AdvancedBridgeConstructionTechnique PrecastSegmentalBoxGirder

ConstructionTechnology

Dr.Songkiat Matupayont
June2015

www.casethai.com
songkiat@casethai.com

PrecastSegmentalBoxGirder WhatisPrecastSegmentalBridge
Thebridgeviaductisdividedinto
smallsegments,thatare
prefabricatedinthegoodquality
controlcastingyard,then,delivered
toinstallbygooderection
equipment.
 ExternalandInternalPrestressing

1. External Tendon
- Reduce friction losses
- Easily construction
- Slim web, Light weight
- Good maintenance

2. Internal Tendon
- High ductility
- Difficult in construction
- Thicker web, heavy weight

StructuralConfiguration
SpanbySpanPrecastSegment D6PrecastSegmentalBoxGirder

D6 Segments

Typical Span for D6 Segments

Span Length = 45.50 m
Width of Segment = 27.20 m. for 6 lanes of traffic
Height of Segment = 2.60 m.
BangNa BangPhli BangPakongExpressway,Bangkok Length of Segment = 2.55 m. for typical segment
= 1.775 m. for pier segments
Thespanbyspanprecastsegmentalerectionw/mainspanof Weights of Segment = 85 tones for typical segment
45.5meters(m)longandouttooutwidthof27.60m.Max = 100 tones for pier segments
External longitudinally pre- stressed tendons = 22 tendons.
weightsegmentis90tonf.
Bearing = 2- Inclined Bearing on Pier Column
 KeyComponents
RangsitInterchange
Improvement

Structural Components of
Precast Segmental Box Girder Bridge

StructuralBehaviorofPrecastSegmentalBeam AdvantagesandBenefits
JointOpeningandMomentatJoint Precast Segmental Construction
(w/ externally prestressing)
1. Construction Simplicity
no cast in-situ concreting such as diaphram, topping
==> reduce complication of in-place formwork and
rebar fixing
 AdvantagesandBenefits AdvantagesandBenefits
Precast Segmental Construction
Precast Segmental Construction
(w/ externally prestressing)
(w/ externally prestressing)
2. Time Savings/Cost Effectiveness
1. Construction Simplicity precast segment to be prefabricated and stored at
easier installation of external post-tensioned tendons casting yard while foundation and sub-structure are
being built.

AdvantagesandBenefits
AdvantagesandBenefits
3. Quality Control - QA/QC
Precast Segmental Construction
precast segment to be produced in factory-manner
(w/ externally prestressing) condition w/ good quality control.

2. Time Savings/Cost Effectiveness minimum interruption natural impacts such as bad

weather, rain.
by using efficient erection method and equipment ==>
the rapid installation of viaduct can be achieved. minimum waste of material
good precision in production
 AdvantagesandBenefits DrawbacksandSpecialRequirements.
4. Inspection and Maintenance
external prestressing tendons can be easily inspected and
repaired if required. SeismicResistance
maintenance program can be scheduled.
Specialtoolforgeometrycontrolduring
segmentcastinganderection
Requiredminimumvolumeofworkbecauseof
highinitialinvestmentcostoncastingyard
anderectionequipment.

KeyComponents SegmentCastingYardComponents
PrecastSegmentalBoxGirderw/External
Tendons 1. Short-Line Match Casting and Casting Mould Units
2. Production and Working Space
Rebar Assembly
Prestressing Work
1. Casting Yard and Segment Production Segment Touch-up/ Repair
(Geometry Control Program and Software) Ready-mixed Concrete Plant
2. Segment Erection/ Installation and Equipments 3. Lifting Equipments
4. Storage Area

Casting Yard Layout

 SegmentCastingYardLayout CastingYardEquipmentsandFacilities

Storage Area
Concrete Plant
Production Area
Gantry Crane
Service Bridge
Service Bridge

Gantry Crane

PlanLayout

OverviewofCastingYard

RebarCagesProduction

Lifting Gantry Cranes

Segment Segment
Storage Production Area
BridgeCoordinatesystem
ShortlineMatchCast
RAMP 1
Operation

