Bridge Construction Methods - PTIA

1 Bridge Construction MethodsBy David TRAYNERC ontentsA. Introduction of SpeakerB. Bridge Construction Methodsi. Pre-castii. Cast in-situiii. OthersC. Precasting TechniquesD. DuctalA. SpeakerDavid - Special Projects Operations Manager : UTS 1990 BEng; UNE 2001 MBA Costain Australia Pty 2004 VSL Heavy Lift Operations NS4 Tsing Mah Bridge Skybridge Petronas Twin Towers Burj Al Arab, 4 New Bangkok International Airport, BKK, onwards VSL Australia, Projects: LHD, BRB, GDE, GUPP recast Concrete Bridges1. I Beams & Super Tee s2. Segmental3. Full Span Cast in-situ post tensioned concrete decksPrecast I Beams & Super Tee s1.

2 Description Standard Beams can be pre & or post tensioned. Cast on site or in existing PC Yard2. Advantages Cheap Simple to erect3. Disadvantages Limited in length (lat torsion buckling) Less efficient Logistics (police escort etc) Aesthetics banned in some countriesCebuCebuSouth Coastal Road South Coastal Road --PhilippinesPhilippinesCebuCebuSouth Coastal Road South Coastal Road --PhilippinesPhilippinesCebuCebuSouth Coastal Road South Coastal Road --PhilippinesPhilippinesPrecast Segmental Techniques1. Description Complete deck cast, delivered & erected in unique cells Segments are prestressed together using external and or internal tendons.

3 Joints can be dry or wet . Typically in Span by Span or Balanced Cantilever mode2. Advantages Structurally efficient and aesthetic Complete with deck when erected rapid & safe Cast during substructure works overlap of activities3. Disadvantages Casting yard setup + logisticsPRECAST SEGMENTAL ERECTION TECHNIQUES1. Erection on Falsework2. Erection by Gantry3. Erection by Crane4. Erection by Lifting Frame5. Full Span Erection Techniques1. ERECTION ON FALSEWORKM7 Crane Erection on FalseworkM7 Crane Erection on Falsework2. ERECTION BY GANTRYA. Span By Span Simply Supported B. Balanced CantileverSegmental Erection By Underslung GirderKCRC West Rail - Hong KongM7 Span By Span by Underslung Gantry Over M4 KRCR WEST RAIL VIADUCT ERECTIONTYPICAL ERECTION KINEMATICS FOR UNDERSLUNG GIRDERKRCR WEST RAIL VIADUCT ERECTIONTYPICAL ERECTION KINEMATICS FOR UNDERSLUNG GIRDERKRCR WEST RAIL VIADUCT ERECTIONTYPICAL ERECTION KINEMATICS FOR UNDERSLUNG GIRDERB angkok Second Stage Expressway Segmental Erection By Segmental Erection By UnderslungUnderslungLaunching Girder,Launching Girder, Bridge Over Mekong River - LaosView of Launching GirderTelok Blangah - SingaporeNorthern Gateway Alliance NZ.

4 Waiwera BridgeShenzhen Western Corridor - HK3. ERECTION BY CRANEM7 BC Over Old Windsor RdM7 BC Over M4 Balanced Cantilever Segmental Erection by CraneBalanced Cantilever Segmental Erection by CraneKCRC West Rail KCRC West Rail --Hong KongHong Kong4. ERECTION BY LIFTING FRAMEI ndustrial Ring Road - BangkokNanjing Second Bridge - ChinaIbiIbiRiver Bridge River Bridge KisosansenKisosansenProject Project --JapanJapan5.. FULL SPAN PRECAST ERECTION TECHNIQUESS ingapore MRT Full Precast Span ErectionSingapore MRT Full Precast Span ErectionFULL SPAN PRECAST ERECTION Taiwan High Speed Rail Contract C215 FULL SPAN PRECAST ERECTION Taiwan High Speed Rail Contract C215 THSR TYPICAL ERECTION KINEMATICS FOR FULL SPAN PRECAST SEGMENTIN-SITU CONCRETE BRIDGESCONSTRUCTION in-situ Post Launched1.

5 Cast in-situ Post tensioned2. BALANCED CANTILEVER Segmental Cast in -situFormwork Travellers2nd Link Singapore / MalaysiaSeacliff Bridge - FormtravellerGungahlin Drive Ext - CanberraMFT on Taiwan High Speed Rail C2157. MFT application toTHSR C2153. INCREMENTAL LAUNCHED Cast In-situIncremental Launching MethodIncremental Launching MethodOthers Pier Head Rotation Arch Lowering Main Span Lifting Techniques1. Segmental shortline2. Segmental longline3. Full Span4. PC Girders1. SHORT LINEPRECASTING CELLSGEOMETRY CONTROLPier Segment in Match Casting Segment in Match Casting Project --JapanJapanSoffitSoffittabletableSoffit SoffitformformSupportSupportframeframe2.

