presentation girder construction

3.1 Gider Cycle Schedule1st day ▪ Casting concrete 2nd day ▪ Curing for concrete ▪ Removal stop end form ▪ Roughing of concrete surface 3rd day ▪ Stressing ▪ Launching of traveler ▪ Sett

GIRDER CONSTRUCTION Chapter 3: GIRDER CONSTRUCTION

Site Condition P3 Side (Bai Chay Side)

l = 9.0m, n=2

Shin - so φ3000

l = 10.5m, n=3 Shin - so φ3000

P1 P2

A2

435000 902500

6700

129500 86000

35000

750

750 86000 129500

GENERAL VIEW OF THE BAI CHAY BRIDGE

SPAN SIDE

PIER TABLE

PIER BASE

4039383736353433323130292827262524232221201918

23 25 27 29 31 32

CLOSURE POUR DISMANTLE OF TRAVELLER

1 3 5 7 9 10 12 14 16 18 20 22 24 26 28 30 32

2 4 6 8 10 12 14 16 18 20 22 24 26 28 30

1

ERECTION OF TRAVELLER

DISMANTLE OF TRAVELLER

SPANSIDECOLUMN TOP PIER TABLE

COLUMN TOP PIER TABLE

1 LIFT~24 LIFT

DISMANTLE OF J/F

ERECTION OF J/F TOWER

TET HOLIDAYS

2 5 7 8 10 12 15 17 19 21 23

1 2 3 5 7 9 10 12 14 16 18 20 22 24 26 27 29

31 CLOSURE POUR DISMANTLE OF TRAVELLER

ERECTION OF TRAVELLER 1

2 3 5 7 9 10 12 14 16 18 20 22

41

WALL SHIN-SO

WORKS ROAD

APR

JUNMAY

AUGSEP

NOVOCTJULMAR

DEC

FEBJAN

APR

JUNMAY

AUGSEP

NOVOCTJULMAR

DEC

WORKS ELECTRICAL ANCILLARY &

TOWER ERECTION OF J/F

DISMANTLE OF J/F

PIER TABLE

Nov.2005

◆Removal Form Traveler

◆Form Traveler Assembling

◆Cycle of Cantilever Work

Pier Table Construction

Form Traveler Assembling

◆Limited Area

◆Inside Tower Crane Radius

◆Limited Weight 135 ton Form Traveler

Form Traveler Assembling

Form Traveler Assembling

Form Traveler Assembling Completion

Main Girder Section

2%

8.00

2.50 40 .25

◆Steel Bracing Pipe

(interval 3.25m, Square Type thk=16mm and

PC Bar & Strand Position

Longitudinal PC Bar Φ32 (40-30Nos/Seg) from 4Seg.30Nos

Longitudinal PC Strand 12S12.7 (Center span 18Seg 20Nos, Side span 24seg(P3),22Seg(P4) 10Nos )

Transverse PC Strand S21.8 (18-12Nos/Seg from 5Seg 12Nos)

Detail of Steel Bracing Pipe (Square Type)

Dead Anchor

Steel Bracing Pipes

3.1 Gider Cycle Schedule

1st day ▪ Casting concrete

2nd day ▪ Curing for concrete

▪ Removal stop end form

▪ Roughing of concrete surface

3rd day ▪ Stressing

▪ Launching of traveler

▪ Setting up form

(External and Bottom)

4th day ▪ Installation of bottom slab and web rebar

5th day ▪ Installation of bottom slab and web rebar

( Steel brace foundation part)

▪ Installation of steel pipe brace

▪ Inner form and upper slab form Setting

6th day ▪ Installation of form for upper steel brace part

▪ Installation of Form Tube

7th day ▪ Re-Bar for stay cable anchor position

▪ Installation of upper slab rebar

8th day ▪ Installation of upper slab and PC materials.

