the construction of the hydraulic jacks, which are remotely
frames. Even though the capabilities main pylons. controlled

GOLDEN EARS BRIDGE PORT MANN BRIDGE GERALD DESMOND BRIDGE

PROJECT TEAM PROJECT TEAM PROJECT TEAM

Client: TransLink Client: Province of British Columbia Client: State of California
Contractor: Golden Crossing Contractor: Kiewit-Flatiron Department of Transportation
JV - Bilfinger&Berger and CH2M General Partnership Contractor: SFI Shimmick
Designer: Buckland&Taylor FCC Impregilo JV
DEAL SUPPLIED Designer: ARUP
DEAL SUPPLIED Launching equipment
Launching equipment 2 pairs of LF-100 lifting frames DEAL SUPPLIED
2 pairs of LF-100 lifting frames Launching equipment
2 pairs of LF-230 lifting frames

DEAL MAG 15
VIRGINIA BEACH / USA / AMERICAS

LESNER BRIDGE REPLACEMENT

OVERSLUNG OR UNDERSLUNG:
ONE PIECE OF EQUIPMENT
DOES BOTH

orrosion had made replacement structed in 1957. The vital route along The gantry enabled
C of the Lesner Bridge a necessi-
ty and the twin segmental struc-
tures of the new crossing now span
US60 carries 41,000 vehicles daily and
connects the Northern part of Virginia
Beach to the tourist destination at the
segments to be delivered
from the previously-
Chesapeake Bay in the City of Virginia oceanfront. erected deck, avoiding
Beach, Virginia.
The replacement has been built using a The replacement bridges have a curved the need for large
specially refurbished launching girder box-girder superstructure on slender cranes to be positioned
that can be used in either underslung piers, which are accented with alternat- in the waterway
or overslung configurations. ing sweeping curves intended to imitate
The aggressive marine environment the waves of the Lynnhaven Inlet. or in close proximity to
had caused the corrosion that was Each of the two bridges feature a the adjacent power lines
found in sections of the original John 16.4m-wide deck that accommodates
A. Lesner Bridge, which had been con- two lanes of traffic, with shoulders on

16 DEAL MAG
 THE PALMETTO DOLPHIN INTERCHANGE

Typical span length 45.7m

Max span length 68.6m
Provision of a refurbished
launching girder
Operation in underslung
and overslung configurations

each side and a multi-use path in each

direction. The eastbound and west-
bound structures could, if required,
accommodate three lanes of traffic in
each direction in the future.

Deal entered into an agreement for the

supply of the refurbished launching
girder, including carrying out the nec- PROJECT TEAM
essary modifications to enable con- Client: City of Virginia Beach,
struction of the segmental superstruc- Virginia
ture. Typical span length is 45.7m; Contractor: McLean Contracting Co.
however, the operation of the equip- Designer: FIGG
ment can be tailored so that it can also
erect the 68.6m-long main span. DEAL SUPPLIED
The gantry enabled segments to be Erection equipment
delivered from the previously-erected Launching girder for
deck, avoiding the need for large cranes span-by-span construction
to be positioned in the waterway or in
close proximity to the adjacent power
lines.

The most innovative aspect of the

refurbishment is the use of the sec-
ond-hand 123m-long launching gird-
er, which was originally designed with
an underslung configuration and then
reconfigured in overslung mode for
the current project. As a result, the cli-
ent has the benefit of a sophisticated
piece of equipment that can be used in
either erection mode on future proj-
ects

DEAL MAG 17
VANCOUVER / CANADA / AMERICAS

THE EVERGREEN LINE PROJECT

SAVING MONEY THROUGH
RETROFITTING OF DEALS
EQUIPMENT

Innovative adaptation of existing casting and launching

equipment has resulted in an efficient and flexible solution
for the elevated section of an LRT project in Vancouver

he Evergreen Line is the exten-

T sion in East Vancouver of the

Millennium Line, which was con-
structed in the late 1990s, also using
Deal equipment. The overall exten-
DEALs 3rd LRT project
in Vancouver
An innovative solution
to deliver flexibility aiding
overall project performance
sion involved a length of tunnel, var-
Adaptation and retrofitting
ious at-grade sections and also about
by Deal of existing casting
3.5km of elevated guideway, which was
machines to reduce costs
built using precast segmental-by-span
Installation using a hinged
erection method was not new to British
type self-launching overhead
Columbia, as two other elevated light
span-by-span truss
rail systems had already been built with
An on-time and on-budget
the same technology. For the Evergreen
performance
Line Project, existing casting machines The hinged feature of the equipment
Reduced learning curve
that had been previously supplied by enabled a single launching truss to be
A complete design-build
Deal were adapted and retrofitted to used for the entire section of elevated
solution
work on the new extension. Reusing line, with little disruption to the local
Design choices driven
the equipment eliminated the need for traffic and neighbourhoods.
by equipment availability
major investment, which was a particu- The state-of-the-art equipment de-
lar benefit as the projects elevated sec- ployed on the scheme ensured on-time
tion was in itself not very long. and on-budget performance, and
greatly reduced the learning curves for
Deal carried out the retrofit of the a project of this size, particularly as the PROJECT TEAM
equipment and successfully reused the equipment was not new to the area. Client: Province of British Columbia
same casting machines without any Deal worked closely with the designer Contractor: EGRT Construction
impact on productivity or the quality of to ensure that all aspects of the equip- Designer: International Bridge
the segments. ment were factored into the final design Technologies Inc.
The erection was carried out using a requirements, anticipating any issues
self-launching overhead span-by-span before they arose. This was the perfect DEAL SUPPLIED
truss, which was of a hinged type in example of a design-build approach, Erection equipment
order to accommodate the alignments with equipment availability driving the An articulated launching girder for
tight radius of curvature. This equip- design choices as much as possible, and a segmental elevated guideway
ment had also been used previously on with the designers of both the equip- Prefabrication equipment
another section of elevated rail line in ment and the bridge working hand in 4 sets of short-line moulds
Vancouver and was adapted for the new hand in order to deliver the most effi-
project. cient solution to the contractor

18 DEAL MAG
LRT PROJECT IN VANCOUVER

DEAL MAG 19
CONNECTICUT / USA / AMERICAS

MOSES WHEELER BRIDGE

RECONSTRUCTION
SMART TECHNOLOGY:
USE OF A BESPOKE GANTRY CRANE
ON A CURVED RUNWAY

A special gantry crane

moving along a curved
alignment
Different gradients
and levels for each rail
Smart electronic control
system to enable a speed
special gantry crane, given the jacks are then automatically extended/ of up to 40m/min

A code name G19, has been de-

signed by Deal for the recon-
struction of the Moses Wheeler Bridge
retracted, to keep the top winch plat-
form in a horizontal position.
The wheel groups are arranged with
High productivity
and a safe work
environment while working
linking Stratford and Milford in Con- vertical pins to allow adjustment along in a challenging location
necticut, USA. the curved rail. In addition, the power
output of the motors for the wheels on
The project demonstrates how the outer rail is greater than that of the
an extraordinary mechanical inner motors, to give a higher speed for
solution coupled with smart the outer wheels on curved sections.
electronics can work together The equipment moves along its runway
to produce high-end equipment with a speed of up to 40m/min. As the
for a challenging task runways alignment and curvature vary
so rapidly, it would be impossible for an PROJECT TEAM
The most distinctive feature of the spe- operator to adjust the various parame- Client: Connecticut DOT
cialist equipment is that its runway rails ters manually. A smart control system Project: New Moses Wheeler
have a curved alignment, with different monitors the position of the equipment Bridge
levels and gradients for each rail. through field sensors and automatically Designer: STV Inc. and GM2
The left side of the gantry is arranged adjusts the telescopic legs and the trav- Associates Inc.
with a pendular leg to allow for the el speed as well as checking the load on Contractor: PCL Walsh
variation in rail gauge. This addition- the wheels to prevent derailment or
al requirement for a variable gauge overturning. DEAL SUPPLIED
was born from the necessity to work on The crane operator performs the same Lifting equipment
two different alignments, in order to activities as on a normal crane but is, Design and fabrication of:
demolish the old bridge and build its in fact, managing a piece of sophisti- 3 special gantry cranes of type
wider replacement. cated equipment that gives higher pro- GC 63/16.6
An electronic system controls in real ductivity and a safer work environment,
time the alignment of the top plat- despite operating in extreme locations
form of the gantry to take account of that would be inaccessible for standard
the changes in level and gradient. The gantry cranes

20 DEAL MAG
LA REUNION ISLAND / AFRICA

Provision of a safe and innovative gantry

crane capable of resisting 240km/h winds

ROUTE DU LITTORAL
HIGHWAY

New coastal highway built

over the Indian Ocean
5.4km viaduct on columns
rising out from the sea
Able to withstand 144km/h
hurricane winds and waves
of up to 10m
Longitudinal travelling
speeds pushed to the limit
(20m/min fully loaded;
60m/min unloaded)

he wave erosion process brings Denis, the administrative capital of La at 20m/min fully loaded and 60m/min

T constant danger for the coastal

road around La Reunion Island,
which is located East of Madagascar, in
the Indian Ocean. Landslides and high
Runion, with La Possession.

