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BBBH CONSORTIUM PHU MY BRIDGE PHU MY BRIDGE PROJECT METHOD STATEMENT For CABLE-STAYED BRIDGE DECK CONSTRUCTION Date Document No. Issue/ Rev. Prepared: Reviewed: Approved: 04 Aug 2008 PM1-CO-MS-07 1/0 TP GM KF 20 Aug 2008 PM1-CO-MS-07 1/1 TP GM KF 25 Sep 2008 PM1-CO-MS-07 2/1 TP GM KF 03 Dec 2008 PM1-CO-MS-07 2/2 TP GM KF 24 Apr 2009 PM1-CO-MS-07 2/3 TP GM KF MS-07 Cable-Stayed Bridge Deck Construction 1 Rev. 3 BBBH CONSORTIUM PHU MY BRIDGE DOCUMENT REVISION SHEET Issue Rev. Description Prepared Reviewed Approved 1 0 Initial Issue TP GM KF 1 Revised Sec. 1, 2, 3, 4.2, 4.4, 4.5, 4.6, 4.7, 4.8, 5, 7, 10 and Appendix 6 as marked. Add Appendix 9. TP GM KF 2 1 Add Appendix 7, 8 and 10 TP GM KF 2 Minor revisions. Updated Appendices 1 and 9. Add Appendix 11. TP GM KF 3 Add Sections 4.9, 4.10, 4.11 and 4.12. Updated Section 5. TP GM KF MS-07 Cable-Stayed Bridge Deck Construction 2 Rev. 3 BBBH CONSORTIUM PHU MY BRIDGE Table of Contents Page No. 1. GENERAL 4 2. DESCRIPTION OF THE WORKS 5 3. TEMPORARY WORKS 6 4. WORK METHODOLOGY 7 4.1 CONSTRUCTION SEQUENCE 7 4.2 CONSTRUCTION ENGINEERING 7 4.3 PIER TABLE CONSTRUCTION 8 4.4 FORM TRAVELLER 9 4.5 DECK CONSTRUCTION 16 4.6 RESTRICTION ON DECK CRANE MOVEMENTS 28 4.7 BUFFETING CABLES 28 4.8 TEMPORARY TIE DOWN ANCHOR 28 4.9 LANDSIDE CLOSURE POUR 29 4.10 MIDSPAN CLOSURE POUR 35 4.11 CONTINUITY STRESSING 38 4.12 DECK FINISHES 38 5. PLANT AND EQUIPMENT 40 6. ACCESS 42 7. ORGANIZATION AND PERSONNEL 43 8. SAFETY 44 9. ENVIRONMENT 46 10. QUALITY 47 11. APPENDICES Appendix 1 : Deck Cycle Appendix 2 : Deck Crane Appendix 3 : Tower Crane Appendix 4 : Telescopic Forklift Appendix 5 : Casting Sequence Appendix 6 : Survey Work Procedure Appendix 7 : Method Statement for Post-Tensioning of Deck Tendons Appendix 8 : Stay Cables Working Procedures (by Freyssinet) MS-07 Cable-Stayed Bridge Deck Construction 3 Rev. 3 BBBH CONSORTIUM PHU MY BRIDGE Appendix 9 : Deck Construction Engineering Records Appendix 10: Form Traveller Operation Manual Appendix 11: Method Statement for Buffeting Cables (by Freyssinet) 1 GENERAL 1.1 Scope of the Method Statement This Method Statement describes the construction of the cable stayed bridge deck. This includes: • Form Travellers: Including design, fabrication, assembly and erection. • Deck Construction: Including construction cycle, traveller operation and stay cable installation. • Construction Engineering This Method Statement is to be read in conjunction with the contract drawings and specifications. 1.2 References to other Controlling Documents The Method Statement must be read in conjunction with the following documents. • PM1-CO-MS-04 - Main Bridge Towers Construction • PM1-CO-MS-05 - Main Bridge Pier Table Construction • PM1-CO-MS-13 - Heavy Lifting Works • PM1-CA-DR-14 - Main Bridge Deck Erection Manual (by LAP) • Form Traveller Operation Manual 1.3 Specialist Subcontractors The following specialist subcontractors will perform the services as described: Supply and install stay cables - Freyssinet Heavy lifting and lowering - Freyssinet Post Tensioning - Freyssinet Form traveller steel fabrication - RIMP Formwork tube steel fabrication - RIMP 1.4 Specialist Consultants The following consultants will perform the services as described: MS-07 Cable-Stayed Bridge Deck Construction 4 Rev. 3 BBBH CONSORTIUM PHU MY BRIDGE Permanent works design for cable stayed bridge - Arcadis Construction Engineering and major temporary works - Cardno 2 DESCRIPTION OF THE WORKS The cable stayed bridge deck has been designed as a cast in-situ reinforced concrete structure with an overall width of 27m. The 250mm deck slab is supported by cross beams at 5m centres with longitudinal edge beams supported by stay cables at 10m centres. The clearance envelope is 45m across a 250m section located at the centre span. The stay cables are in a vertical plane and are located in pods outside of the line of the edge beam. Services are located beneath the deck and will pass through penetrations in the cross beams. A 2.15m wide footpath cantilevers outside of the extent of the edge beam on each side. The cross beam depth is 2.35m at the deck centreline from the top of concrete. The