PowerPoint

1

Contract No. HY/2009/19Central - Wan Chai Bypass Tunnel (North Point Section) and Island Eastern Corridor Link

Segment Launching for BridgeworkDate: Jan 2013

1Highways Department Major Works Project Management Office1

Presentation Contents

Introduction Segment Casting Storage Yard in the Site Delivery and Storage of Segments Movement of Launching Girder

Contract No. HY/2009/19 Central Wan Chai Bypass Tunnel (North Point Section) and Island Eastern Corridor Link 2Highways Department Major Works Project Management Office

Presentation Contents

IntroductionContract DetailsOverview of Contract WorksBridge Arrangement Segment Casting Delivery and Storage of Segments Bridge Segment Erection Movement of Launching Girder

Contract No. HY/2009/19 Central Wan Chai Bypass Tunnel (North Point Section) and Island Eastern Corridor Link 3Highways Department Major Works Project Management Office

VICTORIACENTREHARBOURHEIGHTSHARBOUR GRAND HONG KONGCITY GARDENEXISTING IECIEC (Tunnel Section)BOX CULVERT T1BOX CULVERT U1TUNNEL APPROACH RAMPOverview of Contract HY/2009/19 Works

4EXISTING IEC E/B TO BE DEMOLISHEDNEW IEC W/BNoise EnclosureNEW IEC E/BHING FAT SLIP ROADContract No. HY/2009/19 Central Wan Chai Bypass Tunnel (North Point Section) and Island Eastern Corridor Link Highways Department Major Works Project Management Office4

Bridge Arrangement in HY/2009/19

Contract No. HY/2009/19 Central Wan Chai Bypass Tunnel (North Point Section) and Island Eastern Corridor Link 5Bridge F (F1 to F3)Bridge F4 Bridge D (D1 to D2)Bridge EBridge C (C1 to C5)Bridge F5Bridge F ( F1 to F3)Bridge D3New Eastbound BridgeRe-Construct Westbound BridgeCity GardenProvident CentreHarbour HeightSpan length : 26.5m to 40.0mBridge types : Precast Segments (Bridges D1 to D3, F1 to F3, C2 to C5) U-beams (Bridges C1, E F4, F5) Total nos. of segment : 653 segmentsTotal nos. of U-beam : 60 beamsExisting BridgeVictoria CentrePrecast Segments Bridges Highways Department Major Works Project Management Office

Presentation Contents

Introduction Segment CastingTypical SegmentsCasting YardSegment Casting Delivery and Storage of Segments Bridge Segment Erection Movement of Launching Girder

Contract No. HY/2009/19 Central Wan Chai Bypass Tunnel (North Point Section) and Island Eastern Corridor Link 6Highways Department Major Works Project Management Office

Typical Segment Type

Contract No. HY/2009/19 Central Wan Chai Bypass Tunnel (North Point Section) and Island Eastern Corridor Link 7Type of Segments : Single and Twin Cell Segments

Highways Department Major Works Project Management Office

Typical Segment Type

Contract No. HY/2009/19 Central Wan Chai Bypass Tunnel (North Point Section) and Island Eastern Corridor Link 8Segment Typical DetailSpan Distance26.5m to 40.0mMaximum Super-Elevation3.7%Maximum Gradient4.86%Minimum Horizontal Radius350mMaximum Segment Weight150 tonsHighways Department Major Works Project Management Office

Contract No. HY/2009/19 Central Wan Chai Bypass Tunnel (North Point Section) and Island Eastern Corridor Link Location of Fabrication Yard

Contract HY/2009/19 SitePrecast Segment Fabrication YardZhongshan, ChinaMacauHong Kong9Highways Department Major Works Project Management Office

10

Fabrication Yard Layout

Area for Segment CastingContract No. HY/2009/19 Central Wan Chai Bypass Tunnel (North Point Section) and Island Eastern Corridor Link Highways Department Major Works Project Management Office

Casting Mould for Segments

Contract No. HY/2009/19 Central Wan Chai Bypass Tunnel (North Point Section) and Island Eastern Corridor Link 11

3 nos. casting moulds in the casting yard 2 nos. for twin cells segments 1 nos. for single cell segment

Single Cell Segment Mould2nd Twin Cell Segment Mould1st Twin Cell Segment MouldHighways Department Major Works Project Management Office