One of the most complex aspects

of the work is the construction
unloaded. Strong winds and typhoons
are common on the island and so the
design of the parking system has been
challenging too, in order to resist winds
waves force up to 40 closures a year of the 5.4km viaduct on columns with speeds of up to 240km/h
of the existing route at the foot of the rising out of the sea
islands cliffs.
As a result, the French local authori- The structure is being built to withstand
ty decided to relocate the coastal road 144km/h hurricane winds as well as PROJECT TEAM
onto a bridge running parallel to the waves of up to 10m. Project: Nouvelle Route du
islands perimeter, standing on col- The project involves the use of a large Littoral, Reunion Island (France)
umns rising out of the Indian Ocean at fleet of heavy machinery. Deal has Contractor: Chantier NRL Viaduc
a distance of 100m to 200m from the delivered a special gantry crane with a
shoreline. Once completed in 2018, it 65m span capable of handling the 350t DEAL SUPPLIED
will be the most expensive road ever prefabricated segments in the precast Heavy lifting gantry crane with
funded by France in terms of cost per yard. 350t capacity and 65m span
kilometre. The challenges of the project meant
The new 12.3km offshore highway - pushing the equipments longitudinal
Route du Littoral - will have three lanes travelling speeds to the limit: the crane
in each direction and will connect Saint was designed to handle safe movements

DEAL MAG 21
 A newly built, 178km-long
metrosystem / 6 lines / 85 stations
Deal provision of engineering
services, equipment and
post-tensioning to all three
consortia

22 DEAL MAG
RIYADH / SAUDI ARABIA / ASIA

RIYADH
METRO PROJECT
DEAL OFFERS ITS EXPERTISE
AND EQUIPMENT TO ALL THREE
CONSTRUCTION CONSORTIA

iyadhs population currently stands at about 5.7 mil- Civil Works Joint Venture, a joint venture between Bechtel

R lion but is expected to reach up to 8 million in the com-

ing decade. However, only 2% of commuters use pub-
lic transport and this led the Saudi Government to the idea
of developing a 178km-long metro system for Riyadh. The
(USA), Almabani (Saudi Arabia), CCC (Saudi Arabia) and Sie-
mens (Germany);
FAST Consortium, a joint venture between FCC Construc-
cion (Spain), Samsung (South Korea), Alstom (France),
resulting network, with its six planned lines and 85 stations, Strukton (Holland), Freyssinet SA (Saudi Arabia), Typsa
is the largest infrastructure project ever undertaken in the (Spain) and Setec (France).
Kingdom of Saudi Arabia.
The metro comprises a mix of underground, elevated and Deal has been subcontracted by all three consortia to be
at-grade sections. The work has been divided between three involved in the project, providing engineering services,
consortia: equipment and post-tensioning materials. This is an incred-
Arriyadh New Mobility Civil Work Group, a joint ven- ible achievement, as well as an significant challenge that
ture formed by Salini Impregilo Spa (Italy), Larsen & Toubro demonstrates once again that the company is a worldwide
(India) and Nesma & Partners Contracting JV (Saudi Arabia); leader in the bridge construction industry

DEAL MAG 23
RIYADH / SAUDI ARABIA / ASIA

RIYADH METRO PROJECT

BLUE AND GREEN LINES
(LINES 1 AND 2)

Efficient construction
by the span-by-span method

The span-by-span method

is being used to achieve high
erection rates in the construction
of the elevated sections of two
metro lines

ivil Works Joint Venture made up of

C the well-known companies Bech-
tel, Almabani, Consolidated Contrac-
tors Company and Siemens, is respon-
sible for the design and build works of
Lines 1 and 2 of the Riyadh Metro net-
work.

Line 1 (Blue Line) runs in the North-

South direction along Olaya and Batha
Streets, starting from an area slight-
ly North of King Salman Bin Abdul Aziz
Street and ending in the Dar Al Badia
neighbourhood in the South. The met-
ro will be mostly underground, running
in a bored tunnel along Olaya and King
Faisal Streets, though it will be elevat-
ed on a viaduct along Batha Street and
at the Northern and Southern ends.
Line 1 extends over a length of approx-
imately 38km and features 22 stations,
in addition to four interchange stations
providing connections to the other five
lines.

Line 2 (Green Line) runs underground

in a bored tunnel along King Abdulaziz
Street, between King Abdul Aziz His-
torical Centre and the Riyadh Airbase,
before connecting with King Abdul-
lah Road. The line stretches for about
12.9km and features 10 stations, in
addition to two stations connecting
Lines 1 and 2.

All the elevated sections are being con-

structed using the span-by-span seg-
mental method.
The span-by-span method is based

24 DEAL MAG
 PROJECT TEAM and storage in the precast yard
Client: Arriyadh Development Moulds for precast segments
Authority (ADA) Design and fabrication of:
Contractor: Bechtel Almabani 13 short-line moulds for typical
CCC - Siemens JV (BACS) span-by-span segments
Designer: Aecom 6 short-line moulds for span-by-span
pier segments
DEAL SUPPLIED 2 short-line moulds for typical
Launching equipment single-track span-by-span segments
Design and fabrication of: 1 short-line mould for single-track
5 launching girders for span-by-span pier segments
span-by-span erection 2 short-line moulds for typical
2 new lifting frames for balanced balanced cantilever segments
cantilever erection 1 short-line mould for balanced
2 second-hand lifting frames cantilever pier segments
for balanced cantilever erection 1 short-line mould for balanced
Gantry cranes for the precast yard cantilever expansion joint segments
Design and fabrication of: 3 short-line moulds for station
4 gantry cranes for segment handling segments

on a production cycle that starts in the logistics effort, particularly as Deal ment to Riyadh. Once ashore, Deals
precast yard, where the segments are designs all of its products in house and supervisors coordinate with local per-
manufactured, and ends with the erec- then involves a team of suppliers, locat- sonnel and liaise with the BACS team in
tion equipment that physically builds ed mostly in Europe and China, in all order to get the equipment assembled,
the bridge. All the items of equipment of the manufacturing activities. All the tested and ready to work.
required for the entire process - 29 components then have to be partial- The first segment was cast in April
precasting moulds, four gantry cranes, ly assembled and tested before final 2015 and within just 18 months half of
five launching girders and four lifting delivery to the site. the elevated section had been erected
frames have been provided by Deal. More than 200 containers and flat thanks to the drive of the BACS team,
Deal has to design, manufacture and racks open-topped containers - have with constant support from Deals main
deliver all of the equipment in accor- crossed the Mediterranean Sea and the office and Deals supervisors, who are
dance with a strict schedule - a huge Indian Ocean to deliver Deals equip- always present on site

DEAL MAG 25
RIYADH / SAUDI ARABIA / ASIA

RIYADH METRO PROJECT

RED LINE (LINE 3)
Astonishing productivity
in span erection for
the longest metro line

PROJECT TEAM
Client: Arriyadh Development
Authority (ADA)
Contractor: Arriyadh New
Mobility Civil Work Group:
Salini Impregilo Spa
Larsen & Toubro Ltd.
Nesma & Partners Contracting
Co. Ltd. JV
Designer: International Bridge
Technology (IBT)

