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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 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 Prepared: Reviewed: Approved: Rev BBBH CONSORTIUM PHU MY BRIDGE DOCUMENT REVISION SHEET Issue Rev Initial Issue TP GM KF Revised Sec 1, 2, 3, 4.2, 4.4, 4.5, 4.6, 4.7, 4.8, 5, 7, 10 and Appendix as marked Add Appendix TP GM KF Add Appendix 7, and 10 TP GM KF Minor revisions Updated Appendices and Add Appendix 11 TP GM KF Add Sections 4.9, 4.10, 4.11 and 4.12 Updated Section TP GM KF Description MS-07 Cable-Stayed Bridge Deck Construction Prepared Reviewed Approved Rev BBBH CONSORTIUM PHU MY BRIDGE Table of Contents Page No GENERAL DESCRIPTION OF THE WORKS TEMPORARY WORKS WORK METHODOLOGY 4.1 CONSTRUCTION SEQUENCE 4.2 CONSTRUCTION ENGINEERING 4.3 PIER TABLE CONSTRUCTION 4.4 FORM TRAVELLER 4.5 DECK CONSTRUCTION 4.6 RESTRICTION ON DECK CRANE MOVEMENTS 4.7 BUFFETING CABLES 4.8 TEMPORARY TIE DOWN ANCHOR 4.9 LANDSIDE CLOSURE POUR 4.10 MIDSPAN CLOSURE POUR 4.11 CONTINUITY STRESSING 4.12 DECK FINISHES 7 16 28 28 28 29 35 38 38 PLANT AND EQUIPMENT 40 ACCESS 42 ORGANIZATION AND PERSONNEL 43 SAFETY 44 ENVIRONMENT 46 10 QUALITY 47 11 APPENDICES Appendix : Appendix : Appendix : Appendix : Appendix : Appendix : Appendix : Appendix : Appendix : Appendix 10 : Appendix 11: MS-07 Cable-Stayed Bridge Deck Construction Deck Cycle Deck Crane Tower Crane Telescopic Forklift Casting Sequence Survey Work Procedure Method Statement for Post-Tensioning of Deck Tendons Stay Cables Working Procedures (by Freyssinet) Deck Construction Engineering Records Form Traveller Operation Manual Method Statement for Buffeting Cables (by Freyssinet) Rev BBBH CONSORTIUM PHU MY BRIDGE 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 Heavy lifting and lowering Post Tensioning Form traveller steel fabrication Formwork tube steel fabrication - Freyssinet Freyssinet Freyssinet RIMP RIMP 1.4 Specialist Consultants The following consultants will perform the services as described: Permanent works design for cable stayed bridge Construction Engineering and major temporary works - MS-07 Cable-Stayed Bridge Deck Construction Arcadis Cardno Rev BBBH CONSORTIUM PHU MY BRIDGE 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 Rev BBBH CONSORTIUM PHU MY BRIDGE 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 Rev BBBH CONSORTIUM PHU MY BRIDGE WORK METHODOLOGY 4.1 Construction Sequence The basic sequence of work will be as follows:                 4.2 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 (West) tower complete with pier table falsework by heavy lift Construct the District pier table Install the first stay cables Lower pier table falsework Erect the form travellers for the District deck on each end of the pier table Construct the western balanced cantilever deck working away from the D7 tower Construct the District pier table in parallel Cast the District landside closure pour (after completion of the approach deck) Lower the form travellers and re erect on the District pier table Construct the District balanced cantilever deck working away from the D2 tower Cast the District landside closure pour Cast the midspan closure pour Remove the form travellers and complete bridge furniture and deck finishes 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: 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 Determination of exact forces and deflections of all parts during all erection stages This includes: MS-07 Cable-Stayed Bridge Deck Construction Rev BBBH CONSORTIUM PHU MY BRIDGE     Cable forces and cable length Camber values of superstructure and towers Support reactions Forces in temporary tie down cables 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 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 Rev 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 Rev 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 Cframes 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 MS-07 Cable-Stayed Bridge Deck Construction 10 Rev BBBH CONSORTIUM PHU MY BRIDGE SAFETY All work will be undertaken in accordance with this Method Statement and the relevant safety procedures within the Project Management Plan A risk analysis has been conducted for the works described in this Method Statement and the following risks have been identified: Work Activity General Operations Hazards Control Measures Provide site induction to all persons prior to start to work on site All All persons are to wear PPE Compulsory PPE includes covered shoes and Safety helmets Safety glasses, earplugs and gloves are to be used where conditions require Housekeeping – keep site and access clean and clear at all times All rubbish and loose material must be removed from the form travellers daily Regular toolbox meetings to be held with labour to reinforce safety and organisational matters Fall from