Bridge Construction Methods
By David TRAYNER
Contents
A. Introduction of Speaker B. Bridge Construction Methods i. Pre-cast ii. Cast in-situ iii. Others C. Precasting Techniques D. Ductal
A. Speaker
David Trayner
1. 2. 3. 4. VSL - Special Projects Operations Manager NSW Graduated: UTS 1990 BEng; UNE 2001 MBA 1989-91 Costain Australia Pty Ltd 1991 2004 VSL Heavy Lift Operations Asia
i. ii. iii. iv. v. 1991-92 NS4 Bangkok 1993 Tsing Mah Bridge HK 1995 Skybridge Petronas Twin Towers KL 1997 Burj Al Arab, Dubai 2002 4 New Bangkok International Airport, BKK, Thailand
5.
2004 onwards VSL Australia, Projects: LHD, BRB, GDE, GUP
Precast Concrete Bridges
1. I Beams & Super Tees 2. Segmental 3. Full Span
Cast in-situ post tensioned concrete decks
Precast I Beams & Super Tees
1. Description Standard Beams can be pre & or post tensioned. Cast on site or in existing PC Yard
2. Advantages Cheap Simple to erect
3. Disadvantages Limited in length (lat torsion buckling) Less efficient Logistics (police escort etc) Aesthetics banned in some countries
Cebu South Coastal Road - Philippines
Cebu South Coastal Road - Philippines
Cebu South Coastal Road - Philippines
Precast Segmental Techniques
1. Description Complete deck cast, delivered & erected in unique cells Segments are prestressed together using external and or internal tendons. Joints can be dry or wet. Typically in Span by Span or Balanced Cantilever mode
2. Advantages Structurally efficient and aesthetic Complete with deck when erected I.e. rapid & safe Cast during substructure works overlap of activities
3. Disadvantages Casting yard setup + logistics
PRECAST SEGMENTAL ERECTION TECHNIQUES
1. Erection on Falsework 2. Erection by Gantry 3. Erection by Crane 4. Erection by Lifting Frame 5. Full Span Erection Techniques
1. ERECTION ON FALSEWORK
M7 Crane Erection on Falsework
M7 Crane Erection on Falsework
2. ERECTION BY GANTRY
A. Span By Span Simply Supported B. Balanced Cantilever
Segmental Erection By Underslung Girder KCRC West Rail - Hong Kong
M7 Span By Span by Underslung Gantry Over M4
KRCR WEST RAIL VIADUCT ERECTION TYPICAL ERECTION KINEMATICS FOR UNDERSLUNG GIRDER
KRCR WEST RAIL VIADUCT ERECTION TYPICAL ERECTION KINEMATICS FOR UNDERSLUNG GIRDER
KRCR WEST RAIL VIADUCT ERECTION TYPICAL ERECTION KINEMATICS FOR UNDERSLUNG GIRDER
Segmental Erection By Underslung Launching Girder, Bangkok Second Stage Expressway
Bridge Over Mekong River - Laos
View of Launching Girder Telok Blangah - Singapore
Northern Gateway Alliance NZ, Waiwera Bridge
Shenzhen Western Corridor - HK
3. ERECTION BY CRANE
M7 BC Over Old Windsor Rd
M7 BC Over M4
Balanced Cantilever Segmental Erection by Crane KCRC West Rail - Hong Kong
4. ERECTION BY LIFTING FRAME
Industrial Ring Road - Bangkok
Nanjing Second Bridge - China
Ibi River Bridge Kisosansen Project - Japan
5. FULL SPAN PRECAST ERECTION TECHNIQUES
Singapore MRT Full Precast Span Erection
Singapore MRT Full Precast Span Erection
FULL 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 SEGMENT
IN-SITU CONCRETE BRIDGES CONSTRUCTION TECHNIQUES.
