vslth's presentation: sobrr c1-precast segmental viaducts erection-15 june 2006

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SOUTHERN OUTER BANGKOK RING ROAD PROJECT

SOBRR Contract No. 1 Erection of Precast Segmental Viaduct: Span-by-Span Method using Overhead Erection Gantry Padipat Chaemmangkang, Ph.D.

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Precast Segments Fabrication

Match Casting The successful use of precast segmental construction for bridges relies on the ease with which the contractor can erect and fix the segments and this in turn relies heavily on the quality of the joint between them. To ensure the best possible fit between the segments the concept of Match Casting was developed whereby each segment is cast directly against its neighbor.

VSL ASIA Precast Segmental Construction: Practical Aspects of Segment Fabrication & Erection, Neil Thorburn, Manager - Special Projects

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Short Line Match Casting Principle: Method of casting in which the form is stationary while the segments move from the casting position to the match casting position and then to the storage.


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Short Line Match Casting (Continued) Advantages: - much less space needed compared to long line (approximately three times the segment length) - the entire process is centralized - horizontal and vertical curves and twisting of the structure are obtained by adjusting the conjugate segment - the forms are reusable for other projects Disadvantages: - to obtain the desired structural configuration, the match cast segment must be accurately positioned. This requires a special geometry control software, the right setup in the casting yard and very skilled surveyors.


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Short Line Match Casting (Continued)


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Long Line Match Casting Principle: Method of casting segments on a long casting bed which makes up the soffit of a complete cantilever or span between field closure pours. One or more formwork units move along this line. The formwork units are guided by the preset soffit.


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Long Line Match Casting (Continued) Advantages: - geometry control is done when constructing the soffit which simplifies the geometry control and segment production - after stripping the forms, it is not necessary to take away the segments immediately


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Long Line Match Casting (Continued) Disadvantages: - requires a large area (minimum length is normally slightly more than half the length of the longest span) - requires a firm foundation which will not settle or deflect under the weight of the segments - if the structure is curved, the long line has to be designed curved also - since the form is mobile, the equipment for casting has to move from place to place - the soffit cannot be reused for a new project - the soffit can be made for one casting curve only


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Long Line Match Casting


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TC-JV SOBRR Project Contract No. 1

SOBRR Project Contract No. 1 – Casting Yard

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SOBRR Project Contract No. 1 – Casting Yard

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22 VSL ASIA Precast Segmental Construction: Practical Aspects of Segment Fabrication & Erection, Neil Thorburn, Manager - Special Projects


Geometry Control The effect of match casting the precast segments is to ensure an exact fit between segments on erection, as a result of this there is very little scope to adjust the bridge deck alignment on site and consequently it is important to ensure that each segment is accurately cast and more importantly that any errors which occur during casting are picked up and rectified. This is generally of much greater importance for short line casting than for long line.

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Geometry Control

VSL (Thailand) Co., Ltd. SOBRR Project Contract No. 1 .

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Geometry Control


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Geometry Control


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Geometry Control


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Geometry Control


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Geometry Control


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Geometry Control


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Erection of Precast Segments


There are two principal methods of precast segmental erection: the Free Cantilever Method (FCM) and the Span-by-Span Method. Within these, there are 3 basic techniques for handling and placing the segments: - by Crane - by Lifting Frame - by Launching Girder (Erection Gantry)

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Span-by-Span Method

This system is based on the principle of assembling an entire span onto a temporary support, stressing the segments together to form the single span deck and then placing the span on its permanent supports. Advantages: - Relatively fast - Simple geometry control - Spans are stable once placed – less temporary works Disadvantages: - Limited span and structure size due to need for full span gantry or falsework.


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Span-by-Span Method

Underslung Erection Gantry This system is based on the use of two or more trusses spanning between the piers on which the segments are placed and the span assembled. The segment placing is generally carried out by a crane or lifting frame. Advantages: - Relatively stable support of segments during assembly - Relatively cheap equipment for supporting and moving segments Disadvantages: - Not good on curved structure - Limited by ground conditions below – requires min. clearance below structure


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Span-by-Span Method

VSL (Thailand) Co., Ltd. SARL Project

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Span-by-Span Method


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Span-by-Span Method


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Span-by-Span Method


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Span-by-Span Method


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Span-by-Span Method


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Overhead Erection Gantry In this system the individual segments are hung from an overhead gantry. Once the segments are all in their approximate position they are then aligned and connected (glue/unglue) together to form the final span, which is then lowered onto its bearings. Advantages: - Easy to launch and move - Can cope with curved structure - Not limited by ground conditions Disadvantages: - Segments are relatively unstable in temporary condition - Adjustment and gluing of segments is more difficult

Span-by-Span Method


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GANTRY TECHNICAL

SPECIFICATION

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Erection Gantry Technical Specification

DESIGN CRITERIA Viaduct Perimeters Maximum Design Span Length (Erection) 45m Maximum Design Span length (Launching) 54m Maximum Design Span Weight 1000T Maximum Design Segment Weight 85T Maximum Numbers of Segment per Span 15nos.

