HER SS — Rit RA ARR D al CHINA RAILWAY FIRST SURVEY & DESIGN INSTITUTE GROUP CO., LTD. Mr. Wudianwei Executive Project Manager China National Aero-Technology International Engineering Corporation 30" July 2016 Ref: FSDI-(S01)-CATIC-1634 Dear Sir, Subject: Submission of Method Statement of Cay This refers to the letter No.: CATIC-EPW-FSDI-1438 dated on 29” July 2016 on the above subject. \Wereviewed the letter and attachment and approved it. You are kindly requested to get the approval from the Engineer promptly if there is any change or adjustment for the construction process, method, material and machinery during the construction. Yours faithfully, MEH. Team leader of Section 01 RECEIVED Compa le TENG. Thawe)s Ret 7! BO Name Date :..ee WAAR A LARA A Carte China National Aero-Technology International Engineering Corporation Mr. Colin Aspinall, ‘Team Leader, China Railway First Survey & Design Institute Group Co Ltd, Dear Sir, ‘Subject: Submission of Method Statement of Capping Beam No.: CATIC-EPW-FSDI-1438 Date: - 29 July 2016 Referring to your letter ref: FSDI-($01)-CATIC-1564 dated June 26" 2016, we have revised the method statement in accordance with the Consultant's comments and we are herewith submitting the revised Method Statement of Capping Beam to you for your review and approval at the earliest please. Attachment: MS for Capping Beam Yours teuly, Nid HSI 7 Executive Project Manager R CEIVED | Coreg y Namo: FSOL 99.104, late 3 checked By re teeCONSTRUCTION OF EXTENSION OF SUTHERN EXPRESSWAY FROM MATARA TO HAMBANTOTA SECTION I - FROM MATARA TO BELIATTA. CONTRACT NO: RDA/SEEP/CONT-SL (CH. 00+000 - 30+000 km ) METHOD STATEMENT FOR CAPPING BEAM (BAILEY BEAM SUPPORT) CATIC CHINA NATIONAL AERO-TECHNOLOGY INTERNATIONAL ENGINEERING CORPARATION. Submitted Date: 28" July, 2016EXTENSTION OF SOUTHERN EXPRESSWAY FROM MATARA TO. HAMBANTHOTA ‘SECTION | FROM MATARA TO BELIATTA CH 0+000 TO 30+000 KM Contract No: RDA/SEEP/CONT-S1 EMPLOYER CONTRACTOR : FF [roxopevenormenrauTuonty) | CHINA NATIONAL AERO- F7 ENGINEER ‘TECHNOLOGY INTERNATIONAL fA | Cia RAILWAY FIRSTSURVEY AND ENGINEERING CORPARATION. FSDI | “DESIGN INSTTTUTE GROUP CO.,LTD File No: CATIC/SEEP/MS/ Method Statement For Capping re ; : E Liotta St Sheet INDEX CLAUSE DESCRIPTION REVISION STATUS, B c : PAGE 0 A |B jc |p INDEX 0 10 AIM. 1 0 20 SCOPE I 0 30 REFERENCE 1 0 40 RESOURCE 1-3 0 Go | CONSTRUCTION ear 0 _| TECHNOLOGY PROCESS Go |CULCULATION FORLOADOF| 51, | 0 | THE HOOP CONSTRUCTION QUALITY 70 | contROL bee go | CONSTRUCTION SAFETY e A 0 | GuaRANTEE CIVILIZATION 99 | CONSTRUCTION SAFETY 18 0 GUARANTEE 10.0 MEASUREMENT 18 0 PREPARED BY | | yoy Signature: dy J. Date: off. 7.8 CHECKED BY | foun 04) Fon Signature" Moe. Date: or. J ¢ : [APPROVED BY] Ua Suche. Signature: } $y be Date'go /. 7.24)Table of Content 1 Aim ..., . seteneeseaaens seeeeaneeeeeees ee ve 1 2 Scope 1 3 Reference .. se seseeeeeee o eereeteeete se asnens 1 4 Resource 4.1. Manpower .. 4.2. Equipment... a 4.3, Material.....scccccccesseeee tn eerie fee? 4.4 Organization chart 3 5 Construction Technology Process. 5.1 Construs n Technology 5.2. Preliminary work for construetion 5.3 Column chiseling Ss A\Sebting outlets tires neter terre 5.5.Formwork support, Making & Installation. 5.6 Reinforcement binding and installation....... eee eee eee) 5.7 Side formwork installation... 7 5.8 Pour concrete (Specification of Sri Lanka, 10083 (g)... pas?) 5,9 Remove formwork......+s+ 5.10 Conerete curing. 6 Culculation for load of the hoop system. eee ere 9 6.1 Calculation principle. : 9 (6.2\Load calculation et tere cerita sree cmeteatese cemteneererer ter 9 7 Construction Quality Control... 14 7.1 The control of Materials Source........... errant eea a 7.2 Supervision for concrete at site. 157.3 The preparing work before conerete pouring... 7.4 The site concrete vibratory quality contro. 7.5. Thermal control of concrete... 8 Construction safety guarantee... 