height Safety harnesses to be worn when working outside the fenced areas Personnel to be inducted about safe work at heights Falling objects Handrails to be installed at the edges of the deck Night work Minor falls, cuts and abrasions due to poor visibility Provision of adequate lighting Maintain tidy work area Crossbeam forms to be kept covered prior to Precast Beam installation Materials Storage on Deck Injury due to movement of unsecured materials Oxygen bottles are to be kept in trolley to prevent rolling or stored upright in a secure manner prior to use Working at height Stay cable strand drums to be stood in restraint blocks Stressing strand drums to be stored flat until placed in dispensers Prefabricated cross beams to be properly stored to eliminate the risk of them falling over General Plant Operations at ground level Injury due to objects falling from crane lifts or from swinging loads Tower crane operators and riggers to be experienced Loads to be slung correctly Hand injury concrete pump Pump hoppers to have correct guards from Collision with other vehicles and people MS-07 Cable-Stayed Bridge Deck Construction Spotter to be used to direct traffic during concrete pours Adequate lighting to be made available at night 44 Rev BBBH CONSORTIUM PHU MY BRIDGE Work Activity Hazards Control Measures Vehicle / plant / equipment movements on the deck Collision with other vehicles and people Telehandler and deck crane operators to receive induction regarding working on the deck “No Go” zones to be clearly defined Adequate lighting to be made available at night Designated pedestrian paths made available Work instruction for safe use of both these machines on the deck to be provided and incorporated into the induction Lifting steel reinforcement and other material to deck level Falling objects Pre-fabricated units and steel to be adequately secured and slung by experienced rigger/dogmen Personnel to keep away from beneath lifted items A covered access will be provided to the hoist waiting area The waiting area will also be covered A demarcated area will be provided as a crane pickup and set down area - to be used only for tower crane Form Traveller operation and deck construction Falling objects All gaps on the form traveller are to be sealed Traveller operational malfunction Crews to be trained in the safe operation of the traveller in accordance with the Operation manual Checklists provided in the Operation manual are to be followed during all stages of operation Notwithstanding the above hazard identification study, Job Safety Analyses (JSA’s) shall be conducted for any significant hazard that may exist or where the workers are unfamiliar with the works or environment in which they are to operate MS-07 Cable-Stayed Bridge Deck Construction 45 Rev BBBH CONSORTIUM PHU MY BRIDGE ENVIRONMENT Environmental Issue Risk Control Measures Noise and Vibration District -Remote area – no restrictions District -Remote area – no restrictions n.a Air Quality Dust at batching plants and access roads Control dust on access road by sprinkling water Provide dust filters at batch plant Water Quality Oil spillage Oil absorbent material to available Oil reservoirs hydraulic power-packs to bonded Vegetation There is no significant threatened vegetation in the area of work n.a Waste Management Construction waste build-up Waste to be removed from the decks, travellers and ground area on a regular basis Provision shall be made in designated areas for on-site concrete washout Concrete washout be on be Notwithstanding the status noted in this schedule, BBBH will continue to monitor and implement their works in accordance with the Environmental Management Plan and Specific Environmental Work Instructions MS-07 Cable-Stayed Bridge Deck Construction 46 Rev BBBH CONSORTIUM PHU MY BRIDGE 10 QUALITY All works will be undertaken in accordance with this method statement and the relevant procedures documented in the Project Management Plan, particularly the following:  PM1-CO-ITP-07 “Inspection and Test Plan for Cable-Stayed Bridge Deck Construction”  PM1-CO-MS-09 “Method Statement for Concrete Works”  PM1-CO-ITP-09 “Inspection and Test Plan for Concrete Works” The inspection procedures mentioned in the Inspection and Test Plans stated above will be monitored in the field using standard ITP forms Refer to relevant Inspection and Test Plan documents for copies of inspection sheets and checklists Construction Engineering documents which include load map, stressing release and acceptance of form traveller position and deck survey are attached in Appendix MS-07 Cable-Stayed Bridge Deck Construction 47 Rev BBBH CONSORTIUM PHU MY BRIDGE APPENDIX MS-07 Cable-Stayed Bridge Deck Construction 48 Rev BBBH CONSORTIUM PHU MY BRIDGE APPENDIX MS-07 Cable-Stayed Bridge Deck Construction 49 Rev BBBH CONSORTIUM PHU MY BRIDGE APPENDIX MS-07 Cable-Stayed Bridge