Japan Bridge Association - 国土交通省

1 St l B idQlit MtSteel Bridge Quality Management in JapanpSelamat soreJapan Bridge AssociationVariety of BridgesPlainRiver & StraitMountainous AreaJapan Bridge AssociationOver 100 years BridgesDejima Bridge 1890 Nagasaki Bridge 1886 Ya m a g a t a P r e f .Minami-Takabasi Bridge 1904) TokyoHachiman Bridge 1878 TokyoJapan Bridge AssociationStrait Crossing BridgesKanmonkyo Bridge 1973 Yamaguchi Bridge 1988 Okayama Pref.(Over 20 years.)Yokohama Bay Bridge 1989) Kanagawa Quality ControlthhCttihthroughConstruction phaseto Operation phase- Record and maintainResult of Quality ControlJapan Bridge Association - - Traceability - -Work Flow of ConstructionFull-Size DrawingDouble checkMaterial ProcurementMki /C iMarking / CuttingAssembly / WeldingAssembly / WeldingTemporary ErectionMutual checkShop PaintingMutual checkErectionJapan Bridge AssociationInspection / RepairWork Flow of Construction(Ch kit)Next process( Checking system )NO!

2 PSupplierPrevious processRecord & DocumentJapan Bridge AssociationFull-Size Drawing-developed from information presented on the contract drawingsdeveloped from information presented on the contract drawings- containsbasic Bridge geometrysub-structure locationssizes of all materialldd b l iweld and bolt sizesbasic connection Bridge Association3D-computer generated modelJapan Bridge AssociationRecord and document the informationMaterial ProcurementInspection CertificateSizeTe n s i l e Te s tHtbChemical compositionImpact TestHeat numberJapan Bridge AssociationMaterial Procurement- Tensile Strength Testing -measure Tensile Strength- V-Notch Testing -measure brittle toughnessCertificates- Double-check - Japan Bridge AssociationCertificatesActual testingsWeldingIndividual Panel AssembliesAssembled into GirderArrangementItems factored inItems factored in- Welding type- Welding Processes, position- Thickness of base materialJapan Bridge AssociationWelding / TypesFatigue (cycle)

3 Testing- to study DurabilityCharacteristicsDurability of each welding typesApplication of typesFillet weldingGroove weldingJapan Bridge AssociationWelding / OperationPreparation for WeldingCh kiDuring WeldingChecking gapObserve and control- Interpass temperatureto prevent cracking- Heat inputto prevent getting brittlePreheatingbetterQualityMinimum levelJapan Bridge AssociationworsedeteriorationNondestruct ive Testing (NDT)Radiographic TestingUltrasonic Testing( Detect Embedded Flaws )FlawFlawFlawFlawJapan Bridge AssociationNondestructive Testing (NDT)Magnetic ParticleDye Penetrant( Detect Flaws on the weld )

4 Invisibleinvisiblehighlightshighlightsvi siblevisibleFlawFlawJapan Bridge AssociationFlawTokyo Gate BridgeHigh Durability & Smooth ExteriorJapan Bridge AssociationTemporary ErectionConform with fabrication toleranceComputer SimulationJapan Bridge AssociationShop Painting / BlastBlast cleaning- is to clean prior to paintingppg- is to shoot a mixtureof steel particlespSpecimenpJapan Bridge AssociationShop paintingBrush paintingN-Narrow spaces- Material edgesspray painting- Fluorine resin paint materialis generallsed40years Durabilityis generally usedJapan Bridge AssociationShop paintingCheckTemperature / HumidityDrying and Curing times- Temperature affects- Humidity affectsCondensationMeasure Thickness(E hti l )(Each coating layer )

5 To obtain evenness of the paintJapan Bridge AssociationSite Joint / Torque control boltHigh strength bolt- Torque control boltSplineSnaps offsplineJapan Bridge AssociationAppropriate tension forceSite Joint / Torque control bolt- must be used ii dditiin as-received condition-needs special attentionstorageneeds special attention on cleanliness100% Visual InspectionJapan Bridge AssociationStorage of InformationDesign ReportsDrawingsElectronic FilesFabrication InformationTesting ResultsifilMicrofilmsJapan Bridge AssociationInspections-Ordinary InspectionInspectionOrdinary Inspection - Periodical Inspection- Intermediate InspectionFuture InspectionsData- Specific Inspection- Inspection after Extreme EventhEth kFuture Inspectionssuch as EarthquakeDataRepair worksDSDataJapan Bridge AssociationData StorageSummaryIn Japan .