9 Civilization construction and environmental protection measures .. 10 Measurement ... lo) 16 16 aly 18,Supervisor: Responsible for completing the works stated as the method statement and taking corrective/ preventive action Site Engineer: Plan and conduct construction work, inspect the quality of works. Maintain construction site records and facilitate engineer for necessary inspections. Materials Engineer: Responsible for site tests, collection of materials samples, carryout testing and reporting. 4.2 Equipment Equipment use for capping beam construction. * Water Bowser ‘Survey Equipment © Vibrator & vibrating tamper ¢ Mixer Concrete truck 4.3 Material ‘© Material sample approved by engineer, © Use for the construetion works. Site Manager 4.4. Organization chart Mining Engineer ‘ Material Safety Technician Surveyor EngineerBar Benders, Skill Helpers, 5. Methodology 5.1. Construction Technology ‘The Construction Technology process of Capping beam are as follows. + + Make Formwork — J» Bottom formwork installation Reinforcement Binding Reinforcement Installation + Make Formwork Side Formwork Installation + + aye (_Powing conse) A P ce tt transport, trial and test pera Read Removing Formwork I Thermal controla Curing nerete 5.2 Preliminary work for construction 1) Equipment: ensure all the machine & equipment are under good condition before starting the construction. 2) Power supply: power supplied from the high tension line, there will have one generator for stand-by use. 3) Technology: be familiar with the design drawings & other technical documents, and technical disclosure is necessary, furthermore, the worker shall clear about the exact details of each Capping beam, such as material amount, size. 4) Workshop: a flat reinforcement yard with completed canopy is necessary. 5) Confide a technology & safety secret to every construction personnel 6) Setting out according the approved drawing by Surveyors lofting the Capping beam position and its elevation. 7) After completion of abutment construction works, back calculate the exaet place of the lower beam clamp at column according to the design elevation of cap beam, Mark it clear to ensure hoop accurately in the place. 8) For the convenience of capping beam bottom formwork installation. When pouring concrete, the pier column top elevation shall be 5 cm higher than the design top elevation. 5.3 Column chiseling When the concrete strengthen of pier meet the 75% of the designed strengthen or more, take pier chiseling for the its surface, Chiseling off the cement mortar or weak layer until the conerete layer, also clean with the air pressure. Make sure the top elevation is $ em higher than design elevation to censure the installation of eapping beam bottom formwork. Pier column top surface shall be chipped off or green cut to remove the grout until exposure of aggregate to form a rough surface before placing any fresh concrete. 5.4 Setting Out Before capping beam construction, survey the pier as the basis of bottom formwork installation of capping beam, The measurement & control items including: measurement for center position of column top elevation. Use total station for the center position measurement, Height measurement points are set up according to the construction of temporary level, with level machine directly. 5.5 Formwork support, Making & Installationorton formar Isley Gaard rail b Stee! ‘Transverse slope aaustaent block hoop a 4 (1) Asshown on the sketch above are standard sized formwork fabricated according to the dimensions of the approved cap beam design drawings, column hoops and operating platforms. (2) The column hoop installation Column hoop size 2542*600mm,radius 750mm,plate thickness 14mm;Clamp two column hoops tightly to the column for supporting of the cross beams, capping beam formwork and weight of concrete. Determination of the hoop top elevationHoop top elevation: -apping beam bottom elevation-thickness of bottom