0 MS of cantilever constuction (PK2)

THE SOCIALIST REPUBLIC OF VIET NAM MINISTRY OF TRANSPORT PROJECT MANAGEMENT UNIT NO.85 NHAT TAN BRIDGE (VIET NAM - JAPAN FRIENDSHIP BRIDGE CONSTRUCTION PROJECT) Project: Nhat Tan Bridge Construction Project Contract Package – South Approach Bridge & Road METHOD STATEMENT FOR CONSTRUCTION OF CANTILEVER FOR P7, P8, P9 &P10 (second submission) Ha Noi: 1/2013 Nhat Tan Bridge Construction Project- Contract Package Table of Contents GENERAL CONSTRUCTION SCHEDULE SITE ORGANIZATION MATERIALS 4-1 Material list 4.2 Material for concrete: 4.3 Presstress PC strand: 4.4 Anchorage block and accessories: EQUIPMENT 5-1 Main Machine and Equipment List MATERIALS AND EQUIPMENT MANAGEMENT 6-1 Materials and equipment management CONSTRUCTION PROCEDURE 10 7-1 Flow Chart for Cantilever Construction: 10 7-2 Work Sequence for Assembly of Form Traveler 13 7-2-1 Survey Works: 13 7-2-2 Assembling Form traveler and Formworks 14 7-3 Work Sequence for Cantilever Construction by Form Traveler 17 7-3-1 Survey Works: 17 7-3-2 Setting Form traveler and Formworks 17 7-3-3 Rebar works 18 7-3-4 Arrangement of PC 22 7-3-5 Concrete Works 25 7-3-6 Preventive Measures of Honeycomb: 32 7-3-7 Curing, Finishing, and Construction joint: 33 7-3-8 Pre-stressing 34 7-3-9 Grouting Works 42 7-3-10 Moving the form traveler 44 7-4 Work Sequence for Disassembly of Form Traveler 46 CAMBER CONTROL 50 QUALITY CONTROL 53 10 ENVIRONMENTAL CONTROL 55 11 SAFETY CONTROL 56 Appendix I 61 (Schedule for cantilever of PC box girder in one cycle by form traveler) 61 Appendix II 62 (Example of inspection sheet) 62 Appendix III 63 (Working drawings for cantilever of PC box girder by form traveler) 63 JV of Sumitomo Mitsui Construction Co., Ltd and Vinaconex Construction Co., Ltd Nhat Tan Bridge Construction Project- Contract Package GENERAL This method statement describes the construction procedure, quality control, environmental management, and safety control aspects for construction of cantilever by Form Traveler The piers covered by this method statement are basically located at Pier 7, 8, and Pier 10 In case of special matters according to the pier, this method statement will be added before construction For the method statement of closure segment and side span will be submitted separately GENERAL VIEW 26000 YARD No.4 D No.5 B=6m d, Access roa 36000 CONS TRUC TION YAR UCTION CONSTR Access road, B=6m YARD No.3 Access road, B=6m Access road, B=6m No.2 CONSTRUCTION YARD Access road, B=6m Access road, B=6m Access road, B=6m CONSTRUCTION YARD No.1 6000 15000 HA NOI 36000 CONS TRUCTION 6000 15000 20000 , B=6m Access road 20000 Access road Access road, B=7m JV of Sumitomo Mitsui Construction Co., Ltd and Vinaconex Construction Co., Ltd Nhat Tan Bridge Construction Project- Contract Package 2 CONSTRUCTION SCHEDULE Construction schedule for Cantilever Construction in one cycle by Form traveler is shown on Appendix JV of Sumitomo Mitsui Construction Co., Ltd and Vinaconex Construction Co., Ltd Nhat Tan Bridge Construction Project- Contract Package SITE ORGANIZATION Site Organization Chart for Cantilever construction: JV of Sumitomo Mitsui Construction Co., Ltd and Vinaconex Construction Co., Ltd Nhat Tan Bridge Construction Project- Contract Package MATERIALS 4-1 Material list The list of material for the cantilever construction works is shown below: Material Concrete Steel re-bar PC steel wire Form oil Retarder for Const joint Form traveler Table: List of Material Description Detail Uni t Class C40 40 MPa m3 SD390 ton 12S15.2 ton 1S21.8 ton Sika Separol Sika Rugasol F Sika Rugasol C nos Qty 4100.0 575.0 203.1 40.4 lot lot 04 Note Sika product Sika products (for 02 sets) Detail of concrete volumn of segment: Permanent materials shall be recorded as well as the quantity, location, and supplier to be used for the trace ability purposes and keep on file properly 4.2 Material for concrete: - Concrete to be used for PC box shall be of grade C40, as specification 4.3 Presstress PC strand: - High strength PC strand shall be the type of wire-PC strand 12S15.2mm for longitudinal and 19 wire-PC strand 1S21.8mm for transverse according to JIS G 3536 or equivalent JV of Sumitomo Mitsui