1jn c00 0007 2 Concrete Works - Prefabrication Analysis
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7/23/2019 1jn c00 0007 2 Concrete Works - Prefabrication Analysis
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Originator
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EGYPTIAN – FRENCHNEW ASSIUTB ARRAGEJOINTVENTURE Black None A4 1/19
TECHNICAL DOCUMENTS NUMBERING SYSTEM
Originator Div Type Section Doc Number Ind
L 1 J O 0 0 Q 0 0 1 A
RGBS / ABDC Document review
Ref. letter number Date Name Date
CheckedDrawing number Approval sheet number
ApprovedStatus of approval
A ApprovedThe approval of the drawings will not exonerate the Contractor from anyresponsibility in connection with the works
AN Approved except Noted
RR Returned for correction and Resubmission
2 2013-08-05 E. BLACHE N. KOENIG A. ROUSSIN ISSUED FOR OBSERVATION OBS
1 2013-05-25 E. BLACHE JL. PEREZ N. KOENIG ISSUED FOR OBSERVATION OBS
Ind Date Prepared Checked Reviewed Amendments Status
ARAB REPUBLIC OF EGYPT
Ministry of Water Resources and Irrigation
Reservoirs and Grand Barrages Sector (RGBS)
ASSIUT BARRAGE DEVELOPMENT CONSULTANTS (ABDC)
NEW ASSIUT BARRAGE AND HYDROPOWER PLANT
LOT 1 – CIVIL WORKS
EGYPTIAN – FRENCH NEW ASSIUT B ARRAGE
JOINT VENTURE
CONCRETE WORKS
PREFABRICATION ANALYSIS
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EGYPTIAN – FRENCH NEW ASSIUTB ARRAGE JOINTVENTURE
Color N/A A4 1/19Originator Div Type Element Number Ind
1 J N C 0 0 0 0 0 7 2
po:Koenig
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CONCRETE WORKS PREFABRICATION ANALYSIS
Originator Div Type Element Number Ind
1 J N C 0 0 0 0 0 7 2
Table of Index
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CONCRETE WORKS PREFABRICATION ANALYSIS
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List of Contents
1 Abbreviations ...................................................................................................................................................... 4
2 Reference documents ........................................................................................................................................ 4
3 Scope ................................................................................................................................................................... 5
4 Precast slabs ....................................................................................................................................................... 6
4.1 Precast slabs location ........................................................................................................................................ 6
4.2
Precast slabs characteristics ............................................................................................................................ 9
4.3 Installat ion programme request and fabrication assumpt ions ...................................................................... 9
4.4 fabrication storage ............................................................................................................................................ 10
5 Technical galleries precast slabs .................................................................................................................... 11
5.1
Electrical galleries location.............................................................................................................................. 11
5.2 Electrical galleries characterist ics .................................................................................................................. 12
5.3 Installat ion programme request and fabrication assumpt ion ...................................................................... 12
5.4 Fabrication and storage ................................................................................................................................... 12
6 Technical gallery precast slab ......................................................................................................................... 13
6.1 Location ............................................................................................................................................................. 13
6.2 Characteristics .................................................................................................................................................. 13
6.3 Installat ion programme request and fabrication assumpt ion ...................................................................... 13
6.4 Fabrication and storage ................................................................................................................................... 13
7 Precast channels .............................................................................................................................................. 14
7.1 Precast channels location................................................................................................................................ 14
