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Methor statement, for production of super, T Girder
Method Statement for Production of Super-T Girder CONTENTS General Materials Main Equipment and Tools 1) Fabrication Yard No.1.1 2) Fabrication Yard No.1.2 3) Fabrication Yard No.2 Site Organization Chart Construction Flow Chart Detail Construction Procedure 1) Detail Work Procedure 11 a) Preparation work 11 b) Pre-assemble rebar cage 12 c) Installation rebar cage 12 d) Installation PC strands 13 e) Installation inner formwork 18 Page Method Statement for Production of Super-T Girder f) Casting concrete 19 2) g) Curing and removal of inner formwork 20 h) Cutting tendons 21 i) Lifting girder to stock yard 24 j) Filling the non - shrinkage mortar 25 Cycle Time of Super-T Girders Fabrication 25 Schedule for Production of Super T Girder Quality Control 25 Environmental Control 10 25 Safety Control 11 25 26 Emergency Call out Procedure 36 1) Initiation 36 2) Second Stage 36 3) Third Stage 36 4) Emergency response chart 37 12 Appendix Page 37 Method Statement for Production of Super-T Girder 1) Appendix – 1: Plan of fabrication yard No.1.1; No.1.2 and No.2 2) Appendix – 2: Working drawing for production of super T girder 3) Appendix – 3: General drawing gantry crane 80 tons and tons 4) Appendix – 4: General drawing of formwork system 5) Appendix – 5: Drawing of pre-installation of rebar cage frame for super T girder 6) Appendix – 6: Drawing lifting crane of rebar cage for super T girder 7) Appendix – 7: Drawing of frame system for hanging inner formwork 8) Appendix – 8: Drawing of detail for lifting hook 9) Appendix – 9: Drawing of protection frame during stressing 10) Appendix – 10: Calculation of formwork system 11) Appendix – 11: Calculation of camber of permanents 12) Appendix –12: Lifting device calculation of Super T girder 13) Appendix –13: Calculation for pre-stressing of Super T girder 14) Appendix –14: Inspections and test plan 15) Appendix –15: Inspection sheet form Page Method Statement for Production of Super-T Girder General: Project information: • Project name: North – South Expressway Construction Project (Ben Luc - Long Thanh Section) – Contract Package No.J2 • Page Method Statement for Production of Super-T Girder Location: Can Gio District, Ho Chi Minh city, Viet Nam • This is a Method Statement for Production of Pre-cast Pre-stressed Concrete super T girders for Superstructure of Approach Span Structures in accordance with General Specifications and Approved drawings Length of Super T girder shall be fabricated to adapt with each span length in consideration with the effect of horizontal curve and change in width of carriage-way • This work item shall be done in accordance with the requirements of Clause S07450 concrete structures of the Technical Specifications • Quantity of Super T girder shall be shown on below tables: There are types of Pre-cast super-T girders as below table: Precast Girder Classify Unit Total Work Comme Numbe nt r Precast Super T Girder strand Type IA Interio Pcs 672 L= 44 Type IB Exteri Pcs 192 L= 44 or Type VA Interio 38.3m Pcs 21 r Type Exteri VB or L= 35 34.3m Pcs L= 34.3m Page 35 Method Statement for Production of Super-T Girder Type Interio IVA r Type Exteri IVB or Pcs 98 L= 34 33.3m Pcs 28 L= 34 33.3m Because of site’s characteristic is distributed with two particular locations which are spaced by Cha River so contractor arranges positions and quantities of fabrication yard as below: N Name o • Locatio Type of Girder Total Girder n Fabrication Yard Fabrication Yard Fabrication Yard No 1.1 No 1.2 No.2 38.3 180 m pcs 33.3 45 m pcs 38.3 135 m pcs 33.3 81 m pcs 34.3 27 m pcs 38.3 549 m pcs 180 pcs 180 pcs 657 pcs Materials : The list of main materials for production of pre-stressing super T girders which must be approved by the engineer shall be shown as the below table: Page Method Statement for Production of Super-T Girder Name of Specification material Concrete C50 Reinforcement Remarks y 50MPa Complied with design mix approved S07500 PC strand 15.2mm Mono anchor S07500 Bonding mortar Quantit Sikadur 731 TCVN 