▪ Final Form and Form Tube adjustment

Cantilever Work Concept

C uring Tensioning Form Setting Low er Re-B ar C om pletion U pper Re-B ar Installation U pper Re-B ar Installation U pper Re-B ar Installation C oncrete

Rail B eam Launching Form Traveler Launching Low er Re-B ar Installation Inner Form Setting PC -M aterial Arrangem ent PC -Strand Installation Form Tube Adjustm ent Form Tube C onfirm ationRem oval End Form Form C leaning & Form O il Form W ork C hecking and

Repairing B racing Pipe setting Form Tube setting G rout H ose setting C leaning W ork

C onstruction Joint chipping B lock O ut form Setting

Stop End Form ReterderTransverse Tendon

tensioning inspection

PC -Strand 15.2m m M aterialinspection

PC -Strand m aterial 21.8m minspection (Rust checking)

PC C oupler connectioninspection

PC strand positioninspection Final Inspection for C astingLongitudinal PC B ar Φ32

tensioning inspection

B racing Pipe Assem blingInspection

PC -B ar m aterial inspectionbefore inserting Tapingcondition

PC -B ar setting inspection U pper Re-B ar inspection C asting InspectionLow er Re-B ar Inspection B racing Pipe setting

inspection

Form tube settinginspectionForm inspection

C om pletion inspection for

C ast Segm ent (After 100%

cable stressing)Rail B eam Relocation

checking list

Form Traveler C hecking listbefore launching Elevation of Form checking

Form Traveler Form Setting

C hecking list Re-B ar for U pper Slab

G rout hose checking andnum bering, hose bandconnection taping

Form Traveler beforecasting check list

C leaning condition check

by Torch Lights corners ofbottom form s

Transportation Jack Pum p Form Traveler checking list

for launching

Re-B ar for B ottom Slaband W eb

PC B ar Arrangem ent & PC

-B ar m arking by tape forproper coupling

Transverse StrandElevation checking.(1T22)

Pum p and concrete pipearrangem ent for M &H Tow er C rane & Truckarrangem ent

B ottom finishing 1tim e

w ooden trow el and 1tim esteel trow el

Electric cable arrangem ent

for Jack & Pum p Stressing PC B ar dia 32.

Inner Form Elevation ,

C enter line C hecking

Location and Anglechecking of B racing Pipe PC -B ar length checking

W aste concrete basketsetting up

C hecking G rout H ose byAir after concretecasting.PC -Strands shall be

m oved to check clogging

C hecking list shall beprepared

Survey M arking

C onfirm ation (C enter

,Elevation and Transverse)

Stressing PC strand 1T22 Inner form cleaning and

replacing dam aged form

Location and Angle of FormTube checking

Form traveler anchorposition check

Transverse tendonanchorage treatm ent

C uring w ater preparation(m agic w ater)

C oncrete C hipping

C ondition

Transverse G roup

C ontrolling beforelaunching for cuttingstrands

Form oil applying C oncrete B lock rem oval

from deck

W aste B asket preparation

H ook re-bar arrangem ent

Form oil for box

Re-bar m ortar painting forprevention rust

C leaning W aste C oncrete

M &H and Vinaconex

Keeping Jack & Pum pproperly, covering bysheets

B racing Pipe assem bling

C hecking and D eadAnchor Setting

Tow er crane arrangem entfor concrete block rem oval

C om pressor arrangem entfor grout hose checking

Transverse Anchor headtreatm ent.(C oncrete cap)

C uring C ontrolling on site W eather forecast checking

for concrete casting

B olt setting for elevation

m onitoring (B ench M ark)

C leaning w ork after

concrete casting

Arrangem ent for rain Roofsheet

C hecking W eb portioncom pactionPrecam ber value

confirm ation for form

setting

Lighting system forlaunching W ork becom elate)