typical deck configuration consists of two vehicle lanes in each direction plus one motorcycle lane. The motorcycle lanes are separated by barriers and a line of barriers along the deck centreline separates the eastbound and westbound lanes. The deck is on a vertical curve with a longitudinal grade of 5% at the towers and has a crossfall of 3% either side of centreline. The drainage is via scuppers located on the kerb line outside of the edge beam. The final surfacing consists of 65 mm asphaltic concrete. The deck has been designed as a cast in-situ balanced cantilever with movement joints at each tie down pier and bearings at each tower lower cross beam. MS-07 Cable-Stayed Bridge Deck Construction 5 Rev. 3 BBBH CONSORTIUM PHU MY BRIDGE 3 TEMPORARY WORKS The following main temporary works will be required for the construction of the main bridge: • Design of form travellers • Design of form traveller erection and lowering scheme • Design of pier table falsework and formwork • Design of pier table falsework and formwork erection and lowering scheme • Design of temporary tie down cable system • Design of buffeting cable system • Design of closure pour (midspan and landside) clamping and formwork arrangement • Design of tie down pier falsework • Design of midspan closure jacking arrangement. The construction of tower struts and the heavy lift operation are covered in PM1-CO-MS-04 and PM1-CO-MS-13, respectively. MS-07 Cable-Stayed Bridge Deck Construction 6 Rev. 3 BBBH CONSORTIUM PHU MY BRIDGE 4 WORK METHODOLOGY 4.1 Construction Sequence The basic sequence of work will be as follows: • Construct the lower cross beam on the pile cap directly below its final position. • Erect the pier table falsework knee frames on top of the precast cross beam. • Erect the formwork system on top of the falsework. • Erect the lower cross beam for the District 7 (West) tower complete with pier table falsework by heavy lift. • Construct the District 7 pier table. • Install the first stay cables. • Lower pier table falsework. • Erect the form travellers for the District 7 deck on each end of the pier table. • Construct the western balanced cantilever deck working away from the D7 tower. • Construct the District 2 pier table in parallel. • Cast the District 7 landside closure pour (after completion of the approach deck). • Lower the form travellers and re erect on the District 2 pier table. • Construct the District 2 balanced cantilever deck working away from the D2 tower. • Cast the District 2 landside closure pour. • Cast the midspan closure pour. • Remove the form travellers and complete bridge furniture and deck finishes. 4.2 Construction Engineering The construction engineering will be performed by Cardno in conjunction with their specialist partner Leonhardt Andra & Partners based in Germany. The Construction Engineering involves the detailed calculation of the geometry and cable forces for each stage of the construction. This will be represented by a step by step analysis in which all of the theoretical loads and geometry for every stage of the construction are defined for a given construction sequence. The step by step analysis will be incorporated into a document known as the Main Bridge Deck Erection Manual (PM1-CA-DR-14). The global sequence of work for the construction of the cable stayed deck is defined in the Main Bridge Erection Manual and on the Construction Engineering drawings. The Erection Manual, through reference to the step-by-step analysis, provides the detailed Construction Engineering parameters required for each stage of the construction operation. This includes but is not limited to: 1. Detailed erection sequences for: • Stay cable installation • Installation and adjustment of temporary tie down cables • Re-stressing of cables and cable adjustments • Jacking operations for closure pours MS-07 Cable-Stayed Bridge Deck Construction 7 Rev. 3 BBBH CONSORTIUM PHU MY BRIDGE 2. Determination of exact forces and deflections of all parts during all erection stages. This includes: • Cable forces and cable length • Camber values of superstructure and towers • Support reactions • Forces in temporary tie down cables 3. Adjustment values to account for variations in: • Temperature conditions • Construction live loads • Side span closure procedures • Main span closure procedures It is intended that the Erection Manual will be mainly used by the Construction Engineer, the Design Manager and the Deck Engineer and as such will not be widely circulated. The document will be updated with as constructed information relating geometry, forces and loads at each stage of the construction. The input and updating of the erection manual to determine the correct geometry and cable forces for each subsequent pour will be carried out by the site based construction engineer with input from the deck manager responsible for the construction. The Construction Engineer will convey information to the construction team via the Deck Engineer. Information conveyed to the construction engineer such as all post pour information will be issued via the same engineer. The pro-formas for conveying this information are included in Appendix 9 of this document. 4.3 Pier Table Construction 4.3.1 General The pier table consists of the portion of bridge deck at the tower to be constructed on falsework prior to erection of the form travellers for the segmental deck. This involves a central portion of 10m centrally located at the tower axis and a regular 10m segment with a pair of stay cables on either side of the central segment. These three (3) segments will be cast separately in the sequence of centre, main span and side span. The pier table will be constructed in accordance with Method statement PM1-CO-MS 05. MS-07 Cable-Stayed Bridge Deck Construction 8 Rev. 3 BBBH CONSORTIUM PHU MY BRIDGE MTB Pier Table during Construction (Note the precast anchor pods and the precast cross beams) 4.4. Form Traveller 4.4.1 Design The traveller is the travelling formwork system used for casting each deck segment. Two travellers will be manufactured to facilitate the construction of one balanced cantilever at a time. The travellers will then be relocated to the second tower to repeat the exercise. In addition to providing a platform for the formwork, the traveller also provides sturdy access platforms enabling the completed underside of the previous segment to be accessed following launching to the following segment. This enables all concrete dressing operations to be done off the critical path. The travellers are designed by Cardno with an independent check carried out by specialist partner LAP. The formwork arrangement will be designed by a suitable formwork specialist and will be installed on site during the fabrication and assembly operation. The hydraulic systems will be managed as a design, supply, install and commission contract. Separate supply contracts or purchase orders will be issued for the rollers, sliding shoes and stress bars. Platforms and ladders will be fitted on site during the assembly operation. The traveller is designed as an underslung truss assembly supported from the deck by stress bar during the setting, steel fixing and casting operations. The truss assembly generally consists of a pair of longitudinal trusses connected by a transverse truss spanning between them. The formwork will be supported from the forward section of the truss assembly and the access platforms will be supported from the rear. The centre of gravity will be located forward of the C-frame which means the traveller will always be front heavy. Rear reaction rollers will provide stability during the raising, lowering and launching operation. During casting the pivot point occurs at the C-frame position. For the launching operation the travellers will be lowered sufficiently for the formwork to clear the depth of the cross beams. The lowering will be done using 40mm stress bar located at the C-frame position. The traveller must be lowered perpendicular to the deck to enable the formwork to clear and thus the bars are also square to the deck. MS-07 Cable-Stayed Bridge Deck Construction 9 Rev. 3 BBBH CONSORTIUM PHU MY BRIDGE To maintain the rear reaction during lowering, raising and launching operations a pair of rear props will be provided at the rear of the traveller. Contact with the underside of the deck will be made using 100 tonne capacity rollers mounted on the top