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CSS-Series,Intelligent continuous strand jack system - From China CEEN
CSS-Series,Intelligent continuous strand jack system

CSS-Series,Intelligent continuous strand jack system

In recent years, incremental launching method was widely applied to bridge construction. It’s an advanced no stand and self spanning construction method for pre-stressed concrete continuous beam bridge, no effects on navigation and traffic, shorten project duration and reducing construction cost.  Incremental launching method is to prefabricate the superstructure segments in a casting yard which is located behind the bridge abutment. Each segment is assembled and connected to the previous superstructure. then launched forward step by step with the help of sliding device(stainless and Teflon board) to the final position. KATTOR, based on above construction method, developed the CSS with characteristics of hydraulic transmission, computer control, field-bus technology and multi-point launching. It has been applied successfully in many world class bridge projects.

Features

Working principle

Components

Parameters

Application

  • Automatic control

Computer centralized control

  • High accuracy

Synchronous accuracy of less than 1mm can be achieved

  • Flexible adaptability

Multi-points synchronous action in complicated applications, the max launching, lifting and lowering weight can reach 40,000 tons, the launching distance up to 1000 meters.

  • Easy operation and high efficiency

Modularized design, easy for on-site assembly, operation and management

  • Safety and reliability

Adopt wired or wireless communication, high reliability
Automatic locking and unlocking function

CSS is an intelligent system combined with strand jacks, PLC controlling system and pump station. A strand jack contains two cylinders which work alternately. A bundle of steel strands are guided through the hollow cylinder in the jack, the wedges of anchor system gripping the strand bundle simultaneously, this is how the strand jack carry a load. When the continuous status signal feedback by approach switch components and sent to controlling system, turn on-off the relevant magnetic valve , to control the extend and return of strand jack alternately, in this way to realize heavy-duty launching, lifting and lowering.

CSS 01

CSS 02

 

 

 

Model name Picture Product features Parameters Need Qty
PLC controlling system cssmark001 Modular design,flexible composed of pump station and double-acting hydraulic jack high reliability,Adopt wired or Wireless communication, communication line minimization Synchronous lifting and servo constant force control, applied to working condition of lifting and translation Synchronous precision :1mm Synchronous lifting points: 4,6,and can be increased to 99 points Working voltage: 220V 1 pcs
Continuous strand jack cssmark002 Applied to pre-stressing construction Matched with special tool,anchor and hydraulic system, applied to each kind of bridge and super big & super heavy structures’ lifting,rotate, launching and so on project Rated pressure: 32-55MPa·Rated capacity: 150~400Ton· Rated stroke: 200mm 1set
Hydraulic  pump station cssmark003 Pump station integrated PLC control program·Special valve group design, automatic lifting and lowering control for single-acting jack Rated flow: 0.9,1.5,2.1 L/Min·Synchronous liftingpoints: 1,2,4,6 points·Oil capacity: 40,60,100 L·Motor power: 1.5, 2.2, 3.0 KW
Sensor Sensor High precision pressure and displacement sensor, Rated Pressure: 35~100 MpaAccuracy: 0.25%.Output current 4~20mA 4,8 set
Cable Cable LC, TLC series cable. Stable signal transmission. Fast plug connector, Length can be customized. Length: 5, 10m,customized. 2,4 set
Hose Hose PU coating for corrosion resistant. Including Fast connector and dust cap. Max. bearing pressure: 70MPa.Dia.: 6.4, 9.7mmLength: 18m 2,4 set

Parameters of strand jack

Item

KL100

KL200

KL350

Main cylinder

Rated oil pressure (MPa)

23

25

25

Rated pull (kN)

1130

2050

3500

Stroke (mm)

250

250

250

Clamp cylinder

Rated oil pressure (MPa)

5

Rated pull (kN)

106

Stroke (mm)

38

Weight (kg)

820

1390

3000

Parameters of pump station

Item

KB25

KB35

KB25*2

KB35*2

Main cylinder system

Rated pressure (MPa)

25

25

25

31.5

Rated flow (L/min)

24

35

2*24

2*35

Clamp cylinder  system

Rated pressure (MPa)

8

Rated flow (L/min)

14

Oil capacity( L)

235

235

250

500

Size (mm)

1270*1100*1250

1270*1100*1250

1600*1300*1600

1400*1700*1500

Weight (kg)

760

800

1200

1650

 

 

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·Horizontal movement of bridge and heavy objects
·Rotation project of bridge and heavy objects
·Lowering and lifting of bridge beams and heavy objects

Project name: Hefei-Fuzhou railway Tongling Yangtze bridge

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Project profile:
The length of Tongling Yangtze Bridge is about 6000m, It’s a new key project of Hefei- Fuzhou passenger railway. It was composed of north approach bridge, river-crossing main bridge and south approach bridge. The main bridge is a highway-railway bridge, under-layer designed quadruple track railway, upper layer designed six-lane highway. Tongling Yangtze bridge is a two tower five span steel truss girder bridge, the full length of girder is 1290m, steel truss main girder use N glyph truss, totally 86 internodes and 45 hoisting segments, the max weight of single piece is 366 tons, north shore steel girder side-span use KATTOR CSS to build, main tower steel girder use double cantilever to build.

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The construction project was built in the narrow part of Yangtze river, and the construction period is in flood season, how to solve the working condition of deep foundation, river-way narrow, rapid flow and so on complex terrain.
The length of main span is about 630 meters, create a world most of same type highway-railway dual-purpose cable-stayed bridge, should adopt what kind of technical solution to shorten the construction period, finish steel girder erection.
Synchronous lifting equipment how to ensure the safety of steel truss girder structure during the process of girder Lifting and lowering.

Solution

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After lots of technical exchange between KATTOR R&D team and construction builder, based on incremental launching method and the terrain differences of both shore, KATTOR designed different solution for north and south shore construction: south shore side-span adopted all launching; north shore side-span adopt partial launching for the part on shore.
South shore adopted three kinds of cylinders with 650 tons, 800 tons, 1000 tons which have hydraulic self-locking function, intelligently remote control multi cylinder synchronous lifting and lowering by PLC, implement lifting, lowering, remain with load safely.

This project adopted KATTOR CSS to ensure all cylinders’ synchronized operation. Set up a jacking platform on the shore side and multi temporary bridge pier to opposite shore along bridge direction. Install a set of CSS cylinders on left and right side of each temporary bridge pier. Each cylinder equipped with an independent hydraulic pump station, has independent controller to implement front control, and communication with the main controller through field bus. Computer system control CSS and SLS(synchronous lifting system), to adjust height of each pier, control pulling force and speed according to the supporting force, ensure the pulling force match friction of each pier, at the same time adjust the position of steel box girder.