Construction Co., Ltd and Vinaconex Construction Co., Ltd Nhat Tan Bridge Construction Project- Contract Package - Minimum breaking load for 12S15.2mm is 3128.4 KN - Minimum breaking load for 1S21.8mm is 573.0 KN - Tensile strength 1860Mpa - Presstressed PC strand shall be pucharsed after confirming capacity of supplier and quality of presstressed PC strand meet technical requirements of the project - After delivery of presstressed PC strand to site, checking handing over minutes, certificate from manufacturer and invoices is required If this is in accordance with technical specification, storage and preserve is necessary - The PC strand is placed on wooden sleeper All PC strand shall be kept in roof storage yard with concrete floor to assure dry and unleakage condition - Fabrication works of PC strand shall be carried out following construction requirement PC strand shall be cut by mechanical cutting machine PC strand length shall include PC strand length passing the jack and using for stressing - Taking out PC strand from bundled PC strand shall be made by shape steel system, this shape steel system shall help PC strand to be taken out in order to prevent tangle or distortion of PC strand 4.4 Anchorage block and accessories: - Anchorage block and its accessories should be the type as specified in the approved technical documents All the anchorage block and accessories must have mill certificates of manufacturer in order to be assured of their quality - Testing works for anchorage block and its accessories should be in accordance with the technical specification of the Project and Standards 22TCN 247-1998 as well JV of Sumitomo Mitsui Construction Co., Ltd and Vinaconex Construction Co., Ltd Nhat Tan Bridge Construction Project- Contract Package EQUIPMENT 5-1 Main Machine and Equipment List The list of equipment for the Cantilever segment works is shown below: Item Batching Plant Form Traveler Service crane Service crane Mobile pump Table: List of Equipment (per 1Pier) Model Description Qty 120 m3/hr nos nos CH180 50ton, 1no boom length=34m 7035 35ton 1no ≥60 m3/hr nos Mixer truck 9m3/nos nos Bar cutter Bar bender Max D32 mm Max D32 mm 1 Generator 130 kvA, 50 Hz 1unit Welding Mach 14 KW nos Ø30 Ø50 2units 2units 3nos 6nos Gasket cutter Disk cutter Vibrator Vinyl sheet Wood trowel Steel trowel Air compressor High pressure pump PC Jack Hydraulic Pump Hydraulic Pump Concrete bucket Lighting system Level Total station Steel tape Tools Chain Block Steel brush PC strand cutter 150 m² YCW350B YCW100B YC50Q 350 tons 100 tons 50 tons 50Mpa 60Mpa 1.0 m³ – tons 10nos 10nos 1unit 1unit 02 02 01 02 01 no 10 units unit unit units 2set 4sets 10 nos 1no Remarks 02 sets including standby (1no.) including standby (1no.) including standby (D30-1no.) & (D50-1 no.) For curing and rain protection for cleaning For cleaning For stressing tendons Survey works For const joint JV of Sumitomo Mitsui Construction Co., Ltd and Vinaconex Construction Co., Ltd Nhat Tan Bridge Construction Project- Contract Package MATERIALS AND EQUIPMENT MANAGEMENT 6-1 Materials and equipment management - Re-bar should not put directly on the ground - Re-bar and PC steel wire should be covered by vinyl sheet - Check the machine before starting of the work PC steel wire coil timber Safekeeping of PC steel wire coil JV of Sumitomo Mitsui Construction Co., Ltd and Vinaconex Construction Co., Ltd Nhat Tan Bridge Construction Project- Contract Package CONSTRUCTION PROCEDURE 7-1 Flow Chart for Cantilever Construction: Construction of pier table Disassembly of Bracket system Assembly of Form Traveler on pier table Construction of segment K1 ～ K9 Disassembly of Form traveler and Formwork Diaphragm work Center closure Side span closure This Method will be submitted separately 10 JV of Sumitomo Mitsui Construction Co., Ltd and Vinaconex Construction Co., Ltd Nhat Tan Bridge Construction Project- Contract Package 7.4.4 Install temporary lever block for kept the main truss stable Remove connection bolts between main truss and transverse beams, unload the transverse beam to ground by crane one by one 7.4.5 Remove PC bar of traveler anchor by using anchor jacks and unload by crane one by one 48 