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AL MENAA SPORT COMPLEX – MAIN STADIUM OWNER: IRAQ MINISTRY OF YOUTH AND SPORTS Ministry Headquarters Baghdad-Iraq CONSULTANT: THREESISTY ARCHITECTURE, INC. 300 West 22 nd Street Kansas City, MO 64108-USA STRUCTURAL ENGINEER: THORNTON TOMASETTI 912Broadway Boulevard Suite 100 Kansas City, MO 64105-USA MAIN CONTRACTOR: ANWAR SOURA GENERAL CONT. CO. LTD. Pre-stress Cable Construction Plan of Iraq Al-Menaa Stadium Date: September 9, 2013; Version: 0 Prepared by: REJECTED EXCEPTIONS NOTED NO EXCEPTIONS THORNTON TOMASETTI, INC. (TT) THIS SUBMITTAL CONCERNS ITEMS NOT DESIGNED BY TT. REVIEW IS LIMITED TO ASSESSING, WHERE REQUIRED BY THE CONTRACT DOCUMENTS, THE STRUCTURAL EFFECT OF THE LOADS IMPOSED BY THE REVIEWED ITEM ON THE STRUCTURAL SYSTEM DESIGNED BY TT, AND/OR CONFIRMING, BASED SOLELY ON THE REPRESENTATIONS BY THE CONTRACTOR, ITS SUBCONTRACTORS OR VENDORS OR THEIR ENGINEER ("CONTRACTOR"), THAT THE ITEM REVIEWED CONFORMS WITH ANY APPLICABLE PERFORMANCE CRITERIA ESTABLISHED BY TT IN THE CONTRACT DOCUMENTS AND/OR ANY APPLICABLE PARAMETERS ESTABLISHED BY TT IN THE CONTRACT DOCUMENTS. SUCH REVIEW DOES NOT CONSTITUTE AN INDEPENDENT CONFIRMATION BY TT THAT SUCH REPRESENTATIONS BY THE CONTRACTOR ARE ACCURATE. THE CONTRACTOR REMAINS SOLELY RESPONSIBLE FOR COMPLIANCE WITH THE REQUIREMENTS OF THE CONTRACT DOCUMENTS INCLUDING ANY PERFORMANCE CRITERIA AND/OR PARAMETERS. By Date: APL 17 SEPT. 2013 Menaa MS-05 1600-011 APL/TT 18 Sept 2013 Pre-stress Cable Construction Plan of Iraq Al-Menaa Stadium Contents Chapter 1 Compilation Reference 1 Chapter 2 Erection Summary and Analysis of Construction Key Points 2 2.1 The Erection Summary 2 2.2 Construction control key points and solutions 5 Chapter 3 Construction Process 7 3.1 The construction idea 7 3.2 The construction process 7 Chapter 4 Cable installation & implementation plan 8 4.1 Previous preparation 8 4.1.1 Installation of the mast 8 4.1.2 Set up ring cable packway at stand 12 4.1.3 Erection of high-altitude operation platform 13 4.1.4 Erection of lower cable operation platform 13 4.1.5 Counterforce holes of upper cable ear plate and lower cable ear plate 14 4.2 Laying down and assembling the cable 16 4.2.1 Install the stay cable 16 4.2.2 Release the ring cable in the ground 18 4.2.3 Lay down the ring cable to the packway 21 4.2.4 Hoist cable clamps 25 4.2.5 Connect the lower cable with cable clamp 28 4.2.6 Lay down the upper ring cable 29 4.2.7 Link the ring cable connector 30 4.2.8 Lay down radial cable on the stand 31 4.2.9 Lay down lower cable 35 4.2.10 Connect the upper’s tooling cable 36 4.3 Installation of the upper cable 38 4.4 Installation of the lower cable 41 4.4.1 Conversion tooling to lower cable and synchronous traction 41 4.4.2 Tense the lower cable in place synchronously 42 4.5 Construction equipments and instruments list 43 Chapter 5 Simulation Calculation of Construction 45 5.1 Installation of Mast 45 5.2 Installation of Stay cable 53 5.3 Simultaneously Ascending of Upper Suspension Cable 54 5.4 Simultaneously Ascending of Lower suspension Cable 84 5.5 Conclusion 104 Chapter 6 Monitoring of Construction Process 105 6.1 Principle of Construction Monitoring 105 6.2 Monitoring of Cable Force 105 6.2.1 Measurement Method of Cable Force 105 6.2.2 Record Form of Cable Force Measurement 105 6.3 Monitoring of Structural Deformation 109 6.3.1 Measurement Method 109 6.3.2 Record Form of Measurement 109 Chapter 7 Control of Construction Process and Data Submission 111 7.1 Control Indexes of Construction 111 7.2 Construction Data Content 112 Chapter 8 Decomposition of Project Content 113 Chapter 9 Construction Case of Similar Projects 114 9.1 Panjin Stadium 114 9.1.1 Project Overview 114 9.1.2 Construction Way 116 9.1.3 Pictures of Construction Process 116 9.2 Foshan international furniture expo city 134 9.2.1 Project Overview 134 9.1.2 