CastingyardCoordinatesystem SpanLayoutforPrecastSegment
SPAN LAYOUT

GeometryControl
Software

GeometryControlforShortlineMatchCasting CastingMouldUnit

Casting Yard Layout

Bulk Head

CastingyardCoordinatesystem
 SegmentConcreteCasting GeometryControlofMatchCasting

AdjustmentofSegmentGeometryduringCasting AsCastDataforSpanErection
 SpanInstallationfor
PrecastSegment

CastingDataand
RecordofAsCastData
forSpan
Erection/Installation

MainComponentsforSegmentErection MethodofSegmentErection

1.MethodofErection
2.ErectionTrussandLiftingEquipment
MethodofSegmentErection

CONSTRUCTIONPROJECT
Northbound
RANGSIT INTERCHANGEPROJECT

BridgeSegmentInstallation BridgeSegmentInstallation
SegmentInstallation(insharpcurveandlimitedspace) SegmentInstallation(insharpcurveandlimitedspace)

BridgeSegmentInstallation(insharpcurve) HydraulicJackSystemforLaunchingTruss
LiftingEquipmentandLaunchingFacilities HydraulicJackSystemforTemporarySupport

CompletionofSegmentInstallation CompletionofConstruction
 PrecastColumn(PrecastSegment)

PrecastColumn(Segment)

RESEARCHANDDEVELOPMENT(R&D)
PRECASTSEGMENTALCOLUMN
Northbound
ASIANINSTITUTEOFTECHNOLOGY(A.I.T.)

Viaduct Column footing?

SubStructureSystems R&DforPrecastSegmentalColumn

Pot Bearing

Continuous, span by span

Dia.1.50 m

Dia.1.50 m
Bored Pile

Bored Pile
Double
Single
ExperimentalInvestigation ExperimentalInvestigation

ExperimentalInvestigation ExperimentalInvestigation
 ExperimentalInvestigation
ExperimentalInvestigation

PrecastColumnandCrossBeam

FIRSTIMPLEMENTEDPROJECT
FOR
Northbound
FULLYPRECASTBRIDGECONSTRUCTION
INTHAILAND
 CASESTUDY
LAKSIINTERCHANGEPROJECT ProjectLayoutPlan

North Out-bound

EAST In-bound
Northbound
West Out-bound
Westbound Southbound

South In-bound

EXISTINGCONSTRUCTIONAREA EXISTINGCONSTRUCTIONAREA
 ORIGINALDESIGNEDDRAWINGS NEWDESIGNEDDRAWINGS
ROADCROSSSECTION ROADCROSSSECTION

TRAFFICMANAGEMENTANDDETOUR COLUMNINSTALLATION
North South
North
South

STEP 1 3DModel STEP 2 3DModel

COLUMNINSTALLATION APPROACHABUTMENTSTRUCTURE

STEP 3 3DModel STEP 4 3DModel

FoundationWorkBarrettePile
VIADUCTINSTALLATION

STEP 5 3DModel
PrecastColumnPreparation PrecastColumnCastingProduction

PrecastColumnPreparation PrecastColumnInstallation
PrecastColumnInstallation InstallationofPrecastCrossBeam
InstallationofPrecastCrossBeam ErectionTrussAssembly

SegmentInstallationforViaduct SegmentInstallationforViaduct
SegmentInstallationforViaduct SegmentInstallationforViaduct

SegmentInstallationforViaduct SegmentInstallationforViaduct
 SegmentInstallationforViaduct ProjectCompletion

ConstructionofMRTABlueLine

PRECASTSEGMENTALCROSSBEAM
Northbound FOR
MASSTRANSITPASSENGERSTATION
BLUELINEMRTPROJECT
 AlternativeDesignandConstruction
PrecastCrossbeamasFormwork
forConcourseLevel

Stepof
Construction
ConstructionofPlatformLevelon
4 ConcourseCrossbeam
1

2 5

3 6
Question Answer

Thankyou

Dr.Songkiat Matupayont
www.casethai.com
songkiat@casethai.com
+66(81)8698926