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Nhat Tan Bridge (Vietnam-Japan Friendship Bridge) Construction Project THE SOCIALIST REPUBLIC OF VIET NAM 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 Joint Venture of IHI Corporation and Sumitomo Mitsui Construction Co., Ltd Nhat Tan Bridge (Vietnam-Japan Friendship Bridge) Construction Project MENU OF CONTENTS I GENERAL INTRODUCTION 1.1 Project scale: 1.2 Geometric dimension of Super-T girder: 1.2.1 Girder length: 1.2.2 Dimension of Cross-section: 1.2.3 Weight of girder: II CONSTRUCTION MATERIAL AND EQUIPMENT 2.1 Construction Material: 2.2 Construction equipment: III ERECTION WORKS 3.1 Erection Procedure Chart of Super-T girder: 3.2 Preparation and survey 3.3 Assembling, installation of gantry crane on site 3.3 Bearing installation and grouting 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 Joint Venture of IHI Corporation and Sumitomo Mitsui Construction Co., Ltd Nhat Tan Bridge (Vietnam-Japan Friendship Bridge) Construction Project I GENERAL INTRODUCTION 1.1 Project scale: - Package Nhat Tan Bridge Construction Project includes main bridge and Red River northern approach bridge of which main bridge is L=1500m long and approach bridge is L=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 erection Super-T girder, bearing instalation and grouting, quality control, safety and environment protection, 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 Number No Type of Girder Length (m) Type 38.950 (girder) 15 Span location Type 38.300 75 P18~P23 Type 38.120 15 P23~P24 Type 38.040 270 P24~P27, P29~P37; P39~P46 Type 37.890 30 P27~P28; P37~P38 Type 37.890 30 P28~P29; P38~P39 Type 38.040 15 P46~P47 Type 38.740 15 P47~P48 P17~P18 Joint Venture of IHI Corporation and Sumitomo Mitsui Construction Co., Ltd Nhat Tan Bridge (Vietnam-Japan Friendship Bridge) Construction Project 1.2.2 Dimension of Cross-section: - Heigh of girder: h=1750 mm; - Width of flanged plate: b= 2115mm for side girder and b=2170 mm for middle girder c r o s s s ec t io n o f s uper -T g ir der ext er io r g ir der int er io r g ir der 2115 388 388 22 697 10 10 700 697 388 22 300 430 160 388 160 10 110 110 225 50 300 225 50 300 1600 1750 875 110 110 776 22 1750 875 300 75 75 22 697 75 75 10 2170 776 1600 642 430 160 700 160 1.2.3 Weight of girder: - Concrete volume for girder is V=28m equally to the weight of one girder is about 75 tons Joint Venture of IHI Corporation and Sumitomo Mitsui Construction Co., Ltd Nhat Tan Bridge (Vietnam-Japan Friendship Bridge) Construction Project II CONSTRUCTION MATERIAL AND EQUIPMENT 2.1 Construction Material: Table 2: Main material to be used for Erection of Super-T girder No Item Prestressed concrete girder Transversal beam Wooden sleeper (group 2) Quantity/ Description Unit Super-T girder 465 Tons 34 m3 2.7 Number Remarks Table 3: Auxilary materials to be used for Erection of Super-T girder No Item Scaffolding H200x100x5x8 Steel cable Timber 3-5cm Quantity/ Description Unit D114 Tons 6.9 Tons 2.8 m 100 m3 0.5 D22mm Number Remarks Joint Venture of IHI Corporation and Sumitomo Mitsui Construction Co., Ltd Nhat Tan Bridge (Vietnam-Japan Friendship Bridge) Construction Project 2.2 Construction equipment: Main construction equipments to be used for erection of Super-T girder is shown in the following table: Table 4: Main Equipments for Erection Super-T girder No Name of equipment, material Description Unit Quantity/ Number Gantry crane P=80T, L=40m Nos 2 Mobile crane P=100T Nos Tractor 420HP Nos 4 Trailer 50 tons Nos Mobile crane 50 tons Nos Remarks Joint Venture of IHI Corporation and Sumitomo Mitsui Construction Co., Ltd Nhat Tan Bridge (Vietnam-Japan Friendship Bridge) Construction Project III ERECTION WORKS 3.1 Erection Procedure Chart of Super-T girder: Erection Procedure Chart Preparation and survey Assembling, installation of gantry crane on site Bearing installation and grouting Installation of transversal beam on pier Installation of gantry crane on pier Transportation of Super T girder Erection of Super T girder Disassembling and Moving of gantry crane to next span Construction of Diaphragm and Desk slab NOTE: The works shall be submitted separately Joint Venture of IHI Corporation and Sumitomo Mitsui Construction Co., Ltd Nhat Tan Bridge (Vietnam-Japan Friendship Bridge) Construction Project 3.2 Preparation and survey - Survey work for coordinates and checking elevation of all pier will be done carefully before we can start erection work - The Method Statement, quality control plan, safety plan for erection of Super-T girder with the calculation sheet must be submitted to The Engineer before starting Erection works 3.3 Assembling, installation of gantry crane on site - Gantry crane is pre-fabricated in workshop and transported to the construction site by truck - Arrangement of wooden sleeper for assembling