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ViaPlus™

Bridges, tunnels, noise barriers

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Fast installation on the site, multiple surface finishing options

Building solutions from concrete elements for bridges, tunnels and overpasses. Design from an as-built drawing to installation.

The use of reinforced concrete elements in infrastructure facilities offers several advantages:
– tehasetöö täpsus ja kvaliteet;
– tehaselise betoonpinna kvaliteet;
– mitmed erinevad viimistlusvõimalused;
– elementidele saab anda valuga vajalikud kalded;
– elementidesse saab tehases valada kommunikatsioonitarvikuid;
– tööde teostamise sõltuvus ilmast viidud minimumini;
– tööde kiirus platsil;
– minimaalne raketistööde vajadus platsil;
– paralleelselt paigaldusega säilib võimalus liikluse läbilaskmiseks.

We offer:
– rajatiste konstruktiivset projekteerimist;
– monteeritavate elementide tootmist;
– monteeritavate elementide tarnet;
– elementide paigaldust.

ZIP beam bridges

E-Betoonelement has been offering and producing solutions for precast concrete bridges since 2000. The first bridge based on ZIP beams, the 33-metre-long Kärkna Bridge, was built the same year on the Tartu-Jägeva highway 6,6km over River Amme. It was followed by the bridges of the Estonian Power Plant, Sirgala, Korbatu and Puurmanni. In 2008 the 160-metre-long Vaida viaduct and the 90-metre-long Aruvalla viaduct were built – these are the longest ZIP beam flyovers in Estonia so far.

The ZIP beam superstructure consists of prestressed ZIP beams which have an inverted T-shape cross-section and are assembled side by side. Beams are connected by a cast-in-situ deck slab and reinforced concrete cross-girders at supports.

   

ZIP-beams can also be placed at a longer centre-to-centre distance when there is no need to consider the impact load from below (for example when the clearance exceeds the minimum permitted height or when the bridge crosses a non-navigable river). In this case the deck is created as a composite structure using approximately 70-80mm thick precast concrete slabs as formwork. These precast deck slabs are used to cover the gaps between beams, creating a formwork which supports the load of the cast-in-situ topping and after the monolithic part has hardened they act together carrying traffic loads.

 

Maximum bridge plates for bridges and viaducts resolved by ZIP beams.

– käesolevat graafikut saab kasutada ainult esialgseks sildeehitise ristlõike kõrguse määramiseks.
– kasutatud koormusmudelid vastavad Eesti projekteerimisnormidele EPN-ENV 1.3.
– sildeehitise kõrgus sisaldab sillatala ja monoliitset betoonplaati.

Segment-tunnel 

 

The tunnel-cross-sectional elements or segments form the supporting structure of the segment tunnel. On the working site, the segments are assembled one after the other and, if necessary, tensioned the tunnel body in a longitudinal direction. On the outside of the segments there are concrete console panels to support the board drive, and it is possible to put into the factory the cable and other accessories at the factory. The inner surfaces of the tunnel are poured into shape and allow the use of different surface finishing techniques.

places of use
– kergliiklustunnelid;
– karja- ja ulukitunnelid;
– truubid.

  

Segments dimensions

Possible tiled internal dimensions are (height x width)
2,50×3,50 m
The length of a single segment is 950 mm.
Maksimaalsete sisemõõtudega 2,5×3,5 m segmendi mass on 10,5.

Slab tunnel

Slab tunnel solution consists of L-shaped supporting walls, cast-in-situ floor and prestressed ceiling slabs. Prestressed slabs with a rectangular cross-section and smooth surface can span up to 10 m. This solution is also suited for constructing multi-span structures.

    

Beam tunnel

The idea of a beam tunnel is similar to that of a slab tunnel only the load-bearing ceiling elements are in this case prestressed beams (see ZIP beams) which are assembled side by side. There are openings in the beam webs for installing transverse reinforcement. The space between beams is reinforced and filled with concrete. This makes it a full cross-sectional deck structure. This solution is suitable for spans of 10-16 m. Walls can be either L-shaped supporting wall elements or straight wall panels combined with an in-situ floor.

 

Valmistame müratõrjeseinaelemente ja terviklahendusi. Palun kontakteeru müügiinseneriga.

