Construction method statement of erection of super t girder

Erection Procedure Chart of Super-T girder: Erection Procedure Chart NOTE: The works shall be submitted separately Bearing installation and grouting Construction of Diaphragm and Desk s

MINISTRY OF TRANSPORT PROJECT MANAGEMENT UNIT NO.85

NHAT TAN BRIDGE

(VIET NAM- JAPAN FRIENDSHIP BRIDGE

CONSTRUCTION PROJECT)

CONTRACT PACKAGE-1 MAIN BRIDGE AND NORTH APPROACH BRIDGE

CONSTRUCTION METHOD FOR erection

Of SUPER-T GIRDER (P18 -:- P47)

Hanoi: 11/2010

I GENERAL INTRODUCTION 2

1.1 Project scale: 2

1.2 Geometric dimension of Super-T girder: 2

1.2.1 Girder length: 2

1.2.2 Dimension of Cross-section: 3

1.2.3 Weight of girder: 3

II CONSTRUCTION MATERIAL AND EQUIPMENT 4

2.1 Construction Material: 4

2.2 Construction equipment: 5

III ERECTION WORKS 6

3.1 Erection Procedure Chart of Super-T girder: 6

3.2 Preparation and survey 7

3.3 Assembling, installation of gantry crane on site 7

3.3 Bearing installation and grouting 8

3.4 Installation of transversal beam on pier 9

3.5 Installation of gantry crane on pier 12

3.6 Transportation of Super T girder 14

3.7 Erection of Super T girder 14

3.8 Disassembling and Transportation of gantry crane to next span 16

IV INSPECTION AND ACCEPTANCE OF GIRDER: 18

4.1 Inspection through documentation, construction diary: 18

4.2 Acceptance of the actual production 18

V QUALITY CONTROL 18

5.1 General: 18

5.2 Labor force quality: 18

5.3 Construction equipment quality: 19

5.4 Moving girder from storage yard to erection site: 19

5.5 Acceptance work: 19

VI METHOD FOR SAFETY AND ENVIRONMENTAL PROTECTION 20

6.1 Laboring safety method: 20

6.1.1 Protecting equipment for labor: 20

6.1.2 Safety for labors: 20

6.1.3 Safety for equipment: 20

6.1.4 Safety for working on high: 20

6.1.5 Safety for girder loading out of cast platform and girder installation: 21

6.1.6 Safety works before construction: 21

6.1.8 Other safety works 21

6.2 Method for environmental protection: 22

I GENERAL INTRODUCTION

1.1 Project scale:

northern approach bridge of which main bridge is L=1500m long and approach bridge isL=1580m long

- Super-T girder is used for 31 spans of approach bridge in which each span length is 40m.Cross section is combined of 15 Super-T girders with interval 2200mm

- This Construction Method describes all the involved of Super-T girders including erectionSuper-T girder, bearing instalation and grouting, quality control, safety and environmentprotection, auxiliary works

1.2 Geometric dimension of Super-T girder:

1.2.1 Girder length:

Number of Super-T girders is 465 nos with the length categorised as below:

Table 1:

Summary of Super-T girder length

exterior girder interior girder

cross section of super-T girder

II CONSTRUCTION MATERIAL AND EQUIPMENT

2.1 Construction Material:

Table 2:

Main material to be used for Erection of Super-T girder

Table 3:

Auxilary materials to be used for Erection of Super-T girder

2.2 Construction equipment:

Main construction equipments to be used for erection of Super-T girder is shown in thefollowing table:

Table 4:

Main Equipments for Erection Super-T girder

III ERECTION WORKS

3.1 Erection Procedure Chart of Super-T girder:

Erection Procedure Chart

NOTE: The works shall be submitted separately

Bearing installation and grouting

Construction of Diaphragm and Desk slab

Preparation and survey

Assembling, installation of gantry crane

on site

Transportation of Super T girder

Erection of Super T girder

Disassembling and Moving of gantry

crane to next span Installation of transversal beam on pier

Installation of gantry crane on pier

3.2 Preparation and survey

- Survey work for coordinates and checking elevation of all pier will be done carefullybefore we can start erection work

- The Method Statement, quality control plan, safety plan for erection of Super-T girderwith the calculation sheet must be submitted to The Engineer before starting Erectionworks

3.3 Assembling, installation of gantry crane on site

- Gantry crane is pre-fabricated in workshop and transported to the construction site bytruck

- Arrangement of wooden sleeper for assembling grantry crane at site

- Assembling of grantry crane to 3 blocks (Block 1, Block 2, Block 3)