of the props which roll along the soffit surface of the edge beams during the launching operation. As the travellers are lowered for the stripping and launching operation each of the rear props will maintain contact with the underside of the edge beams due to the out of balance moment of the traveller. To maintain the traveller parallel to the deck soffit the rear of the traveller will be raised or lowered in relation to the props via a pair of hydraulic bar jacks and stress bars with nuts located at the top of the truss and above the jacks. The main hanger bars will be located at the C-frame position and will be pre-stressed between the top of the deck and the main block on the C-frame below the deck to ensure that no vertical movement occurs at the joint during casting. The use of pre-stress also adds to the safety of the system by ensuring that the critical loads are in the structure prior to casting. During the launching operation the dead weight of the traveller is supported by two outside C- frames from the top of the deck which make contact with the launching beams after lowering the traveller. For launching the traveller must be lowered by the depth of the cross beam to provide clearance to the formwork. The raising and lowering operations will be carried out by hydraulic jacks moving a pair of steel blocks up and down the groups of stress bar on each side of the C-frame. The C-frame is rigidly connected at right angles to the main truss members of the traveller. Due to the vertical gradient of the deck, stoppers must be fixed to the underside of the edge beam at the rear roller position prior to lowering to prevent the traveller swinging back on the stress bars. On an uphill grade, the stoppers will be located directly behind the rear prop roller. On a downhill grade, the stopper will be located in front of the roller. The stoppers will cause the traveller to rotate from the rear during lowering which will assist the cross beam infill formwork to clear the beam. The stoppers will be connected to the deck using removable cone anchors. The traveller will be partially supported during casting by the permanent stay cables. The guide tubes will be installed into the traveller in precast concrete pods during launching. The pods will be secured to the traveller by means of temporary stress bar. This system enables the stay cable to be installed into the permanent anchorage prior to casting. Temporary struts will be required to carry the horizontal component of the cable force which is generated prior to placement and strength gain of the deck concrete. These struts will be incorporated into the traveller and will transfer the force back to the previous anchor pod. A mechanism will be provided to simplify the handling of the struts which are located on each side of the traveller. As the stay cables are located outside the line of the edge beams temporary steel support beams will be necessary to carry the full traveller weight between anchorage pods during launching. The guide channels for the sliding mechanism will be located on top of these beams. The beams have been designed as a box girder with lateral support legs. The traveller will be designed to be fabricated in large welded components to minimise the requirement for site welding. Bolted connections will be used for site assembly where practical. For transportation reasons, the C-frame will be delivered in two sections to be assembled and welded on site prior to installation. The weld preparation will be done in the workshop prior to delivery by the fabricator. Upon completion of the District 7 cable stayed deck, the traveller will MS-07 Cable-Stayed Bridge Deck Construction 10 Rev. 3 [...]