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Method Statement For General Pre-Casting Works at Pre-Casting YardPart-5

The document describes the equipment, materials, and construction process for precasting concrete segments of a bridge. It lists the plant and tools used, including long line and short line precasting beds, tower cranes, gantry cranes, concrete equipment, and other tools. It outlines the materials used, including concrete, reinforcement steel, oils, and post-tensioning elements. It describes the three types of segments cast - typical curved segments, typical straight segments, and pier segments - and notes the bridge is constructed by assembling these precast segments.

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Vignesh
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57 views

Method Statement For General Pre-Casting Works at Pre-Casting YardPart-5

The document describes the equipment, materials, and construction process for precasting concrete segments of a bridge. It lists the plant and tools used, including long line and short line precasting beds, tower cranes, gantry cranes, concrete equipment, and other tools. It outlines the materials used, including concrete, reinforcement steel, oils, and post-tensioning elements. It describes the three types of segments cast - typical curved segments, typical straight segments, and pier segments - and notes the bridge is constructed by assembling these precast segments.

Uploaded by

Vignesh
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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 Electricians

3.2 PLANT AND TOOLS

The following equipment shall be used for all precasting works:

• Long Line precasting bed (typical set of mould)


- Fixed bottom form (on concrete foundation) Full length of span
- External side forms (left & right) 2 Nos
- Inner forms (left & right) 2 Nos
Portal frame for inner forms (including the roof) 1 Nos
Stop-End #1 (always stay on long line precasting bed) 1 Nos
Stop-End #2 (Stop-end used to cast the first segment “S1”) 1 Nos
Hydraulic system (for inner forms) 1 Set

Each displayed quantities above belong for only 1 LLT mould. Each long line precasting bed
has 2 Long Line Typical mould, so is able to cast 2 segments simultaneoulsy. 3 long line
precasting beds are provided in the precasting yard.

• Short Line precasting bed


Soffit tables 3 Nos
Manipulator with 4 hydraulic vertical & horizontal jacks 1 Nos
External side forms (left & right) 1 Set
Inner forms (left & right) 1 Set
Portal frame for inner forms (including the roof) 1 Set
Fixed bulkhead (with supports, Stairs & platforms) 1 Nos
Stop-End #2 (Stop-End used to cast the first segment “S6”) 3 Nos for 9 formworks
Hydraulic system (for inner form) 1 Set

The short line precasting bed can be divided in 2 types: Short Line Typical mould for Typical
segments – 3 Nos, and Short Line Pier (SLP) mould for Pier segments – 4 Nos.

 Lifting equipment
o Tower Crane TC#1 (6.89 ton–50m): Dedicated to mould operations & others
activities if needed.
o Tower Crane TC#2 (6.89ton–50m): Fully dedicated to rebar cage assembly
works
o (Cut & Bend steel rebars supply), and lifting rebar cage from rebar jig area to
rebar cage storage.
o Tower Crane TC#3 (4.3Ton – 35m): Fully dedicated to unloading standard
length of rebar, storage of rebar, and Cut & Bend works.
o Gantry crane GC#1 – 10Ton – Span 1 (31.5m) – Lifting for mould preparation
& rebar cages
o Gantry crane GC#2 – 50Ton – Span 1 (31.5m) – Lifting for storage or
relocation segments (42ton)
o Gantry crane GC#3 – 50Ton – Span 2 (31.5m) – Lifting for storage or
relocation segments (42ton)
 Concrete equipment
o Concrete trucks (provided by Sumitomo Corporation).
o Concrete pumps (Expected radius required = 36m)
 Others
o Trailers (for segment delivery)
o Lifting frame for rebar cages
o Lifting frame for segment (also called “spreader beam”)
o Cutting & Bending Machines
o Jigs for assembling reinforcing steel
o Concrete bucket
o Air compressor (for mould cleaning and external form vibration operations)
o External form vibrator (fixed in position within the mould soffit and side-
forms)
o Setting out instruments (Total station, auto-level, etc.)
o Concreting equipments (frequency converters, concrete vibrators, back up
vibrators)
o Electric tools
o Hand tools (trowel, wheel barrow, chute, rubber mallet, etc.)
o Chains / slings / shackles
o Safety signs
o Generator set
o Water & fuel tanks

Gantry cranes run on railways positioned on appropriately designed foundations (designated


as East and West spans). Each span is 31.5m.

One Gantry Crane 10ton will be used for the West Span. This position allows flexibility to
the Tower Crane TC #1 operations, regarding mould preparation works and rebar cages
lifting.

The two gantry crane 50ton, located on each span, will carry out all handling segment works
(transfer to mould, finishing area, storage ½ stacking or loading area with trailers).

For more details and general arrangements of the precast Yard, location of plant, tools and
common areas, refer to Appendix B.
3.3 MATERIALS

 Concrete
 Reinforcement steel rebar
 Demoulding oil
 Curing compound
 Debonding agent
 Concrete spacers
 Lifting holes former (for typical segment, 4 holes for purpose of fixing thru prestress
bar for the lifting of the segments). The holes shall be formed used corrugated duct.
 Post-tensioning elements (ducts, anchor, bearing plates, etc.)
 Lubricants
 Sand, water, woods, steel, etc.

4. CONSTRUCTION PROCESS

4.1 PRELIMINARY

The bridge is built by assembling the segments of variable longitudinal lengths and during the
construction 3 types of segments are used:

 Typical segments of curved span, by means of the Short Line Typical mould (SLT).
 Typical segments of straight span, by means of the Long Line Typical mould (LLT).
 Pier segments of straight & curved spans, by means of the Short Line Pier mould
(SLP).
 TYPICAL SEGMENTS OF CURVED SPANS

 TYPICAL SEGMENTS OF STRAIGHT SPANS

 PIER SEGMENTS OF STRAIGHT & CURVED SPANS

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