DEAL SUPPLIED
Launching equipment
Design and fabrication of:
7 launching girders for
span-by-span erection
2 new lifting frames for balanced
cantilever erection
2 second-hand lifting frames
for balanced cantilever erection
3 towers for launching girder
Deal has worked closely with equipment required for the prefab- erection
the contractor for the metros rication and erection of the elevated 2 towers for span erection along
longest line to achieve structures. Eleven simultaneous work curved sections
an extremely high rate of span fronts along Line 3 required the sup- 1 tower for launching girder
erection for the elevated section ply of an impressive quantity of spe- load tests
cialised equipment with a total weight 8 towers for balanced cantilever
of approximately 7,000t, delivered to stabilisation
xecution of the civil works for Saudi Arabia from overseas by means of Moulds for precast segments
E the infrastructure of Line 3 (Red
Line) has been awarded to Arriyadh
360 standard 40 containers.
Thanks to close and continuous coor-
Design and fabrication of:
6 short-line moulds for typical
New Mobility Civil Work Group, a JV dination between the contractors span-by-span segments
between Salini Impregilo, Larsen & construction team and the Deal engi- 3 short-line moulds for
Toubro and Nesma. The Red Line is neering team, the design of the equip- span-by-span pier segments
the longest on the new Riyadh Metro, ment was defined and tailored to suit 4 short-line moulds for typical
running from East to West for a total of the actual construction requirements. balanced cantilever segments
41.2km - of which 26.7km are formed The benefits of this collaboration were 2 long-line moulds for station
by a viaduct with 22 stations and six recently confirmed by the achievement segments
park-and-ride locations. of an astonishing productivity rate of
Arriyadh New Mobility Civil Work just 1.5 days per cycle for span erec-
Group assigned to Deal the design and tion, using launching girders supplied
supply of almost all the construction by Deal

26 DEAL MAG
RIYADH METRO PROJECT
LINES 4,5 AND 6
Rapid construction
of almost 12km of viaducts

The FAST consortium is living targets for some activities. The results designed, produced, delivered and
up to its name, with rapid achieved by Freyssinet SA are due in assembled in just six and a half months.
progress on Lines 4, 5 and 6 part to Deals involvement in the proj- The order was issued at the beginning
of the Riyadh Metro ect both as a supplier of equipment and of March and the first segment was
through the presence of supervisors ready at the end of September.
and Deal employees on site for the pre- Segment production reached the pro-
he consortium, which is led by FCC fabrication and the launching of seg- grammed one-segment-per-day rate
T Construccion, is designing and
constructing the three lines, which
ments.
Key achievements have included:
for the span-by-span work and one
segment every two days for the balanced
involve extensive elevated sections. Commissioning in 2016 of a third cantilever spans of 52m and 72m. Seg-
In total, 11,904m of viaducts are being launching girder for span-by-span ment installation, which is current-
built using precast segments, with pro- erection. This was manufactured, ship- ly ahead of programme, has averaged
duction taking place in a nearby casting ped and assembled on site in only five 2.5 spans per week, using two work-
yard. Most of the viaducts - 10,420m months - the order was issued at the ing shifts per day. A maximum output
- will be constructed by the span-by- beginning of March and the first span of four spans a week has been achieved
span method, with the balanced can- was launched in August. with the two shifts
tilever method used for the remaining In 2016, two sets of additional moulds
1,484m. were commissioned for the construc-
The planned number of segments for tion of segments: one for 96m balanced
the span-by-span sections is 2,914, cantilever erection and the other for
with a further 404 for the balanced can- 120m balanced cantilever erection. Key
tilevers; all should be produced within a geometrical characteristics of the seg-
period of just 18 months. ments that had to be achieved included
The FAST consortium work that has a height of approximately 7.5m. Despite
been subcontracted to Freyssinet Saudi the challenging design, the two types
Arabia achieved all its objectives set for of moulds - one for typical segments
2016, even surpassing expectations and and one for pier head segments were

PROJECT TEAM Design and fabrication of: 1 short-line mould for typical
Client: Arriyadh Development 2 gantry cranes for handling segments
Authority (ADA) and storage of segments in the 1 set of accessories for expansion joint
Contractor: FAST Consortium: precast yard segments
FCC Construccion Samsung Moulds for precast segments Engineering services
Alstom Strukton Freyssinet Design and fabrication of: Production of the erection manual
Saudi Arabia Typsa Setec JV 6 short-line moulds for typical and loading sequence
Subcontractor: Freyssinet Saudi span-by-span segments Construction analysis
Arabia 3 short-line moulds for span-by-span Provision of a geometry control
Designer: Atkins pier segments system and drawings
For balanced cantilever spans Shop drawings for the segmental and
DEAL SUPPLIED of 52m to 72m balanced cantilever superstructure
Launching equipment 1 short-line mould for pier segments Precasting yard and temporary works
Design and fabrication of: 2 short-line moulds for typical design
3 launching girders for span-by-span segments
erection 1 set of accessories for expansion Supply of post-tensioning equipment
1 lowering system for launching of the joint segments and materials
final spans of the viaduct (using span- For balanced cantilever spans
by-span methodology) of 96m to 120m Technical assistance on site
Gantry cranes for the precast yard 1 short-line mould for pier segments precasting yard and erection

DEAL MAG 27
AL HAIR / ARRIAYADH REGION / SAUDI ARABIA / ASIA

WADI HANIFA BRIDGE

A LANDMARK STRUCTURE
COMPLETED
IN RECORD TIME

Successfully completed
in just one year
A 77m span erected
each week Deal involved
in: estimating, engineering,
procurement of special
equipment, supervision of
precasting and erection,
quality control, cost control,
scheduling and general
management

fficient adaptation of available di Arabia. The valley runs for 120km

E equipment has enabled Wadi

Hanifa Bridge to be completed
successfully in just one year, from the
start of activities at the precasting yard
from North to South, cutting through
the countrys capital, Riyadh.
The new crossing of the 40m-deep val-
ley is a 16.33m-wide two-way bridge
to the erection of the last segment. with a length of approximately 512m
Adding to the challenges of the proj- made up of six 77m spans and two use of everything that had been built
ect were the need to incorporate Rama- 25m-long side spans. The deck is a pre- previously - in particular the piles and
dan into the schedule and the need to cast segmental concrete box girder with the foundation plinths of the piles and
work through the summer in one of the internal post-tensioning, erected using abutment - but would also allow for
worlds hottest areas, with tempera- the balanced cantilever method. maximum optimisation of the erection
tures reaching 50C. The location and The project, which was awarded to local process.
related difficulties made the speed of contractor Al Ayuni, had been put on The geometry and positions of the piles
execution particularly remarkable; the stand-by for various reasons, but fail- were preserved, while the superstruc-
erection reached a completion rate of a ure to complete it would have com- ture - originally designed to be cast
77m span each week following the ini- promised the opening to traffic of the in situ on falsework, was completely
tial learning curve. entire highway. re-engineered by Deal. The new solu-
The bridge crosses the Wadi Hanifa It was therefore necessary to devise a tion involved precast segments, mak-
area in the Nejd Region of Central Sau- new design solution that would make ing use of prefabrication and launching

28 DEAL MAG
PROJECT TEAM
Client: Ministry of Transportation,
Kingdom of Saudi Arabia
Contractor: Al Omaier
Trading & Contracting Company
Subcontractor: Al Ayuni
Investment & Contracting
Company
General designer: EURO
CONSULT
Superstructure design: Deal