mould -thickness of U steel-bailey height-adjustment block height. Setting out the exact top elevation of the hoop with level station and tape and mark it, Installation of the hoop Lift the two hoops with cranes to the level of the installation for assembling and installing .The top of the two hoops must be level, tighten with high-strength bolts so that the hoops will be firmly installed onto the columns. As for Content of the test method for checking whether the high-strength bolt has achieved the working station, we are submitting the test method as follows: Step 1: Use the torque wrench to check the tightness torque of bolts after the bolts are fully tightened by tools. The torque of bolts is 1209N.M. Details: high strength bolts used at site are M30.8.88, Based on JGJ 82-201 1, its sheer and tension capacity is worked out of Table 3.2.3 as 250N/mm2 and 400N/mm2 respectively. Formule for calculating torque of bolts is babulated as follow as per Specifications JGJ 82-201 1- 64.13: TekPtd d-—nominal diameter of bolt, 30mm. k-torque coeeficient average value, which is 0,11~0.15 from Table 6.3.1 ‘And average value is 0.13. P-.- preloading in construction is 310KN as per Table 6.4.13 $oT=0.13*310KN*30mm = 1209 N.M Step 2: When the installation of the platform of bottom formwork for the first capping beam is completed, pre-loading test shall be carried out, And check the deflection and the total torque for the central span, the deflection satisfies the requirement in Clause $56.4 of the Specifications. ‘The load which should apply for the trial of capping beam form work is S76KN. The initial loading of40KN and final loading of S76KN should be tested than Smum. (3) Fabrication and Installation of formwork support and bottom mould Capping, beam formwork vertical support will be I steel 56a beam with length of 13.8m,one beam oneach side Horizontal support will be I steel 14a beam placing from the column and ending by the column with spacing of 44cm, ‘Standard sized formwork will be used for the capping beam; Installing the formwork support following by the chiseling and satisfied survey result. The installation shall startin a bottom —up sequence, which is to install the hoops first then the vertical beam, Fix the 2 vertical I steel beams with tie bar, install the horizontal U steel beams after the vertical beam is stabilized, and then install the capping beam bottom mold.5.6 Reinforcement Binding and Installation According to the specification requirement Division 550 (Sub Section $52.1, 552.2, 552.3, $52.4, 2.5) (1)The technician can binding reinforcement according to the reinforcement size, length, shape mentioned at the column design drawing, and then send to the site for installation. (2)Joints of bars are connected by cold pressed socket or lap. (After checking & get approval for the bottom formwork installation and top elevation of capping beam, install the reinforcement. Reinforcement bar is bending at the reinforcement yard according to the design drawing and specification. To make sure the convenience of construction and safety construction, the capping beam reinforcement bar can fixed at the ground, then lifting by the crane. If the crane is not available, can fix the reinforcement bar on the bottom formwork directly. Pay attention to the bearing pad stone and embedded block reinforcement. (4)Afier completing the reinforcement installation, first self-check according to the above siandard, then request the consultant engineer for inspe n when itis qualified, the consultant will sign and approve, then install the reinforcement (5)Reinforcement will be binded with thin wires, reinforcement hood and reinforcement shall te placed vertically. During reinforcement installing, a temporary framework will be used for stabilizing and supporting to enhance the overall stability of the reinforcement frame, After the reinforcement frame is fabricated, place the concrete cushion