VSLTH's Presentation: SOBRR C1-Precast Segmental Viaducts Erection-15 June 2006

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.
SOBRR CONTRACT NO. 1

1 1
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

2

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.

3

Short Line Match Casting (Continued)
- 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.
Advantages:

4

Short Line Match Casting (Continued)

5

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.

6

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

7

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

8

Long Line Match Casting

9

SOBRR Project Contract No. 1 Casting Yard
TC-JV SOBRR Project Contract No. 1

10

SOBRR Project Contract No. 1 Casting Yard

11

12

13

14

15

16

17

18

19

20

21

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.

22

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

23

Geometry Control

24

Geometry Control

25

Geometry Control

26

Geometry Control

27

Geometry Control

28

Geometry Control

29
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)

30
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.

31
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.
- 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 Advantages:

32
Span-by-Span Method
VSL (Thailand) Co., Ltd. SARL Project

33
Span-by-Span Method

34
Span-by-Span Method

35
Span-by-Span Method

36
Span-by-Span Method

37
Span-by-Span Method

38
Span-by-Span Method
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.
- 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
Advantages:

39
GANTRY TECHNICAL SPECIFICATION

40
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.

41
Erection Gantry Technical Specification
DESIGN CRITERIA (CONT.) Viaduct Alignment Maximum Design Gradient 4.5% Maximum Design Crossfall 6% Minimum Radius in Plan 210m

42
Erection Gantry Technical Specification
MT ELEMENT NO.
LENGTH AT TOP CHORD (MM) 9681 8180 10080 8300 10200 10200
LENGTH AT BOTTOM CHORD (MM) 7740 8180 10080 10200 8300 10200
WEIGHT OF MT ELEMENT (TONS) 8.89 8.95 12.12 25.97 21.11 22.11
11 & 1 10 & 2 9&3 8&4 7&5 6

43
Erection Gantry Main Truss (MT) 2 Trusses
UCB
Function: Lifting of Precast Segments and Relocating LCB

44
Erection Gantry Upper Cross Beam (UCB) 1 No.

45
Erection Gantry Upper Cross Beam (UCB)
ULRS1 (2 Nos.)
ULRS2 (2 Nos.)
Function: Support Structure for MT allowing Longitidinal and Transverse Movements as well as Rotational of MT

46
Erection Gantry Universal Lower Roller Support (ULRS) 4 Nos.

47
Erection Gantry Universal Lower Roller Support (ULRS)

48

49

50
LCB1 (1 No.)
LCB2 (1 No.)
Function: Transverse Load Spreader from MT to LCB Support Leg (SL)

51
Erection Gantry Lower Cross Beam (LCB) 2 Nos.

52
Erection Gantry Lower Cross Beam (LCB)
SL (2 Nos.)
SL (2 Nos.)
SL (2 Nos.)
Function: Support Structure for LCB

53
Erection Gantry LCB Support Leg (SL) 6 Nos.

54
Erection Gantry LCB Support Leg (SL)
RSL (1 No.)
FSL (1 No.)
Function: Temporary Support to MT during some Stages of Operation

55
Erection Gantry Front and Rear Support Leg (FSL/RSL) 2 Nos.

56
Erection Gantry Rear Support Leg (RSL)

57
Erection Gantry Front Support Leg (FSL)
SPB
Function: Precast Segment Erection and Relocation of LCB/SL

58
Erection Gantry Lifting Spreader Beam (SPB) 1 No.

59
Erection Gantry Lifting Spreader Beam (SPB)

60
Erection Gantry Lifting Spreader Beam (SPB)
CB (1 No.)
CB Storage Area
Function: Individual Precast Segment Attachment to both SPB during Lifting and SBS during Erection

61
Erection Gantry Connection Beam (CB) 24 Nos.

62
Erection Gantry Connection Beam (Standard & Deviator Segments)

63
Erection Gantry Connection Beam (Pier Segments)

64
Erection Gantry Connection Beam (Pier Segments)
SBS
Function: Individual Precast Segment Suspension to MT during Erection

65
Erection Gantry Suspension Bar System (SBS) 17 Nos.

66
Erection Gantry Suspension Bar System (SBS)

67
Erection Gantry Suspension Bar System (SBS)
PB
PB
Function: Support for FSL Operation and Provision of Longitudinal Stability of Front LCB/SL (LCB2 for Launching Direction Shown)

68
Erection Gantry Pier Bracket (PB)

69
Erection Gantry Pier Bracket (PB)
CPU for MT (Element 9)
CPU for UCB
Chain Spanner Wheel for MT (Element 3)
Function: Longitudinal Movement of MT and UCB

70
Erection Gantry Chain Pulling Units (CPU)

71
Erection Gantry Chain Pulling Units (CPU) Upper Cross Beam

72
Erection Gantry Chain Pulling Units (CPU) MT (Element 9)

73
Erection Gantry Chain Pulling Units (CPU) MT (Element 9)
VSL (Thailand) Co., Ltd. SOBRR Project Contract No. 1 : 12 June 2006

74
Erection Gantry Overall Structure
GANTRY OPERATIONS
75
Erection Gantry Operations 1 ASSEMBLY 2 ERECTION OPERATION 3 LAUNCHING OPERATION

76
ASSEMBLY
77
Stage 1

78
Erection Gantry Assembly 45M Span

79
Stage 2

80
Stage 3

81

82
Stage 4

83

84
Stage 5

85

86
Stage 6

87

88
Stage 7

89

90
Stage 8

91
Stage 9

92

93

94

95

96

97

98

99

100

101

102

103

104

105

106

107

108

109

110

111

112

113
Erection Gantry
VSL (Thailand) Co., Ltd. SOBRR Project Contract No. 1 : 12 June 2006

114
ERECTION AND LAUNCHING OPERATION

115
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.

