New Landmark for Stralsund

Case Study

On 20.10.2007 the new car and lorry link from Stralsund to the island of Rügen was officially opened on schedule by Germany’s Chancellor Angela Merkel. Despite the extremely tight timeframe it was possible to complete the four-kilometre long and 40 metre-high bridge structure in time for the opening ceremony.
Two Y-shaped supports of steel and self-compacting concrete are characteristic features of Structure 1.2.
The new bridge over the Strela Sound modernises Rügen’s transport links for the requirements of the future.

The Strelasund bridge that is due for completion this October will fit Rügen’s transport links to the needs of the future. The original link with the mainland was always extremely congested, particularly in the holiday season. To keep the three projects simultaneously managed by the teams of the Max Bögl construction group moving, the project managers used the project lifecycle solution of RIB.

Established in 1929, Max Bögl GmbH & Co. KG is characterised today by three words: Mobility, flexibility and know-how. With a total workforce of 4,500, the firm based in Neumarkt in the Upper Palatinate region of Germany is now the country’s largest privately owned construction company. Every year, Max Bögl handles construction projects of all sizes, types and complexities, covering all areas and degrees of difficulty of modern construction – from design through financing and building all the way through to operation. By investing in technology and organisation, Max Bögl has developed over the decades from being a mere provider of construction services into a technology and service company. 

Several projects in one

The new link for cars and lorries from Stralsund to the island of Rügen was officially opened by Germany’s Chancellor Angela Merkel as scheduled on 20.10.2007: In spite of the extremely tight timeframe, it was possible to complete the 2.8 km (4 km including earthwork connections) and 40 m high bridge on the Federal road 96 in time for the opening ceremony. The Max Bögl consortium – responsible for the execution of this superlative bridge building project – put on a sensational final spurt in the last two months in particular with its waterproofing department. After all, carcassing of the new Stralsund – Rügen link had not been completed until August 1st. This was still no problem for the experienced construction company from Neumarkt, which had been commissioned by the DEGES for a total of five parts of this large-scale project: Apart from the overall execution, the project consisted of the sub-projects steel construction, specialised civil engineering, formwork and waterproofing. Max Bögl arranged for various subcontractors to do the hydraulic engineering and the laying of the reinforced concrete.

New cable-stayed bridge building system

For three years – since June 2004 – the Neumarkt teams worked on site with the project managers headed by Martin Steinkühler on the gigantic bridge construction project consisting of six separate structures altogether. Four of these are in prestressed concrete, one is a composite steel construction and the main structure, the cable-stayed bridge, consists of a hollow steel box suspended from a 128m high steel pylon. This was the début of a totally new cable-stayed system in the building of large bridges in Germany. A third of the total structure – 19 of 53 axes – is under water, which necessitated several special measures during the construction work.

“The substructure is founded on more than 415 bored piles,“ explains Alexander Jung, head of the engineering section of the technical project management. “To do this, we had to do some of the work directly from the water, the Strela Sound, with the aid of a catamaran.” 

Continuous drop shape

The heart of the new bridge consists of a 128 m pylon pillar in the shape of a drop. This architectural feature, designed by the Düsseldorf engineering company Schüßler-Plan in cooperation with the architect André Keipke from Rostock, is repeated in the individual bridge structures. Two Y-shaped supports made of steel and self-compacting concrete, a characteristic of structure 1.2, have also been designed in drop shape. Even the supports of the substructure have been given a drop-shaped base.

Structure 2 was a particular challenge for the staff of Max Bögl Stahl- und Anlagenbau GmbH & Co. KG. Each superstructure section was delivered in six individual parts from Neumarkt, welded together on site and then assembled. “The solid superstructure consists of a total of 17 sections, whose individual parts weigh up to 470 tons so that giant cranes had to be used for its assembly“, comments Alexander Jung. Europe’s largest floating crane was specially deployed to assemble the superstructure in the water. As the last concrete superstructures could not be completed until the beginning of August 07, there was no time to lose with the waterproofing. This was another special aspect of this project, as part of it was done directly on steel. And yet another innovative aspect characterises the Strelasund bridge: it is the first bridge in Germany to have a cable-stayed design with parallel strand bundles.

The specialists from Max Bögl built structures 3-5 using an overhead launching gantry specially designed for this task.

Full minimisation of project risks

It was no easy task for Martin Steinkühler and Alexander Jung and their teams to manage several construction projects at the same time with an inexorably approaching deadline. Altogether, the Neumarkt company was responsible for the bore piles on land and in the water, the steel construction, the waterproofing, the concrete engineering and the formwork. Between five and seven members of staff from construction management, purchasing, technical and commercial project management to billing are responsible for time and cost management of each individual project and the project as a whole. “While the project is running, we draw up monthly cost forecasts, as our company management expects us to keep a constant eye on costs and schedules to minimise risk and be able to intervene if necessary,” Jung sums up. For the last four years, the company has been using the project lifecycle management solution of RIB. “The RIB software meets all our business needs from tendering through costing the order and work performed all the way to billing, claim management and regular nominal/actual comparisons,” the head of technical project management continues.

The company also has a specific interface to SAP, which enables the project groups to produce detailed planned/required/actual costs per project and analysis of tax-relevant data such as hours worked or material consumption.

Before the company introduced the RIB CSuite software solution, the project teams worked with spreadsheets. “These programs often came up against their limits, particularly for large-scale projects“, says Jung. “Thanks to the RIB solution we can now communicate data from project to project and from site to site – with the aid of the shared data pool. This minimises risks for the entire project.“ 

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