on both sides of the frame to ensure sufficient concrete cover. In accordance with the design requirements of the concrete cover, we use the same grade of concrete made of SemxSem diameter (diameter 3em, height isSem) and Semx3em(diameter of Scm,height of 3cm) of concrete block. (6)Lapping of the bars shall be carried out in accordance with the approved drawing, §.7Side formwork installation After inspection & get approval for the reinforcement installation of capping beam, install the side formwork of capping beam according to the construction requirement, Provide 19mm chamfers at exposed arises of the capping beam concrete as specified in sub clause $51.8.9 of technical specifications, 5.8 Pour Concrete (Spe ication of Sri Lanka, 1008.3 ( g ) ) Allconerete of capping beam must pour at one time, Otherwise, shall take relative treatment and pour concrete according to the construction specificationMake the ingredients list according to the approved mix design by the material engineer, (Engineer's) batching plant must control all kinds of material source strictly, strengthen the conerete quality control. Prior to pouring concrete, check the formwork, scaffold reinforcement & inserted material, Clean. uw the dirt, water on the steel bar & formwork, Use the truck mixer for conerete transport to the site, and the crane for concreting layer by layer, each layer is 30 cm, with a vibrator vibrating at the same time, pay attention to the top elevation at the end of concreting, After the initial set of concrete, use curing material or gunny bag cover the concrete surface, keep it wet. Use the truck mixer for conerete transport to the site, according to the site condition; crane can be used for conerete the remove of spindle, pouring concrete into the formwork layer by layer, and use vibrator for vibration, When using vibrator, mobile spacing shall not exceed more than 1.5 times of the vibrator action radius, and keep a distance of 50 ~ 100 mm to the side, to insert the previous conerete layer 50 ~ 100mm for vibration. After the completion of each place, should remove ribrator slowly to avoid collisions formwork, reinforcement and other embedded parts. For each. vibration area, must be vibrated to the compactness of this area. Strietly control the concrete drop height, the free pour fell height must be less than 1.5 m height, when the drop height is more than 1.5m, must adopt Chute tube or shuttle tank to decrease drop height. Concrete vibratory follow the principle of “fast push, slow pull”, make sure the surface of concrete no longer have sinks down and take no bubble, to prevent phenomenon of honeycomb or pitting surface. Insert time slightly faster, and puts forward slightly slower and no off while vibration, to avoid any space or empty inside the concrete. Concrete vibratory adopts parallel type or quincunx, but shall not be leakage of vibration, less \ibration, more vibration; After concrete pouring, should vibrating immediately, vibrating to appropriate time, generally can be controlled in 25 s and 40 sadvisable; Vibrator can't contact to the layout within the reinforcement in the formwork; The scene have standby vibrator, once breakdown, can be quickly replaced As for the concrete dropping height, the target of concrete dropping height of 1.5m cannot be echieved due to the fact that the height of capping beam in the drawings is 1.6 m, whose surface is densely covered by reinforcement bars and embedded parts of plinth, stopper and masking wall. Therefore, the discharge outlet of concrete truck shall be closely next to the reinforcement bars to lower the dropping height as applicable. 