JV of Sumitomo Mitsui Construction Co., Ltd and Vinaconex Construction Co., Ltd Nhat Tan Bridge Construction Project- Contract Package 7.4.6 Remove PC bar of rail anchor by using anchor jacks and unload rail beam by crane one by one 49 JV of Sumitomo Mitsui Construction Co., Ltd and Vinaconex Construction Co., Ltd Nhat Tan Bridge Construction Project- Contract Package CAMBER CONTROL Camber of formworks to be controlled shall assign and calculate The level of formwork shall be adjusted by hydraulic jacks and stretchers based on the planned of precamber calculations The calculation for cambers shall be based on deflection of box girder considering the dead load, pre-stressing effect and due to creep and shrinkage The designed camber is equal to the summation of deflection of all segments, prestress and creep and shrinkage of the concrete The deflection coming from the individual casted segment and shall consider the weight of the form traveler and the elongation of PC bars during the application of the load From the beginning for cantilever construction, pre camber must already adopt to the first block to be cast or the pier head 8.1 Measuring cast block: For defining the level in this stage data must accepted by the Engineer The differential between the design and actual level should be attested in measuring segment deflection in early morning Level Measuring Points: 13 14 10 11 12 15 All measurement must keep going until the forms adjustment meet the requirement and raging from allowable limit 50 JV of Sumitomo Mitsui Construction Co., Ltd and Vinaconex Construction Co., Ltd Nhat Tan Bridge Construction Project- Contract Package 8.2 Checking camber control: After setting the form traveler, the elevation of the old cast block shall be match to the calculated design camber After casting the first segment, the elevation shall be checked on its deflection to define the settlement of the form traveler 2.1 Measure the cast segment elevation as per record of casting, two points shall be made for measuring both are the outermost part of the segment po int s t o c hec k k1 new c as t ed s eg ment c l o f t he br idg e/pier k0 po int s t o c hec k k1 new c as t ed s eg ment 2.2 Measure the other wing side and check elevation in order to define if the structure is balance 2.3 Check the vertical alignment of column The plumpness of column must always be monitored every time when there is casting of segments After tensioning PC cable: 3.1 Measure the elevation of the segment at two points, the measurement must be match on the calculated camber Adjustment shall be imposed if there is a deficiency Moving the form traveler: 4.1 After moving the form traveler and set to other segment, the elevation of the segment shall be measured and recorded Measuring shall be made for two points, two points for outermost of the segment Checking cambers and adjusting: 51 JV of Sumitomo Mitsui Construction Co., Ltd and Vinaconex Construction Co., Ltd Nhat Tan Bridge Construction Project- Contract Package Considering all of the above measurements, this data will be noticed if the succeeding segments will adjust its camber by increase or decrease 5.1 After casting the segment, check and measure its actual elevation If the actual measurements exceed or higher than the design individual camber the succeeding segment to be cast shall decrease its camber 5.2 If the actual measurement is less than the design individual camber the succeeding segment to be cast shall increase its camber Checking of Pier settlement: 6.1 Pier settlement shall be checked for every 10 casting of segments Upon Inspection, the following data shall be submitted to the Engineer 7.1 Elevation data before installation of form traveler 7.2 Elevation data of the formworks before casting 7.3 Elevation data of the structure after casting 7.4 Elevation data of the structure after stressing 7.5 Elevation data after moving of the form traveler 52 JV of Sumitomo Mitsui Construction Co., Ltd and Vinaconex Construction Co., Ltd Nhat Tan Bridge Construction Project- Contract Package QUALITY CONTROL Checking work activity, all activities shall be checked, checklist, and Inspection sheet for this works by contractors