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Loureiro Viaduct

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The Imigrantes Second Highway

07 01 2003
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Funchal Airport Extension, 2nd Phase

published: 12 09 2000
Inaugurated in 1964, the Madeira airport and its 1,600 m. runway very quickly showed its limits.

Inaugurated in 1964, the Madeira airport and its 1,600 m. runway very quickly showed its limits. A first extension of 200 m., completed from 1982 to 1986, improved the operational safety of the runway and gave it its present configuration. The new project includes a runway of 2,800 m. designed partly on a pre-stressed concrete structure extending over the ocean at a height of 60 m., on an axis oriented three degrees from the existing centerline.

The structure, designed by the great Portuguese engineer, prof. Edgar Cardoso, is made of an hyperstatic plate, 1000 meters long and 180 meters wide.
This structural plate, longitudinally and transversally post-tensioned, is bearing over a portal structure made of 5 spans with a center distance of 32 meters.

There are 31 portals and each one is restrained over 6 rounded piles, with a 3 meters diameter and a medium height of 50 meters. Being the center distance between piles 32 meters, the beam extends cantilevered for each side by 10 meters. The hyperstatic beam has an height at the restrained end equal to 5,60 meters and at the center line of 3,60 meters. Its transversal section has a shape of double T, with a thickness of 3 meters at the bottom and of 2 meters in the web.

Post-tensioning of the portal’s beams is made with 9 cables type 27MTAI15 and 4 cables type 19MTAI15.
Since the erection system was foreseeing an advance cantilever with self-launching structures, cables have been realised with coupling anchorages both for 27 and 19 strands tendons, using Tensacciai system MTG15 series.

Beams reinforcement has been prefabricated on the ground, with single pieces 12 meters long.
Post-tensioning ducts have been also prefabricated with the reinforcement and later joined with couplers in order to guarantee tightness.
Post-tensioning elements, made of strands type T15S, diameter 15,7 mm, have been threaded on site, before concrete pouring, through high power strand pushing machine.

Since working operation cycle has been realized with 3 self-launching centerings working at the same time, post-tensioning application has been done at high working rhythms.

The plate has been realised after the erection of portals, using centerings of 30 x 32 meters.
Plate, made with a variable section, has an height of 1,70 meters at the incastro with portals and 1 meter in the mid span.

Plate’s longitudinal post-tensioning has been combined with the ducts crossing the portal’s beam already made.
This post-tensioning has been also realised with couplers, in order to guarantee continuity between different spans.
Once completed the plate’s longitudinal post-tensioning, the joining element of 2 meters has been cast after making the coupling of transversal ducts and threading of strands. Stressing of strands has been then completed.
Plate’s transversal cables, being threaded in only one phase, have no couplers and have a length half of the plate’s width, i.e. 90 meters, because they have been designed with an overlapping.

More than 1500 couplers for 27 strands cables have been installed with all relevant operations of strand threading, stressing with MT6000kN jacks, assembly of couplers with auto-locking spring system, grouting, etc.
All these actions have been made in accordance with a huge time-planning system of the jobsite, obviously severe and strict, where each post-tensioning operation was binding for the following operations.

Post-tensioning works have been realized by the Consortium Tensacciai-SPIE BATIGNOLLES T.P., which performed the works turnkey.

In September 2004 this work, chosen between 17 challenging projects, has obtained the IABSE (International Association for Bridge and Structural Engineering) award for international Engineering. That award is in addition to the SECIL 2001 award, got from the Order of Portugal Engineers, who have defined this work as one of the hundred most representatives projects of the twentieth century.

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Project : Funchal Airport Extension, 2nd Phase
Location : Funchal (Madeira) - Portugal
Main client
: ANAM - Aeroportos e Navegacao Aerea da Madeira S.A. (Portugal)
Contractor : J.V. NOVAPISTA: ZAGOPE (Portugal), SPIE BATIGNOLLES T.P. (France), ANDRADE GUTIERREZ (Brazil), OPCA (Portugal)
Designer : CONSULMAR - SEGADAES TAVARES & ASS. (Portugal)
Period : 1998-1999