VSL BEBO® – PRECAST CONCRETE ARCHES

DESIGN
ENGINEERING
SUPPLY
INSTALLATION
VERSATILE AND EFFICIENT IN A MULTITUDE OF
APPLICATIONS
Worldwide network
VSL, a specialist construction company, operates
through 35 subsidiaries as a world-wide network,
including manufacturing facilities in Europe and
Asia. With 4,100 employees including over 1000
Engineers, VSL provides technical consultancy and
services for the full range of works from project
planning (development of preliminary designs,
alternative design proposals) to specialised
construction works, operating in the field mainly
with its own working force and equipment.
Over 50 years of engineering
experience
VSL’s specialist construction systems have been
used throughout the world since 1956 and have
earned an excellent reputation for quality and
reliability. This has made VSL a recognised leader
in specialist construction methods and associated
engineering works.
Reliable partner
VSL provides: skilled, trained staff and construction
specialists; an ability to benchmark and take
advantage of new methods, new equipment and
new materials; specialist equipment designed to be
as modular as possible to be reused in different
configurations. VSL is also committed to offering
innovative contracting approaches including
alliances on major projects, which enable VSL and
the main contractor to focus on what is “best for the
project”.
Changing the way we do business
For VSL, sustainable development means striking a
balance in its development model between the
economic profitability of it’s businesses and their
social and environmental impacts. That
commitment is formalised into the VSL Sustainable
Development programme which focuses on safety,
use of fewer scarce materials, less energy and
reduced production of pollution and waste.
Training: At the heart of strong
performance
VSL is committed to investing in its staff, setting up
training schemes and striving for professionalism.
VSL Academy
VSL has launched the VSL Academy to strengthen
the company culture and to develop knowledge
sharing by formalising and standardising the
training of supervisors and site engineers in post-
tensioning, stay cables and heavy lifting.
The goals of the VSL Academy are to:
• provide a unique training facility and tools within
VSL to train our personnel in the skill and
techniques required to perform the work to the
highest standards specified today;
• provide hands-on practical training on post-
tensioning mock-ups designed to cover all
operational procedures;
• harmonise working procedures and enhance
knowledge.
VSL – a strong QSE culture
VSL’s leading position is based on a rigorous and
committed quality culture. The QSE (Quality,
Safety, Environment) policy represents a major
focus for every service provided.
Local teams ensure co-ordination of actions,
encourage sharing of experience and promote best
practices, with the aim of continuously improving
performance. In VSL’s culture, employees are
vitally important to the competitiveness and
prosperity of the company. VSL is committed to
maintaining the highest levels of client satisfaction
and personnel safety.
PMX – training in project management excellence
The programme’s content combines technical
topics, planning, organisation, risk management
and result orientation with communication topics
and leadership. Through this, VSL’s managers
transfer the fundamentals and culture of the
company while promoting exchanges and useful
networking throughout the group.
On site training
As a specialist contractor, VSL aims to maintain
and develop its staff’s skills on a long-term basis.
Senior staff members are in charge of teaching
VSL Techniques to new recruits. A well-trained
staff is VSL’s most valuable asset in providing the
best-possible service to clients
 Customized VSL BEBO® Arches
VSL provides precast or cast-in-situ concrete arch
solutions which deliver the maximum economy and
design flexibility whilst providing site-specific
clearance envelopes under the arch. The design of
a VSL-BEBO® Arch is carefully tailored to suit the
structural and geometrical requirements of each
project. Whilst standard geometries and designs
are available covering most applications, bespoke
solutions can rapidly be developed. The VSL-
BEBO® Arch system can accommodate high
depths of fill, large live loads, and the heavy
loading conditions often associated with mining
applications.
VSL-BEBO® arches can be installed quickly and
safely over existing roads and live rail or other
services with minimal disruption. The arch design
methodology utilises finite element analysis and
funicular curve theory, to optimise structural
performance and optimise material costs, whilst
ensuring good buildability, durability and a cost
effective total solution.
Turn-key solutions
The VSL BEBO package is tailored to meet the
specific project and customer’s requirement with
options including component design, component
supply through to management and construction of
complete turnkey projects.
Multiple applications
The VSL-BEBO® system meets the project’s most
challenging requirements. Owners, engineers and
contractors worldwide make use of the VSL-BEBO®
system for the construction of many types of
structures. Applications are:
 Bridges
 Cut-and-cover tunnels
 Culverts
 Underground structures such as garages,
depots,...