6 - Construction processes are operated under well controlled condition- Results of operations are confirmed before going next stepdd dddhbili- Reports are recorded and documented to secure the traceabilityto guarantee the quality of the product at the time of completionalsoto keep infrastructures in proper conditionJapan Bridge AssociationTerima kasihThank youJapan Bridge AssociationJapan Bridge AssociationAccelerated Construction of Accelerated Construction of Pt dPt dCCtBidtBidPrestressedPrestressedCConcre te Bridgesoncrete BridgesJapan Prestressed Concrete Contractors Association1 Advantages of Accelerated constructionAdvantages of Accelerated construction Accelerated construction in urban areas Reduction of traffic jam by early opening of a traffic network Load reduction on current road networks via fewer traffic controlsat time of installation Reduction of loads on local residents by pre-casting Acceleratedconstruction in mountainous area Accelerated construction in mountainous area Economic impact by maintaining road networks soon.

7 Rise in convenienceby introducing bypass roads soon Rise in convenience by introducing bypass roads soon. Accelerated construction of large bridges Contributes to economic development by connecting soon to economics that are separated by strait, Prestressed Concrete Contractors Association2 Advantages of rapid Advantages of rapid construction of construction of ltdbid i bltdbid i belevated bridges in urban areaselevated bridges in urban areas Ubeam lifting erection method U- beam lifting erection method Span-by-span construction method Spanbyspan construction method using U-shaped cross sections<Effects>Rd tif t ffi jblif t ffitk Reduction of traffic jam by early opening of a traffic network.

8 Load reduction on current road networks via fewer traffic controlsat time of installationcontrols at time of installation. Reduction of loads on local residents by pre-castingJapan Prestressed Concrete Contractors Association3 UU-- beam lifting erection methodbeam lifting erection methodNasudukuri ViaductPC 20-span continuous box-girder bridgeCompleted in 2009 Japan Prestressed Concrete Contractors Association4 Overview of UOverview of U--girder lifting erection methodgirder lifting erection methodCast-in-Place slabPrecast PanelUSh p dPtPrecast in SitePrecast PanelU Shaped Precast BeamU Shaped beamL=30 38mL3038m(Wmax=240t)

9 H= HeadL=4mLifting GirderPrecastPierHead(W=45t)PrecastLifti ng girderCtiPrecast Pier HeadBearingPrecast pier headFilled concreteLifting girderPtbPrecast panelCasting deck slabPrecast beam5 OOnsite transportation of nsite transportation of 2400kN weight beams2400kN weight beamsJapan Prestressed Concrete Contractors Association6 Lifting ULifting U--beambeamJapan Prestressed Concrete Contractors Association7 Comparison to ordinary methodsComparison to ordinary methodsConstructionme tho dU- beam liftingOrdinaly girder liftingSpan-by-span methodConditionW ithout fabrication yardWith fabrication yard

10 Of Precast beam on siteMethodOutlineComposite Section(U beam + Cast-in-place slab)Box Girder SectionBox Girder SectionDistributed loadConsentrated loadat the ends(U beam + Cast in place slab)CrossSectionMoment ofthe girder18%30%100% Construction period is 1/2 of ordinary span-by-span methodDesignMethodPercially prestressed concrete Percially prestressed concreteNeed to be Fully prestressedconcreteJapan Prestressed Concrete Contractors Association8 Erected girder is 80% lighter Cost reduction achieved SpanSpan--byby--span erection method by span erection method by UUshaped segmentsshaped segmentsUU--shaped segmentsshaped segmentsFurukawa ViaductPC9+9+13+10 span continuousPC9+9+13+10 span continuousbox-girder bridgeCompleted in 2002