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  1. #1
    Join Date
    Apr 2009
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    Kingswood
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    Default New Rail Bridge at Penrith

    The new rail bridge for the Main West railway over Castlereagh Rd in Penrith will be a concrete through-arch, replacing the existing steel through-beams.

    The new bridge has been erected at right angles to the track alignment and about 75 m from its desired location.
    It is currently located on the western side of Castlereagh Rd, directly opposite Jane St.
    Note the high end abutments.

    This means either elaborate on-ground roll/slideways and jacks, or some big cranes (perhaps on crawlers).

    What are the metal-encased piles piles for ?
    There are two semi-complete on the east, and vestiges of similar on the west.

    Can any of the members reference a similar large formed-up concrete structure being moved over this distance ?
    Pre-stressed concrete beam by crane is common, but formed-up structures ?

    Work affecting road traffic is scheduled for 1Nov19 to 24Dec19, then a full closure to replace the bridge 25Dec19 to 31Dec19.

    I will be away and miss the bridge move stage.
    Hope someone is there to get some photos.

    Attached are photos as of 31Oct19.

    John.Pile NE Compr.JPGFlier Compr.JPGBridge Abutment Compr.JPGBridge Abutment Base Compr.JPGCompleted Bridge Compr.JPGExisting Bridge Compr.JPG

  2. #2
    Join Date
    Nov 2007
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    Near Rockhampton
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    270

    Default

    I guess if you've got enough hydraulic power and wheels to spread the load you can move a big structure.

    https://www.youtube.com/watch?v=md24z_gI6aI

  3. #3
    Join Date
    Jun 2007
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    Ipswich QLD
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    Default

    Thanks for photos daughter lives at Londonderry avoiding going through thwt way atm. It still amazes me it doesnt look high enough for todays legal height of heavy vehicles 14+ft? It appears much wider now tho thats a bonus.

  4. #4
    Join Date
    Nov 2019
    Location
    NYC
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    1

    Default

    How wide do you think it is? I can't really tell from pictures.

  5. #5
    Join Date
    Jul 2011
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    Adelaide
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    837

    Default

    Quote Originally Posted by electrosteam View Post
    T

    Can any of the members reference a similar large formed-up concrete structure being moved over this distance ?
    Pre-stressed concrete beam by crane is common, but formed-up structures ?
    The Darlington bridge move in South Australia. 3000T and way further than 75M

    https://www.youtube.com/watch?v=6Gv_jsdwbE8

  6. #6
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    Feb 2013
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    Laidley, SE Qld
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    1,038

    Default

    Maybe 20 years ago an ancient steel rail bridge on the Beenleigh/Gold Coast line over 4 lane Annerley Rd at South Brisbane was replaced using a similar method. An arched concrete bridge was built parallel to the old bridge and 3 or 4 metres away from it. The old bridge was removed, the new bridge was slid into place, rails were laid, overhead electrics were reinstalled. I was living nearby at the time, it was a fascinating project to watch.

  7. #7
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    Apr 2009
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    Default

    Thanks for the links to the various bridge moves.

    But note, all the linked moves were with bridges with innate flexibility.
    One was individual concrete beams spaced with timber elements, another a long steel box section etc.
    I still have not seen a "formed-up concrete structure" moved.

    The Penrith bridge is an all-concrete monolith.
    It has joints that were boxed and filled with concrete.
    Cast concrete joints are always a risk when moved.

    I visited the site today, 19Dec19.
    Attached are photos depicting progress to date, and revealing the method of move/install.

    My interpretation so far:
    - spacer beams between abutments to stiffen the whole structure,
    - beams full length of bridge on each side,
    - beams attached with tension members to the out-rigger legs of the abutments,
    - rubber-tyred carriers support the beams (and bridge) for its journey,
    - journey includes a decline,
    - metal-encased piles support boxed foundations for the bridge abutments.

    Not resolved are the hydraulic jacks and just how the 90 degrees rotation will be achieved.
    One option would be to pull the bridge into the middle of the road intersection (after demolishing all the lights and median strips), then rotate 90 degrees, then down the decline to the railway.

    Also, the foundations going in on the east side are in line with the existing concrete piers.
    This will require rapid removal of the existing bridge piers when the steel bridge is removed.

    Looking at the activity today, the teams are going to be very busy to get this done to schedule.
    John.
    Attached Images Attached Images

  8. #8
    Join Date
    Sep 2009
    Location
    Sydney
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    Default

    It’s been fascinating to watch. Initially I thought they were building a bridge to take cars over the line but then a cabby gave me the more logical explanation

    I’m fascinated to see how they dolly the bridge down the slope as it’s not exactly flat ground from there down to the site even though the trip is short.

    I’ve seen those building moving shows so know it can be done but it would require a level of precision given the slope and ease of cracking the structure they’ve built.

  9. #9
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    Sep 2009
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    Sydney
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    666

    Default

    Quote Originally Posted by Battersby View Post
    How wide do you think it is? I can't really tell from pictures.
    Easy 6 lanes of traffic by 2 trail lines wide. Would be guessing if I tried to put that in metres.