7.2 Precast Channels Characteristics ................................................................................................................... 14
7.3 Installat ion programme request and fabrication assumpt ions .................................................................... 14
7.4
Fabrication and storage ................................................................................................................................... 15
8 Precast stairs .................................................................................................................................................... 16
8.1 Precast stairs location ...................................................................................................................................... 16
8.2 Precast stairs characteristics .......................................................................................................................... 17
8.3
Installat ion programme request and fabrication assumpt ion ...................................................................... 18
8.4 Fabrication and storage ................................................................................................................................... 18
9 Conclusion......................................................................................................................................................... 19
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CONCRETE WORKS PREFABRICATION ANALYSIS
Originator Div Type Element Number Ind
1 J N C 0 0 0 0 0 7 2
1 ABBREVIATIONS
NL DS Navigation Locks, Downstream HeadNL MP Navigation Locks, Middle PartNL US Navigation Locks, Upstream HeadPH EP Powerhouse, East pierPH WP Powerhouse, West pierSW EP Sluiceway, East pierSW WP Sluiceway, West pier
2 REFERENCE DOCUMENTS
General:
(1) 1JN C00 0002-1: Concrete Works, Concrete blocks database
(2) 1JN C00 0003-2: Formwork surfaces analysis
(3) 1JR C03 1101-4: Construction joints, Powerhouse piers, Plan views & sections
(4) 1JR C03 3001-1: Construction joints – Powerhouse, central pier & units 1 to 4 – Plan views & sections
(5) 1JR C04 1001-2: Construction joints, Sluiceway pier axis 16, Plan views & sections
(6) 1JR C04 3001-1: Construction joints, Sluiceway pier axis 1, Plan views & sections
(7) 1JR C05 1001-4: Construction joints, Navigation locks – Downstream head, Plan views & sections
(8) 1JR C05 1002-4: Construction joints, Navigation locks – Upstream head, Plan views & sections(9) 1JR C05 2001-1: Construction joints, Navigation locks – Middle part, Plan views & sections
Concrete works:
(10) 1JR C00 5002-1: Concrete works, precast slabs forming table
(11) 1JR C05 5003-2: Navigation Locks, precast fill-empty channels mould (standard)
(12) 1JR C05 9101-1: Navigation Locks, precast slabs, fill/empty gallery, layout and principles
(13) 1JR C05 9102-1: Navigation Locks, precast slabs, ballast room, layout and principles
(14) 1JR C05 9201-1: Navigation Locks, precast slabs, fill/empty gallery, schedule
Electrical galleries:
(15) 1JD K05 0109-C: Guide drawing, Navigation Locks, plan view level +54.00, from axis F to axis K
(16) 1JD K05 0110-C: Guide drawing, Navigation Locks, plan view level +54.00, from axis K to axis O
(17) 1JD K05 0111-C: Guide drawing, Navigation Locks, plan view level +54.00, from axis O to axis S
Precast stairs:
(18) 1JD K03 0167-A: Preliminary guide drawing, Powerhouse, stair cases, axes 6-7A, 12-13A
(19) 1JD K03 0168-A: Preliminary guide drawing, Powerhouse, stair cases, axes 6-7R, 12-13R
(20) 1JD K03 0171-A: Preliminary guide drawing, Powerhouse, precast stairs, details
(21) 1JD K05 0170-B: Guide drawing, Navigation Locks, stair cases G17, G20
(22) 1JD K05 0171-B: Guide drawing, Navigation Locks, stair cases G18, G19
(23) 1JD K05 0172-B: Guide drawing, Navigation Locks, stair cases O17, O20
(24) 1JD K05 0173-B: Guide drawing, Navigation Locks, precast stairs, details
Planning:
(25) 1JP J00 0003-A: Working programme, revision (A) dated on 15th July 2013
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CONCRETE WORKS PREFABRICATION ANALYSIS
Originator Div Type Element Number Ind
1 J N C 0 0 0 0 0 7 2
3 SCOPE
This document describes the quantities of workshop prefabricated elements:- Precast slab for:
o the fill/empty galleries (NL)o the high rooms, mainly ballast rooms (NL and PH)o the technical galleries (NL and PH)
- Precast channels (NL)- Precast stairs (NL and PH)
- Public road bridge deck precast slab (not yet defined)- Ibrahimia head regulator precast walls (not yet defined)
for following structures:- Navigation locks (NL-DS / NL-MP / NL-US)- Powerhouse: intermediate pier axis 7 (PH-WP) & intermediate pier axis 12 (PH-EP)- Powerhouse: main structure (PH)- Sluiceway: abutment pier axis 1 (SW-WP) & abutment pier axis 16 (SW-EP)
There are no workshop prefabricated elements in Sluiceway bays and standards piers.