The ViaPlus box beams is a closed cross-sectional bridge beam, which is casted in the factory either in one or two stages depending on the geometry of the beam. To this day, we have found the use of this type of tailgate for trapezoid cutting, to provide a smoother deck for the edges. The first object where we have manufactured such beams is Viaducts No 1 and 2 in Maardu, mid-level crossroads of Kroodi. The ends of the turtle are full cross-section in the close-up zone, but the rest of the length is a gap in the center of the body, separated by stiffnesses of ~ 5m.

  

Possible dimensions of E-Betoonelement frame posts:
– laius 950mm
– kõrgus 1000mm
– pikkus kuni 27m
– mass kuni 42t

In the Netherlands, the box-beam is a widespread beam, offering a number of options for a bridge deck
– Taladest moodustatud tekk on võimalik täiendavalt piki- ja põikisuunas järelpingestada
– Võimalik rajada jätkuvaid sildeid
– Suurem väändejäikus
– Puudub monoliitse pealevalu vajadus
– Minimaalne ajaline kestus tekiehitusel

Precast deck plates together with cast-in-situ topping create a composite structure. There are two types of plates depending on whether they are used for constructing a new superstructure or for reconstructing an existing one.

About the solution
When building a new bridge deck, plates are assembled directly on concrete or steel beams. Openings are left in the precast plates for the shear dowels in the beams. Dowel joints and connections between plates are cast together after the assembly of plates. Plates are further joined together by cast-in-situ topping which is approximately 100 mm thick. The lower surface of the precast deck plates is a smooth formwork finishing. The top surface of the element can be cast with initial double-sided transverse slope. When an existing bridge is being reconstructed and the old and usable concrete deck is partially preserved, it is possible to use precast deck plates which are installed on the existing parts. In this case the plates are thinner and lighter. The top side of the plate can then be cast as a mould surface and the lower surface remains a steel floated one.

 

Advantages
– Võimaldab sillateki valamise viia tehase sisetingimustesse.
– Sillateki betoneerimise ja betooni esmase kivinemise ajal ei ole suuri välistingimuste kõikumisi (palavust, pakast, liigset vihma ega lund).
– Betoon kivineb esimese nädala stabiilsetes sisetingimustes ja väheneb pragude tekkimise oht.
– Jääb ära vajadus kasutada töömaal raketisekilpe ja oluliselt lihtsustub tööde teostamine kui sillatakse muutuva veetasemega või kandevõime poolest kehva põhjaga veekogu.
– Paraneb tööohutus platsil, kuna paika tõstetud element moodustab koheselt edasiste tööde teostamiseks vajaliku platvormi.
– Võimaldab kokku hoida ehituseks vajalikku aega, sest samal ajal kui platsil tehakse ettevalmistustöid, saab tehases elemente valada.
– Betoonpinnad on kvaliteetsed ja elementide mõõdud enne platsile toomist kontrollitud.

Slab parameters
Monteeritava plaatelemendi soovitatav plaanimõõt on kuni 10,0×2,4m. Sellisel juhul ei ületata tavatranspordi gabariite ning veoks pole vaja eriluba.
The maximum mass of one slab is up to 12.5 tons and slabs are carried in pairs.
The time required for assembling one slab is less than 30 minutes.

Assembly
– Monteeritakse tekiplaadid.
– Tekiplaatide vastastikku jäävates servades on soon, kuhu tehases paigaldatakse tihend, et vuugi betoneerimise ajal tsemendipiim elementide vahelt alla ei nõrguks.
– Seejärel paigaldatakse pikiarmatuur plaatidevahelistesse vuukidesse.
– Monolitiseeritakse nihketüübli- sõlmed ja plaatidevahelised vuugid.
– Monteeritakse ääreprussi-elemendid.
– Paigaldatakse pealevalu armatuur ning teostatakse pealevalu betoneerimine.
– Ääreprussi elementide vahelised vuugid viimistletakse elastse mastiksiga.

Scope of Works
We offer:
– silla või viadukti pealisehituse (monteeritavast raudbetoonist peakandurid ja tekiplaat) konstruktiivset
- preparing shop-drawings of precast elements;
– monteeritavate elementide tootejooniste koostamist;
– monteeritavate elementide tootmist;
– monteeritavate elementide tarnet;
– elementide paigaldust ja sõlmede ning pealevalu betoneerimistöid.

