RION ANTIRION BRIDGE “CHARILAOS TRIKOUPIS”10 years of Uninterrupted Operation

Panayotis Papanikolas, Ph.D. Struct. Eng.

C.E.O. Gefyra S.A.

Concessionaire’s Obligations

Τ0 Τ1 Τ2

0 3 years 8 years 35 - 40 yrs

Ten

der

Fin

anci

ng

Co

nst

ruct

ion

Operation - Maintenance

120 years

1. Hand back2. Extension of C.A.

Concession term – ~30 years

2

The following obligations are among those arising from the Concession Agreement (C.A.) :

1. Implementation of the infrastructure ( Τ1, with specific cost and time schedule, particularly important

for technologically innovative constructions);

2. Safety of the user, availability of the infrastructure, ensuring the level of service (Τ2);

3. Safeguarding the Public Property (maintenance during the T2 period, technical improvements,

dealing with crises, requirements for delivery/acceptance).

10 years of Operation

Construction

Preserving the asset – inspection & maintenance

Traffic – Toll strategy

3

4

Bridge Location

BRIEF DESCRIPTION OF RION ANTIRION BRIDGE

5

Environmental Site Conditions & Main Design Loads

Weak sea-bed up to 500 m deep

Water depth up to 65 m

High-Seismicity & Strong Wind area

Tectonic movements

65 m.

0

0,3

0 ,6

0 ,9

1 ,2

1 ,5

0 ,0 1 ,0 2 ,0 3 ,0 4 ,0 5 ,0Period [s]

ps

eu

do

ac

ce

lera

tio

n

[g

]

EAK 2000

Seismic risk zone III

Soil cat "Γ "

5% damping

Importance factor I = 1,3

RION-ANTIRION

E.A.K.

• Return period 2000 years

• PGA 0.48 g, max Sa 1.20 g (0.2 up to 1.0 sec)

• Tectonic movements up to 2m (between adjacent piers

• Design Wind speed 50 m/sec (hour mean at deck level)

• Ship collision:

1. 86000 dwt bulk carrier (full laden) at 16 knots

2. 180000 dwt tanker (on ballast) at 16 knots

BRIEF DESCRIPTION OF RION ANTIRION BRIDGE

ΑΝΤΙRΙΟNRΙΟN

Shallow foundation on reinforced soil

4 R/C piers (189m to 227m height) and 2 hinged steel frame abutments

2,252km continuous, composite section deck fully suspended from the top of pylons.

Expansion joints are provided only on the two extremities. in service: +1,26/-1,15m (longitudinal direction)

in ultimate conditions: +2,81/-2,20m (longitudinal direction) and ±2,6m (transversal direction)

Dissipation system (consisted of 4 dampers on each main pier and 2 on each transition pier). in service: the deck is laterally supported by means of a restrainer (nominal load: ±10,5MN for main piers, 3,4MN for TP)

in ultimate conditions: it fuses allowing the dissipation system to absorb the induced energy (dampers stroke: 3,5m)

6

Main Bridge Characteristics and seismic design principles

286 560 560 560 286

(2252)

BRIEF DESCRIPTION OF RION ANTIRION BRIDGE

7

Construction (cont’d)

PERIOD Τ2 BRIDGE “HARILAOS TRIKOUPIS”

Construction of pier base footing in dry dock

8

Construction (cont’d)

1) Underwater foundation2) Transportation of floating part

of pier (height 67m)

PERIOD Τ2 BRIDGE “HARILAOS TRIKOUPIS”

9

Construction (cont’d)

Construction of pylons

Cantilever deck construction

Installation and adjustment/tensioning of cables

PERIOD Τ2 BRIDGE “HARILAOS TRIKOUPIS”

Τ2 Period: the need to manage the infrastructure

The infrastructure management is a major issue for the economy of all countries. It requires the

elaboration of a management system that shall have the following main objectives:

• Guarantee the safety of the users;

• Ensure a targeted level of service (that varies depending on the roads);

• Respond promptly to special events (crisis management);

• Upgrade the infrastructure (corrective works, technical improvements);

• Ensure that the heritage is preserved for future generations (long-term safeguarding of the asset).

The management system consists of a set of procedures that shall aim at ensuring the sufficient

maintenance of all constructions. It includes methods, detailed models, data processing tools,

organizational processes and the required data bases for its implementation.

10Τ2 PERIOD INFRASTRUCTURE MANAGEMENT

13

Structural Maintenance Dept: “Scope of works” Chart

GEFYRA S.A.(Concessionaire)

Structural Maintenance Dpt.

• MB & AV Structural elements & equipment

• Toll Plaza Structures

• Non-Structural equipment (E/M & other)

Monitoring

Material Monitoring

Instrumented Monitoring

Visual Monitoring (inspections)

Structural monitoring system (permanent)

Geometrical monitoring

Maintenance

Regular Maintenance (Planned)

Heavy Maintenance

Special Events Structural Management

Earthquake

Major Accident

Strong wind

Fire

Ship Collision

Additional works

Technical improvement works

Remedial works

Other projects

STRUCTURAL MAINTENANCE DPT →ORGANIZATION, SCOPE

14

Accesses

Cherry picker(Internal platform)

Cradle(Pier shaft)

Secondary platform (under the deck)

Negative platform (Rion Viaduct Offshore)

ACCESS MEANS

Inspection/maintenance

of cable stays

Expansion joint

inspection

Cleaning splash zone

with hydraulic brush

Equipping the pier head

for inspections

Visual Monitoring: Inspection levels

Level A inspectionsEvery Year

Level B inspectionEvery Two years

Level C inspectionEvery Four years

Level D inspectionYear 4 then every 8 years

An

tiri

on

Via

du

ct

Localized inspections close to bearings & dampers. Inspection of extrados and expansion joints.