Deck Construction 50 Rev BBBH CONSORTIUM PHU MY BRIDGE APPENDIX MS-07 Cable-Stayed Bridge Deck Construction 51 Rev BBBH CONSORTIUM PHU MY BRIDGE APPENDIX MS-07 Cable-Stayed Bridge Deck Construction 52 Rev BBBH CONSORTIUM PHU MY BRIDGE APPENDIX MS-07 Cable-Stayed Bridge Deck Construction 53 Rev BBBH CONSORTIUM PHU MY BRIDGE APPENDIX MS-07 Cable-Stayed Bridge Deck Construction 54 Rev BBBH CONSORTIUM PHU MY BRIDGE APPENDIX MS-07 Cable-Stayed Bridge Deck Construction 55 Rev BBBH CONSORTIUM PHU MY BRIDGE APPENDIX MS-07 Cable-Stayed Bridge Deck Construction 56 Rev BBBH CONSORTIUM PHU MY BRIDGE APPENDIX 10 Form Traveller Operation Manual MS-07 Cable-Stayed Bridge Deck Construction 57 Rev BBBH CONSORTIUM PHU MY BRIDGE APPENDIX 11 MS-07 Cable-Stayed Bridge Deck Construction 58 Rev [...]... Manual which will be provided by the Construction Engineering consultant Cardno This will outline the necessary sequence for casting of each stage together with the sequence and timing for installation of temporary tie down cables and buffeting cables A summary of the content of this document is included in Section 4.2 of this document The construction of the cable-stayed deck commences following erection... established by undertaking a 6 strand liftoff test in parallel with the early morning survey on Day 1 of the cycle The results of this test will be provided to the construction engineer and will also be used to verify the strand force tolerance within the bundle Based upon this information, the Construction Engineer will provide;  The adjustment to the cable force MS-07 Cable-Stayed Bridge Deck Construction... nominated “f” value This procedure is included on Form A of Appendix 9 The calculation for the new “f” value will be documented for each segment The calculation will be carried out within the constraints imposed in the Erection Manual After launching and resetting of the traveller on day 2 of the cycle a local survey will be undertaken to check the achieved f value and to review the pod geometry This survey... cable guide tubes will be precast into pod units This serves several functions: 1 It enables the geometry of the guide tubes to be accurately set in a precast bed 2 The careful work of surveying and adjusting the geometry is done off the critical path 3 The stay cable can be installed directly into the permanent anchorage prior to casting the deck segment This avoids the need for a temporary anchorage... 3 BBBH CONSORTIUM PHU MY BRIDGE area for the full curing period To ensure that adequate curing is achieved in this area, a curing compound will be applied to the deck surface from the edge of the deck to the external barrier (i.e., the wing and motorcycle lane areas) in addition to polythene This also covers the deck surface above the edge beam The beam sides and deck soffit will be cured with a suitable... geometry This survey may be carried out at any time of the day and is not temperature dependant This procedure is included on Form B in Appendix 9 The intended deck mix design will be 50D using 480 kg/m3 of cement The expected strength gain is indicated on the 5 day deck cycle included in Appendix 1 of this document The concrete strength limitations required prior to various deck operations as nominated... better suit the production operation depending on the actual concrete strength gained as determined by testing 4.5.2 Reinforcement Reinforcement will be preassembled into cages or mats where possible This will include the edge beams and possibly the mats on the deck for the wings and for the central portion Pre-fabrication of edge beam cages will be done on the deck and the elements will be transported... assembly will be done on a barge adjacent to a suitable jetty at the Lotus Port using the Hitachi 200T crawler crane The components will be unloaded from the delivery vessel and transported to a position within the lifting radius of the Hitachi crane The large truss and C-frame components are likely to weigh up to 20 tonnes necessitating the use of the large crane capacity offered by the 200T crawler crane... pods will be verified by carrying out a trial lift with the deck crane prior to the first erection into the traveller The crane must be located in accordance with the sketches included in Appendix 2 of this document The fundamental requirement is for the front outriggers to be located above the MS-07 Cable-Stayed Bridge Deck Construction 18 Rev 3 BBBH CONSORTIUM PHU MY BRIDGE front cross beam of the... enable the main vertical supply line to be connected to the appropriate deck line A manually operated concrete distributor boom will be located in the centre of the deck at the end of the previous pour This will have a boom length of at least 12m The corners will be reached using flexible hose The horizontal deck pump line will be covered in Hessian which will be kept wet during the pour to keep the