and The Engineer Laboratories and Site Test for Concrete 1.1 On Site Test Slump test and temperature check shall be done on each concrete truck mixers delivered to the site The frequency of test shall be according to specification The tests shall be carried out near the casting site Label shall be placed on top of each specimen for easy identification For Pre stressing: times testing of specimens: First testing shall be conducted on days; the strength should be equal or greater than 360 kg/cm2 If the specimen failed, testing of specimen shall be conducted again on the following day Testing of specimen shall perform daily until it reached the allowable strength within four times of testing In case that on the first testing, when the specimen strength reaches within 90% of the allowable strength, testing of the specimen shall be conducted immediately after six hours If failed, test again after six hours, the same testing procedure if specimen failed until the strength reached the allowable within the four times of testing 1.2 Curing of specimen Specimens shall be cured on the bridge deck together with the concrete of box girder, the specimens shall be covered using a wet straw mat to keep it moist and shall be prevented from any vibration Regular quality control after removal of specimens from formworks, specimens shall be placed on water tank for curing 1.3 Compression Strength Test The test shall be carried out at the laboratory with the Engineer Laboratory Test for Rebar: Sampling shall be done for every delivery at the site The number of sample as follows: 2.1 Tensile Test - specimens for each diameter shall be taken at each delivery 53 JV of Sumitomo Mitsui Construction Co., Ltd and Vinaconex Construction Co., Ltd Nhat Tan Bridge Construction Project- Contract Package (randomly or as directed by the Engineer) 2.2 Bending Test- specimens for each diameter shall be taken at each delivery (randomly or as directed by the Engineer) Tensile and bending test shall be carried out at the approved laboratory Test Item and Frequency Test: Item Standard Test item Tensile strength Rebar ASTM Bending Elongation Frequency of Test - Every 150 tons for each type of rebar Remarks Frequency of Test for Pre-stressing Steel and Anchorage Test Item and Frequency Test: Item Standard Test item Breaking Strength Pre-stressing Steel ASTM Yield Strength Elongation Anchorages SPEC Slipping Test Frequency of Test Before construct and change the combination of pre-stressing steel and anchorage Check on certificate of manufacturers appended to all coils (Every less than 3ton) 3.At each delivery Before construct and change the combination of pre-stressing steel and anchorage Remarks Specimens: For testing = one piece For spare = one piece Treatment for Temporary Holes for construction: 4.1 Clean inside the holes 4.2 Spray with water or cement grout inside the holes before casting 4.3 Pour the holes with cement mortar as same proportion of the structure mixed 4.4 Immediately finish its level by using wooden or steel trowel 54 JV of Sumitomo Mitsui Construction Co., Ltd and Vinaconex Construction Co., Ltd Nhat Tan Bridge Construction Project- Contract Package 10 ENVIRONMENTAL CONTROL "Environmental Management Plan" will be based for the environment control and will be part of this method statement Environment controls comply with the condition of contract and Vietnam's National Law on Protection of Environment and other relevant legislation such as: Government Decree No 175/CP, Government Decree on providing Guidance for the Implementation of the Law on Environment Protection, 1994 Before commencement of the work, the survey of existing condition at site will be carried out to take sufficient number of photographs of the residential houses and other buildings which might be affected by the site activities Waste areas will be established at site for proper control of wastes on Site Waste materials will be disposed from Site to approved disposal area, and apply a mitigation measures to minimize waste or redress any problems that may arise from the waste associated with the works The following protection to avoid harm to living and working environment will be taken: To