New railway overpass over the river Steinach: Installation is proceeding successfully

In the middle of May the assembly of the new railway overpass over the Steinach in Balingen has started. First of all a supporting structure was assembled on which the newly manufactured bridge sections could be placed and welded. After the carriageway slabs were placed on the support structure as the first components, the two large trussed slabs were lifted in. Assembly was not easy here because the 44-metre long trusses had to be delivered backwards under the old railway bridge. This proved to be a big problem due to the low clearance height: The trucks could not pass completely under the bridge. The solution was to lift the long trusses under the old existing bridge using a 700 tonne crane. The crane thus unloaded the trucks, placed the components next to the support structure, erected them and lifted the 64-tonne trusses onto the support structure. A great deal of sensitivity was required here, as the railway traffic on the existing bridge was not stopped during this time.

After this assembly phase, support structure was completed and then the smaller trusses were lifted in. Currently, the entire bridge is being welded and the corrosion protection is being completed. The work is proceeding according to schedule.

Following the steel construction work, the client will dismantle the old existing bridge and will move the new bridge to its final position.


Construction of the third hot-dip galvanizing production line at Salzgitter Flachstahl progressing rapidly

Darmstadt/Salzgitter, July 3, 2020.
In the meantime, the steel structure of hot-dip galvanizing hall 3 at Salzgitter Flachstahl has been almost completely assembled. The assembly of the roof and wall elements runs at full speed. Our technicians on site have met the very tight schedule with great commitment.  The project is fully on schedule. The photos of the process hall show in an impressive way the structural engineering challenge of this construction project.

Key data of the process hall: length 275 m, height 45 m, width 44 m, 4000 t steel construction, 12,000 m² roof area, 25,000 m² wall area

Second construction phase successfully installed

With the lifting of the A46 Westring bridge, an eventful April came to an end for our bridge builders. In the night from April 25 to 26, the 2nd construction phase of the motorway bridge was successfully installed.

Two 300 t cranes at the abutments and a 750 t crane below the bridge ensured that the steel components could be lifted in. The parts were delivered over the bridge, which had already been built in the 1st construction phase, by means of heavy transporters, slewed by two cranes and set down on the new piers.

First, the two outer bays were lifted, each consisting of two hollow boxes with a length of approx. 37 m.  Then followed the end cross beam and the cross beam on the pier. Thus the two hollow boxes were connected with each other.

Finally, the bridge was completed by the two 18 m long central components which were delivered underneath the bridge and lifted in place with the 750 t crane in a single lift.

The total length of the three-span composite steel bridge is 105 m with a total superstructure width of 36 m. 1000 t of steel were used for the entire steel construction of the structure.

Another milestone successfully completed

The second shifting of the bridge north of Bamberg was successfully completed by our technicians on the weekend 17th/18th April 2020.

In the course of the replacement and reconstruction of the Bridge 93b of the BAB A73 Bamberg-Lichtenfels, the steel construction (approx. 1,400 tons) of the steel composite structure was shifted by 45 m over the B4 and the railway line to be crossed with the beginning of the closing break of the German Railway on Saturday and reached the auxiliary pier as planned.

On the following Sunday, the remaining shift took place with a total of 70 m to abutment 40. During the next weekend operation the bridge was then stacked by 1.30 m to its intended final position.

The composite steel bridge consists of two separate superstructures (section 1, Lichtenfels carriageway and section 2, Bamberg carriageway). The two separate superstructures are antimetrically designed, geometrically particularly challenging trough structures made of steel with a concrete roadway slab. The total length of the three-span bridge is 150 m with a total superstructure width of 37.20 m. For the entire steel construction of the structure 2800 tons of steel are required.


Successful lifting of the new railway bridge

In Riederich, two thick plate bridges with an individual weight of approx. 37 tons were placed on the new abutments. The railway overpass consists of two separate superstructures. Each superstructure is designed as a trough bridge with thick plate. A walkway is attached to one side of each of the two superstructures. The span of the bridge is approx. 6.10 m, the construction height is 0.8 m. Each of the superstructures has a width of 4.48 m. The footpaths have widths of up to 1.19 m.

The bridge sections have been placed on top of addition stacks and remain on these until the bearings have been cast. Afterwards the footpaths were added.

In this state the bridge is now waiting to be moved to its final position together with the two abutments.

Lifting of the new railway overpass

In the night from Good Friday to Saturday the lifting of the new railway overpass over the Hattenbergstraße in Mainz took place.

During the day, two 500-ton cranes were used to dismantle the temporary bridges before the assembly of the new bridges could begin in the evening.

The railway overpass consists of three separate superstructures. Each superstructure is designed as a trough bridge with thick plate.  On each of the two outer superstructures a walkway is attached on one side. The span width of the bridges is approx. 22.00 m, the construction height is 1.5 m. Each of the superstructures has a width of approx. 4.50 m. The footpaths have widths of up to 1.35 m.
This resulted in unit weights of up to 135 tons.

The bridges were set down on allowance stacks and then the bearings were cast.

The Hattenbergstraße railway overpass went into operation on schedule.

Floating in the middle segments

Sponsors Cup of the Lilien in Darmstadt

This year the Sponsors Cup of SV Darmstadt 98 took place for the 12th time. Altogether 10 teams played for the popular challenge cup.

The Donges SteelTec team took part in the competition for the first time and was highly motivated. The Donges footballers were cheered on by their colleagues. In the end, they were delighted with their 7th place and one thing was clear for everyone: being there and being together in sport is the most important thing.

New back straight inaugurated at the Merck Stadium

Darmstadt, 02.02.2020. The assembly work of the steel roof construction for the new back straight in the Darmstadt stadium was completed on schedule. The first match of the Lilies could thus take place on February 2 as planned in front of the new backdrop.

Around 400 tons of steel were required for the construction of the new grandstand roof. In addition to the roof structure, Donges SteelTec also supplied and installed the roof and wall cladding.

Installation of the Schwelmetal bridge successfully started with moving traffic

Darmstadt/Wuppertal, January 29, 2020.

Since the beginning of January, the assembly of the steel structure for the replacement of the substructures 2 and 3 of the Schwelmetal Bridge built in 1960 in the course of the BAB A1 motorway has been in progress.

The Schwelmetal Bridge on the A1 motorway at the Wuppertal-Langerfeld junction spans several electrified railway tracks, public roads and waters. Up to 100,000 vehicles pass through the bridge every day. The two inner sections of the bridge, built in 1959 and 1960, are no longer sufficiently load-bearing due to the decades of stress and strain, especially due to increased heavy goods traffic.

The replacement construction of the bridge will be done “from the inside out”. This is the only way to maintain the traffic on the A1 motorway and on the DB AG track systems located underneath the bridge. The upper construction site on the A1 motorway has been set up as an island construction site.

The steel structure is being assembled using self-propelled transporters (SPMT).

Donges SteelTec has been commissioned with the fabrication and erection of the steel structure for the substructures 2 and 3 with a total span of 207m as well as the application of the corrosion protection.