grantry crane at site - Assembling of grantry crane to 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 Joint Venture of IHI Corporation and Sumitomo Mitsui Construction Co., Ltd Nhat Tan Bridge (Vietnam-Japan Friendship Bridge) Construction Project - 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 Surface treatment was carry out 100% of touching surface, cleaning after finishing roughening work - 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 the Engineer - Installation of bearing Joint Venture of IHI Corporation and Sumitomo Mitsui Construction Co., Ltd Nhat Tan Bridge (Vietnam-Japan Friendship Bridge) Construction Project 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 steel brush Surface treatment was carry out 100% of touching surface, cleaning after finishing roughening work - Installing of bottom bearing part to its exactly position - Checking elevation with attention of the Engineer - Assembling of formwork - 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 to position on pier - Checking elevation and position of transversal beam Joint Venture of IHI Corporation and Sumitomo Mitsui Construction Co., Ltd Nhat Tan Bridge (Vietnam-Japan Friendship Bridge) Construction Project - Tightening all archorage bolts to fix transversal beam Joint Venture of IHI Corporation and Sumitomo Mitsui Construction Co., Ltd 10 Nhat Tan Bridge (Vietnam-Japan Friendship Bridge) Construction Project + For P17 + For P18 + For P19-P47 + For P48 Joint Venture of IHI Corporation and Sumitomo Mitsui Construction Co., Ltd 11 Nhat Tan Bridge (Vietnam-Japan Friendship Bridge) Construction Project 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 to position 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 Joint Venture of IHI Corporation and Sumitomo Mitsui Construction Co., Ltd 12 Nhat Tan Bridge (Vietnam-Japan Friendship Bridge) Construction Project ELEVATION t o noi +31.10 t o DONG ANH +30.907 Hozir ontal beam K1 bl ock +27.20 +9.70 +9.55 PLAN CRANE 80TONS MOVE TOWARD TRAILER GANTRY CRANE TRACTOR Sketch 4: Erection of gantry crane on pier Joint Venture of IHI Corporation and Sumitomo Mitsui Construction Co., Ltd 13 Nhat Tan Bridge (Vietnam-Japan Friendship Bridge) Construction Project 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 before continue lifting work - Continue lifting up the Super-T girder, when bottom face of the Super-T is higher than bearing's face about 30cm to put on the brake - Transversal moving of the gantry crane to setting the Super-T girder to its position extracly on the bearing - Keep the beam stable against by wooden sleeper and strut bar Joint Venture of IHI Corporation and Sumitomo Mitsui Construction Co., Ltd 14 Nhat Tan Bridge (Vietnam-Japan Friendship Bridge) Construction Project ELEVATION t o noi +30.907 +27.20 +9.70 +9.55 PLAN GANTRY CRANE MOVE TOWARD TRAILER SUPER-T GIRDER TRACTOR Sketch 6: Erection of Super-T girder Joint Venture of IHI Corporation and Sumitomo Mitsui Construction Co., Ltd 15 Nhat Tan Bridge (Vietnam-Japan Friendship Bridge) Construction Project 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 to position 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 Joint Venture of IHI Corporation and Sumitomo Mitsui Construction Co., Ltd 16 Nhat Tan Bridge (Vietnam-Japan Friendship Bridge) Construction Project ELEVATION t o noi +30.907 +27.20 +9.70 +9.55 PLAN CRANE 80TONS MOVE TOWARD TRAILER GANTRY CRANE TRACTOR Sketch 7: Disassembling and transportation of gantry crane Joint Venture of IHI Corporation and Sumitomo Mitsui Construction Co., Ltd 17 Nhat Tan Bridge (Vietnam-Japan Friendship Bridge) Construction Project 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 and documentation, 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, curing works - 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 quality method 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 high qualification and capability to the construction work, having professional quality control engineers 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 any issues occurred during construction, checking of quality of all items after completion is required - Site Manager, engineer and workmen of the Construction Units should fully obey the requirements in the approved design document and technical specification to ensure the works quality 5.2 Labor force quality: - All of technical staffs, skilled labors that are take part in every work item, construction assembly shall be trained through the technical meetings in order that all men can catch the construction technology steps relating with each work item - The Contractor will arrange suitable labor force in right position All workers shall be responsible in working, conform to instruction and arrangement of the site manager or team leader in oder to ensure the product quality as well