VSL Singapore PTE. LTD. Technical Center Asia/Australia, Precast Segmental Viaduct Erection Gantry: Methodology Report, MF05017/R01A Issue A, 2005.

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Erection Gantry Technical Specification

DESIGN CRITERIA (CONT.) Viaduct Alignment Maximum Design Gradient ±4.5% Maximum Design Crossfall ±6% Minimum Radius in Plan 210m


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MT ELEMENT NO.

LENGTH AT TOP

CHORD (MM)

LENGTH AT BOTTOM CHORD

(MM)

WEIGHT OF MT ELEMENT

(TONS)

11 & 1 9681 7740 8.89

10 & 2 8180 8180 8.95

9 & 3 10080 10080 12.12

8 & 4 8300 10200 25.97

7 & 5 10200 8300 21.11

6 10200 10200 22.11

Erection Gantry Main Truss (MT)

2 Trusses


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Erection Gantry Upper Cross Beam (UCB)

1 No.

UCB

Function: Lifting of Precast Segments and Relocating LCB


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Erection Gantry Upper Cross Beam (UCB)

45

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Erection Gantry Universal Lower Roller Support (ULRS)

4 Nos.

ULRS2 (2 Nos.) ULRS1

(2 Nos.)

Function: Support Structure for MT allowing Longitidinal and Transverse Movements as well as Rotational of MT


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47 VSL (Thailand) Co., Ltd. SOBRR Project Contract No. 1 .


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Erection Gantry Lower Cross Beam (LCB)

2 Nos.

LCB1 (1 No.)

LCB2 (1 No.)

Function: Transverse Load Spreader from MT to LCB Support Leg (SL)


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Erection Gantry Lower Cross Beam (LCB)

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Erection Gantry LCB Support Leg (SL)

6 Nos.

SL (2 Nos.)

SL (2 Nos.)

SL (2 Nos.)

Function: Support Structure for LCB


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Erection Gantry LCB Support Leg (SL)

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Erection Gantry Front and Rear Support Leg (FSL/RSL)

2 Nos.

FSL (1 No.)

RSL (1 No.)

Function: Temporary Support to MT during some Stages of Operation


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Erection Gantry Rear Support Leg (RSL)

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Erection Gantry Front Support Leg (FSL)

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Erection Gantry Lifting Spreader Beam (SPB)

1 No.

SPB

Function: Precast Segment Erection and Relocation of LCB/SL


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Erection Gantry Connection Beam (CB)

24 Nos.

CB (1 No.)

CB Storage Area

Function: Individual Precast Segment Attachment to both SPB during Lifting and SBS during Erection


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Erection Gantry Connection Beam (Standard & Deviator Segments)

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Erection Gantry Connection Beam (Pier Segments)

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Erection Gantry Suspension Bar System (SBS)

17 Nos.

SBS

Function: Individual Precast Segment Suspension to MT during Erection


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Erection Gantry Pier Bracket (PB)

PB

PB

Function: Support for FSL Operation and Provision of Longitudinal Stability of Front LCB/SL (LCB2 for Launching

Direction Shown)


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Erection Gantry Pier Bracket (PB)

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Erection Gantry Chain Pulling Units (CPU)

Chain Spanner Wheel for MT (Element 3)

CPU for MT (Element 9)

CPU for UCB

Function: Longitudinal Movement of MT and UCB


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Erection Gantry Chain Pulling Units (CPU) – Upper Cross Beam

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Erection Gantry Chain Pulling Units (CPU) – MT (Element 9)

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74 VSL (Thailand) Co., Ltd. SOBRR Project Contract No. 1 : 12 June 2006

Erection Gantry Overall Structure

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GANTRY OPERATIONS

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1 ASSEMBLY 2 ERECTION OPERATION 3 LAUNCHING OPERATION

Erection Gantry Operations

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ASSEMBLY

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Erection Gantry Assembly 45M Span

Stage 1

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Stage 2

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Stage 3

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Stage 4

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Stage 5

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Stage 6

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Stage 7

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Stage 8

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Stage 9

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Erection Gantry

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ERECTION AND LAUNCHING OPERATION

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Averaged Erection Cycle: Single Decks - 3 shifts per span Twin Decks - 5 shifts per span Erection cycles include launching of the Erection Gantry, erection of all segments, installation and stressing of required PT, and load transferring of span weight.

Erection and Launching Operations Erection Cycle

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Single Decks – 3 shifts per span: - Span erection (max. 15 segments): 1 shift - PT installation, stressing and load transferring onto span jacks: 1 shift - Launching of the Gantry into next span: 1 shift Twin Decks - 5 shifts per span: - Span erection (max. 15 segments): 2 shifts - PT installation, stressing and load transferring onto span jacks: 2 shifts - Launching of the Gantry into next span: 1 shift


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Erection and Launching Operations 45M Span

Stage 1: upon completion of Span P(N-1) / P(N) two bounds -Store CB at respective position shown. -MT CPU fixity at pier P(N). -Brace LCB2 against previously erected viaduct. -Load transfer MT support from jack shim to crane wheel of ULRS


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Stage 2 -Deactivate LCB2 prop to PB. -Move MT transversely to centerline of twin deck. -Align MT for launching. -Move UCB to centerline of pier P(N-1). -Launch MT forward until C.G. is over pier P(N); Keep UCB at centerline of pier P(N-1). -Engage MT fixity pin to ULRS2. -Activate FSL.