VSL’s commitment to Health and VSL-BEBO® & VSoL® - A sustainable

Safety
VSL and all its employees are committed to
pursuing excellence in everything they do and this
includes the management of health and safety
which includes but is not limited to:
 Preventing illness, injury or loss of life
 Ensuring that risks are assessed and
controlled for all site activities
 Providing a safe work environment
 Implementing safe systems of work
 Ensuring the safe operation of equipment
 Not allowing VSL employees to carry out any
work if the work or the working environment is
considered to be unsafe
 Complying with legal contractual
requirements
 Training employees
 Continually providing performance
and energy efficient alternative
The VSL-BEBO® system is a precast concrete arch
system for the design and construction of earth
overfilled bridges, cut and cover tunnels, culverts
and underground structures. The arch system is the
ideal structural shape to carry vertical loads over a
given span and is therefore a natural “energy
efficient” technique of construction. VSL-BEBO®
precast concrete arches can span up to 30m or
more.
The VSoL® reinforced soil wall system by VSL is a
cost effective construction technique in a variety of
retaining walls applications. The principle of the
VSoL® system is to use the weight of the soil to
generate friction over horizontal “tie backs”
connected to panels which retain the soil. It is
therefore a very “energy efficient” way to build
retaining walls. Complying with international
standards
Combined together, the VSL-BEBO® arch system
and the VSoL® wall system used as spandrel walls The VSL-BEBO standard arches are fully pre-
provide sustainable and energy efficient engineered and designed to meet the requirements
alternatives to traditional small to middle span of various design codes such as:
bridges. Case studies comparing a single span
traditional bridge (reinforced concrete abutments • AASHTO – LRFD Bridge Design Specifications
and deck) and the equivalent solution built with a • British Standards – BS8110, BS5400, BD 37/01
combination of VSL-BEBO® and VSoL® systems • Euro Codes
demonstrate that the cost saving and the carbon • Australian Design Codes – AUSTROADS
footprint reduction are substantial. • Canadian Code – CAN/CSA S6-06
• AREMA
• other bridge design codes
HOW IT WORKS - TECHNOLOGY
How the VSL-BEBO® system works
VSL-BEBO® structures are generally built from a
number of precast reinforced concrete arch
elements placed on cast in situ or precast footings,
piers and/or abutments. After installation, these
elements are backfilled and covered with well-
compacted earth fill. The reinforced concrete
arches have a thickness that is sufficient to provide
substantial sectional capacity, but small enough to
allow an elastic deformations that mobilize part of
the passive resistance of the backfill. The backfill
not only provides the bed for the road surface but
also increases the load carrying capacity of the
structure.
VSL-BEBO® arch elements –
Different shapes and spans
The core of the VSL-BEBO® System are its precast
reinforced concrete arch elements. Three different
series have been developed, in order to cover a
wide variety of applications:
 E-Series arches have an elliptic shape and
cover overfill ranges from 0.5m to 4.0m (and
more) and with standard spans ranging from
3.6m to 25.6m.
 C-Series arches have a circular shape and are
well-suited to carrying high overfills and heavy
loads with standard spans ranging from 9.1 to
16.4m
 T-Series arches form a series of flat arches,
optimized for shallow overfills up to 1.5m and
applications with limited overall structural
heights with standard spans ranging from 12.2
to 30.0m.
 Standard “Single leaf” arches span from 3.6m
to 20.0m (depending on arch type)
 Standard “Twin leaf” arches span from 9.1m to
30.0m
 Special arch types for special applications
The arch / backfill system is analyzed via a state of
the art finite element analysis software (LUSAS)
using proprietary design models for all standard
arch types. These models have been calibrated
against full scale loads tests.
Once overfilled, an exceptional margin of safety
makes VSL-BEBO® system arch structures
relatively insensitive to overloading and the soil
mass around makes them mechanically well
damped. Thus, traffic vibrations do not appreciably
affect the system.
VSL-BEBO® arch elements are designed to be
stored and hauled in the position in which they are
cast. Generally, VSL-BEBO® arch elements should
be handled with a double-drum crane (a crane
having two independent drums with equal
capacity). Where no such equipment is available,
VSL has developed appropriate installation
procedures.
Backfill
VSL-BEBO® arch structures are backfilled and
overfilled with well-compacted earth fill.
Requirements for backfill materials are moderate
and compared with soil properties required for
construction of VSoL® retained earth walls.
Consequently, combining VSL-BEBO® arches and
VSoL® walls is straight forward.
Generally, soils that meet the following basic
requirements are acceptable for the fill :
 ' ≥ 30° (friction angle, compacted)
 wL ≥ 40% (liquid limit)
 Ip ≥ 10% (plasticity index)
Normal compaction equipment can be used and
the “classic” methods of Proctor apply for
determination of optimum moisture content and
quality control of the required degree of compaction
(Proctor standard compaction tests).
Where local soils do not meet the above basic
requirements, the addition of lime or cement to
create “soil-cement” is possible and often more
energy efficient than importing selected fill material.
 Zone B