Contract No. HY/2009/19 Central Wan Chai Bypass Tunnel (North Point Section) and Island Eastern Corridor Link 12

Step 1 - Fabrication of Reinforcement Cage

Step 4- Placing Reinforcement Cage to Segment MouldStep 2 - Matching & Geometric Adjustment of Match Cast SegmentStep 3 - Cleaning Steel MouldSegment Casting Procedure

Highways Department Major Works Project Management Office

Contract No. HY/2009/19 Central Wan Chai Bypass Tunnel (North Point Section) and Island Eastern Corridor Link

Step 6 - Pouring ConcreteStep 5 - Installing Internal Formwork

Step 7 - DemouldingStep 8 - Completed SegmentSegment Casting Procedure

Highways Department Major Works Project Management Office

Presentation Contents

Introduction Segment Casting Delivery and Storage of SegmentsDelivery RouteUnloading PointStorage Yard Bridge Segment Erection Movement of Launching Girder

Contract No. HY/2009/19 Central Wan Chai Bypass Tunnel (North Point Section) and Island Eastern Corridor Link 14Highways Department Major Works Project Management Office

Contract No. HY/2009/19 Central Wan Chai Bypass Tunnel (North Point Section) and Island Eastern Corridor Link Delivery Route to the Site

Contract HY/2009/19 SitePrecast Segment Fabrication YardZhongshan, ChinaMacauHong KongPrecast segments deliver to site by barge15Highways Department Major Works Project Management Office

Contract No. HY/2009/19 Central Wan Chai Bypass Tunnel (North Point Section) and Island Eastern Corridor Link Precast Segment Unloading Point on Site

PORTION III16PORTION VIIHighways Department Major Works Project Management Office

Contract No. HY/2009/19 Central Wan Chai Bypass Tunnel (North Point Section) and Island Eastern Corridor Link 17

Side ViewFront ViewStacking ArrangementStorage Yard Arrangement

Segment Storage(Max. Capacity = 20 Segments)Unloading DerrickSegment BargeBridge Loading Area(After completion of Bridge D3)

Highways Department Major Works Project Management Office1818

Lifting Equipments at Storage Yard

Contract No. HY/2009/19 Central Wan Chai Bypass Tunnel (North Point Section) and Island Eastern Corridor Link

Unloading Derrick

Truck for Transporting Segment (Example Photo)Portal Crane

Highways Department Major Works Project Management Office

Presentation Contents

Introduction Segment Casting Delivery and Storage of Segments Bridge Segment ErectionLaunching GirderMain Support and Lifting BeamInstall Bearing and Segment at Piers by Crawl CranesSegment Erection by Launching Girder Movement of Launching Girder

Contract No. HY/2009/19 Central Wan Chai Bypass Tunnel (North Point Section) and Island Eastern Corridor Link 19Highways Department Major Works Project Management Office

REAR LEG (RL)FRONT LEG (FL)MASTER WINCH (MW01)MASTER WINCH (MW02)MAIN SUPPORT (MS1)MAIN SUPPORT (MS2)MAIN TRUSSLaunching Girder Configuration20Contract No. HY/2009/19 Central Wan Chai Bypass Tunnel (North Point Section) and Island Eastern Corridor Link Dimension (L x W x H)103.44m x 8.4m x7.5mMax. Lifting Capacity160 TMax. Hanging Capacity700 T (7 segments)FabricationWuhu, ChinaGeneral SpecificationMAIN SUPPORT (MS3)Highways Department Major Works Project Management OfficeContract No. HY/2009/19 Central Wan Chai Bypass Tunnel (North Point Section) and Island Eastern Corridor Link

Launching Girder Main SupportJack for adjustment of crossfall and longitudinal fall of segmentJack for adjustment of transverse movementMain Beam UnitRotation Table for Truss RotationJack for launching forward of main trussSectionElevationHighways Department Major Works Project Management OfficeContract No. HY/2009/19 Central Wan Chai Bypass Tunnel (North Point Section) and Island Eastern Corridor Link