This document doesn’t describe in situ prefabrication which includes:- Sluiceway gantry crane beams- Sluiceway service gallery- Public road bridge deck precast beams
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CONCRETE WORKS PREFABRICATION ANALYSIS
Originator Div Type Element Number Ind
1 J N C 0 0 0 0 0 7 2
4 PRECAST SLABS
4.1 PRECAST SLABS LOCATION
Precast slabs for the fill/empty galleries (NL-DS):
Precast slabs for the fill/empty galleries (NL-MP):
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Precast slabs for the fill/empty galleries (NL-US):
Precast slabs for the rooms (NL-US):
Precast slabs for the rooms (NL-DS):
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Precast slabs for the rooms (PW):
Precast slabs for the rooms (PW-WP):
Precast slabs for the rooms (PW-EP):
Precast slabs for the rooms (SW-Pier axis 16):
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Precast slabs for the rooms (SW-Pier axis 1):
4.2 PRECAST SLABS CHARACTERISTICS
Precast slab thickness: 0.07m for the Navigation locks fill/empty galleries top slab0.12m for the Navigation locks and Powerhouse ballast rooms top slab
Above element: Wall (mainly gallery)Slab (shoring height superior to 5m)
Distribution of precast slab quantities:
Workshop p refabrication elements
Precast slabs Th: 7cm Th: 12cm Total
Navigation Locks
Upstream 552 m² 650 m² 1202 m²
Downstream 533 m² 305 m² 838 m²
Middle part 1291 m² 0 m² 1291 m²
Powerhouse
Intermediate piers 0 m² 1854 m² 1854 m²
Main structure 0 m² 305 m² 305 m²
Sluiceway
Abutment pier axis 0 m² 1967 m² 1967 m²
Standard piers and bays 0 m² 0 m² 0 m²
Total 0 m² 5082 m² 7458 m²
4.3 INSTALLATION PROGRAMME REQUEST AND FABRICATION ASSUMPTIONS
Installation programme request:If first concrete structures start on the 21
th August 2013 as per working programme, first installation of precast slabs
will be on the middle of December 2013.
Fabrication assumptions:Equipment: 3 prefabrication tables of 36m² (4.90*7.40m) used currently for about half of capacity
Slab areaTable area
Average ratio table/slab: ~ 0.6Equipment capacity: 325 m² (table) / week
Production assumption: 1 batch of precast elements / table / 18h (curing)Lifting assumption: f cj ≥ 12 MPA minimum for the precast slab liftingInstallation assumption: f cj ≥ 90% f c28 (~2 weeks between casting and installation in situ)
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CONCRETE WORKS PREFABRICATION ANALYSIS
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1 J N C 0 0 0 0 0 7 2
Storage assumption:
4.4 FABRICATION STORAGE
0
1000
2000
3000
4000
5000
6000
7000
8000
P r e c a s t s l a b s q u a n t i t i e s ( m ² )
Progress (in week)
Sluiceway
Powerhouse
Navigation locks
Prefabrication rate: to minimise storage ( )145 m²/week from November 2013 up to July 201430 m²/week from July 2014 up to July 2015
Storage:Storage period: 2 months from November 2013 up to July 2014
6.5 months from July 2014 up to July 2015Needed storage area: 800 m²
If first concrete structures start on the 21th
August 2013 as per working programme, prefabrication should start middleof November 2013 and first installation of precast slabs will be on the middle of December 2013.
Precast slabs
Thickness DimensionStorage
superpositionPrecast slab
storedStorage area
Ratio(m²/m²)
7 cm 3×5m 7 elements 105 m² 35 m² 3
12 cm 1.5×6m 6 elements 54 m² 28 m² 1.9
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CONCRETE WORKS PREFABRICATION ANALYSIS
Originator Div Type Element Number Ind
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5 TECHNICAL GALLERIES PRECAST SLABS
5.1 ELECTRICAL GALLERIES LOCATION
Two electrical galleries are present in Navigation locks.