T-beam bridges
We have manufactured T-shaped bridge beams which are mainly used for reconstructing old precast beam bridges.

Border and edge elements for bridges
Precast reinforced concrete border and edge elements can have various cross-sections. The shell elements are usually 3-4 m long but we have also manufactured up to 7.5 m long pieces. These elements can be used for both cast-in-situ and composite decks. Elements are fixed with temporary fastenings during assembly and are later connected to the deck by means of protruding rebars or special steel connections. Joints between elements are finished with elastic mastics. Sleeve anchors with internal threads can be cast in the elements for fastening safety barriers. The top and outer surface of elements can be treated with a suitable impregnating substance. The edge element can have a curved design or various patterns including dummy joints, formliner surface or even graphic concrete.

The use of reinforced concrete elements in infrastructure facilities offers several advantages:
– tehasetöö täpsus ja kvaliteet;
– tehaselise betoonpinna kvaliteet;
– mitmed erinevad viimistlusvõimalused;
– elementidele saab anda valuga vajalikud kalded;
– elementidesse saab tehases valada kommunikatsioonitarvikuid;
– tööde teostamise sõltuvus ilmast viidud minimumini;
– tööde kiirus platsil;
– minimaalne raketistööde vajadus platsil;
– paralleelselt paigaldusega säilib võimalus liikluse läbilaskmiseks.

We offer:
– rajatiste konstruktiivset projekteerimist;
– monteeritavate elementide tootmist;
– monteeritavate elementide tarnet;
– elementide paigaldust.

ZIP beam bridges

E-Betoonelement has been offering and producing solutions for precast concrete bridges since 2000. The first bridge based on ZIP beams, the 33-metre-long Kärkna Bridge, was built the same year on the Tartu-Jägeva highway 6,6km over River Amme. It was followed by the bridges of the Estonian Power Plant, Sirgala, Korbatu and Puurmanni. In 2008 the 160-metre-long Vaida viaduct and the 90-metre-long Aruvalla viaduct were built – these are the longest ZIP beam flyovers in Estonia so far.

The ZIP beam superstructure consists of prestressed ZIP beams which have an inverted T-shape cross-section and are assembled side by side. Beams are connected by a cast-in-situ deck slab and reinforced concrete cross-girders at supports.

   

ZIP-beams can also be placed at a longer centre-to-centre distance when there is no need to consider the impact load from below (for example when the clearance exceeds the minimum permitted height or when the bridge crosses a non-navigable river). In this case the deck is created as a composite structure using approximately 70-80mm thick precast concrete slabs as formwork. These precast deck slabs are used to cover the gaps between beams, creating a formwork which supports the load of the cast-in-situ topping and after the monolithic part has hardened they act together carrying traffic loads.

 

Maximum bridge plates for bridges and viaducts resolved by ZIP beams.

– käesolevat graafikut saab kasutada ainult esialgseks sildeehitise ristlõike kõrguse määramiseks.
– kasutatud koormusmudelid vastavad Eesti projekteerimisnormidele EPN-ENV 1.3.
– sildeehitise kõrgus sisaldab sillatala ja monoliitset betoonplaati.

Segment-tunnel 

 

The tunnel-cross-sectional elements or segments form the supporting structure of the segment tunnel. On the working site, the segments are assembled one after the other and, if necessary, tensioned the tunnel body in a longitudinal direction. On the outside of the segments there are concrete console panels to support the board drive, and it is possible to put into the factory the cable and other accessories at the factory. The inner surfaces of the tunnel are poured into shape and allow the use of different surface finishing techniques.

places of use
– kergliiklustunnelid;
– karja- ja ulukitunnelid;
– truubid.

  

Segments dimensions

Possible tiled internal dimensions are (height x width)
2,50×3,50 m
The length of a single segment is 950 mm.
Maksimaalsete sisemõõtudega 2,5×3,5 m segmendi mass on 10,5.