Launching Girder Main Support

Jack for adjustment for crossfall and longitudinal fall of segmentJack for adjustment of transverse movementMain Beam Unit of Main SupportHighways Department Major Works Project Management OfficeContract No. HY/2009/19 Central Wan Chai Bypass Tunnel (North Point Section) and Island Eastern Corridor Link

Launching Girder Main Support

Jack for launching forward of main truss girderMain TrussHighways Department Major Works Project Management Office

Contract No. HY/2009/19 Central Wan Chai Bypass Tunnel (North Point Section) and Island Eastern Corridor Link

Launching Girder Lifting BeamJack for adjustment of crossfall of segmentJack for adjustment of longitudinal fall of segmentSectionJack for adjustment of longitudinal fall of segmentElevationPlanPin joint for connecting with hanger beamStrings hung from Master WinchHighways Department Major Works Project Management Office

Contract No. HY/2009/19 Central Wan Chai Bypass Tunnel (North Point Section) and Island Eastern Corridor Link

Launching Girder Hanger Beam for Segment Erection40mm High Strength Bar40mm High Strength BarFor Single-Cell ArrangementFor Twin-Cells ArrangementSectionPin joint for connecting with lifting beam of master winchHighways Department Major Works Project Management OfficeContract No. HY/2009/19 Central Wan Chai Bypass Tunnel (North Point Section) and Island Eastern Corridor Link

Launching Girder Hanger Beam for Hanging Segment at End Span

50mm High Strength BarHanger BeamMain Truss of Launching Girder

SectionElevation Erect the segment by master winches Hang and fix the segment by 50 High Strength Bar Release the master winches after fixing with high strength bar Repeat 1 to 3 for the rest of the segment at end span

Hung From the Main Truss of Launching GirderHanger BeamHighways Department Major Works Project Management Office

Before Segment Erection

Contract No. HY/2009/19 Central Wan Chai Bypass Tunnel (North Point Section) and Island Eastern Corridor Link 27Installing the bearing and temporary hydraulic jacks on the piers

Temporary Hydraulic Jack

BearingAdjusting Jack

Temporary Hydraulic JacksBearings(Example Photo)Highways Department Major Works Project Management Office

Before Segment Erection

Contract No. HY/2009/19 Central Wan Chai Bypass Tunnel (North Point Section) and Island Eastern Corridor Link 28MJ SegmentsPier Segments

2. Erect MJ and pier segments at the piers by cranes

Highways Department Major Works Project Management Office

Before Segment Erection

Contract No. HY/2009/19 Central Wan Chai Bypass Tunnel (North Point Section) and Island Eastern Corridor Link 29Fix the MJ and pier segments at the piers

Fixed by high strength barsFixed by Nailing At Movement Joint Pier

At Intermediate Pier

Highways Department Major Works Project Management Office

Before Segment Erection

Contract No. HY/2009/19 Central Wan Chai Bypass Tunnel (North Point Section) and Island Eastern Corridor Link 30Install launching girder on the erected pier/MJ segments:- Install main support main truss girder master winches on main truss girder

2. Install Main Truss Girder3. Install Master Winches1. Install Main Support on erected segment1. Install Main Support on erected segmentHighways Department Major Works Project Management Office

Contract No. HY/2009/19 Central Wan Chai Bypass Tunnel (North Point Section) and Island Eastern Corridor Link Before Segment Erection

Proceed the load test of the launching girder (trial lifting Master Winches)Lift the heaviest segment plus extra10% of SWL (160T)Visual check of launching girder after liftingLower the loaded segment after satisfaction by RPE

Example Photo of Load Test of Master Winch

Load test at the middle of the spanLoad test at the other span

Additional weight by concrete block Highways Department Major Works Project Management Office

Contract No. HY/2009/19 Central Wan Chai Bypass Tunnel (North Point Section) and Island Eastern Corridor Link Before Segment Erection

Proceed the load test of the launching girder (Trial Launching)Launch the main truss forward/backward for the short distanceWithout any load on Master Winches during trial launching

Launch main truss forward/backwardThe certificate of launching girder issued by RPE once the load test is satisfactory.