1651:2008 ASTM A421-91/A416-99 Patch end side of girder at strand areas PVC pipes D18/22 and D50/56 Anchor hook D32 Form release Sika separol TCVN 1651:2008 Apply per manufacture agent • Material stocked at side shall be kept off the ground by sleeper from rain and dirty by roof or others measures • Material quality control at site, especially rebar, stressed cable which are sensitive against corrosion shall be carefully stocked and controlled in dry condition • Detailed quantities shall be indicated and shown on the working drawing which is approved by the engineer Main Equipment and Tools: The quantity of equipment’s below may be changed with required actual conditions Page Method Statement for Production of Super-T Girder 1) Fabrication Yard No.1.1: N Item Capacity Unit Q’ty Remark Gantry crane 80 Ton unit 01 Lifting and shifting Gantry crane Ton set 02 Pouring concrete Bar Cutter As requirement set 01 Rebar fabrication Diesel Generator As requirement set 01 Electric supply Welding Machine As requirement unit 02 Concrete Bucket 0.8~1.2m3 unit 02 Pouring concrete Air Compressor As requirement unit 01 Cleaning work Survey Instrument As requirement set 01 Surveying work Concrete Rod Vibrator φ30mm unit 04 Pouring concrete Concrete Rod Vibrator φ50mm unit 06 Pouring concrete Plate vibrator 2.2Kw unit 90 Mono Pre-stressing Jack ≥ 240kN set 03 Pre-stressing 2HP set 02 For curing concrete set 03 Production SPT Welding 1 Water pump Casting bed type 38.3m girder Outer 38.3m formwork type set 03 Production girder Page SPT Method Statement for Production of Super-T Girder Inner formwork type 38.3m 2) Fabrication Yard No.1.2: N Item set 01 Production SPT girder Capacity Unit Q’ty Remark Gantry crane 80 Ton unit 01 Lifting and shifting Gantry crane Ton set 02 Pouring concrete Bar Cutter As set 01 Rebar fabrication set 02 Electric supply unit 03 requirement Diesel Generator As requirement Welding Machine As Welding requirement Concrete Bucket 0.8~1.2m3 unit 02 Pouring concrete Air Compressor As unit 01 Cleaning work set 01 Surveying work requirement Survey Instrument As requirement Concrete Rod Vibrator φ30mm unit 04 Pouring concrete Concrete Rod Vibrator φ50mm unit 06 Pouring concrete Plate vibrator 2.2Kw unit 90 Mono Pre-stressing Jack ≥ 240 kN set 03 1 Page Pre-stressing Method Statement for Production of Super-T Girder Water pump 2HP set 02 For curing concrete set 03 Production Casting bed type 38.3m girder Outer formwork type 38.3m set 03 Production Inner formwork type set 01 38.3m set 01 33.3m 3) Fabrication Yard No.2: N Item Production Production Capacity Unit Q’t Remark Lifting and shifting Gantry crane 80 Ton unit 02 Gantry crane Ton set 06 Pouring concrete Bar Cutter As set 03 Rebar fabrication set 02 Electric supply unit 05 requirement As requirement Welding Machine SPT girder Diesel Generator SPT girder type SPT girder SPT As Welding requirement Concrete Bucket 0.8~1.2m3 unit 04 Pouring concrete Air Compressor As unit 02 Cleaning work Page 10 Method Statement for Production of Super-T Girder Page 78 Method Statement for Production of Super-T Girder Appendix-9: Drawing of protection frame during stressing Page 79 Method Statement for Production of Super-T Girder Page 80 Method Statement for Production of Super-T Girder Appendix-10: Calculation of formwork system Page 81 Method Statement for Production of Super-T Girder Appendix-11: Calculation of camber of permanents Page 82 Method Statement for Production of Super-T Girder Page 83 Method Statement for Production of Super-T Girder Appendix-12: Lifting device calculation of Super T girder Page 84 Method Statement for Production of Super-T Girder Page 85 Method Statement for Production of Super-T Girder Appendix-13: Calculation for Pre-stressing of Super T Girder 38.3m Page 86 Method Statement for Production of Super-T Girder Page 87 Method Statement for Production of Super-T Girder Appendix-14: Inspections and Test Plan Page 88 Method Statement for Production of Super-T Girder Page 89 Method Statement for Production of Super-T Girder Appendix-15: Inspection Sheet Form Page 90 Method Statement for Production of Super-T Girder Page 91 [...]