Zone A

Soil Structure Interaction

For an overfilled arch structure, the fill represents

more than a loading. Through its passive
resistance, it significantly contributes to the load
VSL’s scope of work
carrying capacity of the arch and thus becomes a
structural part. The phenomenon is commonly VSL offers the complete services for the
known as soil-structure-interaction. construction of these arches:

 Preliminary and final design

 Prefabrication
 Construction
 Backfilling
 Spandrel walls with the VSoL® Retained Earth
wall system
ADVANTAGES OF THE VSL-BEBO® ARCH SYSTEM

Excellent Longer life of the Easy to dismantle

performance under
seismic conditions
VSL-BEBO® structures are particularly well suited
for construction in seismically active regions as
they provide the high degree of structural damping
needed to absorb large energy releases associated
with earthquakes.
bridge Dismantling, salvage and remediation of VSL-
BEBO ® structures is easy and environmentally
The oldest bridges one can find around the world friendly. Precast panels can be removed and
transported offsite without the need for destructive
are virtually all arch bridges. Their age is the best
proof of the longevity of arch structures. Because of works.
its shape, in an arch bridge the main concrete
elements are always in compression, when
concrete works best, and is therefore the most
durable.
Due to the compacted earth fill, the precast arch
bridges are insensitive to vibrations and can carry
much higher accidental loads than designed. This
was proven during load tests done in different parts
of the world.

NICE PHOTO IN LARGE FORMAT.

Saving in materials Quality Low bridge

The arch sections are slender in design, concrete
savings can reach up to 50% compared to
traditional applications such as box culverts or slab-
or frame-type structures.
The VSL-BEBO® arch structures have an ideal
structural shape to carry vertical loads. That leads
to savings in reinforcement steel of up to 50% and
more compared to traditional applications such as
box culverts or slab-type structures .
The requirements for back- and overfill
Material are moderate. Further savings in materials
can be achieved because:
 No bridge bearing
 No bridge joint
 No approach slab and simple and cost
effective construction procedures
Quality is achieved through compliance with
BEBO-VSL® specifications and guidelines. VSL’s
experience and the extensive technical support
instills confidence in the product.
Overfill reinforced concrete arch bridges are
extremely durable and require virtually no
maintenance (low life cycle costs)
VSL-BEBO® structures have no exposed bridge
deck, no transition joints or
approach slabs and no moving bearings, which are
generally the weak parts requiring regular
maintenance and/or replacement.
The arch shape is aesthetically pleasing and very
well received by officials, contractors, private
property developers and the public
maintenance cost
The main items to be maintained on traditional
bridges are the bearings and expansion joints.
Precast arch bridges avoid them. As the precast
arch elements are resting in the keyways on strip
footings, pedestals or pile caps, there is no
movement joint which needs any maintenance.
The deck of the bridge is of compacted earth fill,
which provides excellent protection for the precast
arch segments. The earth fill protects the concrete
arch from extreme temperatures, traffic vibrations
and accidental spillage of corrosive chemicals or
fire from the top.
Easy and fast construction
One truck – One crane – Four people
The construction of the arch solution is simple, rapid, and predictable with a small crew and conventional
equipment. Normally the arch is built by assembling prefabricated concrete segments in a symmetrical
pattern.