1.Cast in-situ Post Tensioned 2.Balanced Cantilever 3.Incrementally Launched
1. Cast in-situ Post tensioned
2. BALANCED CANTILEVER Segmental Cast in -situ
Formwork Travellers 2nd Link Singapore / Malaysia
Seacliff Bridge - Formtraveller
Gungahlin Drive Ext - Canberra
MFT on Taiwan High Speed Rail C215
7. MFT application to THSR C215
3. INCREMENTAL LAUNCHED Cast In-situ
Incremental Launching Method
Incremental Launching Method
Others
Pier Head Rotation Arch Lowering Main Span Lifting Skybridge
C.Precasting Techniques
1. 2. 3. 4. Segmental shortline Segmental longline Full Span PC Girders
1. SHORT LINE PRECASTING CELLS
GEOMETRY CONTROL
Pier Segment in Match Casting Position. Kisosansen Project - Japan
Soffit form Support frame
Soffit table
2. LONG LINE PRECASTING BEDS
View of Precasting Formwork on Long Line. Pakse Bridge - Laos
View of Precasting Yard. Pakse Bridge - Laos
Segment Transporter, Pakse Bridge - Laos
3. FULL SPAN PRECASTING BEDS
TAIWAN HIGH SPEED RAIL FULL SPAN PRECASTING
4. I BEAM PRECASTING BEDS
View of Precasting Formwork. Cebu South Coastal Road - Philippines
View of Precasting Formwork. Cebu South Coastal Road - Philippines
View of Prefabricated Rebar Cage. Cebu South Coastal Road - Philippines
D. Ductal Reactive Powder Concrete
D. Ductal a Reactive Powder Concrete
RPC was initially developed by Lafarge, Rhodia and Bouygues the parent company of VSL, and is marketed under the name of Ductal. Ductal (RPC) consists of cement, sand, silica fume, silica flour, superplasticiser, water and high strength steel fibres.
Normal-strength Concrete
Steel fibres
High-strength Concrete
Reactive Powder Concrete
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Behaviour of Ductal
Mechanical Behaviour
In Compression - Mean test strength in compression: 175 - 185 MPa - Design (characteristic) strength: 140 160 MPa - Design Youngs Modulus: 47 GPa - Ductile softening behaviour unlike ordinary high-strength concretes
200 180 160 140
Stress MPa
120 100 80 60 40 20 0 0 2000 4000 6000 8000 10000 12000 14000
Normal-strength concrete
M icro Strain
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Behaviour of Ductal
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/m
40 35 Bending Stress MPa 30 25 20 15 10 5 0 0
Fiber reinforced concrete Plain concrete
2 4 Deflection m m 6 8
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Durability Properties of Ductal
Ductal exhibits extremely high resistance to aggressive agents, due to the absence of capillary porosity.
DESIGN LIFE CALCULATION FOR DURABILITY for exposure to marine environment
Assumptions 1. Non cracked section 2. Diffusion coefficient Dc constant (conservative, as Dc tends to decrease with time)
Cx = Cs[1-erf{x/(2(Dc.t)^0.5)}]
where Cx = Cs = Dc = x= t= erf[X] = concentration of chloride at depth x (%) = maximum of 0.5% nominal concentration of chloride at the surface (%) = 4% chloride ion diffusion coefficient (mm^2/s) depth to reinforcement (mm) time (seconds) error function Design Life - Concrete f'c = 50 MPa x= 50 mm Dc = 1.0 x 10^-6 mm^2/s
Durability properties of Ductal: Total porosity: 2-6% Micro porosity: <1% Abrasion coefficient: 1.3 Water absorption: 2.5 kg/m2
Design Life - Ductal f'c = 160 MPa x= 43 mm Dc = 2.0 x 10^-8 mm^2/s
Design life
611
years
Design life
17
years
Chloride ion diffusion: 210-8 mm2/s
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Ductal Solution: Durability
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 11.1 x 2.33m, effective depth 68mm, 163 kg/m2 Old prestressed blanks being removed
Ductal planks being installed
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Production of Ductal
Casting
Ductal is almost self-placing. Batching requires a special shear mixer. Current Ductal solutions are precast. In-situ applications are being researched.