as project schedule as stipulated Joint Venture of IHI Corporation and Sumitomo Mitsui Construction Co., Ltd 18 Nhat Tan Bridge (Vietnam-Japan Friendship Bridge) Construction Project 5.3 Construction equipment quality: - Whole construction equipment to be used shall be regularly tested to ensure good operating condition: + Ensuring good features and safety operation + Operating capacity should be suitable with construction schedule of each work item as well as entire project + Regularly maintenance for equipment - For the girder lifting equipment (Gantry crane 80 tons): before puting in use, lifting equipment shall be carried out the load test at site Independent inspection unit will be invited to check its technical and safety features as stipulated for specialized lifting equipment 5.4 Moving girder from storage yard to erection site: - Super-T girder will be stored in storage yard at least months before transportation to erection site - Super-T girder will be transportation to erection site by truck and trailer with capacity 50 tons - Moving process shall be done carefully and slowly at both ends of girder - The velocity of gantry crane is ensured at -10m/minute to be stable and avoid shaking of girder 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 after completing each girder production Joint Venture of IHI Corporation and Sumitomo Mitsui Construction Co., Ltd 19 Nhat Tan Bridge (Vietnam-Japan Friendship Bridge) Construction Project VI METHOD FOR SAFETY AND ENVIRONMENTAL PROTECTION 6.1 Laboring safety method: 6.1.1 Protecting equipment for labor: - Helmet 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 be worn if required Technical staffs, workers who take part in Super-T 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 6.1.3 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, specially 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 + 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 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 Joint Venture of IHI Corporation and Sumitomo Mitsui Construction Co., Ltd 20 Nhat Tan Bridge (Vietnam-Japan Friendship Bridge) Construction Project 6.1.5 Safety for girder loading out of cast platform and girder installation: - Girder will be lifted up slowly and evenly at both ends of girder until girder’s bottom higher than casting platform surface about 30-50 cm, watching out to ensure that there is no obstacle then moving cross to put girder on storage yard 6.1.6 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 6.1.7 Electric Safety: - 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 6.1.8 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 Joint Venture of IHI Corporation and Sumitomo Mitsui Construction Co., Ltd 21 Nhat Tan Bridge (Vietnam-Japan Friendship Bridge) Construction Project 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 be paid attention in working or passing 6.2 Method for environmental protection: - Whole places at site that store material, equipment and accessories shall be cleaned The - inflammable and dangerous materials should be stored at specified places Waste material and garbage shall be removed out of working place and stored at specified - area accepted by the Engineer Construction materials, equipments and accessories stored at site shall be arranged in order and tidy Joint Venture of IHI Corporation and Sumitomo Mitsui Construction Co., Ltd 22 Nhat Tan Bridge (Vietnam-Japan Friendship Bridge) Construction Project SITE ORGANIZATION CHART OF ERECTION FOR SUPER-T GIRDER CONTRACTOR (IHI CORPORATION) PROJECT MANAGER Teruhisa Koike SEFETY CONTROL Tojuro Nishi DEPUTY PROJECT MANAGER Kenji Matsuno CONCRETE CONSTRUCTION MANAGER Mitsuhiro Yamashita QUALITY CONTROL MANAGER Nakayama Masaaki SUBCONTRACTOR (VINACONEX E&C) EQUIPMENT PLANNING Masato Endo MATERIAL CONTROL Shinzi Izumi SUPERVISOR Masato Endo NHAT TAN BRIDGE PROJECT MANAGEMENT OFFICE - VINACONEX E&C Do Hoang Tu TECHNICAL SAFETY ERECTION TEAM OF SUPER-T GIRDER ON SITE ERECTION TEAM No.1 ERECTION TEAM No.2 SUPPORT TEAM - Welder - Operator - Operator - Operator - Workers for Erection - Workers for Erection - Workers for other works Joint Venture of IHI Corporation and Sumitomo Mitsui Construction Co., Ltd 23 Nhat Tan Bridge (Vietnam-Japan Friendship Bridge) Construction Project APPENDIX 1: CALCULATION OF TRANVERSAL BEAM FOR GANTRY CRANE APPENDIX 2: CONSTRUCTION METHOD DRAWINGS FOR ERECTION OF SUPER-T GIRDER Joint Venture of IHI Corporation and Sumitomo Mitsui Construction Co., Ltd 24 ... 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... Bridge) Construction Project 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... erection work - The Method Statement, quality control plan, safety plan for erection of Super- T girder with the calculation sheet must be submitted to The Engineer before starting Erection works 3.3