DEAL SUPPLIED
Erection equipment
1 launching truss for balanced
cantilever construction
1 trailer for segment
transportation
2 finishing platforms
Moulds for segment precasting
3 short-line moulds
for constant-height segments
1 short-line mould
for variable-height segments
1 mould for pier segments
4 segment manipulators
Precasting equipment
1 gantry crane (100t capacity)
for segment handling
5 jigs for segment rebar cages
10 moveable sheds for segment
moulds and rebar jigs
Specialised materials
Supply though subsidiary of:
Post-tensioning hardware
and specialised equipment
Pot bearings, shear keys
and shock transmitter devices
Expansion joints
Engineering services
Redesign of the superstructure
from the original cast-in-situ
to precast segmental
Construction engineering
and shop drawings for the
superstructure
Detailed design of the temporary
equipment that was already available Deal provided the client with extensive
works and precasting yard
and almost ready to use. Fabrication of support throughout the project, includ-
Project management
the precast elements was able to start ing estimating, engineering, procure-
Provision of staff and
just four months after the award of ment of the special equipment and
management to ensure:
the contract, thanks to the work done supervision of the precasting and erec-
Timely execution of the bridge
during the re-engineering stage to tion operations, as well as quality and
The required quality of works
prepare and ship to site all of the spe- cost control together with programme
Remaining within the agreed
cially modified prefabrication equip- and general management.
budget
ment.
At the same time, the launching equip- Deal was involved in the redesign of
ment that was available was customised the viaduct, the supply of all the spe-
for the project and shipped to the site cial equipment and the supply of all
in time for the launching and erection post-tensioning materials and equip-
phase of the segments and girders to ment as well as bearings and expansion
start in March 2015. joints. In addition it provided the engi-
The first carriageway was completed neering for all construction phases and
and opened to traffic in August 2015, most importantly full work super-
while the entire project was delivered vision for the viaduct construction,
in November 2015. through its seconded technicians

DEAL MAG 29
KUWAIT CITY / KUWAIT / ASIA

JAMAL ABDUL NASSER STREET

UPGRADE OF KUWAIT CITYS
MAIN TRANSPORT ARTERY
INTO A MOTORWAY
Use of an alternative method to erect most of the precast
segments for a 7.2km-long elevated highway has enabled Deal
to increase production rates and save materials

PROJECT TEAM
Client: Kuwait Ministry of
Public Works (MPW) Roads
Engineering Department
(Motorways)
Contractor: Rizzani de
Eccher Spa, OHL SA, Boodai
Construction, Trevi Spa Joint
Venture
Designer: Louis Berger

DEAL SUPPLIED
Launching equipment
2 launching girders
for span-by-span construction
a pair of lifting frames for
balanced cantilever construction
he Jamal Abdul Nasser (JAN) the route. The scope of works also

T Project, also known as RA 167,

is one of the main infrastructure
and road development projects taking
place in Kuwait and is part of the Min-
includes diversion and upgrading of a
number of utility networks, including
electrical and communications cabling,
sewerage and stormwater drainage.
Precast segment mould design
and fabrication
6 short-line moulds
for segments of types A and DA
1 short-line mould
istry of Public Works strategic plan to for segment type DB
improve motorways and other roads. The project features: 7 short-line moulds
The project will transform and upgrade a 7.2km-long elevated highway (ap- for segments of types C and DC
the existing street into a motorway that proximately 8,500 precast segments); 1 short-line mould
meets international standards, with a six different types of segments (types for segment type E
structural design life of 100 years and DA, DB, DC, A, C, and E); Other equipment
capacity to accommodate growing traf- six to eight lanes on the elevated high- Design and fabrication of:
fic flows for many years to come. The way; 4 gantry cranes for
upgrade will be achieved by construct- a four-level interchange at Ghazali Road; the precasting yard
ing several complex bridges and ele- three other interchanges. Engineering services
vated highway sections along the full Support for precasting yard
length of Jamal Abdul Nasser Street and The original design solution assumed design and logistics
at intersections. that all 8,500 segments would be erect- Temporary works design
The scheme will guarantee smoother ed using the balanced cantilever meth- Geometry control
and more efficient traffic flow, as well od. Instead, Deal proposed adopting the Erection engineering
as easier access to universities, hospi- span-by-span method for most of the
tals and other key city buildings along project, in order to increase the produc-

30 DEAL MAG
JAMAL ABDUL NASSER STREET

DEAL MAG 31
KUWAIT CITY / KUWAIT / ASIA

32 DEAL MAG
 JAMAL ABDUL NASSER STREET

One of Kuwaits key

infrastructure and road
development projects
Use of precast segmental
erection methods
to construct 395,000sqm
of viaducts
Design life of 100 years
In order to increase
the production rate and
to optimise the quantities
of materials (rebar and
tendons), Deal proposed
an alternative construction
method for part of the
project
Longest span 57m

tion rate and to reduce the quantities of vation enables faster and easier instal- the mobile configuration allows the
rebar and tendons needed. lation while avoiding the need for any lifting frame to raise the segments from
Both systems are used on the project: transverse hanging beams for the seg- any position underneath the portion of
6,800 segments erected using the ments. cantilever already erected, transport
span-by-span method (80% of seg- Another challenge is the great vari- the load along the viaduct and install
ments); ability in the length of the spans on the the segments in place;
1,700 segments erected using the bal- project; the shortest span has a length the static configuration allows the lift-
anced cantilever method (20% of seg- of 32.5m, whereas the longest is 57m. ing frame to raise the segments from
ments). The equipment deployed by Deal has the tip of the cantilevers and place them
A twin set of specially designed launch- the capability to use a dual approach to in their final positions.
ing girders has been provided by Deal construct the longest spans, by erect-
to carry out the span-by-span erection. ing a small section by the balanced can- Deal has also supplied 15 sets of moulds
The equipment is capable of erect- tilever method and then completing to cast all 8,500 segments, as well as the
ing three different types of segments - the erection using the span-by-span four gantry cranes for their handling.
types DA, DB and DC. Each type has approach. In addition, a pair of lifting In addition, Deals technical office has
a different distance between the webs frames has been supplied to support been involved in the:
and so Deal decided to develop a tele- erection of the balanced cantilever por- design of the precasting yard;
scopic system that allows automatic tion of the project. The lifting frames temporary works design;
adjustment to take account of the dis- can be set both in static and mobile geometry control;
tance between the girders. This inno- configurations: erection engineering

DEAL MAG 33
KUALA LUMPUR / MALAYSIA / ASIA

KUALA LUMPUR MRT

SUPPLYING OPTIMISED
CONSTRUCTION TECHNOLOGY
FOR A MAJOR EXPANSION
OF METROPOLITAN RAIL INFRASTRUCTURE

Part of Kuala Lumpurs

massive infrastructure
improvement
The launching gantry has
a lowered configuration
operating mode to allow
work in areas with restricted
clearance such as airports
Use of Deals methods and
guidelines ensured
maximum savings and
efficiency

Improvements being put in place Right from the tender stage, Deal has Deal established a close working rela-
for Kuala Lumpurs MRT system had a successful cooperative arrange- tionship with the client and the bridge
are designed to bring about ment with a local company, Acre designer from the very beginning of the
a dramatic enhancement Works. This has involved deploying an project to ensure well-defined guide-
of the coverage of the citys public in-house solution - including the pro- lines and methods so that savings and
transportation network vision of optimised construction meth- efficiency would be maximised during
odology - that had been developed for a the prefabrication process. The spe-
previous project in Vancouver. cial structures were erected using three
For the KL project, Deal supplied sets of lifting frames that employed tru-
he aim is for transport in the Acre Works with four sets of launch- ly state-of-the-art technology for this

T Greater KL metropolitan area

to achieve the same ranking as
the worlds most modern and devel-
oped cities. As part of this upgrade
ing girders for span-by-span erec-
tion. The equipment had been spe-
cifically designed to suit the project
requirements; in particular, one of the
field. In particular, in addition to the
usual static and mobile configurations,
the lifting frames were designed to col-
lect a bridge segment previously stored
programme, the existing Ampang Line launching girders has a lowered con- on the deck, travel forward fully load-
is being significantly extended in its figuration operating mode that allows ed and then - once anchored at the tip
South-West direction. Contractors work in areas with low clearance, par- of the cantilever - finally erect the seg-
have invested heavily in technology and ticularly in close proximity to airports. ment in its place.
equipment in order to stay at the tech-
nological forefront and capitalise on For the special structures being erect- Deals scope of works also includ-
the many opportunities offered by the ed by the balanced cantilever method, ed provision of geometry control for
new rail infrastructure projects in Kua- Deal is providing three sets of short- prefabrication and the erection of the
la Lumpur. line casting moulds. bridge segments