5.9 Remove Formwork Afier conerete, and strength reach the requirement of Division 550. (551.8.7), can remove the formwork. As required by the Chapter 551.8.7 of the Specifications, the lateral formwork of capping beam can be removed on condition that the concrete strength reaches 14Mpa. The bottom formwork of capping beam and false work can be removed when the conerete strength reaches 21Mpa. When removing formwork, must pay attention to the concrete surface protection and avoid 8collision or damage the capping beam on the surface of concrete, affecting the appearance quality. The removed formwork must be promptly cleaned up and nap, coated with release agent or clean the oil alter grinding, turn to the next set of Capping beam construction. 5.10 Concrete curing As for the concrete curing, the curing shall be strictly executed in accordance with the requirement of the Chapter of 551.12.1 stated: Concrete surfaces shall be kept completely and continuously moist. Curing shall be continued for a period of at least 7 days. This curing period may be reduced ifthe contractor presents evidence that the in place concrete has attained 70% of the specified strength for the class of concrete under cure. Under no circumstances, shall the period of eure be less than 3 days. Sackeloth (hessian) shall be used for the concrete curing and kept wet during the curing period. 6 Calculation for load of the hoop system 6.1 Calculation principle A Deflection control will be considered in the case that structural load has been satisfied B Considering the safety of the structure comprehensively; . Adopting realistic mechanical model D. Maximize the use of existing components and method of support which has been applied. E, Steel mold will be used for the capping beam bottom mold. The U steel beam installed under the ‘oll is for the putpose of elevation adjusting and enhancing the strength of the strueture. In the case, the strength of the steel mold has been sufficient, t's unnecessary to calculate the bearing strength of the U steel beams. F For the uniformed distribution of part of the structure, the larger uniform load will be adopted for its asymmetry GAs a safety margin, this calculation is not included the capping beam weight bear by the column.6.2 Load calculation 6.2.1 Sketch of the Components for calculation 800 T | h tf | | | pet, 808 g grN al terete 000 1 i am wee ,15| 3600 L 500 {92s i I ribs ‘ 6.2.2. Selection of the load partial coefficient Load is & value used to indicate the uncertainty of the bearing capacity associated with the structural reliability in the design calculation .The permanent load and variable loads require different partial cvefficients. (1)Pemmanent load partial coefficient y Gein the case that the permanent load resulting unfavorable effect on the structure, for the composition under the control of variable load effect y G=1.2while for the composition under the control of the permanent load effect y G=1.35,In the case that the effect is favorable, normally y G=1.0;For calculating tipping and slipping y G=0.9;For some special ‘cases, the value of the y G shall comply with the relevant specification, Variable load factors partial coefficient G normally is 1.4 6.2.2.1.Load analysis Capping beam bottom area:(10.85-2)*2.4=21.24m’ (calculated as in most unfavorable case, more of conservative) (1)Conerete weight of the capping beam:41m'*26KN/m*=1066KN Q1=1056/21.24=50,2KN/a Note: Including reinforcement >2%, load partial coefficient=1.2 (Q)As per manufacturer, formwork weight 3921.02kg, gravity: 3921.02*9.8N/kg=38.SKN Q2=38.5/21.24=1.81KN/m Note: g-9.8N/kg » load partial coefficient=1.2 (3) 32a U steel 19 pieces 4.5m lay on the bailey steel Hl total weight: 19°4,5*38.2=3266.1*9,8N/K g-32007.78N=32KN Note: Including reinforcement >2%, load partial coefficient=1.2 (4) Bailey Steel weight 108 pieces 3.1m bailey steel will be used for each capping beam. bailey steel weight:8"275*9.8N/Kg=21560N=21.6KN Note: Including reinforcement >2%, load partial coefticient=1.2 (5) Weight of hoop, operating platform, adjustment block, tie bar, screws ‘As per manufacturer the hoop is 1197.5kg,opetating platform is 350.8kg,adjustment block is 45kg.tie bar 8.59kg,screws and other 12kg. Hoop:1 197.59. 