Railway bridges manufactured by Mostostal Puławy are a part of a large investment executed by a consortium formed by the following companies: Pihl & Son A.S. i Züblin (Joint – Venture Pihl – Züblin). The goal of the consortium is design and construction of a road connection with a tunnel. The construction of Nordhavnsvej Street is supposed to provide a connection between the Elsinore motorway and the Strandvænget way in “Østerbro” – located in the vicinity of Copenhagen. The entire length of this road connection shall be 1650 meters, 620 out of which shall be passing through an underground tunnel.
It is a large-scale project “Nordhavnsvej – Vej-og Tunnelenterprise”. In cooperation with an engineering company Danpro A/S, Mostostal Puławy has created steel frames and constructions of four railway bridges:
- Site 1 – Length of ca. 90 meters and approximate weight of ca. 370 tonnes
- Site 2 – Length of ca. 70 meters and approximate weight of ca. 280 tonnes
- Site 4 – Length of ca. 60 meters and approximate weight of ca. 205 tonnes
- Site 5 – Length of ca. 50 meters and approximate weight of ca. 200 tonnes
The sites have been supplied in two stages, “4” and “5” have been sent in July 2012 and were transported on 16 trucks, whereas currently we are loading and transporting sites “1” and “2”, for which 27 transporting trucks have been planned.
The heaviest elements of the bridges weighed up to 39 tonnes.
Summarising, we can say that it has been a relatively complicated project, both from the logistics point of view and in regards to the entire technology of its execution and implementation. It proved to be very challenging to design the entire execution technology for several thousand bored holes for screws in such a way that the entire construction could be assembled. The construction of girders has been performed according to the highest requirements implied by the new norm related to creation of steel constructions, namely, EN 1090 – execution class EXC4.
Taking care for quality and competitiveness of steel constructions offered on the European market as a goal, we have performed several investments into manufacturing halls and equipment. We have doubled the manufacturing area and increased the maximum weight of manufactured elements up to 40 tonnes. Machines forming parts of production units are controlled numerically, enabling their support included in new software used for designing steel constructions. By performing the thermal cutting procedure using CNC machines we are able to achieve repeatability of parameters, thus we are able to obtain proper surface quality according to the EN ISO 9013 standard, depending on the construction class, as well as correct values of hardness for different steel types, expressed using HV scale. According to the contract related to manufacturing steel constructions of the bridges to be built in Denmark, we had to provide edge hardness after thermal cutting below the level of 380 HV10.
The very high standard of execution and precision required a very high level of qualifications from our team, as well as an utmost care aimed at the high quality of the constructions.
