CONSTRUCTION OF BALANCE CANTILEVER APPROACH SURAMADU BRIDGE
CONSTRUCTION OF BALANCE CANTILEVERAPPROACH SURAMADU BRIDGEBy Masakazu MatsubaraResident Engineer for Approach & Main BridgeSuramadu Bridge Project1. DESIGN1.1. Concept of Design of Cantilever Erection MethodIn the cantilever-method bridge, segments (pre-cast segment or cast in situ)are connected so that the structure as the whole girder would be completedand during the erection stage, statically-indeterminate force from the creepand dry-shrinkage will occur inside the structure. Therefore, accumulativesection forces during the each construction stage and staticallyindeterminate should be the design section force.The necessity of the analysis in accordance with the construction step andthe necessity of the analysis of affection by the change of structural system inthe design are the difference from the other erection methods.Construction Of Balance Cantilever Approach Suramadu BridgeMasakazu Matsubara1 / 18
1.2. Design FlowCantilever erection method is that 2-5m blocks would be connected at theboth sides of a pier to the completion of the girder. In the design stage, it isnecessary to trace the work sequence accurately, therefore, the type of thestructure, case of examination and sections of examination would be morethan the design of the other erection methods and be more complicated andneed great deal of work.Fig. 1.2. Shows the design flow of cantilever-erection method.Construction Of Balance Cantilever Approach Suramadu BridgeMasakazu Matsubara2 / 18
1.3 SpanThe span of Suramadu Approach Bridge is shown in the following drawingsfor Surabaya and Madura side.Surabaya SideDrawing SD-A-003Construction Of Balance Cantilever Approach Suramadu BridgeMasakazu Matsubara3 / 18
Madura SideDrawing SD-A-004Construction Of Balance Cantilever Approach Suramadu BridgeMasakazu Matsubara4 / 18
Cross section is also shown.Drawing SD-A-005Construction Of Balance Cantilever Approach Suramadu BridgeMasakazu Matsubara5 / 18
1.4 Design of SegmentThe design of segments is shown in the drawing SD-A-008 for the first spanin Surabaya side (P36-P37) and SD-A-009 is for the second span andconsecutive span (P37 ).Dimension of segment would be decided by the capacity of traveller,location of PC tendons, and span length.Drawing SD-A-008Construction Of Balance Cantilever Approach Suramadu BridgeMasakazu Matsubara6 / 18
Drawing SD-A-009Construction Of Balance Cantilever Approach Suramadu BridgeMasakazu Matsubara7 / 18
1.5 . Arrangement of PC TendonsComparison is made in the arrangement of PC tendons between CantileverBridge and T-shape girder.Drawing SD-A-015Construction Of Balance Cantilever Approach Suramadu BridgeMasakazu Matsubara8 / 18
Drawing SD-A-016Example of the tendon arrangement of the typical T-girderConstruction Of Balance Cantilever Approach Suramadu BridgeMasakazu Matsubara9 / 18
2. EXECUTIONWork sequence in the model of the cantilever-method bridge is shown in thefollowing drawing figure 2.1. The work sequence is based on the conceptdesign of cantilever-method.Cast-in situ method and Pre-cast segment method are used in the cantileverbridge.Cast-in situ method has the advantage that the accuracy of the girdercould be kept since during the construction, the deflection and/or the precamber control could be easily done.Fig. 2.1. Cantilever-method conceptConstruction Of Balance Cantilever Approach Suramadu BridgeMasakazu Matsubara10 / 18
2.1 SchedulePractical schedule for Suramadu Approach Bridge is shown in the next page:(Example)Construction Of Balance Cantilever Approach Suramadu BridgeMasakazu Matsubara11 / 18
2.2 Pier TablePhoto of scaffolding is shown here.2.3 Cycle Time for Cantilever SectionStandart cycle time for the cantilever section is shown in the following tableand the flowchart of one cycle is also shown in the next.Construction Of Balance Cantilever Approach Suramadu BridgeMasakazu Matsubara12 / 18
2.4 ConcreteIn Japan usually high-early strength concrete is used for cantilever-method toreduce the cycle time and to avoid the affection from cold climate. However,because of thedifference of climate in Suramadu Bridge, Portland Cementconcrete is used and the strength of the concrete is more than 85% of thedesigned strength of concrete that is 85% of K500 K425 at the tensioningof the cables. And curing time should be more than 4 days including pouring.Flow chart of one cycle for one segment2.5 TravellerIn this Suramadu Bridge Project, CCC is the main Contractor and CIC is thenominated sub-Contractor to CCC. CCC uses his own traveller. CIC also has hisown traveller system which was introduced in the previous seminar.Because the length of the pier table is only 7 m, CCC’ two travellers were notbe able to be assembled simultaneously. Therefore, erection girder is utilized forthe first two segments for both sides of a pier. CIC’s traveller was designed so asto that the two sets of the traveller could be assembled simultaneously within 7m for the both sides of a pier.Construction Of Balance Cantilever Approach Suramadu BridgeMasakazu Matsubara13 / 18