8N/kg=11735.5N=11.7KN Opetating platform, tie bar» screws: 370.59*9.8N/KG~3631.7N=3.6KN Adjustment block: 45*9.8N/KG=441N=0.44KN. Note: g=9.8N/kg, load partial coefficient=1.2 (6) The impact load for pouring eonerete and vibrating Impact load is 0.8T/m(including load from vibrating concrete) that is 8KN/m, load partial coefficient=I.4 (7) Load of construction equipment and workers Construction workers,material delivery,stacking load is 0.25'T/m,that is 2.5KN/m,load partial coefficient =1.4 6.2.3. Combination of load calculation (1) When calculating the bottom mold load stress,simple beam calculation stereotype shall apply.for the U steel beam bears the surface load transferred from the mold,the bottom mold bears a linear load: That is -Q=Q1*1.2+Q2*1,.2+0.8*1.4+0.25*1.4= 50.2*1.2+1.81*1.2+0.8" 1.4+0.25*1.4=63.88KN/m (2) When analyzing 32a U stee! beam load stress, the calculations as based on that the load is uniformly distributing on the U steel(uniformed load distribution ranges 10.85m) load combined is: QEL (1066+38.5132+0.36) *1.2+1.4+0,8"0.25"1.4]/4,5/10.85=27.97KN/m (3) When calculate hoop load stress, the calculation is based on that the hoop surface and the concrete surface friction to resist the concentrated load above the hoop. That is + Q=[single (1066+38,5'32421.610.4443.6) *1,2+.4+0,80.25*1.4)/2698.12 6.2.4.Bailey beam calculation 6.2.4.1. Selection of the load partial coefficient Load is a value used to indicate the uncertainty of the beating capacity associated with the structural reliability in the design calculation .The permanent load and variable loads require different partial coefficients (Permanent load partial coefficient y G: In the case that the permanent load resulting unfavorable effect on the structure, for the composition under the control of variable load effect y G=1.2while for the composition under the control of the permanent load effect G=1.35,In the case that the eifect is favorable, normally y G=1.0;For calculating tipping and slipping y G=0.9;For some special cases, the value of the y G shall comply with the relevant specification. @Variable load factors partial coefficiency G normally is 1.4 6.2.4.2. Load analysis (Concrete weight of the capping beam: WI=41m'*26KN/m'=1066KNNote: Including reinforcement > 2% , load partial coefficient=1.2 @Q)As per manufacturer, formwork weight 3921.02kg, gravity: W2=3921.02*9.8N/kg=38.SKN Note: g=9.8N/kg, load partial coefficient=1.2 (3) 32a Usteel 19 pieces 4.5m lay on the bailey steel. 132a total weight: W3=19*4.5"38.2-3266.1*9.8N/Kg=32007,78N=32KN Note: Including reinforcement > 2% , load partial coefficient=1.2 (4) Bailey Steel weight 8 pieces 3.0m bailey stee! will be used for each capping beam. 04 pieces are allocated each single side. bailey steel weight: W4=8*275*9.8N/Kg- N=21.6KN Note: Including reinforcement > 2% , load partial coefficient=1.2 (5 ) operating platform, adjustment block, tie bar, serews ‘As pet manufacturer the opetating platform is 350.8kg, adjustment block is 45kg, tie bar 8.59kg, serews and other 12ks. Opetating platform, tie bar , screws : 370.59*9.8N/KG Adjustment block : 45¢9.8N/KG=441N=0.44KN W5=3.6+0.44=4.04KN Note: g=9.8N/kg, load partial coefficient=1.2 .6KN ( 6 ) The impact load! for pouring concrete and vibrating, Impact load is 0.8T/m (including load from vibrating concrete) that is 8KN/m. Load of construction equipment and workers, Construction workers, material delivery, stacking load is 0.25T/m, that is 2.SKN/m, Wo=842.5-10.5K N/m load partial coefficient =1.4 6.2.4.3. Combination of load calculation The bailey steel structures are reinforced single rowed and single layered at one side of capping teams during construction. As per reference books, properties for bailey steels are 1y=577434.4 em! , W,=7699.1 cm? , E=2.110°Mpao Upon analysis, the load to bear includes W1 W2 W3 W4. W5 Wo. This load is born at two sides of bailey steels, so the load for each single side is calculated as: We (W1+W2+W31 W4+W5+-WO*the bailey length) /2 = ( 1066+38.5+32 121,644.04 ( 842.5 ) #12) /2 =644,07KN Note: the total length of bailey steels: 4 pieces * 3.0m each single piece = 12m each single side, the calculation for even los! to bear is as follows: = W/L=644,07/12=53.67KN/m. Based on the situation lor erections of bailey steels and hoop support at the bottom, the simple model is detailed as follows:Calculation for bailey steel deflection: fqL/384EI*(5-24a°/L7) : =53.6747,0'(384*2,1*10°*577434.4)*(5-242. 