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Metal corrugated prefab constructionSUPERCOR®

SUPERCOR® manufacturing process consists of flat, metal formation to corrugated and rolled sheets, which are galvanized with hot dipping later on. These sheets may be covered with epoxy coat additionally. All these processes are carried put in covered premises.

S315 MC grade steel is used for the manufacture of SUPERCOR® conforming to the LST EN 10149-2 or LST EN 10025-2 standards. Viscosity limit of this steel is 315 MPa.

SUPERCOR® sheet cross-section parameters

Sheet thickness, mm Area, mm2/mm Inertia momentum, mm4/mm Resistance momentum, mm3/mm
5,5 6,968 17 141,15 235,62
7,0 8,867 21 897,45 297,92

A sheet thickness is selected as per calculations referring to the structure diameter, a width of a gap, a height of filling, temporary loads. Manufacturing as per order, other configurations are possible. Please address to the specialists of the UAB Viacon Baltic for detailed consultations.

Calculating the SUPERCOR® structures, the loads of roads and railways are taken as per EUROCODE EN 1991-2 or local standards.

Anti-corrosion protection
Zinc layer thickness

Characteristics for steel sheets  LST EN 1461
Minimal local zinc layer thickness (µm) Minimal average zinc layer thickness (µm)
≥6 mm 70 85
≥3 mm iki <6 mm 55 70
≥1,5 mm iki <3 mm 45 55
Screws, nuts, anchor screws 40 50

Durable anti-corrosive protection is received covering steel products with hot dipping of an anti-corrosive layer. A combination of this layer with an additional epoxy coat – this is the ViaCoat system conforming to the requirements of the LST EN ISO 12944-5 standards.

An epoxy coat is frequently used, but the surfaces, effected with the UV rays may be additionally covered with upper polyurethane layer.

A standard epoxy thickness is 80÷200 μm, it may be increased to provide larger durability of a metal structure. To improve adhesion between an epoxy layer and galvanized steel, the surfaces are teaseled with sandblasting. Required minimal adhesion force between the galvanized surface and an epoxy layer is 4 MPa – controlled with tearing test in accordance with LST EN ISO 4624 standard.

It is painted at the painting workshop complying with the strict technological mode, ensuring long-term anti-corrosive protection.

Screws, nuts, anchor bolts.

  • Corrugated sheets are interconnected with M20 8.2 grade bolts.
  • The length of the bolts is selected as per the thickness of appropriate sheets, a quantity of connecting sheets and a type of joints. There are two types of bolt heads – oval and conical.
  • Bolt lengths – 50 mm, 63 mm, 70 mm.
  • 20 mm diameter bolts and nuts conform to the requirements of LST EN ISO 898-1 and LST EN 20898-2 standards.
  • 20 mm diameter and 225 mm or 365 mm length steel anchor bolts conform to the requirements of the LST EN 10025-2 standard.
  • Foundation insertion parts – metal troughs, whose dimensions 157 x 190 x 38 x 5 conform to the requirements of the standard LST EN 10025-2.

All the above-mentioned connection parts are supplied together with corrugated sheets and they are parts of the SUPERCOR® structure.

A structure turn corner as per road axle
Minimal allowable turn corner as per road axle is 55°. Under this corner, it is recommended to design concrete rims of overflow ends. A special armature framework is used to fix them to the SUPERCOR® structure. Please address to the specialists of the UAB Viacon Baltic for recommendations.

Additional stiffness sheets
Additional stiffness sheets are designed, when the structure stiffness options are exceeded. They are used for any cross-section structures.

Possible placement alternatives

Across structure:

  • On the upper part of the structure
  • Through all the structure perimeter

Along structure:

  • Along all the length of a structure
  • Gaps at every 762 mm, 1143 mm, 1524 mm

In order to increase the holding power of the structure, the gaps between the additional sheets and main sheets may be concreted (C25/30 grade concrete). Such a solution may be necessary for larger cavity structures. Additional stiffness sheets permits to increase the cross-section area of an arch structure, reducing stretching in the structural walls. They allow to increase the stiffness of the structure in the box cross-section structures.

Advantages:

  • Simple designing selecting standard products;
  • higher holding power;
  • cost-effectiveness;
  • simple and quick assembly;
  • possibility to mount in negative temperature;
  • possibility to mount without traffic stoppage;
  • possibility to mount the prefab elements in the construction site;
  • easy transportation to difficult to approach or distant locations due to little weights;
  • little time and finance costs.

Usage areas:

  • Construction of engineering structures over the roads, railways, and under them:
    Overflows; bridges; viaducts; tunnels; underground passages; ecological passages for animals; hangars; sheds; warehouses; covers/shells of conveyor lines; covers/shells of pipelines.
  • Repair of old reinforced concrete or stony overflows, inclusion of a new structure in the old structure, and filling in the gap with concrete (during the repair the traffic is not stopped, the road sub-grade is not dismantled);
  • runs of animals.

Gofro bangos matmenys_SuperCor

Additional information in a booklet.