Slab tunnel

Slab tunnel solution consists of L-shaped supporting walls, cast-in-situ floor and prestressed ceiling slabs. Prestressed slabs with a rectangular cross-section and smooth surface can span up to 10 m. This solution is also suited for constructing multi-span structures.

    

Beam tunnel

The idea of a beam tunnel is similar to that of a slab tunnel only the load-bearing ceiling elements are in this case prestressed beams (see ZIP beams) which are assembled side by side. There are openings in the beam webs for installing transverse reinforcement. The space between beams is reinforced and filled with concrete. This makes it a full cross-sectional deck structure. This solution is suitable for spans of 10-16 m. Walls can be either L-shaped supporting wall elements or straight wall panels combined with an in-situ floor.

 

Valmistame müratõrjeseinaelemente ja terviklahendusi. Palun kontakteeru müügiinseneriga.

The ViaPlus box beams is a closed cross-sectional bridge beam, which is casted in the factory either in one or two stages depending on the geometry of the beam. To this day, we have found the use of this type of tailgate for trapezoid cutting, to provide a smoother deck for the edges. The first object where we have manufactured such beams is Viaducts No 1 and 2 in Maardu, mid-level crossroads of Kroodi. The ends of the turtle are full cross-section in the close-up zone, but the rest of the length is a gap in the center of the body, separated by stiffnesses of ~ 5m.

  

Possible dimensions of E-Betoonelement frame posts:
– laius 950mm
– kõrgus 1000mm
– pikkus kuni 27m
– mass kuni 42t

In the Netherlands, the box-beam is a widespread beam, offering a number of options for a bridge deck
– Taladest moodustatud tekk on võimalik täiendavalt piki- ja põikisuunas järelpingestada
– Võimalik rajada jätkuvaid sildeid
– Suurem väändejäikus
– Puudub monoliitse pealevalu vajadus
– Minimaalne ajaline kestus tekiehitusel

Precast deck plates together with cast-in-situ topping create a composite structure. There are two types of plates depending on whether they are used for constructing a new superstructure or for reconstructing an existing one.

About the solution
When building a new bridge deck, plates are assembled directly on concrete or steel beams. Openings are left in the precast plates for the shear dowels in the beams. Dowel joints and connections between plates are cast together after the assembly of plates. Plates are further joined together by cast-in-situ topping which is approximately 100 mm thick. The lower surface of the precast deck plates is a smooth formwork finishing. The top surface of the element can be cast with initial double-sided transverse slope. When an existing bridge is being reconstructed and the old and usable concrete deck is partially preserved, it is possible to use precast deck plates which are installed on the existing parts. In this case the plates are thinner and lighter. The top side of the plate can then be cast as a mould surface and the lower surface remains a steel floated one.

 

Advantages
– Võimaldab sillateki valamise viia tehase sisetingimustesse.
– Sillateki betoneerimise ja betooni esmase kivinemise ajal ei ole suuri välistingimuste kõikumisi (palavust, pakast, liigset vihma ega lund).
– Betoon kivineb esimese nädala stabiilsetes sisetingimustes ja väheneb pragude tekkimise oht.
– Jääb ära vajadus kasutada töömaal raketisekilpe ja oluliselt lihtsustub tööde teostamine kui sillatakse muutuva veetasemega või kandevõime poolest kehva põhjaga veekogu.
– Paraneb tööohutus platsil, kuna paika tõstetud element moodustab koheselt edasiste tööde teostamiseks vajaliku platvormi.
– Võimaldab kokku hoida ehituseks vajalikku aega, sest samal ajal kui platsil tehakse ettevalmistustöid, saab tehases elemente valada.
– Betoonpinnad on kvaliteetsed ja elementide mõõdud enne platsile toomist kontrollitud.

Slab parameters
Monteeritava plaatelemendi soovitatav plaanimõõt on kuni 10,0×2,4m. Sellisel juhul ei ületata tavatranspordi gabariite ning veoks pole vaja eriluba.
The maximum mass of one slab is up to 12.5 tons and slabs are carried in pairs.
The time required for assembling one slab is less than 30 minutes.