Highways Department Major Works Project Management Office

Segment Erection Methods

Contract No. HY/2009/19 Central Wan Chai Bypass Tunnel (North Point Section) and Island Eastern Corridor Link 33

Segment Erection at Pier(Balanced-Cantilever Erection)

At End Span Erection(Hanging Erection)

Types of Segment Erections Methods

Highways Department Major Works Project Management Office

Contract No. HY/2009/19 Central Wan Chai Bypass Tunnel (North Point Section) and Island Eastern Corridor Link Typical Segment Erection at Pier34Permanent Prestressing to carry out at each pair segment erectionDesign check for permanent structure (e.g. pier) due to segment erection is required.

Temporary Prestress Barsto connect during each pair segment erection prior to the permanent stressingTemporary Prestress Bars to be removedHighways Department Major Works Project Management Office

1234567

Contract No. HY/2009/19 Central Wan Chai Bypass Tunnel (North Point Section) and Island Eastern Corridor Link Typical Segment Erection at End Span35As-constructed Segment CantileverConstruct Stitch JointPermanent Prestressing to carry out after the completion of stitch jointTemporary Prestress Barsto connect the segment prior to the permanent stressingTemporary Prestress Bars and Supports to be removedDesign check for permanent structure (e.g. pier) due to segment erection is required.

Highways Department Major Works Project Management Office

Contract No. HY/2009/19 Central Wan Chai Bypass Tunnel (North Point Section) and Island Eastern Corridor Link

Segment Erection Applying Glue for Joining Segments

Apply epoxy glue on segment face before joining segment Amount of epoxy glue in accordance with the manufacturers recommendation Curing time: 4 8 hrs (initial); 2 7 days (final)Applying epoxy on segment face

Mixing epoxy glue

Highways Department Major Works Project Management Office

Contract No. HY/2009/19 Central Wan Chai Bypass Tunnel (North Point Section) and Island Eastern Corridor Link Segment Erection Applying Glue for Joining Segments

PHYSICAL AND CHEMICAL PROPERTYESSpecification3050Density1685kg/m31685kg/m3Pot time>35 minutes>20 minutes Open time>60 minutes>60 minutes Compressive strength @ 24 hours>65MPa >70MPaCompressive strength @7 days

>80MPa>80MPa Highways Department Major Works Project Management Office

Contract No. HY/2009/19 Central Wan Chai Bypass Tunnel (North Point Section) and Island Eastern Corridor Link Segment Erection - Temporary Prestressing

Segment held by high strength MaCalloy Bars (36mm dia., UTS =1030N/mm2) Each bar is stressed to the specified force by hydraulic jack.(524KN or 598KN)During application of epoxy glue, a minimum average compressive stress of 0.2 N/mm2 across the whole section shall be achieved. To be removed after completion of permanent prestressing.

Bar is stressed by Hydraulic JackSteel blister at bridge deckTemporary Prestressing BarBar is stressed by Hydraulic JackInside the Bridge Deck(Example Photo)

At Bridge Deck (Example Photo)

Temporary Prestressing BarHighways Department Major Works Project Management Office

Temporary Prestressing General Arrangement

Contract No. HY/2009/19 Central Wan Chai Bypass Tunnel (North Point Section) and Island Eastern Corridor Link 39

For Twin Cell Segment

For Single Cell Segment

Elevation

Steel BlistersSteel BlistersConcrete BlistersPrestressing barsPrestressing barsRecess Hole for Temp PrestressRecess Hole for Temp PrestressConcrete BlistersHighways Department Major Works Project Management Office

Contract No. HY/2009/19 Central Wan Chai Bypass Tunnel (North Point Section) and Island Eastern Corridor Link Stitch Joint Construction 40

Stitch Joint Construct between the cantilever and end span or between two cantilevers. Adjust the vertical and horizontal alignment of the erected cantilever tips

Stitch FormworkHighways Department Major Works Project Management Office

Permanent Prestressing

Contract No. HY/2009/19 Central Wan Chai Bypass Tunnel (North Point Section) and Island Eastern Corridor Link 41

Thread strand through the tendon ductApply prestressing force gradually until required stressing force is attained.(Min=784KN ,Max=4312KN)Release the pressure, allow the wedge to draw-in and lock strand

Installing Hydraulic Jack (Example Photo)

Stressing Prestressing Strand (Example Photo)

Highways Department Major Works Project Management Office

Contract No. HY/2009/19 Central Wan Chai Bypass Tunnel (North Point Section) and Island Eastern Corridor Link Permanent Prestressing