34 DEAL MAG
 KUALA LUMPUR MRT

PROJECT TEAM
Talking about us
Client: Kerajaan Malaysia
Kementerian Pengangkutan, Venugopal Nambiar, Executive Director Acre Works
Prasarana
Contractor: Bina Puri DEAL, PARTNER
Tim Sekata JV
Subcontractor: Acre Works MORE THAN SUPPLIER
Sdn. Bhd.
Designer: Opu Ace Vector
Konsortium, Hssi Consulting
Engineers, MMSB Consult the end-user, such as ourselves, in our
Sdn. Bhd. pursuit for innovation. Deal was able to
listen and respond accordingly to our
DEAL SUPPLIED specific requirements.
Launching equipment
4 sets of launching girders How important was Deals background
3 sets of mobile lifting frames and know-how for the success of the proj-
Precast segment moulds ect?
3 sets of moulds for balanced We were able to work closely with
cantilever segments Deal on some very complex sections,
Engineering services by jointly developing some innovative
Geometry control Why did you chose Deal as a technical solutions
partner project?
Deal has a strong global reputation What is, in your opinion, Deals best fea-
as a launcher/lifter solution provider. ture that you would recommend to other
Deal has a comprehensive expertise in Clients?
design, fabrication and support of the Deal is an honourable, reliable and
end-user of specialist launching equip- fast-responding partner. They treat us
ment. This rare combination supports more as a partner than just as a client

DEAL MAG 35
KUALA LUMPUR / MALAYSIA / ASIA

ULU JELAI HYDRO-ELECTRIC

POWER STATION
SETTING NEW STANDARDS
DEEP IN THE GROUND

Reaching high elevations

isnt always the biggest challenge
for lifting equipment

n the case of a Malaysian hydro

I project, Deal was requested to

provide a gantry crane to trans-
port personnel, materials and equip-
ment down a vertical shaft, to a depth of
500m. The demanding safety require-
ments and exceptional depth as well as
the constraints of a confined and barely
accessible environment required a new
approach to the design of the crane. The
result has set new standards for equip-
ment operating in this field of con-
struction.

The work was for the Ulu Jelai hydro-

electric power station.
The cranes working platform can
either carry the people involved in the
shaft construction or it can be used as
a hook with a 30t capacity to deliver
drilling equipment down to the bottom.
Site personnel travel in an elevator bas-
ket at the considerable speed of 60m ble emergency brakes; a protection sys-
per minute; this speed was necessary Demanding safety tem is in place to prevent objects from
to optimise the travelling times for the requirements falling while people are boarding the
workers and to guarantee rapid evacua- Exceptional lifting range elevator.
tion in case of emergency. involving a 500m-deep shaft
In the unlikely event of a power break- Confined and barely The gantry crane has two configura-
down, the gantry crane can still bring accessible environment tions: one for 15m-diameter shafts and
people back to the top of the shaft as Speeds of 60m per minute the other to set up equipment in small-
it has also been equipped with a high- complete with personnel er, 9m-diameter shafts. In both con-
performance, self-propelled safety winch. Two configurations figurations, the crane can also be set up
of the gantry crane for use inside restricted-height tunnels
In addition to the safety winch, some thanks to its low profile.
other equally demanding safety require- The complexity of the equipment sup-
ments have guided the design of the plied coupled with the need to trans-
equipment. A double-rope system is port people meant that obtaining a CE
automatically activated in case of rope stamp required the approval and moni-
failure; winches are equipped with dou- toring of a third-party certifier

36 DEAL MAG
 ULU JELAI HYDRO-ELECTRIC POWER STATION

Talking about us
Giuseppe Gelmi,
Technical Director Edilmac
BE ABLE
TO UNDERSTAND
THE CLIENTS
REQUIREMENTS

Why did you choose Deal as a technical

partner in this project?
We were evaluating the option of
refurbishment or the replacement of
our major piece of equipment: a gan-
try crane, used to reach the bottom lev-
els of shafts, with depth up to hundreds
meters.
One of our freelance supervisors, who
is working for Deal too, proposed Deal
as a possible supplier, and it was the
right choice!

How important was Deals background

and know-how for the success of the proj-
ect?
Very important, as from the begin-
ning we have worked as a team: we pro-
posed the methodology, while Deal
provided technical guidance in the
development and upgrade of the equip-
ment, using the most innovative tech-
nological solutions.
PROJECT TEAM DEAL SUPPLIED What is, in your opinion, Deals best
Contractor: Salini Impregilo Spa Shaft gantry crane feature that you would recommend to oth-
Subcontractor: Edilmac er clients?
dei F.lli Maccabelli Srl Surely, the capability to understand
the clients requirements and to design
equipment that satisfies such needs

DEAL MAG 37
HO CHI MINH CITY / VIETNAM / ASIA

MRT SYSTEM
FOR HO CHI MINH CITY
THE FIRST METRO
IN THE VIETNAMESE
MEGALOPOLIS

High levels of quality and productivity

are being achieved on the construction
of the Ho Chi Minh City metro project,
which is using Deal equipment

he aim of the first line of the new

T metro system is to provide alter-

native transportation methods to
relieve heavy traffic congestion in Viet-
nams southern economic capital.
An elevated viaduct approximately
11km long will connect the North-East-
ern part of the city to its centre, starting
from a depot area and passing through
six stations. On the first section, the
alignment runs parallel to an existing
highway, while the second section, at
the entry to the urban area, becomes
curvy and crosses the Saigon River.
The U-shaped cross section of the via-
duct takes as inspiration, in terms of
both aesthetics and noise-reduction
characteristics, the excellent results
achieved by the Dubai Metro Project
in the United Arab Emirates. Of note is
that the same joint venture that execut-
ed the works in Dubai is now prefab-
ricating and erecting the segments for had been previously used on the Dubai
the new project. Metro and have now been adapted to Supply of a full package
Deal has been asked to supply a full suit the specific characteristics of the of specialised equipment
package of specialised equipment: Ho Chi Minh project. 11km-long elevated viaduct
three sets of long-line moulds for the An excellent level of quality and pro- U-shaped cross section
straight spans, three sets of short-line ductivity is being achieved through- inspired by the Dubai Metro
moulds for the curved spans and four out the project thanks to the equipment project
sets of short-line moulds for pier seg- supplied by Deal: every day 11 segments Excellent levels of quality
ments. In addition, Deals scope has are cast in the precasting yard and every and productivity
included modification and refurbish- week six spans with a length of 37m are
ment of three launching girders that erected

38 DEAL MAG
 HO CHI MINH LRT SYSTEM

PROJECT TEAM Rizzani de Eccher JV) Moulds for segment precasting

Client: Ho Chi Minh City Peoples Designer: Systra Design and fabrication of:
Committee Management Authority for 3 long-line moulds
Urban Railways DEAL SUPPLIED for straight spans
Contractor: Sumitomo Cienco6 Launching equipment 3 short-line moulds
Consortium Design and fabrication of modifications for curved spans
Contractor for civil works: GS E&C to three existing launching girders for 4 short-line moulds
Subcontractor: FVR (Freyssinet VSL use in span-by-span construction for pier segments

DEAL MAG 39
DOHA / QATAR / ASIA

DOHA METRO
CONSTRUCTION OF THE WORLDS
MOST TECHNOLOGICALLY
ADVANCED RAIL TRANSIT SYSTEMS

he Doha Metro will service both the piers using a launching girder. Both The extensive preparatory studies

T Qatars capital and the citys sub-

urbs, providing easy and conve-
nient access to all key locations.
The metro system is being built in two
the span-by-span and balanced canti-
lever methods are being used.
The main contractor, the RLR Joint
Venture, brought in Deal right from the
enabled the prefabrication and launch-
ing works to be completed without any
problems and ahead of schedule.

