PIANC Work Group 173 - SMART Rivers 2017 Timothy Paulus, USACE St Paul District September 20th, 2017

Presentation Outline Scope Site Visits Report Content Conclusions Questions

PIANC WG 173 – Rolling Gates and Movable Bridges Focus on mechanical and electrical design of rolling gates and movable bridges Scope: Establish a working group of mechanical, electrical and construction engineers to assemble “lessons learned” from navigation bridges and rolling gates and their operating systems and to give recommendations for future design.

Scope of Report From a mechanical and electrical perspective there are many similarities between rolling gates and movable bridges The aim and purpose of the report is to determine technological guidelines for design, fabrication, construction, operation and maintenance of both rolling gates and movable bridges. Case Studies

Similarities Drive systems – common components Wire rope and wire rope tensioning systems for example Remote operation Many times rolling gates are utilized as a movable bridge The effect on navigation traffic is similar if there is a failure of the drive system

Differences Standard of reliability Counterweights vs buoyant tanks A rolling gate structure, including the carriage assembly, has many components that are submerged Maintenance practices

Site Visits Antwerp Belgium June 2014 Panama Canal September 2014 Bremerhaven Germany April 2015 Amsterdam Netherlands October 2015 Montreal Canada June 2016

Bremerhaven Germany Kaiser Lock April 2015

Panama Canal in Front of New Rolling Gates

Report Outline Chapter 2 provides the report conclusions Chapter 3 provides some history and similarities and differences between rolling gates and movable bridges Chapters 4 to 10: Rolling Gates Chapters 11 to 18: Movable Bridges Appendices

Rolling Gates Most of European locks utilize redundant gates on both ends of lock as does the new Panama Canal locks Wheelbarrow vs Classical Design Largest locks/gates currently are the wheelbarrow design including Kieldrecht, Berendrecht, and Panama Canal 3rd Lane Kaiser Lock (Bremerhaven) and Northern Lock in Ijmuiden both classically supported Rolling gate table in Appendix Well proven gate system

Rolling Gate Topics Report looked at buoyancy conditions Framing – different types framing systems – single and double skin plates Operating speed Filling and emptying systems Ship impact Support systems and guiding systems Rail tracks and carriages Maintenance concerns and issues Sustainability

Machinery for Rolling Gates Most rolling gates today utilize a wire rope winch system for opening and closing the gate Chain systems are also used to drive rolling gates – push/pull chain systems in Bremerhaven/Brunsbuttel The older Bremerhaven Sea Locks utilize chain drive Wire rope tension systems

Berendrecht Lock Machinery – all mechanical drive system The rolling gates are two to three times (or more) the weight of a miter gate leaf. The motors at the Antwerp Locks utilize between 250 kw and 300 kw motors.

Winch drum – two per gate Note alternate lay of wire rope – this is to prevent torsion of the wire rope as it spools on and off the drum

Machinery for Rolling Gates Rack and pinion drive – Gouda Rack and pinion drive – new lock at Ijmuiden Hydraulic drive systems – Northern Lock Ijmuiden

Gouda and Brusbuttel drive system

Ijmuiden drive system

Kaiser Lock Rolling Gate Top portion of gate is lifted with hydraulic jacks to fill and empty the lock chamber Gates are 21 meters tall

Kieldrecht Lock 68 meters wide (223 feet) by 500 meters long (1640 feet) by 18 meter (59 feet) depth over sill Gates floated into place as opposed to Panama gates installed in dry

Panama Canal New Locks New lock construction on both the Pacific side and Atlantic side will provide a third lane of traffic Both new locks are triple lift (back to back to back locks) New locks will accommodate post-Panamax vessels New locks will be 55 meters wide (180 feet), 427 meters long (1400 feet), and 18.3 meters water depth (60 feet) New locks will utilize rolling gates as opposed to miter gates – wheelbarrow design Double rolling gates on each end of locks Goal is 99.6% reliability

Why Rolling Gates? European design preferences Some seismic concerns with miter gates on Pacific side Limited design and construction experience for miter gates on a 55 meter wide lock Rolling gates can be recessed and dewatered for repair – essentially a dry dock facility – gates can be lifted and supported in the recess Rolling gates are buoyant to reduce load (although the existing Panama miter gates are also buoyant) Will have a removable lower carriage 4 hour change out

Pacific Side Rolling Gate Gate will be 105 feet tall and 33 feet wide and 189 feet long Air chamber is at bottom of gate – all Panama rolling gates are designed to have removable lower carriage

Rolling Gate Installation

Panama Canal Gates Compression column and load limiting device for lower carriage

Movable Bridges Rock Island Arsenal Swing Bridge Duluth Aerial Lift Bridge

Movable Bridges Types – Bascule, Vertical Lift, Rolling Bascule, Swing Bridges Design Standards Looked at difference in design codes between European and American bridge designs Safety concerns Focus on a number of case studies

Movable Bridge Drive Systems Many similarities to rolling gate drive systems

Movable Bridge Drive Systems

Botlek Bridge Old and new bridges side by side

Botlek Bridge

Conclusions Panama Gates The design of the compression column and load limiting device works well for the requirements of the Panama Canal high reliability standards. For a lock with more outage times, a standard replacement arrangement by floating the gate and removing the lower wheels from the bottom may suffice.

Conclusions Rolling Gates A wire rope winch drive system generally will be the simplest drive system and is recommended for new designs. To help and facilitate maintenance, it is recommended to install condition monitoring systems on all drive components such as motors, brakes, and gearboxes

Conclusions Movable Bridges Regardless of the type of movable bridge selected, span weight and balance are critical in order to minimize the size and power requirements needed to operate a movable bridge. One consideration is to install sensors embedded on parts of the bridge structure and used periodically to monitor the loads on the bridge bearings

Questions? Contact Tim Paulus at timothy.m.paulus@usace.army.mil for further details on any of the slides presented here or further details on the working group report