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CONCRETE WORKS PREFABRICATION ANALYSIS
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5.2 ELECTRICAL GALLERIES CHARACTERISTICS
Location: G17-Q17 G20-Q20Level: + 53.45 +53.45Span: 1.35m 1.35mGallery length 215m 17.55m (span: 0.50m) and 173m (span: 1.35m)Gallery height 1.90m 1.90mPrecast slab surface 294m² 245m²
Total precast slab surface: 539m²
5.3 INSTALLATION PROGRAMME REQUEST AND FABRICATION ASSUMPTION
Installation programme request: at the end of NL concrete works: February 2015
Fabrication assumptions:Equipment: same equipment as precast slabs
3 prefabrication tables of 36m² (4.90*7.40m) used currently for about half of capacity
Slab areaTable area
Average ratio table/slab: ~ 0.6Equipment capacity: 325 m² (table) / week
Production assumption: 1 batch of precast elements / table / 18h (curing)Lifting assumption: f cj ≥ 12 MPA minimum for the precast slab liftingInstallation assumption: f cj ≥ 90% f c28 (~ 2 weeks between casting and installation in situ)
Storage assumption:
5.4 F ABRICATION AND STORAGE
Prefabrication rate: 145 m² / week
Storage:Storage period: 6 weeksNeeded storage area: 200 m²
Precast slabs
Thickness DimensionStorage
superpositionPrecast slab
storedStorage area
Ratio(m²/m²)
7 cm 3×5m 7 elements 105 m² 35 m² 3
12 cm 1.5×6m 6 elements 54 m² 28 m² 1.9
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CONCRETE WORKS PREFABRICATION ANALYSIS
Originator Div Type Element Number Ind
1 J N C 0 0 0 0 0 7 2
6 TECHNICAL GALLERY PRECAST SLAB
6.1 LOCATION
One technical gallery is present in Power House.
6.2 CHARACTERISTICS
Location: C8-C9 and C10-C11Precast slab level: + 27.30Span: 1.40mGallery length 22.10m (C8-C9) and 21.2m (C10-C11)Gallery height 1.10mPrecast slab surface 61m²
6.3 INSTALLATION PROGRAMME REQUEST AND FABRICATION ASSUMPTION
Installation programme: at the beginning of PH concrete works: August 2014
Equipment: same equipment as precast slabs3 prefabrication tables of 36m² (4.90*7.40m) used currently for about half of capacity
Slab areaTable area
Average ratio table/slab: ~ 0.6
Equipment capacity: 325 m² (table) / week
Production assumption: 1 batch of precast elements / table / 18h (curing)Lifting assumption: f cj ≥ 12 MPA minimum for the precast slab liftingInstallation assumption: f cj ≥ 90% f c28 (~ 2 weeks between casting and installation in situ)
Storage assumption:
6.4 F ABRICATION AND
STORAGE
Prefabrication rate: 145 m² / week
Storage:Storage period: 2 weeksNeeded storage area: 25 m²
Precast slabs
Thickness Dimension
Storage
superposition
Precast slab
stored Storage area
Ratio
(m²/m²)7 cm 3×5m 7 elements 105 m² 35 m² 3
12 cm 1.5×6m 6 elements 54 m² 28 m² 1.9
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CONCRETE WORKS PREFABRICATION ANALYSIS
Originator Div Type Element Number Ind
1 J N C 0 0 0 0 0 7 2
7 PRECAST CHANNELS
7.1 PRECAST CHANNELS LOCATION
The precast channels are located in Navigation locks Middle part.