phases: tender stage to work on the analysis of In November 2016, a new record was
the first involves construction of three the structural solution for the elevated set on the Red Line North Project: Deal
of the four lines (Red, Gold and Green) section of Red Line North. Deal drew on used the span-by-span method to con-
and 37 stations. The lines are expected its experience in the design and con- struct a section that included 52m spans
to come into use in late 2019; struction of similar works and intro- with a U-shaped cross-section. The
the second phase will be completed by duced a series of optimisations in the work involved creation of a continuous
2026 and will involve the expansion of structural concept, which also allowed deck unit composed of four spans hav-
the phase one lines and the construc- significant savings. ing lengths of 34m+52m+52m+30m.
tion of the fourth route the Blue Line. This was a first for this kind of structure
In total, another 72 stations will be built Following the award of the project to and Deal had to push to the limits both
in phase two. RLR, Deal has been involved in the the span-by-span methodology and the
About 2,200m of the alignment runs on detailed design and engineering for erection equipment in order to achieve
an elevated double-track viaduct com- the construction of all the decks and the challenging goal. The innovative
posed of precast segments. The seg- has been able to put into practice all the solution has also achieved cost benefits
ments are fabricated in a dedicated pre- optimisations proposed during the ten- compared to the traditional balanced
casting yard and then launched across der stage. cantilever method

PROJECT TEAM DEAL SUPPLIED Gantry crane for segment handling

Project: Doha Metro project - design Launching equipment and storage in the precasting yard
and build Red Line North elevated and Design and fabrication of: Transporter for segment handling
at-grade sections Launching girder for span-by-span behind the launching girder
Client: Qatar Rail erection
Contractor: RLR Joint Venture Rizzani Precast segment moulds Deck design
de Eccher Lotte Redco International Design and fabrication of:
Designers: Typsa & Progin JV. 2 short-line moulds for typical Engineering services
Alignment design, geotechnical design, span-by-span segments and geometry control
station design, cut & cover and trough 1 short-line mould for span-by-span
design, viaduct substructure design; pier segments Post-tensioning equipment
Salfo: design of traffic diversion and 1 short-line mould for typical and materials
utilities relocation and protection; and special segments
Rizzani de Eccher: design of bridges

40 DEAL MAG
Significant savings
are being achieved
on the Doha Metro project,
thanks to optimisation
of the design and
construction methods

DEAL MAG 41
42 DEAL MAG
DEAL MAG 43
DOHA / QATAR / ASIA

DOHAS NEW CONNECTING HIGHWAY

VIADUCT CONSTRUCTION
by the balanced cantilever method

onstruction is under way of a Port to the East-West Corridor in the In total, 2,168 concrete segments will

C new 45km dual carriageway that

includes four grade-separated
interchanges. It is located to the South
of Doha City and will connect Al Wakra
North as well as to Al Wakra Bypass in
the East and to the Orbital Highway.
The interchanges include 6,200m of
viaducts to be built using balanced can-
be installed by means of crawler cranes
equipped with self-propelled remot-
ed-controlled lifting spreader beams
capable of positioning each segment
Mesaieed Highway and the New Doha tilever precast segmental technology. precisely

PROJECT TEAM DEAL SUPPLIED 9 short-line moulds for typical

Client: Public Works Authority, Qatar Equipment segments for balanced cantilever
(Ashghal) Design and fabrication of: spans
Contractor: J&P-AVAX S.A JV 2 straddle carriers 3 short-line moulds for pier segments
Project management consultant: KBR 3 motorised spreader beams for for balanced cantilever spans
Supervision consultant: AECOM launching segments using mobile Deck design
Design consultant: WSP cranes Engineering services and geometry
Subcontractor for design and 6 stressing platforms control design
construction of bridges: Rizzani de Precast segment moulds Post-tensioning equipment and
Eccher Spa, Qatar Branch Design and fabrication of: materials

44 DEAL MAG
HONG KONG / CHINA / ASIA

Hong Kong-Zhuhai-Macao Bridge

THE RETURN OF THE RED DRAGON

The Red Dragon has returned to equipment to the mythological creature

bridge-building after a few years of so popular in Chinese folklore. Construction
inactivity. The distinctive launching Despite a nickname rooted in folklore, of two parallel viaducts
girder is being used to construct the launching girder had to be designed Maximum span length 75m
prefabricated viaducts as part of to overcome daunting real-world chal- Balanced cantilever
a major bridge and tunnel project lenges on its latest project. These construction method
that will connect the cities of Hong included variable dimensions of spans Use of a launching gantry
Kong, Zhuhai and Macao on the and segments, problematic access to that can be used to erect
Pearl River Delta the erection area and a very tight hor- segments of both viaducts
izontal radius of curvature, not to men- by shifting transversally
tion the high performance standards
he longest bridge section of the required of the equipment in terms of

T Hong Kong Zhuhai Macao

Project is 29.6km long and
includes three cable-stayed spans with
lengths of between 280m and 460m.
erection cycles.

The Red Dragon is capable of picking

up prefabricated segments delivered PROJECT TEAM
The equipment is being used for the either from the already erected deck or Client: Hong Kong Highways
construction of prefabricated elevat- from barges. During the self-launching Department
ed viaducts between the Hong Kong operation, the equipment is positioned Contractor:
boundary and Scenic Hill. Work con- symmetrically between the two via- Dragages - China Harbour VSL JV
sists of two parallel viaducts - one for ducts. The main supports are equipped Designer: Mott MacDonald YWL
each carriageway - with a maximum with long rail tracks, which means that Engineering
span length of 75m; construction is by the launching girder can then erect
the balanced cantilever method. alternate segments for each viaduct, by DEAL SUPPLIED
Local people had become fond of the shifting transversally. Launching equipment
Red Dragon, which gained its nickname In terms of cycle times, this represents Second-hand launching girder
when it was deployed on the East Tsing a significant saving for the project as
Yi Viaduct. Its red steel coating and post-tensioning operations can be
the fabled engineering feats it accom- overlapped with the assembly of the
plished led the local press to liken the adjacent bridge, and vice versa

DEAL MAG 45
BASRA / IRAQ / ASIA

Careful planning during design development has brought

benefits in the construction of a new bridge in Iraq

AL SEWYRAH BRIDGE
DEAL HELPS
CROSS THE TIGRIS RIVER

etraco Contracting Offshore car- two 60t-capacity straddle carriers superstructure, in order to select the

S ried out a successful project to

build the bridge over the Tigris
River, close to the city of Basra.
The Al Sewyrah Bridge was commis-
for beam handling and the system
employed to launch the bridge girders.
The client approached Deal with an
offer to develop a complete set of effi-
best construction methods.
The result was optimisation and full
integration between the design of the
permanent structure and the equip-
sioned by the State Corporation of Road cient, flexible and easily relocatable ment needed for its construction. For
& Bridges of the Republic of Iraq. All equipment for constructing the bridge example, the same mould can be used
equipment for bridge construction was deck using precast pre-stressed beams. to cast both T- and I-shaped beam
supplied by Deal, including moulds for Deals scope also included design cross-sections and can accommodate
self-compacting concrete T-beams, review & development for the bridge different beam lengths