avoid destruction of flora and fauna To avoid excessive noxious gaseous smoke emission from construction site and emission from other operations in connection with the Works To avoid disposal of harmful materials such as diesel, oil and chemicals directly to the ground or to the water channel To avoid damage or interruption to water courses, irrigation channels and drainage paths 55 JV of Sumitomo Mitsui Construction Co., Ltd and Vinaconex Construction Co., Ltd Nhat Tan Bridge Construction Project- Contract Package 11 SAFETY CONTROL 11.1 General: - A check sheet will be prepared and safety assistant and site engineer should check the - safety facity and PPE base on it The check sheet will be filed The content of the above check sheet is below items (please see attached check sheet) Safety staff and site engineer shall stay during assembly and relocation of the form traveler 11.2 Protecting equipment for labor: - Helmet Safety belt Protective clothes Protective shoes 11.3 Safety for labors: - Whole labors have to wear protective clothing during working time and safety belt - must be worn if required Technical staffs, workers who take part in PC box girder construction have to learn to catch firmly the technology of girder casting and laboring safety regulation on electricity usage, anti-fire, high lifting safety and specially the safety regulation for stressing of PC 11.4 Safety for equipment: - There are only skilled operators whom are permitted to operate construction equipment at site For new operating workers, they must be checked carefully their skill before employment Whole construction equipment must be checked and maintained regularly before putting into operation The stability of ground and platform for equipment working, especially at position of stabilizers of crane must be checked carefully - Crane machine is special equipment for loading of structural elements, equipments and building parts In order to avoid industrial accidents, following instructions shall be conformed strictly: - Technical status of important parts such as: brakes, lights, horns must be checked carefully 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 56 JV of Sumitomo Mitsui Construction Co., Ltd and Vinaconex Construction Co., Ltd Nhat Tan Bridge Construction Project- Contract Package + No working in strong wind, dark, fog, weak light conditions + Strictly cooperate with signalman, sling man 11.5 Safety for working on high: - Safety handrail shall be installed on working scaffolding when working on high to - avoid workers fall down Safety net shall be applied when working on high place Lighting system shall be prepared for emergency or working on night 11.6 Safety methods for concreting process: a Before concreting: - Electric light must be checked carefully Hand light shall be prepared for standby in the case of sudden electricity off b During concreting: - When moving to other concreting position, concreting bucket must be closed to avoid - concrete material fall in workers Workers have to stand off bucket and concrete discharge pipe end 11.7 Safety methods before and in stressing process: a Before stressing: - PC strands, high strength steel bars, hydraulic jacks and other material that will be used must be checked and inspected regularly and all equipment must be ensured - good working condition Warning boards shall be placed at the position of stressing to avoid accident b During stressing process: - When jack working, all of workers must be stand by side of casting platform, strictly - prohibit from standing behind jacks Monitoring Engineer shall be arranged to watch out and rhythmically adjust pressure gauge of jack, elongation of PC strand in accordance with each pressure grade at both ends of girder It’s strictly prohibited to carry out stressing over designed tensile force 11.8 Safety works before construction: - Before construction, foreman shall carry out: Organizing the group meeting Checking protection clothing and equipment of each worker Checking health condition for each worker Arranging suitable job for workers Inspecting and instructing to worker as plan 11.9 Electric Safety: 57 JV of Sumitomo Mitsui Construction Co., Ltd and