Section

Erection

Main Truss of launching girderStressing platformWinch for hanging hydraulic jackPlatform for workers of prestressing work (for balanced cantilever segment erection only)It is hung under the main truss of launching girder

Highways Department Major Works Project Management Office

Contract No. HY/2009/19 Central Wan Chai Bypass Tunnel (North Point Section) and Island Eastern Corridor Link 43

Cut the excess strandCheck clearance of duct and leakage checkPump the grout into the ductSeal all outlet vents

Grouting Tendon Duct after Permanent Prestress

Completed cutting excess strand (Example Photo)

Pumping grout into the duct (Example Photo)

Completed grouting (Example Photo)

Highways Department Major Works Project Management Office

Presentation Contents

Introduction Segment Casting Storage Yard in the Site Bridge Segment Erection Movement of Launching GirderForward LaunchingForward Launching in Curve SectionTyphoon AnchorsGeneral Erection Sequence

Contract No. HY/2009/19 Central Wan Chai Bypass Tunnel (North Point Section) and Island Eastern Corridor Link 44Highways Department Major Works Project Management Office

Contract No. HY/2009/19 Central Wan Chai Bypass Tunnel (North Point Section) and Island Eastern Corridor Link Launching Girder Forward Launching

Pier D8Pier D9Pier D10Pier D11Pier D12Assemble LG on pier D8,9,10 as shownInstall segments of T span by pair Install segments of end spanCast the stitchLaunch LG to D9,10,11Engage RL,move MS to the positon as shown.Launch LG forwardMove MS again as shownLaunch LG forward until reach D11Erect temporary prop and engage FL on itErect pier segment at D11Move MS to D11Erect segments of T spanCast the stitchRepeat steps before to Launch LG to D10,11,12Erect MJ segment at D12Move MS onto D12Erect segments of T spanCast the stitchErect segments of end spanCast the stitchErect external tendonsHighways Department Major Works Project Management Office45

Contract No. HY/2009/19 Central Wan Chai Bypass Tunnel (North Point Section) and Island Eastern Corridor Link 46Launching Girder Forward Launching in Curve Section Shift and rotate the main truss transversely by hydraulic jack on main truss

Launch the main truss forward to the designated position

Main SupportMain TrussMain SupportMain TrussHighways Department Major Works Project Management Office

Contract No. HY/2009/19 Central Wan Chai Bypass Tunnel (North Point Section) and Island Eastern Corridor Link 47Launching Girder Forward Launching in Curve Section Main truss will not extend to existing bridge.

Main SupportMain TrussEdge of Existing BridgeHighways Department Major Works Project Management Office

Contract No. HY/2009/19 Central Wan Chai Bypass Tunnel (North Point Section) and Island Eastern Corridor Link 48Launching Girder Forward Launching in Curve Section Supporting beam will not extend to existing bridge.

Pier F8300mmHighways Department Major Works Project Management Office

Contract No. HY/2009/19 Central Wan Chai Bypass Tunnel (North Point Section) and Island Eastern Corridor Link 49Launching Girder Typhoon Anchorage Operation

40 HIGH-STENGTH PT BAR(PRELOADED TO 700KN EACH)40 HIGH-STENGTH PT BAR(PRELOADED TO 700KN EACH)Highways Department Major Works Project Management Office

Segment Erection SequenceContract No. HY/2009/19 Central Wan Chai Bypass Tunnel (North Point Section) and Island Eastern Corridor Link BridgesSequenceDuration (Approx.)New Eastbound BridgePier D8 to Pier F8 > Pier D8 to Pier D1206 DaysRe-Construct Westbound Bridge (Towards Causeway Bay Direction)Pier 28 to Pier 43 > Pier 28 to Pier 22187 DaysRe-Construct Westbound Bridge (Connect to Approach Ramp)Abutment D12 to Pier F8 >Abutment D12 to Pier F3100 DaysNew Eastbound BridgePier F8Pier D1Pier 28Abut D12Pier 43Pier 22Pier D8Re-construct Westbound Bridge(Towards Causeway Bay Direction)Re-construct Westbound Bridge(Connect to Approach Ramp)Pier F3Highways Department Major Works Project Management Office51

THE END

51Highways Department Major Works Project Management Office51