Construction Scheme 135 9.2.3 Pictures of Construction Process 135 9.3 Xuzhou Olympic Sports Center Stadium 144 9.3.1 Project Overview 144 9.3.2 Construction Way 146 9.3.3 Pictures of Construction Process 146 9.4 Comparison of Labor, construction time and equipment 151 1 Chapter 1 Compilation Reference 1 Calculation model provided by design unit 2 This project’s construction drawings of construction structure and steel structure 3 Construction progress of the related units and overall construction & erection progress plan 4 Designed construction drawings and product specifications of related manufacturers 2 Chapter 2 Erection Summary and Analysis of Construction Key Points 2.1 The Erection Summary The Iraq Al-Menaa Stadium is a long span cable-membrane structure. The plane shape is oval, the maximum size of the long axis is about 276m and the maximum size of the short axis is about 232m, and the maximum height of the mast is about 45m. The whole structure is constituted by the outer steel frame, the main cable system of the roof and the membrane roof. The outer steel frame is constituted by shuttle-shaped column, steel truss and toroidal pressure ring. The main cable system of the roof includes stay cable connected to the mast, upper cable and lower cable respectively 48 root, 48 root valley cable at the membrane surface, 16 root cross cable of the mast and a ring cable (8 root); the membrane surface is arranged between the steel truss and truss, and it across 48 root valley cable to form the undulating surface modeling. The stadium structure’s layout drawing, three-dimensional diagram, single cross layout drawing and the related nodes drawing are shown below. 3 Layout drawing The Iraq Al-Menaa stadium three-dimensional diagram 4 The overall elevation drawing Single cross section drawing Upper cable: 900KN Lower cable: 700KN Stay cable: 1150KN Ring cable: 1850KN 5 The mast end node Ring cable-ridge cable node The cable quantity and specification of the Iraq Al-Menaa Stadium Cable position Cable specifications Cable number Length of the cable Upper cable Φ80 48 root 34m Lower cable Φ55 48 root 28m Stay cable Φ115 48 root 42m Ring cable Φ65 32 root 8 root of a ring cable,4 segment of a root,130m/segment Cross cable Φ55 16 root 24m 2.2 Construction control key points and solutions Key Point 1: The fix of the mast, the installation of the stay cable Solution: Through the two wind ropes to reinforce the mast, through the crawler crane to install the stay cable’s fixed end and the through the tool to install the adjustable end. Key Point 2: How to guarantee the stability of the mast in the process of ascension This stiffness of the engineering’s peripheral structure is relatively weaker than other similar structures, the mast will form large deformation in the whole process of ascension so must ensure the stability of the mast (especially the lateral stability) Solution: By reasonable arrangement of wind rope to ensure lateral stability of the mast, observing the deformation of the mast at any time in the process of ascension and immediately taking measures to rectify if the deformation exceeds a certain value. [...]... due to the construction process and strictly control of site operation 6 Chapter 3 Construction Process 3.1 The construction idea The idea of pre-stressed cable total construction is: erect the mast and ring beam firstly, then install the stay cable and at the same time hoist the upper cable and install it in place, lastly, install the lower cable 3.2 The construction process Set up ring cable packway... to release the ring cable in the ground Step 1: Use crane to put cable on the cable tray that located in flat car 18 Ring cable Cable tray Step 2: Use crane to put one cable head on the ground and the other cable head fixed Fixed cable head 19 Step 3: The cable rolling out smoothly on the ground as the car forward and the rotation of the cable tray Step 4: Use the crane to lift cable head to the ground... the construction of cable smoothly 4.1 Previous preparation The cable construction previous preparation work includes: the installation of the surrounding steel structure, the precise measurement of the steel structure construction error, the precise measurement of the cable blanking error , the ring cable construction packway erection, the operating platform erection of the upper cable and lower cable. .. 