46 DEAL MAG
 Talking about us

Charbet Abdallah, Technical Director

Setraco Group
DEAL, A TRUSTWORTHY PARTNER
THAT HELP CLIENTS
WITH FULL COMMITMENT

PROJECT TEAM
Client: State Corporation
of Road & Bridges, Republic of Iraq
Contractor: Setraco Contracting
As we expanded our operations to Iraq
Offshore SAL
in 2012, we continued our coopera-
Designer: Deal
tion with Deal to execute a 420-m-long
bridge over the Tigris river, composed
DEAL SUPPLIED
of 35-m-long pre-stressed girders,
Precast moulds
positioned in place using a launching
Design and fabrication of a mould
girder.
for T- and I-shaped beams
Launching equipment
How important was Deals background
Design and fabrication of:
and know-how for the success of the proj-
2 straddle carriers
ect?
of type SC 60/4.5
1 launching girder
Deals involvement was a key factor in
of type LG 120/40
the success of Al-Sewyrah Bridge con-
Engineering services
struction. Their technical assistance in
optimising the superstructure design,
the construction method, as well as
their staff presence on site with a day-
to-day follow up of any modification
Why did you choose Deal as a technical or adjustment, was a major element of
partner in this project? completing the project on time with a
zero-accident result. Deals know-how
Being one of the leading infrastruc- led to a successful selection and quan-
ture contractors in Nigeria, we always tification of pre-stressing equipment
search for a reliable and trustful part- and materials, making the on-site exe-
ner to successfully deliver our projects. cution in a remote and risky region like
When we were awarded contracts for Iraq smooth and punctual.
the construction of several long-span
bridges in 2001, we began to look for a What is, in your opinion, Deals best fea-
world leader in launching equipment ture that you would recommend to other
for bridges, supplier of pre-stressing clients?
materials, and a strong technical part-
ner which was Deal. Deal is a trustworthy partner who can
The success of this partnership lead to perfectly deliver:
several further cooperations in bridge 1. the best suitable method for a bridge
construction, such as: superstructure construction;
1. 612-m-long bridge composed of 2. the exact equipment needed to per-
36-m-long pre-stressed girders posi- form the job;
tioned in place using a launching gird- 3. cost-effective pre-stressed materi-
er; als;
2. 645-m-long bridge composed of 4. detailed superstructure design and,
31-m-long pre-stressed girders, posi- subsequently, all back-ups that might
tioned in place using a launching gird- be required during the construction
er; phase.
3. 850-m-long bridge composed of On top of that, Deal has very profes-
95-m-long spans, made of pre-cast sional and dedicated commercial and
segments, erected with balanced canti- technical staff that do their best to help
lever method using a launching gantry. clients with full commitment

DEAL MAG 47
HONG KONG / CHINA / ASIA

The Liantang Project

A UNIQUE SOLUTION TO ACHIEVE
FLEXIBILITY IN NARROW
AND CONGESTED AREAS
An alternative and faster route is being created
for the movement of people and goods
between Mainland China and Hong Kong

Unique equipment:
the special mobile lifting
frame
Maximum flexibility
Just one loading position
needed for each cantilever

ontract 3 of the Liantang/Hueng This unique working cycle ensures the

C Yuen Wai Boundary Control

Point Site Formation and Infra-
structure Works (Liantang 3) is located
in the New Territories near the border
maximum flexibility in terms of seg-
ment feeding, with just one loading
position needed for each cantilever.
The special mobile lifting frame is a
PROJECT TEAM
Client: Civil Engineering
& Development Department
Contractor: Chun Who
between Hong Kong and Shenzhen. piece of equipment that had already Construction
The projects contractor is using a been used successfully on the Dallas & Engineering Co. Ltd.
unique piece of equipment a special High-Five Project in Texas and has been Subcontractor: Freyssinet
mobile lifting frame - for the erection modified to suit the characteristics of Construction Asia Ltd.
of prefabricated viaducts crossing over the new project. In particular, the seg- Designer: Meinhardt
the MRT railway. ment spreader beam is now equipped
with retractable arms in order to avoid
The lifting frame is able to pick up any possible interference with the DEAL SUPPLIED
segments along the longitudinal axis already erected and adjacent viaducts. Launching equipment
underneath the bridge, move them to For safety purposes, arm extension/ Redesign and adaptation
the end of the cantilever and load the retraction and geometrical adjustment of an existing special mobile
segments inside the frame above deck of the segment positions are performed lifting frame
level. It can then travel with the load up by means of a hydro-electric system
to the tip of the other side of the can- powered by an on-board electric gen-
tilever, where it finally erects each seg- erator that can be controlled via radio
ment in its final position. remote control

48 DEAL MAG
HANGZHOU / CHINA / ASIA

HANGZHOU BAY BRIDGE PROJECT

Construction of
a record-breaking sea bridge

eals extensive experience se- two rubber-wheeled gantry cranes

D cured it a key role providing the

highly specialised equipment
needed for construction of one of the
worlds longest bridges.
with a capacity of 50t to handle the
rebar cages in the precasting yard;
two rubber-wheeled gantry cranes
with a capacity of 800t to handle the
PROJECT TEAM
Client: China Railway Bridge
Bureau Group Co. Limited
Contractor: China Railway
The 36km-long Hangzhou Bay Bridge prefabricated elements in the precast- Erju Co. Limited
- the worlds longest sea bridge at the ing yard; Designer: Hardesty & Hanover,
time it opened in 2008 - is located near two rail-mounted 800t-capacity gan- LLP
where the Qiantang River enters Hang- try cranes for positioning the prefab-
zhou Bay, an inlet of the East China Sea. ricated elements on top of previously DEAL SUPPLIED
It consists of two parallel structures erected sections of the viaduct; Launching equipment
designed to carry a dual-carriage- a special 1,600t-capacity transport- Launching gantry of 1,600t capacity
way road of six lanes; the main span of er to carry the full span to the erection Other equipment
the cable-stayed bridge is 448m long, area; 2 straddle carriers of 50t capacity
flanked by 50m-long prefabricated a launching gantry for the final erec- 2 straddle carriers of 800t capacity
spans, each weighing 1,500t. tion stage of the 1,500t prefabricated 2 gantry cranes of 800t capacity
spans Transporter of 1,600t capacity
The main challenge for the proj-
ects contractor was finding a com-
pany capable of designing, manufac-
turing and supplying the high-quality Deals equipment was
specialist equipment needed for safe highly successful,
transportation and launching of such
heavy spans. demonstrating the
importance of entrusting
Thanks to its thirty years of experience such complex work
in the field, Deal was able to devel-
op the most suitable solution and was to only the most
appointed to supply: experienced companies

DEAL MAG 49
AUCKLAND / NEW ZEALAND / OCEANIA

A state-of-the-art
launching girder nicknamed
Dennis has been developed
by Deal to meet the
demanding equipment
requirements
of a motorway scheme
in Auckland

50 DEAL MAG
 WATERVIEW CONNECTION PROJECT

THE GREAT NORTH ROAD

INTERCHANGE (GNRI) DENNIS
overcomes tight construction space
and environmental restrictions

PROJECT TEAM
Client: NZ Transport Agency
Contractor: Well Connected Joint
Operation (WCJO)
Subcontractor: Deal

DEAL SUPPLIED
Launching equipment
Launching girder for beam
erection

he Waterview Connection Proj- Right from the tender stage, a truly

T ect is one of the most import-

ant infrastructure developments
ever to take place in New Zealand. It will
complete a motorway ring route around
cooperative spirit has developed natu-
rally between the teams of the contrac-
tor and Deal. This resulted in the choice
of clearly defined and highly suitable
Strict limits
on the equipment weight
Tight curvatures, both
horizontal and vertical
the city of Auckland and will bypass construction methods and design char- Variable span lengths
central Auckland to the West, State acteristics for the equipment.
Highway 1 (SH1) and the Auckland Har- The rather small diameter of the piers
bour Bridge). imposed a strict limit on equipment
The project includes construction of weight, while the particularly tight ver-
a major interchange - the Great North tical radius of the alignment brought
Road Interchange - connecting the new additional challenges. As a result, Deal
SH20 tunnel with the existing SH16 introduced a new type of support that
tunnel over an existing road. The inter- could be easily adjusted hydraulically.
change includes four ramps near the In addition, the need to adapt to the
northern entrance, with a total length combination of very tight horizontal
of approximately 1,700m. and vertical curvatures, variable span
lengths and the limitations on equip-
Deal has supplied a self-launch- ment weight contributed to the creation
ing truss for erecting the beams of the of a state-of-the-art solution for this
ramps. The choice of this type of equip- type of equipment.
ment was dictated by the construction The yellow launching girder nicknamed
sites location within a heritage area Dennis has become a partner for
and close to sensitive coastal marine Alice, the giant tunnel boring machine
environments, which prevented the (TBM) excavating the motorway tun-
use of conventional and invasive lifting nels: a friendly face for a very compli-
methods. cated and challenging project!

