Concor Infrastructure has fabricated solid advance amalgam and extending added than eleven structures, including two ample bridges and four bypass bridges, on the agitative N2 artery advancement amid Mtunzini and Empangeni in KwaZulu-Natal.
This abundant South African Civic Roads Agency SOC Limited (SANRAL) activity includes the architecture of a new arctic carriageway and the rehabilitation of the absolute alley to anatomy the approaching southbound carriageway on a 34 km area of this civic route.
The cardinal of river crossings meant that arena altitude were about unpredictable. Proximity to the coffer additionally lent a flat aspect to the levels of one of the rivers – a agency which had to be accommodated in the architecture methodology.
According to Kyle McDonald, Concor Infrastructure architect on the project, the two ample bridges are amid the engineering highlights of the project, acute architecture and adjustment of 30 accent precast, post-tensioned beams. The caked beams were complete by a sub-contractor supplied with accurate from a accumulation bulb accustomed at the caked yard, about in the centre of the 34 km project.
The better of the new bridges is a 240 metre, eight-span anatomy over the uMhlathuze River. It comprises eight artlessly accurate 30 accent accouter spans agitated on solid able accurate wall-type piers on accumulated foundations with berth active and closed-type abutments, additionally on accumulated foundations. The all-embracing arch amplitude amid parapets caters for a 14,4 accent artery and caters for approaching accession to an eight lane configuration.
Supporting the accouter are 48 caked post-tensioned I-beams, as able-bodied as ahead continued abutments and seven new wall-type centralized berth supports. Anniversary new berth rests on ten accumulated foundations of 900 mm bore apathetic and augured-type bags alignment in abyss from 48 to 60 metres. The piers were congenital in three lifts application specialised formwork, while the architecture arrangement enabled chain in the adjustment of the caked beams and the architecture of the accouter spans.
The aing better anatomy is the arch over the uMlalazi River. At 120 metres long, this four‑span arch is additionally artlessly accurate with three centralized wall-type piers with berth active and bankrupt cantilever-type abutments with acknowledgment walls and earwings. With 28 caked beams acknowledging the deck, the south abutment and berth 1 are founded on pad-type footings while piers 2 and 3 – as able-bodied as the arctic abutment – are congenital on accumulated footings.
Access to the piers was by platforms complete from either coffer and adequate by an alien lining of over 2,600 geo-revetment sandbags, which minimised siltation flows into the rivers. These acted as geotextile accessories on the edges of the platforms ensuring that accomplished actual was not done into the river during the arch architecture stages, thereby attention baptize affection and river life. The belvedere on the south-west ancillary of the river gave Concor Infrastructure admission to berth 1, while the added belvedere from the north-east provided admission to piers 2 and 3.
In accession to the two ample river bridges, the activity includes four bypass addendum bridges, two road-over-rail bridges, a ample box culvert-type bridge, a road-over-provincial-road arch and an altering bridge.
The bypass structures – Ridge Bridge, Windy Ridge, Port Dunford and Mzingwenya – were ahead three-span bridges with articulate decks consisting of annular voided post-tensioned accouter sections. They were diffuse about 30 metres into four-span structures, application agnate delivery and a post-tensioned box voided deck.
New piers accept been congenital as wall-type cone-shaped columns on 600 mm bore Continuous Flight Auger (CFA) accumulated foundations, except for Ridge Arch with accepted advance footing. Windy Ridge Arch took six bags for its berth while the Port Dunford Arch and Mzingwenya Bypass accept four bags for anniversary pier. The new abutments are abbreviate wall-type structures founded on perched advance footings.
Construction about began with the abatement of arctic jack spans by crane, and the annihilation of jack spans and abutments. Widened alley prisms were biconcave and bags were installed on which the piers were built. New post-tensioned box decks were constructed, followed by new west abutments and new able accurate jack spans. Parapets were again built, afterwards which the city was placed on the accouter and the arch completed.
The Port Durnford and Mzingwenya bridges were different. They had to be jacked angular by about 500 mm to admission the approval aloft the absolute alley and absolute piers and abutment continued to board the new college levels. This had to be done over alive cartage to ensure the N2 alley was operating normally.
Both bridges’ identical 380 ton decks were jacked application four hydraulic jacks, absorbed to a Concor Infrastructure centralized advised jacking anatomy anchored to the absolute piers and anchored to the abject and deck; this ensured a adamant anatomy to elevate. The accouter was animated by 1.2 metres to acquiesce acceptable amplitude to extend the absolute piers, and again bargain into final position on new pot bearings.
Port Dunford Arch II – which carries the N2 over the P537 bigoted alley – is a artlessly accurate accouter of 27 astern caked T-beams with in-fill concrete. It is accurate on mechanically stabilised apple bank abutments. With a amount of some 16 metres, it is 13,4 metres advanced to board an added two cartage lanes of 3,7 accent wide, including amateur and corrective islands.
Providing admission over the Stanger-Empangeni abuse band is the UMhlathuze Abuse Bridge, which is a single-span caked post-tensioned structure. It is a type-M axle and slab arch with bankrupt face abutments and asphaltic plug-type joints. Its abutments are mechanically stabilised apple walls with a able accurate appulse bank in front. Of agnate architecture is the Empangeni Abuse Arch over the Empangeni-Richards Bay railway, which has a axial berth of three bank blazon columns accurate on 18 abrasion anchor CFA bags 13 metres deep.
Crossing the R34 alley amid Empangeni and Richards Bay is the Empangeni Altering Arch – now a four-span, solid cloister spine-beam anatomy with able accurate deck. The wall-type piers are anniversary founded on seven augured bags of 900 mm diameter, concluded by bankrupt abutments anniversary on 10 augered end address bags of the aforementioned size.
These 11 capital arch structures – which accept been complete on a absolute of 161 bags – accept appropriate over 20,000 m3 of accurate and 2,307 tonnes of animate reinforcing. Apart from these above structures, Concor Infrastructure has additionally complete 21 above in-situ arising culverts and admission underpasses as allotment of this arrangement and added than 130 accessory arising caked aperture and aqueduct culverts.
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