4.2.5 Connect the lower cable with cable clamp Pull cable to cable slot by chain block and crossarm and then tighten plate nut 28 Tooling 4.2.6 Lay down the upper ring cable Laying down the upper cable by using the method of laying down lower cable, aligning the mark point and tightening plate nut 29 4.2.7 Link the ring cable connector Ring cable connector 30 Link the ring cable connector in similar... fixed end of the stay cable Stay cable 16 The installation of stay cable s fixed end in similar projects Step 3: Use the tooling to install the adjustment end of the stay cable Haulage tooling The installation of stay cable s adjustment end in similar projects 17 The installation of stay cable s adjustment end in similar projects 4.2.2 Release the ring cable in the ground Use cable tray and flat car... Lay down the lower cable 7 upper Chapter 4 Cable installation & implementation plan The installation and tension of cable is the key process in the process of structural construction that serves as a link between the construction of steel structure and cable membrane and it has high technical difficulty It needs to develop detailed construction process from previous preparation to construction process... 4.2.3 Lay down the ring cable to the packway Use 3 cranes to lay ring cable together, setting a pole beam under each hanger and there are four lifting points on each pole beam Step 1: Lay down the innermost ring cable 21 The first ring cable The first ring cable 22 Tooling of laying down the cable The laying down of ring cable in similar projects Step 2: Lay down other position ring cable in turn 23 It... markers of the four ring cables in during the laying process Alignment method: adjusting the position of the cable by a chain when laying down every 10m ring cable with crane, reinforcing after aligning the mark point The mark point form 24 4.2.4 Hoist cable clamps Step 1: Hoist the first cable clamp Cable clamp 25 26 Hoist cable clamp in similar projects Step 2: Hoist other cable clamps in turn 27... Lay down the lower ring cable Install the ring beam Install the cable clip and put the lower ring cable into the slot Loosen the wind rope Lay down the upper ring cable and put them into the slot Install the back cable Lay down the upper cable and connect it to the ear plate by tooling Lay down the lower cable and connect it to the ring beam by the strands Lay down the lower cable and connect it to... developing the upper cable and tensing the lower cable, the position and size of the counterforce hole as shown in the figure below: 14 Counterforce hole of upper suspension cable Counterforce hole of lower cable 15 4.2 Laying down and assembling the cable 4.2.1 Install the stay cable Loosening the wind ropes after the mast and ring beam hoisting is completed, then installing the stay cable in turn Step . node Ring cable- ridge cable node The cable quantity and specification of the Iraq Al -Menaa Stadium Cable position Cable specifications Cable number Length of the cable Upper cable Φ80. CRITERIA AND/OR PARAMETERS. By Date: APL 17 SEPT. 2013 Menaa MS-05 1600-011 APL/TT 18 Sept 2013 Pre-stress Cable Construction Plan of Iraq Al -Menaa Stadium Contents. includes stay cable connected to the mast, upper cable and lower cable respectively 48 root, 48 root valley cable at the membrane surface, 16 root cross cable of the mast and a ring cable (8 root);