Bridges Coped with the Load

photo of gray building and bridge

Construction of the acrylic acid and acrylates complex (Gazprom Neftekhim Salavat) is still in progress. The earthworks on the future plant site are almost finished, foundations for buildings and facilities have been poured. Two outsized reactors required for butyl acrylate production were delivered to the construction site in September 2014. More than 85 percent of machinery has been already supplied.

Among the first items delivered to the construction site were the absorption column, 54 meters high (weight – 91 tons, width – 6.5 meters), vessels and heavy reactors Р-101 (270 tons) and Р-102 (200 tons). The large-tonnage load from Antwerp and Deggendorf was shipped to Nizhnekamsk on the river-sea vessel. Then the tug/barge towing arrangement took it along Kama and Belaya Rivers to Ufa. The equipment was reloaded on the haul rig to be carried to Salavat. Overall extension of covered federal, regional and local roads came up to 163.8 kilometers. The driving speed from Ufa to Salavat was as high as 12 kilometers per hour. For safety purposes the power lines along the way were lifted or deenergized, if lifting was not possible.

Transportation of the out-of-gauge equipment for GNS complex construction was awarded to Transterminal, Ufa. Keen-Mark performed the haulage using the following special-purpose vehicles: 2 eight-by-four MАN TGХ 41.604 ballast rigs and articulated Goldhofer modular trailers. The Contractor completed the transportation in several phases. At first, they delivered the absorption column and then the reactors. Three other oversize items from Antwerp were taken along the same route in August.

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It is worth mentioning that seamless delivery of the breakbulk equipment to the destination point was preceded by significant preparatory works: the roads under communication lines (overpasses) were deepened, clearance under process facilities maximized and the road surface repaired. Prior to arrival of the bulky units, the access bridges on the construction site were elevated, new gatehouse Severnaya-2 was built and a special-surface road laid out.

Reinforcing the bridge and flyover framework was one of the conditions for successful delivery of the cargo to Gazprom Neftekhim Salavat construction site. Five bridges in the Republic of Bashkortostan were reinforced by means of carbon fibers. To increase the bearing capacity of highway bridge structures the specialists applied external reinforcement system based on carbon tapes. They consist of carbon fibers with unique properties – high strength capacity and ultimate resistance to any corrosive environment. This exceptional technology allows adding up to carrying capacity of structures in the event of increased design loads and repairing structural damage in service within the shortest possible time.

Necessity and efficiency of the external reinforcement system for increasing carrying capacity of the span girders were proved and substantiated in design documentation and estimate calculations developed by PIK (Omsk).

Reinforcement of the five structures was completed in no time at all due to unique performance of materials: easy fabric proofing, good adhesion to concrete surfaces and rapid hardening of products. Bridge reinforcement called for 1.5 kilometers of carbon tape.

In the course of transportation PIK monitored technical condition of the span structures reinforced with carbon fibers by means of measuring center girder deflections. They used electronic tape measures mounted on fixed tripods and dial gauges with 0.01 millimeter of scale division. It turned out that the measured deflections did not exceed predicted values. Upon the haulage, the bridge structures were inspected and no changes or new deformations were found.

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Installation started upon delivery. For this purpose the experts set up two Liebherr cranes with the lifting capacity of 750 tons and 350 tons and also invited the manufacturer’s representatives. Installation was carried out by SOPiG.