• Location: Guadarrama (Madrid – Segovia, Spain) SEE MAP
• Scope of Works: Construction Detailed Design.
• Client: IBERPISTAS ABERTIS
• Date of project: 2004-2009
• Opening date: 2012
• Main Features: Widening of the platform of a toll motorway and rehabilitation of the bridges.
• Length of the section: 31 km

As part of the work to widen the platform of the AP-6 toll motorway, Valle de los Caidos – Villacastín section, it was necessary to prepare, repair and widen the existing structures located on the section.

As a previous phase of the design project, an inspection and analysis of the condition of the structures of the section was carried out. Core samples of concrete were taken and an analysis of chlorides was done on them. Analysing the results of these inspections and tests, decisions about the actions required in each structure were made, including their rehabilitation, reinforcement, or even demolition and subsequent construction of a new structure, as in the Arenales, Lavadero and Sotillo Viaducts.

On undertaking the rehabilitation designs, an analysis of the bearing capacity of existing structures was done. But there was also another condition that the structures must be kept open to the traffic at all times. At least two lanes must always be kept open during the period of time that the rehabilitation works were in progress.

In the section between the Valle de los Caídos and San Rafael, new viaducts were built parallel to the existing San Rafael and of La Jarosa Viaducts. It was also necessary to strengthen and rehabilitate the existing viaducts (mainly replacing some damaged beams and reinforcing some pier caps) as well as on the existing “pergola” and the structure located at STA 52 +100.

The widening of the platform (3 lanes) on the San Rafael – Villacastín section entailed the extension of some underpasses and culverts in order to accommodate the third lane of each platform. The Arenales, Sotillo and Lavadero Viaducts were also affected. A new deck, attached to the existing one, was built supported by new piers and abutments. Then, when the traffic was diverted onto the new viaducts, the existing decks were demolished and new viaducts were built in the old location. Finally, both new structures were connected.

This Rehabilitation and Widening Design Project of the AP-6 toll motorway includes extensive and diverse activities: inspection of existing structures, analysis of their condition and bearing capacity, widening or enlargement of some of these structures, strengthening and rehabilitation of others and the construction of new viaducts to achieve the platform section needed. In addition, some strict operating conditions concerning the traffic had to be considered.