Assembly
– Monteeritakse tekiplaadid.
– Tekiplaatide vastastikku jäävates servades on soon, kuhu tehases paigaldatakse tihend, et vuugi betoneerimise ajal tsemendipiim elementide vahelt alla ei nõrguks.
– Seejärel paigaldatakse pikiarmatuur plaatidevahelistesse vuukidesse.
– Monolitiseeritakse nihketüübli- sõlmed ja plaatidevahelised vuugid.
– Monteeritakse ääreprussi-elemendid.
– Paigaldatakse pealevalu armatuur ning teostatakse pealevalu betoneerimine.
– Ääreprussi elementide vahelised vuugid viimistletakse elastse mastiksiga.

Scope of Works
We offer:
– silla või viadukti pealisehituse (monteeritavast raudbetoonist peakandurid ja tekiplaat) konstruktiivset
- preparing shop-drawings of precast elements;
– monteeritavate elementide tootejooniste koostamist;
– monteeritavate elementide tootmist;
– monteeritavate elementide tarnet;
– elementide paigaldust ja sõlmede ning pealevalu betoneerimistöid.

T-beam bridges
We have manufactured T-shaped bridge beams which are mainly used for reconstructing old precast beam bridges.

Border and edge elements for bridges
Precast reinforced concrete border and edge elements can have various cross-sections. The shell elements are usually 3-4 m long but we have also manufactured up to 7.5 m long pieces. These elements can be used for both cast-in-situ and composite decks. Elements are fixed with temporary fastenings during assembly and are later connected to the deck by means of protruding rebars or special steel connections. Joints between elements are finished with elastic mastics. Sleeve anchors with internal threads can be cast in the elements for fastening safety barriers. The top and outer surface of elements can be treated with a suitable impregnating substance. The edge element can have a curved design or various patterns including dummy joints, formliner surface or even graphic concrete.

An all-in one solution from a single partner

Planning
Planning and project management
Designing
BIM and cooperation with CES
Producing
High quality manufacture
Transport
Controlled deliveries
Assembly
Fast and accurate

Planning

When preparing an offer, if necessary, a model is made, which is preferably based on an architectural design in the ifc format created by the architect. However, we can also use AutoCAD dwg files. Read more here.
The way around is also possible, we can give the structural model created to the architect to use as a basis for their work. This approach has been used many times, for example, for our Bashall™ product.

The quotation model indicates the design and element distribution of the load bearing part of the building (shapes and layouts of panels). The model enables to estimate the volumes and weights of the elements.
Aat a bidding model, it can be seen the building´s carrier part structure and distribution of elements (panel statues and spreads). On the basis of a model, a summary can be made about the volumes and element weighs.

Project management

When purchasing a solution, we determine the in-house project manager to coordinate our work. For the contractor, this means communication with only one representative of the E-Betoonelement in relation to all works and services.

Designing

In the design we are focused on the all-in solutions of prefabricated reinforced concrete. As specialists in our field, we are able to prepare the most optimal structural solution for the building at an early planning and design stage. For large-scale projects, we cooperate with our sister company CES.

The preparation of well-thought-out and correctly executed product drawings for elements based on the created solution for the use of factory workers is equally important. In designing, we use the 3D model (Tekla) and its advantages.

Read more about designing here.

Production

Prefabricated reinforced concrete elements are mostly manufactures in our factories — in Tamsalu and Harku. For large volume projects, we cooperate within the Baltics with our sister companies.

If we organize the design of a prefabricated reinforced concrete part in-house it means that we can transfer all the information necessary for manufacture to the drawings in a timely manner, the elements are feasible and surface finishes, the location of steel parts in the element, as well as other details are well-thought-out based on the element specifications. We use materials that ensure functioning and compliant connections. We determine the order of manufacture of elements in accordance with the installation schedule.

We manufacture the products in accordance with the applicable standards and regulations in Estonia. See factories issued certificates.

Transport

In the case of a full-service solution, the delivery of elements to the site is organised by our installation team. Therefore, the client does not have to engage in scheduled ordering of the elements or the organization of unloading the elements.

Assembly

By using in-house installation team, we can be sure that the end result is realized with the best assembly techniques. In addition to the fact that the right elements will be correctly installed and the safety of work is ensured, skilful installation means that during assembly, the deviations within the tolerances of the elements and the installation are levelled. The accumulation of permissible tolerances is avoided and the visual side of the final solution is always kept in mind.
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