... Installation of free-end strand loop into the bottom anchorage MS- 07 Cable-Stayed Bridge Deck Construction 25 Rev 3 BBBH CONSORTIUM PHU MY BRIDGE Erection of Cable Sheath – Panama Bridge Assembly of Cable Sheath – Panama Bridge MS- 07 Cable-Stayed Bridge Deck Construction 26 Rev 3 BBBH CONSORTIUM PHU MY BRIDGE Stay Cable Erection in Panama Bridge (Note that the stay cable for PMB will be installed on... for Phu My Bridge for pod installation) MS- 07 Cable-Stayed Bridge Deck Construction 13 Rev 3 BBBH CONSORTIUM PHU MY BRIDGE MTB traveller in the raised/casting position MTB Traveller in the raised/casting position (Note the rolling beam which must be moved forward following the casting to enable the traveller to launch to the next position) MS- 07 Cable-Stayed Bridge Deck Construction 14 Rev 3 BBBH CONSORTIUM... “Deck – Segments WTD-WA16 & ETD-EA16 Reinforcement Sheet 1 to Sheet 8” - BBBH Shop Drawings No SK-SB-568 “Longitudinal Prestressing Cable L2/L14” - BBBH Shop Drawings No SK-SB-592 “Sidespan Closure Details” - BBBH Shop Drawings No SK-SB-5 93 ~ 600 “Side Closure Segment – Deck Slab Formwork” - LRP Rebar Drawing No PM1-LR-C-ST-490 “Cable Stayed Bridge Deck Segments WTDWA16 and ETD-EA16 Deck Segments Reinforcement”... CONSORTIUM PHU MY BRIDGE MTB Form Traveller (Note the launching beams on top of the deck above the edge beams Also note the precast pods installed by the deck crane during launching) MTB form traveller launched and re-set ready for rebar installation MS- 07 Cable-Stayed Bridge Deck Construction 15 Rev 3 BBBH CONSORTIUM PHU MY BRIDGE Sliding shoe arrangement from Panama traveller The Phu My Bridge traveller... document A flowchart MS- 07 Cable-Stayed Bridge Deck Construction 16 Rev 3 BBBH CONSORTIUM PHU MY BRIDGE of the cycle showing the key constraints to various operations is also included in Appendix 1 for clarity The anticipated 5-day cycle will be as follows: Day 1 As-built Survey Construction Engineering Calculation Strip stop ends & clean up Strip stitch forms Relocate launching beams to Segment n Partial... Closure 4.10 Midspan Closure Pour MS- 07 Cable-Stayed Bridge Deck Construction 34 Rev 3 BBBH CONSORTIUM PHU MY BRIDGE The midspan closure will start after the completion of Segment EM-18 on District 2 and is a regular 10m segment in length but without any stay cable or pods The midspan closure will connect Segment EM-18 on District 2 to Segment WM-18 on District 7 utilizing the mainspan form traveller 4.10.1... Midspan Closure - Main Bridge Deck Erection Manual 2nd Final “Mainspan Closure Sequence Sheet No 10 and Global Deck Erection Stage D20 Sheet No 020” - BBBH Shop Drawings No SK-SB-566 “Longitudinal Prestressing Cable C2 – Segment WM17 / EM17” - BBBH Shop Drawings No SK-SB-567 “Longitudinal Prestressing Cable C1 – Segment WM18 / EM18” - BBBH Shop Drawings No SK-SB-489 “Penetration and Embedded Items Segment... carried out just prior to launching.) Dual Strand Dispensers and Coils ( 3- tonne coils) 4.6 Restrictions on Deck Crane Movements MS- 07 Cable-Stayed Bridge Deck Construction 27 Rev 3 BBBH CONSORTIUM PHU MY BRIDGE The crane location for installation of pods and cross beams shall be in accordance with the description provided in Sec 4.5 .3 and the sketch included in appendix 2 of this document The crane shall... hanging platforms located on the outside of the tower head and permanent platforms inside the tower head Access to the external platform will be via the man hoist and access to the internal platforms will generally be via ladders and platforms down from the jump form or later, down from the top of the tower MS- 07 Cable-Stayed Bridge Deck Construction 22 Rev 3 BBBH CONSORTIUM PHU MY BRIDGE Hydraulic... tendons first stage to the required force xxi Cast Segment WM-16 xxii Complete all formwork and rebar installation for the closure pour xxiii Prepare sufficient lighting and cast closure Segment WA-16 starting at 21:00 hour to avoid any temperature differential during curing MS- 07 Cable-Stayed Bridge Deck Construction 33 Rev 3 BBBH CONSORTIUM PHU MY BRIDGE Final Rebar Installation for the D7 Closure Pour . PM1-CO -MS- 07 1/1 TP GM KF 25 Sep 2008 PM1-CO -MS- 07 2/1 TP GM KF 03 Dec 2008 PM1-CO -MS- 07 2/2 TP GM KF 24 Apr 2009 PM1-CO -MS- 07 2 /3 TP GM KF MS- 07 Cable-Stayed Bridge Deck Construction 1 Rev. 3 BBBH. documents. • PM1-CO -MS- 04 - Main Bridge Towers Construction • PM1-CO -MS- 05 - Main Bridge Pier Table Construction • PM1-CO -MS- 13 - Heavy Lifting Works • PM1-CA-DR-14 - Main Bridge Deck Erection. beam. MS- 07 Cable-Stayed Bridge Deck Construction 5 Rev. 3 BBBH CONSORTIUM PHU MY BRIDGE 3 TEMPORARY WORKS The following main temporary works will be required for the construction of the main bridge: •