One of the largest EPS structures ever built

Because of the weak subsoil and the short lead time, a number of structures on the new A16 Rotterdam were founded on EPS. Commissioned by construction consortium De Groene Boog, Bonneveld Gewapende Grondconstructies has processed more than 80,000 m3 of EPS in the project in recent years. The new viaduct KW22 over the High Speed Line HSL takes the crown. With approximately 30,000 m3 of EPS under each abutment, it is one of the largest EPS constructions in our country.

Shortly after Rijkswaterstaat awarded the A16 Rotterdam to De Groene Boog, we already started our work, says estimator Leon van der Heiden of Bonneveld Gewapende Grondconstructies BV. "So we started laying the foundation for KW22 over the HSL as early as November 2022. An EPS construction was deliberately chosen here because the subsoil could not tolerate a regular preload. It would cause too much settlement on the HSL and that was not desirable." De Groene Boog first excavated the site at both abutments to 1 meter below ground level. It was then leveled by Bonneveld and they started "stacking.

20 layers high

Under both abutments of KW22 is an EPS construction totaling 20 layers high over an area of 47 by 32 meters on either side. "If you consider that we are working with EPS blocks measuring 4 by 1.25 meters and 50 centimeters high, you can imagine that it was quite a job," acknowledges project manager Hans van Beek of Bonneveld Gewapende Grondconstructies. The Bunschoten-Spakenburg-based firm had about 25 weeks of work on this artwork alone. "We were able to process about 600 m3 per day, taking into account the other work on the project. Accessibility was also a thing. We had to make the work over our own. Therefore, among other things, we used a long-reach 45-ton crawler excavator with an 18-meter-long arm equipped with an EPS clamp we developed ourselves. The machine is used to lay the blocks on the structure, after which they are processed by a team with small equipment, placed in the correct position and anchored with staple plates. 

Editable

Bonneveld Armed Ground Constructions is an expert in building EPS structures. "Over the years we have also built our own tools to process the blocks as efficiently as possible." In addition to the clamp mentioned, Leon is also referring to the in-house developed sword to cut the blocks precisely to size on the job, without releasing Styrofoam sawdust which then ends up in the environment. After KW22, Bonneveld completed several more smaller EPS structures for De Groene Boog. "For KW25, a small viaduct over a service road, we processed a total of 2,500 m3 of EPS in the ramps. Incidentally, this construction was a bit more laborious and required quite a bit of cutting. Then we moved on to KW52, which accounted for 15,000 m3 and later another 6,000 m3 of EPS that had to be applied in a curve. Also very laborious, in other words." Fairly recently, Bonneveld made the EPS construction for the temporary artwork TK58 across the Hoofdweg. A total of 1,600 m3 with another 8,500 m3 in the access and exit ramps.

Because of the huge amounts of EPS in this project, we had to buffer a lot to ensure speed, Hans says. "There was so much EPS going in that factories couldn't keep up. That's why a depot was created in advance on the project from which we could draw." Both men look back on a successful project and a pleasant cooperation with the construction consortium. "Unfortunately, nothing of our constructions will be visible in the final situation," Leon concludes with a laugh.