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Routine and special inspections revealed a significant corrosion problem with the existing post-tensioning installed in the early 1960’s. This necessitated an emergency closure of the bridge just before Christmas 2011 to allow further investigations. The bridge was re-opened a few weeks later in early January but with reduced load limits and lane closures.

In December 2011 Freyssinet were appointed by Amey to assist with the design phase. Various options were considered to strengthen the bridge, with a target to complete the work in order to open the bridge to full traffic prior to the 2012 London Olympic Games. The solution adopted was to install additional post-tensioning (PT) tendons above and below the top slab within a new widened central reserve. The post tensioning  was required to be durable, replaceable and adjustable (re-stressable) – all of which are satisfied by the Freyssinet C-Range ‘System 2’ pre-stressing system.

Freyssinet were awarded the contract to supply and install the additional post-tensioning, valuing approximately £4 million. They commenced work on site in late January 2012, with the removal of around 200m of the existing concrete central reservation using hydrodemolition and wall sawing techniques. Works progressed well on site using a double shift pattern helped by unseasonably fine weather in February and March.

Once the reservation had been removed, a survey of the existing reinforcement in the deck was completed. An additional top slab was cast in the central reserve. Freyssinet carried out coring for the installation and stressing of vertical post tensioning ‘Freyssibars’, and cast new post tensioning concrete blisters above and below the top slab.

Freyssinet’s skilled post tensioning operatives then installed and stressed horizontal 19C15 tendons, un-bonded in pre-grouted HDPE (High Density Polyethylene) ducts. After stressing operations were complete, the Freyssibar ends were finished and capped and treated with corrosion protection.

Freyssinet had operatives working around the clock and contributed to over 30,000 hours being worked on site without a reportable incident. A dedicated health & safety advisor help to ensure that any safety issues were dealt with quickly and that there was good safety co-ordination with the Principal Contractor.

At the height of the work Freyssinet employed up to 80 operatives, supervisors and managers. Using specially developed formwork and post tensioning support systems they were able to remain ahead of the target programme and finish well ahead of a challenging programme in a race to reopen the flyover in time for the London Olympics. Freyssinet works were completed in early May 2012. The works completed to date bring Hammersmith Flyover back to full load capacity, and it was re-opened on May 28th 2012.

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CCSL were appointed by Jackson Civil Engineering to investigate all ICCP systems at Bunns Lane Bridge, Scratchwood Railway Bridge, Berrygrove Interchange and Deansbrook Viaduct, assessing their current condition and the operability of the systems.

Having completed these assessments, CCSL then undertook repairs to the systems, including repairs to the transformer rectifiers, the internal workings of the TRs, the power supplies and the ability of these devices to communicate with their respective remote control monitors.

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The Forth Road Bridge is located in Scotland, connecting Fife and the north east of Scotland with capital city Edinburgh and the south. When the bridge was opened in 1964, it was the fourth longest in the world, and the longest outside the United States, with a main span of 1006 meters between the two towers. In total, the structure is over 2.5km long.

Maintenance to the Forth Road Bridge is ongoing and a large capital programme to strengthen the bridge is also continuing. In 2009 the Forth Estuary Transport Authority (FETA) embarked on a competitive tender process for the Viaduct Bridge Bearing Replacement project, estimated to total £15 million.

The contract is the biggest single contract awarded since the bridge opened. It has involved the replacement of all the mechanical bridge bearings on the Forth Road Bridge’s north and south approach viaducts, which sit at either end of the bridge on each shore, connecting the A90 and M90 with the main body of the suspension bridge. The steel bearings support the bridge deck and enable it to move as required by changes in temperature. The contract also required an extensive overview of the concrete pier condition in conjunction with concrete repair works and the installation of an impressed current CP system.

Freyssinet was chosen to design, supply and install the bridge bearings, and complete associated concrete repair and cathodic protection works on the structure, having demonstrated a successful track record with this type of work.