6 LONG LINE PRECASTING BEDSView of Precasting Formwork on Long Bridge - LaosView of Precasting Bridge - LaosSegment Transporter,Pakse Bridge - Laos3. FULL SPAN PRECASTING BEDSTAIWAN HIGH SPEED RAIL -FULL SPAN PRECASTING4. I BEAM PRECASTING BEDSView of View of Coastal Road South Coastal Road --PhilippinesPhilippinesView of View of Coastal Road South Coastal Road --PhilippinesPhilippinesView of Prefabricated Rebar of Prefabricated Rebar Coastal Road South Coastal Road --PhilippinesPhilippinesD. Ductal Reactive Powder Concrete85 RPC was initially developed by Lafarge, Rhodia and Bouygues the parent company of VSL, and is marketed under the name of Ductal.

7 Ductal (RPC) consists of cement, sand, silica fume, silica flour, superplasticiser, water and high strength steel Ductal a Reactive Powder ConcreteReactive PowderConcreteHigh-strengthConcreteNorma l-strengthConcreteSteel fibres8602040608010012014016018020002000 400060008000100001200014000 Micro StrainStress MPaNormal-strength concreteMechanical Behaviour In Compression-Mean test strength in compression: 175 - 185 MPa-Design (characteristic) strength: 140 160 MPa-Design Young s Modulus: 47 GPa- Ductile softening behaviour unlike ordinary high-strength concretesBehaviour of Ductal87 Mechanical Behaviour In Tension:-Mean test results, Modulus of Rupture: 25 - 39 MPa-Design (characteristic), Modulus of Rupture: 15 MPa-Total fracture energy: 20,000 30,000 J/m051015202530354002468 Deflection mm Bending Stress MPaFiber reinforced concretePlain concreteBehaviour of Ductal88 Ductal exhibits extremely high resistance to aggressive agents, due to the absence of capillary porosity.

8 Durability properties of Ductal:-Total porosity: 2-6%-Micro porosity: <1%-Chloride ion diffusion: 2 10-8mm2/s-Abrasion coefficient: absorption: kg/m2 DESIGN LIFE CALCULATION FOR DURABILITYfor exposure to marine environmentAssu m p ti o n s1. Non cracked section2. Diffusion coefficie nt Dc consta nt (conservative , a s Dc tends to de cre ase w ith time)Cx = Cs[1-erf{x/(2( )^ )}]whereCx =concentration of chloride at depth x (%)= maximum of =nominal concentration of chloride at the surface (%) = 4%Dc =chloride ion diffusion coe fficient (mm^2/s)x =depth to re inforce ment (mm)t =time (se conds)e rf[X] =e rror functionDe sign Life - Ducta lDe sign Life - Concre tef'c =160 MPaf'c =50 MPax =43mmx =50mmDc = x 10^-8 mm^2/sDc = x 10^-6mm^2/sDesign life611yearsDesign life17yearsDurability Properties of Ductal89 Eraring Power Station Weir Covers, Australia Existing post-tensioned planks failed after 15 yrs of continuous salt water spray Durability the primary design requirements (design life 100 yrs) Ductal planks x , effective depth 68mm, 163 kg/m2 Ductal planks being installedOld prestressed blanks being removedDuctal Solution: Durability90 Production of DuctalCasting Ductal is almost self-placing.

9 Batching requires a special shear mixer. Current Ductal solutions are precast. In-situ applications are being Production of Ductal (RPC) by VSL Australia commenced in early 2003. Heat treatment (90ofor 48h) is optional and improves durability and mechanical behaviour. Primary Ductal facility located in Melbourne. Majority of Ductal production is exported. 91 Design using Ductal Design rules developed from extensive research by Bouygues (France), VSL and Australian Universities. Design guide in accordance with the intent of AS 3600 prepared by the University of New South Creek Road Bridge : AustraliaFrom Research to Practice: Shepherds Creek Highway Bridge , Australia RTA evaluation trial of Ductal, design procedure and constructability Ductal beams: Precast and prestressed I-beams, no shear reinforcement, 1/3 weight of ordinary concrete beams (280kg/m) Bridge : Span , 4 traffic lanes, beam spacing Construction : Precast Ductal beams with ordinary RC in-situ concrete deck93 Ductal Solution: Design & FabricationFrom Research to Practice.

10 Shepherds Creek Highway Bridge , Australia RTA load testing after completion of the first two lanes and again 1yr later Test load = x T44 Serviceability Load September 2005: RTA issued a policy statement giving approval for Ductal to be used on RTA bridges and structuresLoad testDuctal beams in place94 Completed: World s first Ductal Bridge for highway trafficAustralian Ductal ApplicationFrom Research to Practice: Shepherds Creek Highway Bridge , Australia95 650mm deep post-tensioned PI-beam section Section forms deck and beam; wide, 50mm thick no reinforcement No anti-burst reinforcement in anchorage zones Match-cast in Australia using specialised formworkAuckland Footbridges: New ZealandBuilt in Australia and Shipped to New Zealand96 Auckland Footbridges: New ZealandBuilt in Australia and Shipped to New Zealand Segments shipped to Auckland on standard 40-foot flat-rack containers97 Auckland Footbridges: New Zealand Papatoetoe Footbridge upgrade to give access to existing train stations Other bridges completed: Penrose, Middlemore, Papakura98 Auckland Footbridges: New ZealandPenrose Station: 265m total linear length99 Architectural Ductal Solutions1.