CCC’s TravellerCCC’s erection girder for segment A1Japanese traveller length is usually from the main jack to anchor jack is 5m,therefore, the design of unsymmetrical cable (tendon) arrangement could beutilized when the pier table has insufficient length for two travellers.Construction Of Balance Cantilever Approach Suramadu BridgeMasakazu Matsubara14 / 18
Fig. 2.5.1 shows the unsymmetrical arrangement of tendon.2.6 Pre-camberPrecamber is one of the most important elements in cantilever-methodbridge. During cantilever stage, the vertical movement of the girder can beobserved. Therefore, during the construction, pre-camber shall be considered atthe installation of the slab formwork in order that the actual elevation couldmeet the designed elevation at the completion of the girder and/or the end ofcreep. For this reason, the deflection at each construction stage shall becalculated in the design stage.The considerable types of deflection are as follows:1.2.3.4.5.6.7.By the concrete dead load ( )By the weight of traveller ( )By the pre-stress ( )By the traveler’s own deflection ( )By creep and shrinkage ( )By the superimposed load ( )By removal of traveller (parapet, pavement) ( )JapanAnd as additional deflection are calculated in China as follows:1. ½ @ live load ( )2. Elongation of Anchor bar of traveller ( )(If the tensioning is not given to the Anchor bar)The photos show the measurement point for checking the elevation of thegirder. At the moment in Suramadu Bridge 20 mm of the tolerance isspecified for the elevation during the construction. Therefore, somecorrection or revisions shall be needed of the value of pre-camber for thefollowing segment according to the result of survey of the elevation. ThisConstruction Of Balance Cantilever Approach Suramadu BridgeMasakazu Matsubara15 / 18
difference between the actual elevation and designed is because of theassumption of E, I of the concrete girder itself at the design stage.In Suramadu Bridge, at least 4 times of elevation checking for one segment isexecuted.1. At the installation of slab formwork.2. After the pouring concrete.3. After the tensioning.4. After the forward movement of the traveller.Measurement point2.7 . Scaffolding for The Side Span (Tail Girder)Following drawing shows the hanger-type scaffolding used in the SuramaduBridge by CCC. The corbel at P57 supports the one end of the scaffolding.The other end is supported by the hanger from the cantilever segment.Construction Of Balance Cantilever Approach Suramadu BridgeMasakazu Matsubara16 / 18
2.8 . Scaffolding for The Center ClosureThe following drawing shows the scaffolding for the center closure. This is alsohanger-type scaffolding which is used by CCC. In the other projects, traveller isalso utilized as the scaffolding for the center closure.Construction Of Balance Cantilever Approach Suramadu BridgeMasakazu Matsubara17 / 18
3. CONCLUSION (ADVANTAGES OF CANTILEVER METHOD)1. This type of bridge could be erected without any scaffoldings from theground.2. Accordingly erection need not to be affected by the land condition(River, Sea, Valley, and Ravine) and/or road, railway surrounding theerection spot.3. Could be erected SAFELY and be erected by a small number of workers,because of the repetition works.4. Arrangement of the PC tendons and the bending moment distributionare similar. Therefore, the rational design could be done.5. Reference of this type of bridge in Japan is more than 2,200.6. Can be applied for the span length of 40 m-300 m.7. Can be applied for the certain curve alignment.Construction Of Balance Cantilever Approach Suramadu BridgeMasakazu Matsubara18 / 18
design of cantilever-method. Cast-in situ method and Pre-cast segment method are used in the cantilever bridge. Cast-in situ method has the advantage that the accuracy of the girder could be kept since during the construction, the deflection and/or the pre- camber control could be easily done. .
Fig. 3 (a): Mode 1 of cantilever beam (b) Mode 2 of cantilever beam (c) Mode 3 of cantilever beam III. MODAL ANALYSIS OF CANTILEVER BEAM (ANALYTICAL) For a cantilever beam Fig. (12), which is subjected to free vib
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