- Arrange and assemble scaffolding for assembling of gantry crane

- Assembling of gantry crane block, one by one by crane 50 tons

- Installing and Assembling of both leg of gantry crane by mobile crane

- Instalation of purleys systems and steel cable for hanging systems

- Installing electric system for gantry crane

3.3 Bearing installation and grouting

3.3.1 Installing of Elastomeric bearings

- Install working platform and safety net

- Preparing, transporting all material and equipment for construction bearing to the pier

- Cleaning, roughening pier surfaces up to stone appearance by steel brush Surfacetreatment was carry out 100% of touching surface, cleaning after finishing rougheningwork

- Assembling of formwork for bearing seat

- Pour non-shrinkage mortar when reach requirement elevation

- Before installation, bearing seat should have checking and inspection with attention of theEngineer

- Installation of bearing

Sketch 1: Installing of bearing seat for elastomeric bearing

3.3.2 Installing of Pot bearings

- Install working platform and safety net

- Preparing, transporting all material and equipment for construction bearing to the pier

- Cleaning, roughening pier surfaces and anchorage holes up to stone appearance by steelbrush Surface treatment was carry out 100% of touching surface, cleaning after finishingroughening work

- Installing of bottom bearing part to its exactly position

- Checking elevation with attention of the Engineer

- Pour non-shrinkage mortar when reach requirement elevation

- Installation of bearing follow drawings and instruction of manufacturer

Sketch 2: Installing of Pot bearing

3.4 Installation of transversal beam on pier

- Checking machine and equipment for safety before erection works

- Mobilization of two cranes 80T and positioned at P17 and P18

- Hook up and fixing the transversal beam

- Gradually lifting up transversal beam

- Cranes shall operate simultaneously to lift transversal beam and slide transversal beam toposition on pier

- Checking elevation and position of transversal beam

- Tightening all archorage bolts to fix transversal beam

+ For P17

+ For P18

+ For P19-P47

+ For P48

3.5 Installation of gantry crane on pier

3.5.1 Moving of gantry crane to position on the site

- Checking all the material and equipment before transportation

- Tractor and trailer be used for transportation of Gantry crane

- Arrange worker and facilities to ensure safety during transport

- Steel cable shall be used for fix the gantry crane during of transportation

Sketch 3: Mobilization of gantry crane

3.5.2 Erection of gantry crane to position on the pier

- Checking machine and equipment for safety

- Mobilization of two cranes 80T and positioned at P17 and P18

- Install and assemble cross beam on P17 and P18 pier

- Hook up and fixing the gantry crane

- Gradually lifting up gantry crane

- Two cranes shall operate simultaneously to lift gantry crane and slide gantry crane toposition of cross beam

- Two cranes turning to set gantry crane on cross beam

- Putting gantry crane on cross beam shall be carried out by each side

Sketch 4: Erection of gantry crane on pier

CRANE 80TONS

ELEVATION

PLAN

+9.70 +27.20

+9.55

to ha noi

+30.907 K1 block

Hoz irontal beam +31.10

3.6 Transportation of Super T girder

- Move the trailer in to position in storage yard, move out the tractor

- Transport Super-T girder from storage yard to the trailer position by gantry crane 80 tons

- Slowly put down the Super-T girder on the trailer

- Installing of holding clamps

- Move out the gantry crane

- Move the tractor and installing trailer tongue to connect trailer with tractor

- Transportation of Super-T girder to erection site

Sketch 5: Transportation of Super-T girder

3.7 Erection of Super T girder

- Super-T girder were fabricated in fabrication yard

- Transport Super-T girder from storage yard to the erection site by tractor and trailer

- Gradually lifting up the Super-T girder by gantry crane 80 tons

- Lift up Super-T girder about 30cm and check carefully gantry crane's brake system beforecontinue lifting work

- Continue lifting up the Super-T girder, when bottom face of the Super-T is higher thanbearing's face about 30cm to put on the brake

- Transversal moving of the gantry crane to setting the Super-T girder to its positionextracly on the bearing

- Keep the beam stable against by wooden sleeper and strut bar

Sketch 6: Erection of Super-T girder

+9.70 +27.20

3.8 Disassembling and Transportation of gantry crane to next span

- Checking machine and equipment for safety

- Mobilization of two cranes 80T and positioned at P17 and P18

- Mobilization of two trailer 50T and positioned at P17 and P18

- Disassembling of trailer tongue and move out the tractor

- Hook up and fixing the gantry crane

- Gradually lifting up gantry crane

- Two cranes shall operate simultaneously to lift gantry crane and slide gantry crane toposition of the trailer