C oncrete m aterial stockchecking

C oncrete com paction

C hecking foot of bracingpipe

H and rail m aterial

arrangem ent for Form

O pening form B lister, inner

form and bottom of B racing

pipe to check honeycom b

Vinaconex Re-B ar m aterialtransportation andarrangem ent

PC M aterial Arrangem ent

Elevation m arking for bench

m ark After Stay cabletensioning 100%) Vibrators controlling,m inim izing hitting D ucts.Repairing H oney C om b Survey arrangem ent for

after launching(B oth side)

Form Tube M aterialArrangem ent Stop End form Reterder

C oncrete can not be run

m ore than 1m basically.Survey arrangem ent for

after concrete casting

B racing Pipe C ablePrevious Segm ent C utting

C hecking G round C onditon

to confirm the accessibility

of truck m ixers

Spraying w ater forconstruction joints

C hecking W ater Tank

C apacity and volum e

Plastic sheet for shading.Avoiding sunshine forconcrete

G routing W ork C leaning Surface W ork Request for Inspection

Arrangem ent D aily Report C hecking

Lighting systemconfirm ation for finishingSeparate W ork and D aily Activity

C oncrete B lock rem oval from deck

Tensioning Record for stressing bracing pipeTensioning Record Stressing PC B ar 26 for B racing Pipe

B racing Pipe 15.2m m tensioning inspection

B racing Pipe PC -B ar Φ26 tensioning inspection

Stressing B racing Pipe(After com pletion ,im m ediately

inform to Stay C able Team Stressing PC B ar 26 for B racing Pipe

3.2 Cantilever Cycle Schedule

Date Description

Stressing

Upper Slab Bracing Pipe & Form Tube Setting

Date Description

Stressing

Upper Re-Bar Bracing Pipe & Form Tube Setting

8 6

4

Pre-Stressing

Concrete ( 90m3/block )

3 2

　and Bottom Slab

Stay Cable

Form&Form Tube

Adjustment

◆Morning Time Survey

1 2

1stDay

Casting Concrete Bottom Slab

1stDay

Casting Concrete Upper Slab

1stDay

Casting Concrete

1stDay

Curing Concrete

2Days

After Casting End Form Condition

Checking PC Bar Condition

3Days

◆Carefully Checking

◆Accurate Record

Transverse PC Strand Stressing

3Days

◆Don’t Stand Behind Jack

◆Listening to abnormal Sounds

◆Clear Signal, Confirmation Step by Step

◆Both side ,Elongation checking

◆Don’t hurry up

Longitudinal PC Bar Stressing

3Days

Bracing Pipe 12V15 Stressing

3Days

Final Check (Before Concrete)

installed to Mainframe.

RearCarriage uplift wheels are loose.

7

FrontTruss is supported properly on Mainframe-FrontBraceBeam.

FrontTruss is able to rotate into vertical plane Keeper bolts at base plate are adjusted.

previous segment.

Work Team Leader Vinaconex

Jo Engineer Leader

Form Traveller Checking List (No.5/5)

Form Traveler Checking

1 Rail Beam Relocation

2.Form Traveler Before Launching

3.Form Traveler During Launching

4.Form Traveler Form Setting

5.Final Checking Before Concrete

Traveler Form Down

3Days

Inner Form Down

3Days

Front Side Anchors Removal and Main Jack Down

3Days

Rear Anchors Removal

3Days

Launching Form Traveler

3Days

◆Cleaning Condition

◆Material Controlling

◆Obstruction Checking

◆Following Check List

◆Checking each other

◆Checking underneath

Launching Completion & Form Setting

Stop End Formwork

4 Days

◆Cleaning and Form Oil

◆Material Arrangement

Rebar in Bottom Slab

Steel Pipe Brace (Square Type)

Steel Pipe Brace (Round Type)

Inner Form Set Form Tube Setting

Rebar Installation in Upper Slab

Upper Re-Bar and PC Setting

Final Checking before Casting

Stay Cable Form Tube

Horizontal PC Strand 1S21.8 Longitudinal PC Bar Φ32

Form Traveler Anchors Hole Position

Site Condition P4 Side (Hon Gai Side)

GIRDER CONSTRUCTION TEAM