Vinaconex Construction Co., Ltd Nhat Tan Bridge Construction Project- Contract Package - Electric works must be only carried out by electrician Prohibit from putting conductors close to electric line or upper electric box When working close to electric line, experienced inspector should be arranged to be a - signalman If detecting any damage of electric equipment, it should be informed to electrician - immediately and request him to fix this problem Ground connector is the important part of equipment; it’s prohibited to cut off Always checking working condition of electric equipment before use High voltage electric line and electric equipment should have insulated cover and protecting accessories 11.10 Other safety works a Flood preventing: - Whole material that can be floated must be fastened or removed to safe place in the - case of typhoon and flood Weather condition information around construction site, especially water level data should be updated usually b Fire preventing: - In the case of sudden fire, any man who is near to fire should stop fire by ready accessories at site and inform immediately to site manager and make phone call to the - fire brigade Alarming to entire site and all of workers shall be removed out of site and gathered to safe place c First aid: First Aid room shall be prepared in construction site area with main acessories as follows: - Treatment room Antiseptic equipment Medicine box with necessary first aid medicines First aid stretcher Competent nurse d Lighting system: - Poor lighting condition may contribute to industrial accidents All of working positions or roads must be arranged sufficiently natural light or artificial light or both and be suitable with working actions e Instruction and Warning Boards: - Instruction and warning boards shall be placed at danger or safety positions to warn or instruct the dangerous or safe condition that is paid attention in working or passing 58 JV of Sumitomo Mitsui Construction Co., Ltd and Vinaconex Construction Co., Ltd Nhat Tan Bridge Construction Project- Contract Package emer genc y c ommunic at ion net wor k of Vinac onex (vinac onex's sc ope of wor k ) PMU 85 (046.2580.290) (Nguyen Hong Trang Tran Manh Toan (PM of Vinaconex-0913.233.429) SMCC&Vinac onex J oint vent ur e (sa f et y o ffi c er ) Odate: 0904.045.958 0982.230.482) Nguyen Ngoc Son (D.PM of Vinaconex0169.499.3333) Emergency Police (Nobuyuk i Uc hida 0167.905.3659) Bach Mai Hospital Le Xuan Duc Fire Brigade 043-869.3731 (Safety Staff-097.805.4667) 114 Thang Long Hospital Site Engineers Hanoi Police station 043-951.8147 Nguyen Kim Cuong 0915165433 Nguyen Trong Hung: 0978.976.799 Nguyen Van Den: 0913.446.996 Dao Van Huy: 0977.533.859 Tran Huy An 0989706321 Nguyen Dang Hieu 0989531248 043-942.21321 t he Engineer - 046.2580.271 113 Water Management Agency 043-883.2213 Ac c ident /Inc ident Emer genc y c ase 59 JV of Sumitomo Mitsui Construction Co., Ltd and Vinaconex Construction Co., Ltd Nhat Tan Bridge Construction Project- Contract Package Appendix I (Schedule for cantilever of PC box girder in one cycle by form traveler) 60 JV of Sumitomo Mitsui Construction Co., Ltd and Vinaconex Construction Co., Ltd Nhat Tan Bridge Construction Project- Contract Package Appendix II (Example of inspection sheet) 61 JV of Sumitomo Mitsui Construction Co., Ltd and Vinaconex Construction Co., Ltd Nhat Tan Bridge Construction Project- Contract Package Appendix III (Working drawings for cantilever of PC box girder by form traveler) 62 JV of Sumitomo Mitsui Construction Co., Ltd and Vinaconex Construction Co., Ltd ... Access road, B=6m CONSTRUCTION YARD No.1 600 0 1 500 0 HA NOI 3 600 0 CONS TRUCTION 600 0 1 500 0 200 00 , B=6m Access road 200 00 Access road Access road, B=7m JV of Sumitomo Mitsui Construction Co., Ltd... cutter 1 50 m² YCW350B YCW 100 B YC50Q 3 50 tons 100 tons 50 tons 50Mpa 60Mpa 1 .0 m³ – tons 10nos 10nos 1unit 1unit 02 02 01 02 01 no 10 units unit unit units 2set 4sets 10 nos 1no Remarks 02 sets... Class C 40 40 MPa m3 SD3 90 ton 12S15.2 ton 1S21.8 ton Sika Separol Sika Rugasol F Sika Rugasol C nos Qty 4 100 .0 575 .0 203 .1 40. 4 lot lot 04 Note Sika product Sika products (for 02 sets) Detail of concrete