Visual inspection of surfacing without specific accesses except for inspection at mid-span.

Complete detailed concrete inspection

Rio

n V

iad

uct

Inspection of the anticorrosion protection system

Localized inspections close to bearings & dampers. Inspection of extrados and expansion joints. Steel/Concrete Interface for corrosion

Check of specific checkpoints on steel and concrete. Inspection of anti up-lift device on P7 and T0.

Complete detailed concrete inspection

Mai

n B

rid

ge d

eck

Complete inspection of the intrados for checking of water infiltration and corrosion at steel/concrete interface.

Inspection of the expansion joints.

Inspection of extrados around gusset anchorage for watertightness checking.

Inspection of the anticorrosion protection system of the deck and rotating frames.

Dampers, fuses and anchorages.

10% of the cable-stays anchorages (specialized).

Visual inspection of the cable stay anchorages including EHD

Check of specific checkpoints and complete inspection on intrados steel.

Visual inspection of the concrete.

Gussets and segment 24 complete inspection.

Inspection of the rotating frames.

Complete inspection of the extrados.

Detailed visual inspection of the cable stay duct

Complete detailed concrete inspection.

Mai

n B

rid

ge

Pie

rs/P

ylo

ns

Inspection of the anticorrosion protection system of the pylon head

Complete visual inspection except submerged zone but including splash zone

Inspection of scour protection and external faces of footing & cone (submerged zone).

15MONITORING OVERVIEW → VISUAL MONITORING

16

Visual Monitoring: Tools (cont’d)

Computerized Inspections performed by in-house inspection engineers:

Inspectors use Rugged Tablet PC on site Rope access inspectors use a specially prepared paper support on site , then

data & photos are integrated by inspection engineers

Concrete inspection on Intrados with Secondary

platform

Steel deck inspection with Secondary platform

Concrete inspection with rope access in pier head

MONITORING OVERVIEW → VISUAL MONITORING

STRUCTURAL MONITORING: Instrumentation (Cont’d)

Sensors overview

MONITORING OVERVIEW → INSTRUMENTED MONITORING 17

DATA RECORDS AND APPLICATIONS (cont’d)

Data files categories• History files (0.5 sec averaged values recorded at regular

intervals)

• Dynamic files (High sampling frequency >100 Hz)

• Automatic(recorded every 2 hours)

• Alert (Recorded due to threshold overpass)

• Request (on end user demand)

Variation of induced force on deck with respect to wind

Wind occurrence calculation

MONITORING OVERVIEW → INSTRUMENTED MONITORING 18

Mode 1

Mode 318

Data Management Strategy Plan

19

Monitoring data

Data Storage Data analysis Decision

No Action

Regular/Heavy Maintenance or Major remedial/

Technical Improvement works

Specific Monitoring

Data Management

Strategy Plan

Material monitoring

NDT/DT on • Concrete• Pavement• Steel welds

Visual Monitoring (inspections)

Structural monitoring system (permanent)

Geometrical monitoring

Instrumented Monitoring

Regular Inspections Specialized Inspections

MONITORING OVERVIEW

1. Regular maintenance (e.g. steel corrosion protection, etc.);

2. Specialized maintenance (e.g. cables, joints, etc.);

3. Special events (e.g. earthquakes, strong winds, etc.);

4. Heavy maintenance (e.g. asphalt pavement replacement,etc.);

5. Technical improvements / upgrading (e.g. lighting protection system, dampers).

Maintenance

20

Structural Maintenance Works

21

Maintenance on fasteners of HSFG joints

REGULAR MAINTENANCE

Complete restoration of corrosion protection of bichromated surfaces

Exposed reinforcement (low cover)

S/N HEAVY MAINTENANCE CATEGORIES 2013 2014 2015 2016 2017 2018 2019 2020 2021 2022

1 Maintenance of pavement & joints

1.1 Pavement asphalt & concrete, footpath

waterproofing

HM

1)Applying micro-surfacing on

the Bridges

2) Corrective works at the Toll

Plaza

HM

Replacement of asphalt

pavement

1.2 Main Bridge expansion joints

1.3 Approach viaducts expansion joints HM

Replacement

2 Maintenance of concrete, steel

surfaces & Cables, IEDD system, non-

structural & E/M equipment

2.2 Cable stays & Lighting Protection

Cables

HM

Specialized inspection -

maintenance

HM

Specialized inspection

- maintenance

HM

Specialized

inspection -

maintenance

HM

1) Specialized inspection -

maintenance

2) Strands check

HM

Specialized

inspection -

maintenance

2.6 Concrete surfaces HM

Underwater inspection –

maintenance

HM

Underwater

inspection –

maintenance

HM

Underwater

inspection –

maintenance

2.7 Steel surfaces

2.8 Main Bridge seismic damping system

2.9 Approach viaducts seismic damping

system

2.10 Non-structural & E/Μ equipment

22

Heavy Maintenance Program for 2013-2022

MAINTENANCE HEAVY MAINTENANCE

Conclusions

31CONCLUSIONS

The management strategy adopted on the offers:

Safety and comfort for the users / availability of the crossing

Preservation of the asset Decisions based on rational monitoring data / Structural health assessment

Optimization of the processes of inspection and maintenance (regular & heavy)

Use trained local resources (supported by external expertise)

Manage special events

Perform necessary improvements

Financial viability during crisis / Toll Policy Products adopted to the needs of the users with special attention to the frequent/local users

ETC products – interoperability

Promote the co-existence with ferries

THANK YOU

FOR YOUR ATTENTION