Production
Production of Ductal (RPC) by VSL Australia commenced in early 2003. Heat treatment (90o for 48h) is optional and improves durability and mechanical behaviour. Primary Ductal facility located in Melbourne. Majority of Ductal production is exported.
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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 Wales.
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Shepherds Creek Road Bridge: Australia
From 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 15.4m, 4 traffic lanes, 1.3m beam spacing Construction: Precast Ductal beams with ordinary RC in-situ concrete deck
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Ductal Solution: Design & Fabrication
From Research to Practice: Shepherds Creek Highway Bridge, Australia
RTA load testing after completion of the first two lanes and again 1yr later Test load = 1.5 x T44 Serviceability Load September 2005: RTA issued a policy statement giving approval for Ductal to be used on RTA bridges and structures
Ductal beams in place
Load test
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Australian Ductal Application
From Research to Practice: Shepherds Creek Highway Bridge, Australia
Completed: Worlds first Ductal bridge for highway traffic
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Auckland Footbridges: New Zealand
Built in Australia and Shipped to New Zealand
650mm deep post-tensioned PI-beam section Section forms deck and beam; 2.2m wide, 50mm thick no reinforcement No anti-burst reinforcement in anchorage zones Match-cast in Australia using specialised formwork
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Auckland Footbridges: New Zealand
Built in Australia and Shipped to New Zealand
Segments shipped to Auckland on standard 40-foot flat-rack containers
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Auckland Footbridges: New Zealand
Papatoetoe Footbridge upgrade to give access to existing train stations Other bridges completed: Penrose, Middlemore, Papakura
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Auckland Footbridges: New Zealand
Penrose Station: 265m total linear length
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Architectural Ductal Solutions
1. 2. 3. 20mm Ductal faade panels, France Acoustic panels (1600 m2); Monaco 20mm Curved shell elements and supporting structure (white Ductal); Canada 1
3
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Ductal Protective Solutions
Realisation that Ductal has excellent Impact and Blast Resistance Group level investment into strategic R&D
100
Blast & Impact Resistance
Blast tests at Woomera, Australia (2004)
2 blasts of 5t of Hexolite (6t TNT equivalent) 2 types of Ductal panels tested at 3 distances Actual blast pressure and panel deflections measured Panels Types: - Size: 2m (span) x 1m x 100,75 and 50mm 1 - pretensioned - at 30, 40 and 50m 2 - plain - at 40 and 50m Design reflective pressure for 10 msec: 5500 kPa at 20m 1500 kPa at 30m 650 kPa at 40m 420 kPa at 50m
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Woomera Blast Tests, 2004
BLAST 1 - 100mm stressed at 30m; ready for blast test
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Woomera Blast Tests, 2004
Panel 1 100mm stressed at 30m Movement 50mm in from datum then to 37mm out from datum and then to final position on datum Undamaged
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Woomera Blast Tests, 2004
Panel 5 - 75mm stressed at 30m Fractured, 150mm final deformation, no fragmentation
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Ductal Blast Resistant Panels
Installed Roof panels Steel connections for redundancy Rubber bearings for additional energy absorption Drainage covers and tolerance panels
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Concluding Remarks: Ductal Solutions
Ductal is not a replacement for conventional concrete; instead it can create opportunities, and provide economical and innovative solutions in performance structures. Exceptional properties of RPC give engineers the ability to design enhanced bridge and other performance structures. Typical enhancements include: o o o o o Significant reduction of dead load Excellent material ductility Improved durability and longer service life with reduced maintenance High flexural strength reducing the need for complex reo arrangements Expanding the range and freedom of structural shapes and forms
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Thank you for your kind attendance
Should you require any additional information please do not hesitate to contact:
E-Mail Address: Telephone:
Dtrayner@vsl-australia.com.au (02) 9484 5944