40No. permanent mechanical bearings were specially designed to BS 5400, and manufactured in Freyssinet Ltd’s factory in Telford in quality controlled conditions that exceed the requirements of BS EN ISO 9001.

Freyssinet also designed and supplied 35No. temporary support bearings and over 100No. hydraulic jacks to meet the requirements of the temporary support and restraint works. In addition Freyssibar, Freyssinet’s own high-tensile pre-stressing bars, was supplied and stressed to assemble and fix the longitudinal restraint frames onto the structure.

Freyssinet were responsible for all the hydraulic jacking and monitoring of the bridge deck to allow removal of the existing bridge bearings. The bridge bearing replacement work by Freyssinet considered also the careful coordination of hydrodemolition works, steel cutting and drilling, and heavy lifting and positioning techniques to all allow the careful and safe positioning of each bearing into an extremely restricted access gap.

The impressed current CP system utilised three anode systems; titanium mesh, titanium ribbon and discreet mixed metal oxide anodes. In addition, galvanic anodes were installed into repairs outside the impressed current zones.

Over 14,000m of titanium ribbon anode strip was installed into the concrete faces of the pier head cross beams and legs to form part of the CP system. Freyssinet introduced an innovative technique that utilised a special chase cut into the concrete using a remote operated wall saw. This cut up to 60m per day without exposing operatives to excessive hand arm vibration or concrete dust.

Corrosion Control Services (CCSL), a sister company of Freyssinet, were involved in the procurement of specialist materials and supplied the necessary specialist site supervision / technical commissioning as required by the contract

The Forth Road Bridge is a category ‘A’ listed structure and consent had to be granted for the works to be carried out. Selection of all repair materials and methods of placement were carefully considered in technical trials prior to the start of the works in order to meet the requirements of the consent.

Freyssinet’s Northern Area Manager, Paul Wood, says “Works have progressed well, and are projected to successfully complete in August 2012, on time and within budget.”

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Compact, parallel strand stay cables to minimise the effects of the wind
For the Freyssinet team responsible for installing the stay cables and dampers, everything started in July 2011 with the positioning of the first pair of stay cables at a height of 186 metres. From that date on, the operations proceeded with the installation of the 8 planes of 21 stay cables as the bridge was built, with a total of 3,700 tonnes of strands! Due to the exceptional length of the stay cables (the longest being 582 metres, another record), Freyssinet developed individually-protected parallel strand stay cables to minimise the effects of the wind on the structure. These “compact” stay cables feature a greater number of strands, which allows the outer sheath to be saturated (approximately 20% more strands in relation to a sheath of the same diameter). The outsides of the sheaths are also fitted with helical ribs to prevent vibrations resulting from the combined effect of wind and rain. Individually anchored by wedges on upper and lower blocks arranged in the towers and in the deck, the strands and all the stay cable bridge components have a service life of 100 years.

Dampers adapted to the size of the bridge
Since 25 March and the positioning of the last stay cables, Freyssinet has been focusing on installing the dampers. These dampers, developed and patented by Freyssinet, are external for the longest stay cables and internal for the shortest ones. Furthermore, the longest stay cables installed on the central span are equipped with magnetorheological dampers, the viscosity of which is adjusted electrically in line with the vibration frequency (Maurer technology). The finishing work, which also benefits from Freyssinet innovations, is next in line.

Golden Horn, Vladivostok’s second bridge
Just 5 kilometres from the Russky Island Bridge, Freyssinet has also designed, supplied and installed 192 stay cables for the Golden Horn Bridge. Located in the heart of Vladivostok, this cable stay bridge connects the northern and southern parts of the city. With a span of 737 metres (and a total length of 1,389 metres), it will be the 10th largest cable-stayed structure in the world when it opens.

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Freyssinet Limited has recently been awarded three further contracts within the Highways Agency Area 9 &10, Construction Management Framework.