... bed 4 type 38.3m type girder set 01 34.3m type Outer type 5 formwork 38.3m type set 01 set 07 Inner formwork type Production SPT Production SPT girder set 01 Production SPT girder set 01 33.3m 1 SPT girder 34.3m type Production girder 33.3m 1 SPT Production SPT girder set Page 11 03 Production SPT Method Statement for Production of Super- T Girder 6 38.3m girder type set 01 34.3m SPT girder type set 01... maintained between anchorages until the concrete has reached the compressive strength required at time transfer of stress to concrete, it is the minimum 85% of design concrete strength Page 21 Method Statement for Production of Super- T Girder - In any case the jacking stress shall not exceed 75% of specified minimum ultimate tensile strength of the pre-stressing steel - Determine coefficient of friction... of inner form out of girder In Page 29 Method Statement for Production of Super- T Girder operation we need process it very carefully and lightly to prevent impact between inner form and girder Lifting Support frame Removal bolt for PC bar Inner form Casting bed - Removal of form shall be taken with care not to damage or injure the newly cast super- T girder - Exposed surface of girder (top surface of. .. pre-camber on the top surface of girder along longitudinal centre line of girder after finishing of cutting of the strands Marking at centre of bearing and centre of to monitor the pre-camber Checking the pre-camber at these positions before and after cutting the strands • Using cutting machine to cut the strands at surface of end of girder End of girder shall be covered by Sikadur 731 i) Lifting Girder. .. 300mm 6 5 4 3 2 1 Method Statement for Production of Super- T Girder • Curing Concrete: - After casting concrete, we need prevent affects of forces outside on girder when girder concrete strength has not reached 85% of design strength, especially positions on the girder flange - Create a rough for surface of flange girder after casting concrete from 2 to 4 hours - After casting concrete process make rough... combine installing PVC tube in girder web, using tie steel to hold PCV tube on positions which are marked Gantry crane 80 Tons Lifting Support frame Fix inner form system by PC bar Inner form Casting bed f) Casting Concrete: Page 25 Method Statement for Production of Super- T Girder • Preparation of Concrete Casting: - This Stage shall be set before casting concrete - Before casting concrete girder, using... Checking the calibration of jack and gauge Checkingand andinspection recording the elongation curing duration, temperature Measure of strands Confirmation of concrete strength (85% design concrete elapsed Page time 13 for removal of inner form strength) • Measure and record the pre-camber Method Statement for Production of Super- T Girder • Carefully install inner form after tensioning • Checking the stability... be cut with enough length PVC pipes with outer diameter 22mm and inner diameter 18mm and adhesive tapes shall be installed at end of strands for de-bonding Page 20 Method Statement for Production of Super- T Girder • Each tendon shall be passed through by handwork when processing it we must notice position of each tendon at ends girder must be same • The strands are inserted through holes of end forms... shall be taken care to prevent dislocation during casting concrete Page 27 Method Statement for Production of Super- T Girder - Once completion of concrete pouring and concrete in initial setting time if surface exposes shall be repaired and leveled Waiting for mortar setting down then leveling 2nd time for smoothly and make roughness Gantry crane 5 Tons Q = 5 Ton Concrete Bucket No.1 Mix truck Gantry crane... • Preparation of tensioning: - Before carry out the tensioning work, having to check whether the forms and casting bed have the defects or not, in case of defects have no repair - Checking the test result of the strands and the certificate of anchor wedge - The combination of jack and gauge shall be calibrated once every six months or otherwise instructed by the Engineer - Stressing on all strands shall