DEAL MAG 51
SYDNEY / AUSTRALIA / OCEANIA

M4 WIDENING
MINIMISING TRAFFIC CONGESTION
ON AUSTRALIAS LARGEST
INFRASTRUCTURE PROJECT

The need to keep traffic flowing Deal was awarded a contract covering
while beams are erected on a site both the design of the projects elevat- PROJECT TEAM
with limited access is among ed structures and the supply of special- Client: New South Wales
the challenges that Deal has had ist construction equipment. Government - Roads & Maritime
to address on the project to widen The equipment provided includes two Services
the M4 in Sydney sets of moulds for casting T-shaped Contractor: WestConnex
beams, as well as two gantry cranes Construction JV
and two straddle carriers for handling Designer: Deal
he project is part of WestConnex, the beams and a beam launcher for the

T the largest integrated transport

scheme under way in Austra-
lia. Work includes the renovation and
upgrading of both public transport and
erection stage.

Special attention was needed during the

structural design and equipment design
DEAL SUPPLIED
Precasting yard equipment
2 sets of moulds for T-shaped
critical road infrastructure. The M4 phases to meet the challenges of erect- beams
and M5 motorways are to be extended, ing the structures for the new lanes 2 gantry cranes of 80t capacity
widened and joined together to form while keeping traffic flowing on the 2 straddle carriers of 60t capacity
a continuous, free-flowing motorway existing ones. Adding to the complexity Launching equipment
with connections to the city, airport, were further constraints resulting from Launching gantry type 150/50
port and harbour. limited access and the challenging erec-
tion procedures required.
The M4 Widening project involves An additional aim was to minimise the
upgrading the motorway from three to use of conventional lifting and han-
four lanes in both directions. dling equipment at the erection site

52 DEAL MAG
SYDNEY / AUSTRALIA / OCEANIA

SYDNEY METRO SAVING TIME

WITH DEALS INNOVATIVE
DE-MOULDING TECHNOLOGY
Innovative solutions developed by Deal are helping
cut the production times for segments on Australias
first fully-automated metro rail system

First fully-automated
metro rail system
in Australia

he Sydney Metro is Australias it can then be moved on using a moto-

T largest public transport infra-

structure project and includes the
construction of 15km of twin tunnels
and 6.3km of prefabricated viaducts.
rised rail-based system.
Time is crucial on the project and so
Deals designers have paid particular
attention to developing technical solu-
PROJECT TEAM
Client: Transport for NSW
Contractor: Salini Impregilo Spa
Australia Branch
The project is on track to come into ser- tions that minimise the mould set-up Designer: SMEC
vice in the first half of 2019. time needed to adapt to the characteris-
Its execution is taking place in two stag- tics of the various segment types. There DEAL SUPPLIED
es: firstly the Metro Northwest section are typical, deviator and station seg- Moulds for the precasting
(formerly the North West Rail Link) ments, with lengths from 2.5m to 4m. of segments
and secondly the Metro City & South- In addition, Deal has supplied the cli- Design and fabrication of:
west Section. The system will have eight ent with its state-of-the-art geometry 3 short-line moulds for typical
new stations and there will be 4,000 control system, which has been devel- span-by-span segments
commuter car parking spaces in Syd- oped and upgraded in recent years. The 1 short-line mould for
neys growing Northwest area. system is specifically designed to sim- span-by-span station segments
Deal has been appointed to supply six plify operations in the precasting yard 1 short-line mould for
sets of short-line casting moulds for the and, therefore, minimise the possibil- span-by-span pier segments
prefabrication of the viaduct segments. ity of errors during the casting of seg- 1 short-line mould for span-by-
ments span station pier segments
The main challenge is that the equip-
ment has also to be capable of casting Engineering services
the station segments, which have rein-
forcing ribs under their wings. Deals
engineers have addressed this by devel-
oping an innovative de-moulding sys-
tem that allows the sides of the moulds
to be moved horizontally: this simpli-
fies the release of the segment so that

DEAL MAG 53
JAKARTA / INDONESIA / ASIA

Tajung Priok Road

A NEW 12.1KM ACCESS ROAD
TO INDONESIAS BUSIEST SEAPORT

nfrastructure cannot keep up with It was important to avoid the use of Use of an innovative
I the economic growth in Indonesia,
which has a population of 250 mil-
lion. A new masterplan has been cre-
ated by Japan International Coopera-
large-capacity ground-based cranes for
the handling of the prefabricated ele-
ments and so Deal designed, fabricat-
ed and supplied a special beam-lifter
beam lifter has
proved ideal for the
tion Agency (JICA), in cooperation with capable of erecting the 140t, 40m-long erection of precast
the Government of Indonesia, to help beams.
address shortcomings in the Jakarta
beams in a congested
Metropolitan Area. The system brought several advantages: area of Jakarta
reduced traffic impact;
The Tanjung Priok access road is part reduced capacity needed for the ser-
of this massive programme: the proj- vice crane;
ect involves building a 12.1km, six-lane reduced impact on the permanent
toll road to Tanjung Priok Port in order structure, thanks to the light weight of
to create a connection between the the equipment.
North-Eastern section of Jakarta Outer
Ring Road (JORR) and the Jakarta har- Heavy traffic in the project area meant
bour road. that the beams were delivered in pieces
and assembled underneath the spans.
Deal had worked with client Obayashi The equipment supplied by Deal was
on a previous project in the Gulf area capable of moving outside the line of
and built up a strong spirit of coopera- the pier caps, picking up the beam,
tion. This led to Deal developing innova- lifting it to the pier height, shifting it
tive equipment for beam erection in the transversally and then setting it in its
congested areas of the Jakarta project. final position

PROJECT TEAM
Client: Obayashi - Jaya
Konstruksi Joint Operation
Contractor: Ministry of Public
Works
Subcontractor: Deal

DEAL SUPPLIED
Beam lifter for beam erection

54 DEAL MAG
RENNES / FRANCE / EUROPE

Viaduct construction for Rennes Metro

DEALS FIRST LAUNCHING GIRDER
CAPABLE OF ERECTING
TWO SPANS SIMULTANEOUSLY
Deal is supplying
special equipment
for the construction
of the segmental
superstructure
of one of the largest
public works projects
currently under way
in France

Reduced relocation time

for the launching girder
Faster erection cycle
Reduced loads on the spans
On-site support for the
client from Deals technicians
during all operations

he 13.8 km, 15-station Line B structures have been particularly chal-

T is the second driverless VAL

(Vhicule Automatique Lger)
route to be built in Rennes and is
expected to be used by 110,000 passen-
lenging due to restrictions imposed by
the architect arising from the futuristic
appearance of the viaduct.
PROJECT TEAM
Project: Viaduct de Rennes Lot
4 Rennes (France)
Contractor: Eiffage Genie Civil
gers a day. This has, however, given Deal the Designer: Egis
Deals L105 launching girder (LG) pro- opportunity to design an innovative
vides a great advantage compared to the solution with many advantages, such as DEAL SUPPLIED
usual span-by-span launching equip- a reduced time for relocation of the LG Double-span launching girder
ment designed to erect just one span from one pier to another, faster erec- (two 500t spans, 40m long each)
at a time in simply supported condi- tion cycles and reduced loads on the
tions (isostatic configuration). Instead, permanent works.
the innovative design means that two
40m adjacent spans (also known as Deals technicians are supporting
bi-trave) are temporarily hung from the client on site during all assem-
the main trusses and then simultane- bly and erection operations because
ously lowered into position, with the of the high levels of accuracy required
LG operating on three supports, some- in the equipment positioning and the
times on a tight horizontal radius too. increased attention needed for load
The design of the equipment and the monitoring, geometry control and sur-
method for anchoring to the permanent veying checks

DEAL MAG 55
DEAL APPROACH
TO CONSTANTLY IMPROVE
SPECIAL EQUIPMENT

To face new challanges, we stuck to our

trademark approach to first under-
standing the clients specific require- Hoppers Oil&Gas
ments and then work out the solution solutions
that perfectly serves such requirements.
We supply tailor-made solutions, not
only as a mere equipment supplier, but
as a long-term partner with whom to
develop innovative systems and meth-
ods. Providing design, special equip-
ment and assistance, we define the ide-
al point of convergence between costs,
efficiency and reliability

Underwater
construction

56 DEAL MAG
DEAL / INNOVATIVE TECHNOLOGIES FOR BRIDGE CONSTRUCTION

Deal Srl T+39 0432 607900

via Buttrio, 36 F+39 0432 607902
33050 Cargnacco [email protected]
(Udine) Italy www.deal.it