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Stage 3 -Activate RSL to free ULRS1. -Deactivate LCB; Lift LCB1 off SL using UCB. -Move and position ULRS1/LCB1 near mid-span of P(N-1) / P(N). -Rotate LCB 1 by 90°.


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Stage 4 -Lift up and position LCB1 between MT. -Move ULRS1/LCB1 to mid-span of P(N) / P(N+1). -Lower down LCB1.


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Stage 5 -Rotate LCB1 by 90° and move ULRS1/LCB1 to pier P(N+1). -Engage LCB1 onto SL.


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Stage 6 -Deactivate FSL and load transfer MT support to ULRS. -Move FSL away and install LCB1 prop to PB. -Release LCB1 temporary prop. -Deactivate RSL.


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Stage 7 -Disengage MT fixity from ULRS2. -Launch MT forward to erection position; Keep UCB at centerline of pier P(N+1).


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Stage 8 -Move MT transversely to centerline of left / right bound. -Move in CB storage trailer and position between pier P(N-1) and P(N). -Launch MT backward until C.G. is over P(N); Keep UCB at centerline of pier P(N+1). -Engage MT fixity pin to ULRS2. -Activate RSL on single deck.


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Stage 9 -Move UCB to pier P(N-1); Disengage and lift SL to span between P(N) and P(N+1) to be lowered to ground. -Move UCB to pier P(N); Disengage and lift PB to span between P(N) and P(N+1) to be lowered to ground.


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Stage 10 -Move UCB to lift and park 6 nos. of CB onto CB storage trailer. -Keep 1 no. of CB (for pier segment) suspended on SPB and move UCB to centerline of pier P(N+1). -Deactivate RSL.


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Stage 11 -Disengage MT fixity from ULRS2. -Launch MT forward to erection position; Keep UCB at centerline of pier P(N+1). -Load transfer MT support from crane wheel to jack shim. -Transfer MT CPU fixity from pier P(N) to P(N+1). -Gantry is ready for span P(N) / P(N+1) construction.


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Stage 12 -Rotate and fix RSL. -Deliver segment over previously erected deck. -Pick up segments using UCB/SPB/CB. -Move and hang segments to suspension bars on MT. -Stagger segments as shown to allow for last segment rotation.


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Stage 13 -Rearrange and joint segments using UCB/SPB/CB from pier P(N) to about final level. -Install longitudinal PT required. -Stress longitudinal PT required at pier P(N+1) and lower ULRS jacks in stages to load transfer span weight from Gantry to piers.


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Stage 14 -Release and remove suspension bars from CB and store in MT. -Brace LCB2 against placed viaduct. -Store CB using UCB on placed viaduct. -Load transfer MT support from jack shim to crane wheels. -Repeat stages 8 to 14 for adjacent viaduct.


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ERECTION GANTRY KINEMATICS FOR 49.5M-54M-49.5M SPAN

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134 VSL Singapore PTE. LTD. Technical Center Asia/Australia, Erection Gantry Kinematics for 49.5m-54m-49.5m Span, MF05017/KN/22 Revision B, 2005.

Erection Gantry Kinematics 49.5M-54M-49.5M Span

Stage 1 - Span erection for Span 45-2/45-3 completed.

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Stage 3 -Deactivate FSL/RSL -Launch MT to position shown -Erect Span 45-3/45-4

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Stage 4 -Erect Span on Pier 45-4 as shown

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Stage 7 -Deactivate RSL -Launch MT to position shown -Erect Span 45-4/45-5

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Stage 8 -Erect Span on Pier 45-5 as shown

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Stage 11 -Deactivate RSL -Launch MT to position shown -Erect Span 45-5/45-6

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Erection Gantry Kinematics 40M-70M-40M Span

Stage 1 -Shorten FSL module during MT launching into Span 45-19/45-20 -Erect Span 45-19/45-20

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Stage 2 -Launch MT to position shown -Activate FSL/RSL

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Stage 3 -Move ULRS1/LCB1 to position shown with special support shims on deck

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Stage 4 -Deactivate FSL/RSL -Launch MT to position shown

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Stage 6 -Move ULRS2/LCB2 to position shown with special support shims on deck

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Stage 9 -Move ULRS1/LCB1 to Pier 46-2

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Stage 12 -Move ULRS2/LCB2 to Pier 46-3

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Stage 13 -Remove and lower PB from Pier 46-2 -Gantry is ready to erect Span 46-2/46-3

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Erection and Stressing Works First Span

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Span-by-Span Method


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vslth's presentation: sobrr c1-precast segmental viaducts erection-15 june 2006

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