116
Erection and Launching Operations Erection Cycle
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

117

118
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

119
Erection and Launching Operations 45M Span
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.

120
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.

121
Stage 4 -Lift up and position LCB1 between MT. -Move ULRS1/LCB1 to mid-span of P(N) / P(N+1). -Lower down LCB1.

122
Stage 5 -Rotate LCB1 by 90 and move ULRS1/LCB1 to pier P(N+1). -Engage LCB1 onto SL.

123
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.

124
Stage 7 -Disengage MT fixity from ULRS2. -Launch MT forward to erection position; Keep UCB at centerline of pier P(N+1).

125
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.

126
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.

127
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.

128
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.

129
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.

130
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.

131
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.

132
ERECTION GANTRY KINEMATICS
FOR 49.5M-54M-49.5M SPAN

133
Stage 1 - Span erection for Span 45-2/45-3 completed.
VSL Singapore PTE. LTD. Technical Center Asia/Australia, Erection Gantry Kinematics for 49.5m-54m-49.5m Span, MF05017/KN/22 Revision B, 2005.

134
Erection Gantry Kinematics 49.5M-54M-49.5M Span
Stage 3 -Deactivate FSL/RSL -Launch MT to position shown -Erect Span 45-3/45-4

135
Stage 4 -Erect Span on Pier 45-4 as shown

136
Stage 7 -Deactivate RSL -Launch MT to position shown -Erect Span 45-4/45-5

137
Stage 8 -Erect Span on Pier 45-5 as shown

138
Stage 11 -Deactivate RSL -Launch MT to position shown -Erect Span 45-5/45-6

139
Stage 1 -Shorten FSL module during MT launching into Span 45-19/45-20 -Erect Span 45-19/45-20

140
Erection Gantry Kinematics 40M-70M-40M Span
Stage 2 -Launch MT to position shown -Activate FSL/RSL

141
Stage 3 -Move ULRS1/LCB1 to position shown with special support shims on deck

142
Stage 4 -Deactivate FSL/RSL -Launch MT to position shown

143

144
Stage 6 -Move ULRS2/LCB2 to position shown with special support shims on deck

145

146

147
Stage 9 -Move ULRS1/LCB1 to Pier 46-2

148

149

150
Stage 12 -Move ULRS2/LCB2 to Pier 46-3

151
Stage 13 -Remove and lower PB from Pier 46-2 -Gantry is ready to erect Span 46-2/46-3

152

153
Erection and Stressing Works First Span

154

155

156

157

158

159

160

161

162
Span-by-Span Method

163

164

165

166

167

168

169

170

171

172

173

174

175
176

VSLTH&#39;s Presentation: SOBRR C1-Precast Segmental Viaducts Erection-15 June 2006

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

VSLTH&#39;s Presentation: SOBRR C1-Precast Segmental Viaducts Erection-15 June 2006

Uploaded by

Copyright:

Available Formats

SOUTHERN OUTER BANGKOK RING ROAD PROJECT

SOBRR Contract No. 1

SOBRR CONTRACT NO. 1

Precast Segments Fabrication

SOBRR CONTRACT NO. 1

Precast Segments Fabrication

SOBRR CONTRACT NO. 1

Precast Segments Fabrication

SOBRR CONTRACT NO. 1

Precast Segments Fabrication

SOBRR CONTRACT NO. 1

Precast Segments Fabrication

SOBRR CONTRACT NO. 1

Precast Segments Fabrication

SOBRR CONTRACT NO. 1

Precast Segments Fabrication

SOBRR CONTRACT NO. 1

Precast Segments Fabrication

SOBRR CONTRACT NO. 1

Precast Segments Fabrication

TC-JV SOBRR Project Contract No. 1

SOBRR CONTRACT NO. 1

Precast Segments Fabrication

TC-JV SOBRR Project Contract No. 1

SOBRR CONTRACT NO. 1

Precast Segments Fabrication

TC-JV SOBRR Project Contract No. 1

SOBRR CONTRACT NO. 1

Precast Segments Fabrication

TC-JV SOBRR Project Contract No. 1

SOBRR CONTRACT NO. 1

Precast Segments Fabrication

TC-JV SOBRR Project Contract No. 1

SOBRR CONTRACT NO. 1

Precast Segments Fabrication

TC-JV SOBRR Project Contract No. 1

SOBRR CONTRACT NO. 1

Precast Segments Fabrication

TC-JV SOBRR Project Contract No. 1

SOBRR CONTRACT NO. 1

Precast Segments Fabrication

TC-JV SOBRR Project Contract No. 1

SOBRR CONTRACT NO. 1

Precast Segments Fabrication

TC-JV SOBRR Project Contract No. 1

SOBRR CONTRACT NO. 1

Precast Segments Fabrication

TC-JV SOBRR Project Contract No. 1

SOBRR CONTRACT NO. 1

Precast Segments Fabrication

TC-JV SOBRR Project Contract No. 1

SOBRR CONTRACT NO. 1

Precast Segments Fabrication

TC-JV SOBRR Project Contract No. 1

SOBRR CONTRACT NO. 1

Precast Segments Fabrication

SOBRR CONTRACT NO. 1

Precast Segments Fabrication

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

SOBRR CONTRACT NO. 1

Precast Segments Fabrication

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

SOBRR CONTRACT NO. 1

Precast Segments Fabrication

VSLTH's Presentation: SOBRR C1-Precast Segmental Viaducts Erection-15 June 2006

VSLTH's Presentation: SOBRR C1-Precast Segmental Viaducts Erection-15 June 2006