New Technologyfor Highway Deck Plate Replacement‫ﺗﻜﻨﻮﻟﻮﺟﯿﺎ ﺟﺪﻳﺪة ﻻﺳﺘﺒﺪال ﻟﻮﺣﺔ اﻟﺴﻄﺢ ﻟﻠﻄﺮق اﻟﺴﺮﻳﻌﺔ‬Hanshin Expressway has maintained 250-km long elevated highways in Osaka and Kobe Area, Japanfor more than a half century. Consequently, 40% of entire network is older than 40 years under theheavy urban traffic. The introduction of a new technology to replace aging and damaged concrete
bridge deck plates is a cutting-edge solution to realize longer-life expressway structures.

Water-Jet Cutting for quick removal of deteriorated rigid
concrete bridge deck plate
For shortening road closure, some parts of rigid concrete are preliminary removed to expose connection studs
between bridge girder and deck plate.

Advantage of Water-Jet
Cutting Method
During road closure, rigid concrete deck plate
can be removed easily by simply removing
remaining stiffener used during construction
and cutting connection studs by plasma cutter.

Apply WJ to remove theconnecting concrete

Install temporary reinforcement(flange guard) between the girder
and the floor base4 Suspended waterproof

1 Joint removal using WJ withscaffold equipped withsoundproof and water leakdetection system

the road above
remaining in service

2 Temporary reinforcement

after joint removal

3 Speedy cutting of

exposed studs

Ultra strong Fiber reinforced Concrete for bridge deck plate-Lightweight, durable and easy installationNewly developed lightweight and durable rigid concrete bridge deck plate called “Ultra-strong Fiber-reinforced
Concrete (UFC)”. deck plate is lighter and more durable than conventional pre-stressed concrete deck plate .
UFC deck can be flexibly applied to existing deck replacement projects and, therefore, is highly useful for bridge
rehabilitation project especially in urban area.

Advantage of UFC deck
High durability material and two-dimensional pre-stressing technology
contributes weight reduction for two-third, thickness reduction by 17%.

Installation
MachineUFC Deck

Less preliminary treatment needed to the main girders
UFC floor base
RC floor base(old standard)

Pre-tensioned PC steel(positioned at the rightangle to the bridge axis)

2/3 Thickness
Reduction!

Bridge Girder

PC floor base

Reduction of Deck Thickness

Post-tensioned PCsteel(along the bridgeaxis direction)

Components of UFC

HANSHIN EXPRESSWAY COMPANY LIMITED
https://www.hanshin-exp.co.jp/english/

Use of Fibers inside Concrete

Installation of UFC Deck Plate

Ageing Road Assets‫ﻣﺘﻘﺎدم‬9,0008,000

 At least 40% of the total bridge-length and 20% of total tunnel-length were also
constructed more than 30 years ago and they are facing increased risk by the aged
deterioration.
 The total vehicle weight is increasing with the increase in the number of large-scale
vehicle on the expressways. The expressways are under severe conditions such asincreasing in the usage of anti-freezing agent (NaCl) and the increase in the amountof extreme rainfall for a short time.

60

10～19 years
20～29 years
5030～39 years

Total expressway Length(km) At least 40% of the total expressways-length has been operated for more than
30 years and because of this, the expressways are seriously deteriorated.

Less than 10years

7,000

40～49 years
More than 50 years

6,000

40

Average

5,000
30
4,000
20

3,000
2,000

10
1,000
00

Elapsed years of the expressway transition

Concrete cracks and float

Severe environment in snow region

Concrete free lime

Damaged Condition

Average Service Period (years)

Current situation and problem of expressways

10,000Expressway Renewal Project‫اﻟﺘﺠﺪﻳﺪ‬Severe deterioration on slab lower surface

Large-scale renovation for bridges
e.g. Replacement of RC concrete slab with PC precast slab

Two-way trafficregulation

Open to Traffic (1963)

Deteriorated Structure (2014)

Bridge renovation work

Undergoing Renewal Works (2019)

Renewed Segment (planed in 2026)

Expressway Inspection & Diagnosis‫اﻟﺘﻔﺘﯿﺶ واﻟﺘﺸﺨﯿﺺ‬BridgeRoad Surface
One of unique road surface inspection vhiecles, not only can measure rutting, cracking,and flatness (σ10ft, IRI) but also longitudinal and transverse pavement measurementswithout making contact with the pavement.
It can smoothly and safely perform all 6 functions at 100km/h without impacting the flowof other traffic.

High-Speed Road Surface Measuring Vehicle (Road Tiger)

Tunnel Liner
Tunnel liner inspection vehicle:

High definition images taken by digital camera or video camera makes it possible toinspect the surface of a structure in the same way as the close visual inspection.
Through a computer analysis of the images, the clacks are automatically detected.

Infrared Camera System –Delaminations /spill inspection:
The infrared camera system takes images which isanalyzed automatically and displays the damagelevel in three stages. Because damages areobjectively analyzed by software, bias oroversight in measuring caused by skill difference
can be prevented. In addition, this system helps tocreate a research report since the detected results
are easily captured on spreadsheets or word
processing software. This system has gotten trackrecords in the U.S.

Infrared thermal image

Bridge inspection using
Infrared Camera System

It is now possible to obtain a clearer image at a speedof 100km/h by adopting the line sensor camera insteadof the conventional video camera. In addition, because
the photographing illumination using LED infrared
illumination is not visible to the naked eye, it no longer
influences on the passing vehicles on the opposite
direction. Moreover, this vehicle automatically identifies
the cracks by the captured image.