  10. #10
    Join Date
    Apr 2009
    Location
    Kingswood
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    Default

    There is similar precedent, the Boundary Road bridge in Roseville:
    https://www.youtube.com/watch?v=Fh3xGW-Xjo4
    This 1200 T bridge was erected adjacent and slid into place.

    Following are photos at Penrith, 1000 h on 23Dec19.
    Got clarification of several aspects by a Railway engineer.

    The bridge is 2-track.
    Future duplication is assumed to be a similar bridge adjacent to the south.
    The bridge is supported by wire ropes off the beams.
    The bridge has a mass of more than 2200 T, with the total lift being closer to 2700 T.
    The abutment ties are cables, not beams, to ensure the abutments don't swing out from the as-cast position.
    Carriers are arranged in strings of 3, with the middle one lifted off the roadway.
    There are 6 strings, 3 at each end of the beams.
    The carriers are Ok on matting laid on loose ground.

    While I was there, they did a lift of 40 mm.
    This was apparently the third lift as they calibrate all the transducers and check equipment loadings.

    The end marked "A" (currently the N end) will be placed at the east end of the destination.
    Moves:
    - into the interesection with clockwise rotation, 25Dec day,
    - down the slope a bit, 25Dec night,
    - final location, 26Dec.

    All the heavy earth moving equipment will make the new roadway during the move.

    There have only been a few comparable moves world-wide.
    This one will be the first of an as-cast structure of this mass on rubber tyres in Australia.

    John
    Attached Images Attached Images

  11. #11
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    Apr 2009
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    Kingswood
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    Default

    Apologies, got the dates wrong !

    The road closure is from 10:00 pm tonight, 25Dec19.
    So the first move is scheduled for tomorrow morning, 26Dec19.

    Went past this morning on an ice acquisition trip.
    Perhaps 10 guys on site, most in groups talking with a couple on scaffolding near the cable lifts.

    The local flier shows the road closure as only affecting Castlereagh Road, not Jane Street.
    I would think that the cramped location means that any rotation will encroach into the intersection, forcing a closure.
    Perhaps that is why there will be a short traverse to the start of the grade, to clear the intersection as soon as possible.

    The bush fires have cancelled our expected celebrations at Bilpin today, and my movements tomorrow will be planned to try and get an appreciation of the operation, hopefully with some photos.

    Let's hope the Railways do another video like the Boundary Street example.

    Enjoy the season,
    John.

  12. #12
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    Apr 2009
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    Kingswood
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    Missed the first moves, they occurred from midnight 25Dec.
    I was safe in bed sleeping off a good dinner.

    Apparently the rotation did affect some of the intersection, but not that much.
    The reason for the short move and parking on the grade becomes obvious, it ensure access for equipment without fouling the intersection.

    The bridge is suspended level with the carriers parked and silent on the grade, good brakes.

    They are not going to use oxygen lances or shears on the old bridge because they don't want it dropping on to the roadway, partly I am sure to avoid possible damage to the new piers on the east side.

    The plan is to take out the old piers and lower the bridge to rails on the road and then drag it out of the way.
    They may be cutting it in two for the drag.

    The final positioning is scheduled for tomorrow sometime, 27Dec.

    It will be interesting to see what height clearance they achieve, the old bridge is very low (4.4 m I think).
    Helping somewhat may be the new bridge could be thinner under the rails.



    John.
    Attached Images Attached Images

  13. #13
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    Apr 2009
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    Kingswood
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    Default

    Got back to the site at 1500 h today, 29Dec19.
    The photo shows the bridge in place and work progressing.
    It really is impressive.

    The bridge mass is closer to 2500 T.
    The final move was at about 1800 h on 27Dec19.
    The bridge is within 4 mm of the target position, the allowed tolerance was 15 mm, so all the engineers are very pleased.
    The road will be re-opened with 4 lanes, it will take a few months to progress to 6 lanes.
    The rail level was not changed, but the thinner bridge deck design introduces an additional 1500 mm of roadway clearance (from 4.4 m).

    John
    Attached Images Attached Images

  14. #14
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    Apr 2009
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    Kingswood
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    Returned to Penrith on 3Jan20.

    The bridge is operating with trains and cars, albeit with only 4 road lanes and height bars at 4.4 m.
    It does look as good as the photos.
    This project will become the benchmark for the future in Australia.

    I have been assured that there is a website that showed the progressive work, but I have not been able to find it.
    Any member having that link is invited to post it here.

    Unless something dramatic happens, this will be my last post on this thread.

    Note the interesting fabricated steel embankment retaining walls, and the remnants of the lift cables.
    John
    Attached Images Attached Images

  15. #15
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    Oct 2010
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    NSW
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    Default

    Quote Originally Posted by electrosteam View Post

    I have been assured that there is a website that showed the progressive work, but I have not been able to find it.
    Any member having that link is invited to post it here
    Very interesting project. Thanks John.
    Photos are here

    Photo Gallery Discovery

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