- Two cranes put down to set gantry crane on the trailer

- Putting gantry crane on trailer shall be carried out by each side

- Installing of trailer tongue to connect with the tractor

- Mobilization the gantry crane to next span

Sketch 7: Disassembling and transportation of gantry crane

+9.55

to ha noi

+30.907

IV INSPECTION AND ACCEPTANCE OF GIRDER:

4.1 Inspection through documentation, construction diary:

In order to inspect one girder, Contractor shall prepare several relevant drawings anddocumentation, including:

- Shop drawing indicating all design changes accepted by the Design Engineer

- Letter of requesting and accepting erection works

- Minutes of Inspection for partial works such as casting concrete Super-T girder, curingworks

- Other relevant documentation

4.2 Acceptance of the actual production

Checking dimension of girder to assure this dimension to be suitable with designed drawings.Tolerance of dimension should be in accordance with technical specification of the Project

V QUALITY CONTROL

5.1 General:

In order to keep the good quality method, the Contractor will follow the company qualitymethod that is suitable with the requirements and procedures specified in the design documents(Technical Specification of Project) as followings:

- Assigning officers, engineers, workmen who have professional certificates and highqualification and capability to the construction work, having professional quality controlengineers to supervise the work quality

- Recording the executed works and comments of supervisors via the construction diary

- Coordination with the design and supervision Engineers and leaders to dealing with anyissues occurred during construction, checking of quality of all items after completion isrequired

- Site Manager, engineer and workmen of the Construction Units should fully obey therequirements in the approved design document and technical specification to ensure theworks quality

5.2 Labor force quality:

- All of technical staffs, skilled labors that are take part in every work item, constructionassembly shall be trained through the technical meetings in order that all men can catchthe construction technology steps relating with each work item

- The Contractor will arrange suitable labor force in right position All workers shall beresponsible in working, conform to instruction and arrangement of the site manager orteam leader in oder to ensure the product quality as well as project schedule as stipulated

5.3 Construction equipment quality:

- Whole construction equipment to be used shall be regularly tested to ensure goodoperating condition:

+ Ensuring good features and safety operation

+ Operating capacity should be suitable with construction schedule of each work item aswell as entire project

+ Regularly maintenance for equipment

- For the girder lifting equipment (Gantry crane 80 tons): before puting in use, liftingequipment shall be carried out the load test at site Independent inspection unit will beinvited to check its technical and safety features as stipulated for specialized liftingequipment

5.4 Moving girder from storage yard to erection site:

- Super-T girder will be stored in storage yard at least 3 months before transportation toerection site

- Super-T girder will be transportation to erection site by truck and trailer with capacity 50tons

- Moving process shall be done carefully and slowly at both ends of girder

- The velocity of gantry crane is ensured at 5 -10m/minute to be stable and avoid shaking ofgirder

5.5 Acceptance work:

- Geometric dimension is checked to ensure the technical requirements

- Following main information shall be marked on Super-T girder:

+ Girder number, symbol code

+ Length of Super-T girder

+ Concreting date

- All of acceptance sheets shall be gathered and submitted for approval to the Engineer aftercompleting each girder production

VI METHOD FOR SAFETY AND ENVIRONMENTAL PROTECTION

6.1 Laboring safety method:

6.1.1 Protecting equipment for labor:

- Safety belt

- Protective clothes

- Protective shoes

6.1.2 Safety for labors:

- Whole labors have to wear protective clothing during working time and safety belt must beworn if required

- Technical staffs, workers who take part in Super-T girder construction have to learn tocatch firmly the technology of girder casting and laboring safety regulation on electricityusage, anti-fire, high lifting safety and specially the safety regulation for stressing of PC

6.1.3 Safety for equipment:

- There are only skilled operators whom are permitted to operate construction equipment atsite For new operating workers, they must be checked carefully their skill beforeemployment Whole construction equipment must be checked and maintained regularlybefore putting into operation The stability of ground and platform for equipment working,specially at position of stabilizers of crane must be checked carefully

- Crane machine is special equipment for loading of structural elements, equipments andbuilding parts In order to avoid industrial accidents, following instructions shall beconformed strictly:

- Technical status of important parts such as: brakes, lights, horns must be checkedcarefully before operating and following instructions shall be conformed:

+ No loading bigger out of correlative boom

+ No loading when unstable sling

+ No loading over specified speed

+ No loading when worker stands on loaded parts

+ No floating loading in rest

+ No standing on soft soil ground and just filled ground

+ No working in strong wind, dark, fog, weak light conditions

+ Strictly cooperate with signalman, sling man

6.1.4 Safety for working on high:

- Safety handrail shall be installed on working scaffolding when working on high to avoidworkers fall down

- Safety net shall be applied when working on high place

- Lighting system shall be prepared for emergency or working on night