Inspection vehicle

Filming in a tunnel

Digital camera/video camera system - Crack inspection:

Crack analysis(minimum 0.2mmin width)

Bridge inspection using Digital
Camera System

Automatic crack-analysis by computer

Damage is detected bycomputer analysis

Video CameraSystemDisaster Management‫اﻟﻮﻗﺎﻳﺔ ﻣﻦ اﻟﻜﻮارث‬Use of rest areas as disaster-management bases

Disaster Prevention
Disaster caused by extreme
rainfall for a short time

 Ground anchor

 Slope Protection WorkNew type of anchor installation filling up
traditional anchor with inadequate
Existing conventional
anticorrosion function

Measures against land slide

anchorIn the Great East Japan Earthquake, the Self-Defense Forces and firefighters heading to stricken areas used
expressway rest areas as relay and support bases. Based on this experience and various issues, authorities arebolstering their disaster-response capabilities across Japan to respond effectively and efficiently to emergencies,
using Moriya SA on the Joban Expressway as their model.
 Moriya Service Area (Southbound) on Joban Expressway, as a disaster management base

New type of anchor
addedEmergency vehicle
entrance/exit
Used by emergency
vehicles to enter and exit
outside of expressway intimes of disaster

Disaster-response warehouse
Inflatable tents for outdoor use,
emergency food and rations, reliefsupplies, traffic regulation equipment
and other suppliers are store at thisDisaster-response warehouse

The recovery of the Tomei expressway in Makinohara areaImmediately after the Surugawan earthquake, NEXCO-Central started emergency checkup and stopgap recovery, and 4 days
later, finished temporary recovery for general traffic.

Aug. 11th 2009

Generators and rooftop
solar-power generation
facilities

Solar-power generation
panels on the roofs ofcommercial facilities

Heliport for mid-size
Helicopters
Nighttime illumination anda helicopter office havebeen installed, enablingsafe landing and take-off
day and night

Generators enable
continuous use for
72 hours

Aug. 15th 2009 (4 days later)

Earthquake Museum for educational assistance on disaster prevention
Great Hanshin-Awaji Earthquake occurred in January 1995, took precious
lives and destroyed cherished livings of local communities. Earthquake
Museum conveys how Hanshin Expressway responded in the 623 days tocomplete the restoration of the expressway system. It displays damaged
structures and introduces new technologies and various activities which
put into practice based on the lessons including disaster management
support and educational assistance for disaster prevention.

Well
A well has been dug in caseof interruption of watersupplyThe food court is used as adisaster management office(1st Floor)
The food court layout can berearrange for use as a disastermanagement office, underdisaster situations- Electrical power outlets and TV
antenna terminals are installed- Large monitors and whiteboards
are installed

First-aid space (2ndFloor)
The employee break lounge
can be used as a first-aidroom.

General situation

Emergency situation

NEXCロ・.
Ez‑‑
2Japan'sExpresswaysarebuiltandoperatedbys
i
xcompanies.
Thetotallengthi
noperationi
s10，351km，
and331kmi
sunderconstruction.
Sapporo

WEST

CompanyName:
WestNipponExpresswayCompanyL
imitedHeadO
ffice:Osaka
Expresswaysi
nOperation:3，533km

NEXCロ

TrafficVolume:2.
95millionvehiclesjday

Er:
lS T

Tol
IRevenue:US$7.
1billion

CompanyName:
imitedEastNipponExpresswayCompanyL

Expresswayunderconstruction:72km~る

Hanshin
Expressway

CompanyName:
HanshinExpresswayCompanyL
imitedHeadO
ffice:Osaka
Expresswayi
nOperation:250.
4km

HeadO
ffice:Tokyo
Expresswayi
nOperation:3，943kmNEXCロT
rafficVolume:2.
95millionvehiclesjday

山 E5T

Tol
IRevenue:US$7.
82billion

Honshu‑Shikoku
BridgeExpressway

ExpresswayunderConstruction:75km

NEXCD
E日 5 T

TrafficVolume:0.
72millionvehiclesjday

量NEXCOCENTR日 L

Tol
IRevenue:US$1.7
billionCompanyName:Cent
ralNipponExpresswayCompanyL
imitedExpresswayunderConstruction:34.2km

日Honshu‑Shikoku
BridgeExpressway

HeadOffice:Nagoya

FukuokaExpresswayi
nOperation:2，132km

shutokoCompanyName:
Honshu‑shikokuBridgeExpressw
ayCompanyL
imited.98millionvehiclesjdayTrafficVolume:1
Tol
IRevenue:US$6.
30billion
ExpresswayunderConstruction:132km

HeadO
ffice:Kobe
Expresswayi
nOperation:172.9km

shutoko

TrafficVolume:0.
12millionvehiclesjday

IRevenue:US$0.
6billionTol

NEXCD
CENTR日 L

CompanyName:
imitedMetropolitanExpresswayCompanyL
HeadO
ffice:Tokyo
Expresswayi
nOperation:320.1km

Inoperation
.
.
.
.
.
.
.
・・園
田・ Underconstruction

Hanshin
Expresswayst，Aso
fJULY120192019andc
alculatedbyt
heexchanger
ateo
f110JPYfor1US$
Note:Revenuei
sforyearendedMarch31，

TrafficVolume:1.02millionvehiclesjdayTol
IRevenue:US$2.
4billion
ExpresswayunderConstruction:17.5km