Innovate
 

This project is all about innovation!

New Construction process for movable formwork using precasted keystone zero advancing over the piles

The innovative action is an improvement that consists on executing a segment of the deck (the keystone zero that is 5m and which includes the diaphragm) prior to the launch of the movable formwork.

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Combination of two structural typologies in a single bridge: evolutionary wide cross sections (35m mono-drawer beam with javelins) in wide span viaducts (up to 210m cantilevered and 70m movable falseworks).

Transversally, this method maximizes the load-bearing capacities of the mono-drawer section to widen the transverse width of the upper slab using javelins up to 35m, executed evolving in 2 phases. Lengthwise, the extension of the span is achieved using the necessary typology of works (cantilever advance up to 210m span, 70m on a viaduct with self-propelled access) and making the most out of new auxiliary construction resources available on the market.

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Scour study and hydraulic analysis combining physical models and 3D models in the Danube Bridge.

This hybrid model consists on the combination of a physical scale model with a moving bed and a 3D numerical model, both calibrated and validated with each other and in turn with a 2D model -also calibrated-. This is innovative and extraordinary as it far exceeds the studies commonly used to analyze the hydraulic behavior of flow in bridge foundations. In addition to corroborating the draughts and elevations obtained from the previous two-dimensional study, the physical and numerical model obtained the depth of scour of the piles in the construction and service phase. Knowing with reasonable precision the value of the local scour in the piers of the main channel of the Danube allowed optimizing the design of the breakwater protection, being able to also analyze its stability. In addition, the hybrid model was used to study in detail the turbulence, vortices and current path around the piles, pile caps and between the piles. Hydraulic pressures were also obtained on the pile caps and finally, and perhaps most recently, the physical model was used to study the behavior of the foundation in the face of floating (debris) in the event of floods.

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Development of an early flood warning system on the bridge over the Danube 

The warning system identifies different scenarios and levels of risk for the different pits (Kayak, Danube) based on the data for flow and draught forecasts in stations upstream. The Technical Direction has developed a protocol of action that allows the work team to take the appropriate measures in case the river floods during the bridge’s construction. This is of special interest in the locations that meant a temporary occupation of the riverbed, such as the peninsulas for the execution of the foundations of the piers of the Kayak channel, and the enclosures of sheet piles for the execution of the foundations in the main channel, which were accessed by pontoon paths.

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Hydrodynamic piles in Danube with exempt piles and pile caps at the level of the water sheet. Construction process and cantilevered deck blocking system.

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Radar Shield Wall – development of a solution to avoid interference of future traffic at D4 with the navigation and operation system at Bratislava Airport, since vehicles can be wrongly identified as navigation by the radar.

Together with experts from different Universities (UPV in España, TU Bratislava and other military schools in Slovakia),  Ferrovial Construction developed a solution based on a metal wall along with an electromagnetic shielding that ensures adequate attenuation of the radar signal and prevents, with its superior shape / finish, in the areas of approach to the airport, diffraction and possible return of radar signal. This project is multidisciplinary and pioneer in this area, and responds to the unique characteristics of the problem.

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Danube- instrumentation and sensorization

The monitoring project carries out a full-scale research work on the bridge over the Danube River, a unique structure with a project design and construction methodology intended to be the reference for future bridges. To this end, one of the objectives was to define the instrumentation that would make it possible to control the deformations of the bridge during its construction. This is a pioneering development project in Ferrovial Construcción of this type (large-width decks built in phases: first a central box and then the lateral overhangs).

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Drones for topography and monitoring of the works

Hover Box Element

The topography department of the work uses AUV technology (drones) to carry out certain operations such as topographical surveys of deposits and loans. Despite the local legal limitations in this matter and the proximity of the airport, military areas and the petrochemical SLOVNAFT. The activities carried out consisted mainly of obtaining volumes of some of the largest reserves of the project. This objective was achieved thanks to the good planning process of the georeferenced flight/s, flight and capture of the area of interest, calculation and adjustment of an orthophotos mosaic of the work, extraction and cleaning of the point clouds of the objects of our interest to create a 3d surface and calculation of their respective volumes. The greatest benefits of these operations are the level of detail of the models (we would never get it with traditional methods) with a similar accuracy to that of terrestrial RTK GNSS methods, the speed of the survey operation (great savings compared to traditional survey methods) and, especially for areas of rapid “daily change”, the fact of having a time scenario almost specific to the surveyed element. You also get graphic results that can be useful for meetings, presentations or disputes.

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Automatic bitumen transfer system between asphalt plants and between tanks of the same plant

The project includes different asphalt mixtures which have different types of bitumen, mainly conventional bitumen and modified bitumen. Foreseeing that the work needed to manufacture different mixtures in different periods and even in the same day, it was necessary to store sufficient capacity for different bitumens, so it was considered that each plant should adapt their tanks to the possibility of storing different bitumen, but it was also necessary to have circulation between the tanks, to transfer the bitumen from one tank to another depending on the requirements of the work.

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Preparation and use of BIM 4D models (space/time) for Danube Bridges to monitor the execution of the works and prevent interferences

Hover Box Element

The innovative action consists on the preparation and use of a 4D BIM model. This model is the combination of a 3D model of the bridges over the Danube with the Work Program of these structures and is particularly useful to monitor the progress of work, prevent possible problems and can be used as an As-Built of the work. Among others, the model has allowed to analyze the geometry of the structures, to obtain the quantities to be made of these objects, to obtain points that have been used by the topography team to mark the works, to visualize and to modify interferences between elements of the mentioned structures as interferences between active-passive steel.

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Found in D4R7 the largest archaeological site in decades

Hover Box Element

Due to the excellence of the archaeological site discovered in the D4R7 project layout, an above-standard approach was necessary. This created a first class international team. In addition to the eight archaeologists of the subcontractor VIA MAGNA, we cooperated with anthropologists from the Department of Anthropology of Comenius University in Bratislava, with the Department of Archaeology of the University of Ljubljana, the Archaeological Scientific Society of Stik in Ljubljana, the Archaeological Scientific Society of Labrys in Prague, and students from the departments of archaeology of Trnava, Nitra and Brno participated in the research. In total, about 100 people participated in the research.

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Noise barriers in corten steel.

We explored other options that would allow us to quickly and industrially execute such a large amount of Accoustic screen, and above all that it could be executed within the estimated budget.

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Use of 3D control and guidance systems for heavy machinery

The innovative action consists on the use of the most innovative and advanced 3D systems in a generalized way for the execution of earth movements works. More than 85% of the total earth-moving machinery that has been involved in the work on our site was equipped with these systems, which has represented a major challenge from the organizational and management point of view in the preparation, among others, of the 3D models necessary for its operation and which have had to be prepared in the different systems/brands that are available today.

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