7.2 PRECAST CHANNELS CHARACTERISTICS
Quantity of elements: 96 elements with: 80 elements done with standard mould ( ) 16 elements done with mould and extension ( )
7.3 INSTALLATION PROGRAMME REQUEST AND FABRICATION ASSUMPTIONS
Installation programme request:Starting of Middle Part casting: 23
th October 2013
Installation period: March / September 2014 (6 months)
Installation period assumption: Installation of pier axis 20 24 units Beginning of MarchInstallation of pier axis 18-19 48 units Beginning of May
Installation of pier axis 17 24 units Middle of July
Fabrication assumptions:Equipment: 1 mould & extensions setProduction assumption: 1 precast channel / 18h (curing)Lifting assumption: f cj ≥ 12 MPA minimum for the precast slab liftingInstallation assumption: f cj ≥ 90% f c28 (~ 2 weeks between casting and installation in situ)
Storage assumption: 3 elements stored on 3*3m area
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7.4 F ABRICATION AND STORAGE
0
10
20
30
40
50
60
70
80
90
100
Oct-13 Nov-13 Jan-14 Mar-14 Apr-14 Jun-14 Jul-14 Sep-14 Nov-14
C h a n n e l q u a n t i t i e s ( u n i t )
Programme of installation
Channels installation
Prefabrication:Prefabrication rate: 3 channels / weekPrefabrication period: 32 weeks ~ 7monthsStarting of prefabrication: Mid of November
45 elements have to be produce before the beginning of period installation(14 weeks before)
Storage:Maximum storage period: 6 monthsMaximum precast channels stored: 45 elementsNeeded storage area: 200 m²
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CONCRETE WORKS PREFABRICATION ANALYSIS
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8 PRECAST STAIRS
8.1 PRECAST STAIRS LOCATION
Precast stairs (NL-DS, axis O17/O20):
Precast stairs (NL-DS, axis G17/G18/G19/G20):
Precast stairs (PH-EP, axis 12-13R):
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Precast stairs (PH-EP, axis 12-13A):
Precast stairs (PH-WP, axis 6-7R):
Precast stairs (PH-WP, axis 6-7A):
8.2 PRECAST STAIRS CHARACTERISTICS
Quantities: 34 units with:o 16 units in Navigation Locks
Precast stair type PCS 9: 2 Precast stair type PCS 10: 4 Precast stair type PCS 10A: 2 Precast stair type PCS 11: 5 Precast stair type PCS 11A: 3
o 18 units in Power house
First flight of stairs: 2 Precast stair type PCS 7: 4 Precast stair type PCS 7A: 2 Precast stair type PCS 8: 2 Precast stair type PCS 10: 4 Precast stair type PCS 12: 4
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CONCRETE WORKS PREFABRICATION ANALYSIS
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8.3 INSTALLATION PROGRAMME REQUEST AND FABRICATION ASSUMPTION
Installation programme request:NL precast stairs: October 2013 to March 2014PW precast stairs: November 2013 to December 2015
Fabrication assumptions:Equipment: 1 mould & extensions set
Production assumption: 1 precast channel / 18h (curing)Lifting assumption: f cj ≥ 12 MPA minimum for the precast slab liftingInstallation assumption: f cj ≥ 90% f c28 (~ 2 weeks between casting and installation in situ)
Storage assumption: 3 elements stored on 3*3m area
8.4 F ABRICATION AND STORAGE
Fabrication:Prefabrication rate: 1 precast stairs a weekPrefabrication period: 34 weeks ~ 7.5 months
Storage:Maximum storage period: 15 monthsMaximum precast stairs stored: 16 unitsNeeded storage area: 150 m²
0
5
10
15
20
25
30
35
40
P r e c a s t s t a i r s ( u n i t )
Programme of installation
Precast stairs installation
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CONCRETE WORKS PREFABRICATIONANALYSIS
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9 CONCLUSION
Precast slabs
Prefabrication 145 & 30 m²/week
Storage (×) peak : 800m²
Ins tallation in s itu continuous
Electrical galleries (NL)
Prefabrication 145 m²/week
Storage (×) peak : 100m² ×
Ins tallation in s itu continuousTechnical gallery (PW)
Prefabrication 145 m²/week
Storage (×) peak : 100m² ×
Ins tallation in s itu continuous
Channels
Prefabrication 3 channels /week
Storage (×) peak : 100m² ×
Insta llation in s itu d iscontinuous
Precast stairs
Prefabrication 3 stairs/week
Storage (×) peak : 150m²
Insta llation in s itu d iscontinuous
×
×
2013
9
2014
9 10 11 12 4321 10 10 11 12
2015
6 7 81 2 3 4 51211Prefabrication programme
98765
Recommendations:- Storage area peak: 1000m² (January to April 2014)
- To be considered: Mould fabricationPrecast slabs design (done by JV)Precast stairs design (done by designer)Concrete formula ad hoc which authorizes 12 MPA for theprecast lifting