As a guide, a typical VSL-BEBO® arch system erection crew may include:

 crane operator, dog man and rigger

 two workers to receive and set elements
 one working foreman/ supervisor

With smooth and careful operation, it may be expected that 15 to 25 VSL-BEBO® elements can be erected
per eight hour shift accounting for an installed structure length of about 15m to 25m for twin-leaf arches and
up to about 50m (!) for single leaf arches, depending on the span and width of unit designed for the project.
Installation rates generally depend on site, accessibility and logistics.

As soon as backfilling is completed, the bridge can be used for the construction vehicles, thus allowing road
construction to proceed and in most cases avoiding long temporary traffic diversions.

Installation of a 30 meter long structure

.

1. Precast foundations on sand bed 2. Delivery of precast arch elements

3. Installation of ½ shelf, truck is used as temporary 4. Connection foundation and arch

support

5. One ring completed 6. Last bevel set, followed by casting of the in-
situ crown joint
TECHNOLOGY
Different shapes and widths are available. The core of the VSL-BEBO® System are its precast reinforced
concrete arch elements. Three different standard series have been developed, in order to cover a wide
variety of applications.

E-Series Elliptical arch shapes  Span Range  Overfill heights

3.6m to 12.8m for single leaf solutions,
and 14m to 25.6m for twin leaf solutions
 Single leaf solutions
For the smaller spans up to 12.8m span a
single arch element forms a complete
arch ring. The thickness of the concrete
section along the development is
constant.
The standard range of overfill above the
arch crown is 0.5m (minimum) to 5.0m.
VSL-BEBO® arches can handle
shallower and higher overfill. Such non-
standard applications are designed on a
project to project basis by VSL’s technical
staff.

 Twin leaf solutions

For the larger spans from 14.6m to 25.6m
two elements form one arch ring. The
thickness of the concrete section is
constant except for the crown area. The
connection of the two arch elements, the
patented crown joint, incorporates a
locally thickened section to allow for easy
in-situ casting of the monolithic
connection (no formwork required).

C-Series Circular arch shapes

 Span Range  Overfill heights
9.1m to 16.4m The standard range of overfill above the
arch crown is 0.5m (minimum) to 5.0m.
 Twin leaf solutions only C-Series arches, however, can handle
Due to the dimensions of the circular- considerably higher overfills up to 20m
shaped arches, for all spans, two arch and more. Such non-standard
elements form one complete arch ring. applications are designed on a project-
The thickness of the concrete section is by-project basis.
constant along the development except
for the crown area. The connection of the
two arch elements, the patented crown
joint, incorporates a locally thickened
section to allow for easy in-situ casting of
the monolithic connection (no formwork
required).

T-Series Flat arch shapes

 Span Range
12.2m to 30m and more

 Single-and twin leaf solutions (depending

on arch dimension)

 Overfill Heights
The standard range of overfill above the
arch crown is 0.5m (minimum) to a
maximum of 1.0m
 Foundations
T-Series arches require a special
foundations to account for large
horizontal support forces. Such
foundations have to be designed on a
project-by-project basis taking account of
the site specific geotechnical data.
APPLICATIONS
VSL-BEBO® technology can be used in a wide variety of applications including but not limited to
transport, mining, industry, energy, water, military infrastructures,...

Bridges
 Spans of 3 metres to 31 meters and more
For highway, road, railroad, river, lake, cycle path,
and culvert applications and many more.
 Low rise applications for small trade separation
Design code specific live loads can be handled
even for small overfill applications
 High rise profiles such as sailboat underpasses
 Large span / low rise profiles for wetland crossings
 High overfill and very large live load applications
such as aircrafts or mining trucks are feasible
 Aesthetically pleasing structures due to distinct
accentuation of the true arch shape
 Smooth transition from fill to bridge
No approach slabs required – no hump
 Durability – low life cycle costs
Triple span E42 bridge after completion, Traffic runs on overfill, not on exposed bridge deck.

Lima, Ohio .