The works, which commenced on site in March 2012, include:
• A40 Bridstow Bridge – Concrete bridge repair, cathodic protection, bearing refurbishment and joints
• M50 Queenhill Viaduct Phase 3 – Concrete repair, cathodic protection and drainage works
• M50 Pendock Sledge and Queens Arms – Concrete repair, cathodic protection and joints

The CMF is a collaborative approach to maintaining £75billion worth of assets for HA in these areas over the next 4 years. It consists of a number of different contractors from different specialist areas who work together to deliver network improvement and maintenance schemes on the all purpose trunk road and motorways in Highways Agency Area 9 and 10, which covers much of the West Midlands and North West.

Freyssinet Ltd, and their sister company Corrosion Control Services Ltd (CCSL), both form part of the CMF, having been selected for their skills and experience in concrete structure repairs and concrete corrosion prevention techniques.

To date Freyssinet Ltd and CCSL have completed six other contracts under the CMF agreement:
• AC5/AC7 Gravelly Hill – Concrete repair, bridge bearing replacement works and cathodic protection
• Oldbury Viaduct – Cathodic protection
• M6 Rayhall Viaduct – Concrete repair and cathodic protection
• M50 Kempley Road Bridge – Concrete bridge repair
• M5 Northway Decks – Concrete repair and deck strengthening
• Bromford Viaduct – Concrete repair and cathodic protection

The CMF contract is different to the traditional sub contract relationship. It is based on partnering, encouraging open working relationships and providing opportunity to develop and share innovative practices.

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The services offered include identification of the bridge bearings, condition assessments, and advising on the practicalities of refurbishment, and/or bearing replacement. As part of the service, a comprehensive report is available, which would be photographically illustrated, and available in an electronic format as necessary. This allows the client to integrate our report into their own tender documentation and reports as required.

Freyssinet are the leading bearing manufacturer and experts in the fields of bridge bearing replacement, you can be assured that your new bridge bearings and bridge bearing replacement works will be of the highest quality. Freyssinet offer the full range of bearing manufacture and bearing replacements, both elastomeric and mechanical, from their UK factory. The designs are to BS 5400, and the quality control of bearing manufacture and bearing replacement exceeds the requirements of BS EN ISO 9001.

The team of leading designers at Freyssinet are able include suitable modifications into original designs of bearing manufacture, so that later bearing replacement operations can be made easier.

The replacement of bridge bearings and other operations, such as bridge expansion joint replacement, require extremely specialised jacking and propping solutions to facilitate the work. Freyssinet can offer a wide range of appropriate techniques, no matter how demanding or challenging the situation is. Freyssinet are able to supply vertical jacks to prop up structures, and also horizontal jacks, to facilitate movement of structures.

1000 tonne capacity, hydraulic jacks are available from Freyssinet with locking collars and swivel heads. To complement these, Freyssinet can use their manufacturing expertise to add to the jack heads, elastomer and PTFE sliding surfaces. These surfaces give the jack heads the ability to accommodate a limited amount of horizontal, and vertical, structural movement.

For both permanent and temporary situations, Freyssinet also supply flat jacks up to a 1000 tonne capacity, which are able to be used in gaps of 50mm or even less. For temporary solutions, where removal of the jack will be required, the inflation would be with hydraulic oil. If the bearing is to be used in a permanent situation, such as structural lifting or bearing pre-loading, a cementitious grout may be used. Alternatively, at a later date, the grout can be transfused under load if the situation requires.

Control over the entire jacking operation, can be monitored either manually or electronically, offering extremely high levels of control. The jacks can be grouped together into complex circuits, where they can be operated either in groups, or individually as required.

If the client has specified a more conventional propping system for a temporary situation, Freyssinet’s in-house designers are well placed to accommodate this, offering big advantages in terms of cost, speed and access. Propping also eliminates the need for excavation and temporary foundations.

Whether you require experts for bearing testing, or a bearing manufacturer for a bridge bearing replacement project, Freyssinet’s are the ones you should turn to.

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