Tunnels
 Cut-and-cover tunnels with overfill heights of up to
30m
 Pedestrian and bicycle crossings under traffic
infrastructure
 Multiple cell applications and viaducts
Motorized traffic as well as public transportation
(railroads, light rail or metro)
 Variety of shapes and spans
Accommodate various clearance profiles, for
example railroads or multiple traffic lanes

Completed twin tube cut-and-cover

tunnel

Culverts
 Stream or creek crossings under traffic
infrastructure
 Drainage channels under heavy airport
loading
 Belt conveyor channels for mining
applications
High- or heavy overfill situations (e.g. Iron on
mining and storage) can be handled
 Open mining with heavy traffic loads

Underground parking Germany

SIDE WALLS WITH VSoL® ASSOCIATED TO VSL-
BEBO® ARCH –
A SUSTAINABLE AND COST-EFFECTIVE SOLUTION
Presentation of the VSoL® reinforced soil wall system
VSoL® is a reinforced soil wall system which
combines advanced engineering, reliable
performance, ease of construction and good
aesthetics to provide a very economic wall solution.
Available using steel mesh reinforcement (VSoL®
steel system), or with polyester friction ties (VSoL®
polymeric system), the VSoL® technique uses a
range of facing panel shapes, sizes and finishes,
which connect to the soil reinforcement using
simple, reliable connection details. When combined
with compacted backfill, these components form an
internally stable reinforced soil block, suitable for
spandrel walls, bridge abutments, approach ramps
and general retaining wall construction
Comparison of carbon footprints of VSoL® walls with L-shape
concrete walls
Up to 60% reduction of CO2 footprint,
and above
The combination of thin facings, reinforcement and
site-won backfill as primary structural elements
makes VSoL® walls very efficient in terms of
material use. This dramatically reduces the need
for concrete and rebar and therefore reduces the
overall CO2 footprint of the construction project.
In addition to excellent structural performance, the
VSoL® system is extremely quick to install, leading
to significant savings in time and cost over
conventional retaining wall solutions. The use of
precast panels permits a wide range of
architectural finishes to be considered to meet the
aesthetic requirements of a project. Furthermore,
VSoL® walls can be designed to accommodate
significant foundation settlements and for
particularly poor ground conditions. Where ground
improvement is the only option, combined wall and
foundation packages can be provided to suit project
requirements.
Original design
Carbon footprint values are for a 100m-long wall
compared to a conventional reinforced concrete
cantilever wall. CO2 emissions have been
calculated with CarbonEco® developed by VSL
• Loading on wall: 10kN/m2 (Life Loads) = 1T/m2
• VSoL® wall backfill material: all imported from
20km
• L-shape with backfill material:
• walls below 6m height: all local (1km)
• walls above (and including) 6m height: 50%
local (1km) and 50% imported from 20km
Shatin Heights, Hong Kong - 2006
Highway A8, Spain - 2005
Case study: VSL-BEBO® arch an
efficient alternative to small to
medium span reinforced
concrete bridges
This carbon footprint comparison compares a
conventional bridge solution with a solution
combining VSL-BEBO® precast arches and VSoL®
reinforced soil wall for an overpass bridge on the
Etihad Rail project in Abu Dhabi, UAE.
Alternative VSL-BEBO® arch
design
The alternative design consists in replacing the
reinforced concrete footings, the reinforced
concrete abutment walls and the prestressed
precast reinforced concrete beams by VSL-BEBO®
reinforced concrete arches (with the corresponding
foundations and footings) and VSoL® reinforced
soil walls.
The VSL-BEBO® + VSoL® solution presents a
reduction of nearly 74% of CO2 emissions for the
structure construction. The VSL-BEBO® arch
solution, combined with the VSoL® soil wall
system, provides a sustainable and energy efficient
alternative to the original bridge design.
Castle Peak Road, Hong Kong - 2004
Geelong Bypass, Australia - 2011

Airport Interchange, Oman - 2006 Peninsula Link, Australia - 2012

Creating sustainable solutions

together
Combined together, the VSL-BEO® arch system
and the VSoL® reinforced soil wall, show that
sustainable practices and economic success can
go hand-in-hand. The grouping of both systems
offer significant advantages with regards to
sustainable development:

 Important saving of construction material

 Reduced emissions of greenhouse gases
(CO2)
 Long life span due to high quality materials,
proven track record and ease of inspection
 Low maintenance and repair costs through
the life of the structure due to the properties
of prestressing
 Low sensibility to earthquakes as vibrations
can be absorbed effectively