5/7) =5.37mm , less than the allowable deflection, which satisfies the sp Calculation for bailey stce! bending moment: M ovax=QL7/8 * ( 1-4" a2/L? ) =53.67*7.0°/8* ( 1-4*2.5°/7" ) = 161 KN.n Mana < [MI 687.5 KN.m, which satisfies the requirements, [M] is allowable moment for reinforced single rowed and single layered bailey steel bending, Referring Table 11.2 tor Bailey User Manual of 321 type of year of 2007, the allowable internal force [M]:=1687.5 KN.m. ___ ‘Table 11.2: The allowable intemal force of Bailey User Manual of 321 type nae | Now reinforced bridges Reinforced bridges ‘Single | Doudte | Three | Double | Three | Single | Double | Three | Double [ Three Allowable | rowed | vowed | rowed | rowed | rowed | rowed | rowed | rowed | rowed | rowed inwml | & | & | & | & | @ | a | a@ | &@ | a | @ force | single | single | single | Double | Double | single | single | single | Double | Double layered | layered | layered | layered | layered | layered | layered | layered | layered | layered al 7a82 | 1576.1 | 2246 | 32654 | sess 1687.5 | 3375.0 | 4809.4 | or00 9618.8 Inaccordance with above facts, allocation of bailey steels satisfies construction requirement and itis safe. 62.5.Hoop cals tition Load calculation I set of hoop will be installed on each side of the pier where the capping beam is to be constructed cn,total two sets of hops to support the load above.As per the calculation above,the counter force of the base is: RI=R2=698.12KN ‘The maximum value of the vertical force the hoop needs to withstand as N,this value is the fictional force iced tw be generated by the hoop.Hoop load force calculation ® Number of bolts ‘The vertical force the hoop needs to withstand is N=698.12KN ‘The vertical force the hoop hear is generated by the M30 high-strength bolts shear force ,Refer to “Design Code for the Stee! Structure” for the bearing load allowed for M30 bolts: [NL}-0.8P un In the formula; P—- pre-stressing force of the high-strength bolt,count as 35SKN; 1 Hietion coefficient,count as 0.3; n—the number of face the force transmission have contact with,count as 1; 0.8—ununiformed load force coefficient for the bolts. ‘Therefore:[N1]=0.8*355*0.3 -85.2KN M=NI[N1 }-698.12/85.2=8.19=9pieces, the number of the bolts on the hoop section count as 36 pieces. Then ,the shee force yenerated by each high-strength bolt is P=N/32=698.12/36 12.39KN< [NL] =85,.2KN Therefore. the Loop beatin: force is satisfactory for the load force. ®Bolt axial tension ealeutivion Provided a layer of rubber !'ctween the concrete and the bolt axial,according to which the coefficient of ftction between the rubber and steel count as u-0.3; Then,the pressure generated by the hoop is Pb=Nfu 98.12/0,3-2327.07KN bear by high-strength bolts N=Pb=2327.07K Hoop pressure geucrsted hs the stressing force of M30 high-strength bolts, That each bolt stressing foree is NAPD/36-2327.071.N/36. 41,1KN-<[S]35SKN.Therefore,the strength of high-strength bolts satisfied the require @Hoop components tensile stress caleulation Hoop wall (cusile stress 55 "1 SN1=8*64,64=517.12KN, 14Hoop wall panel using 514mm steel plate,height 0.75m,the hoop longitudinal cross- sectional area is 014x1.5x3.14/2=0.03297(m2) S=N’/S=2327.07/0.03297=70581.44Kpa=70.6Mpa< {o] =140Mpa which satisfied the requirements. ‘The shear stress of the hoop components =RA(Q2S1)=698.12/(2*0.0297)=11752.86Kpa=1 1.75Mpa< [2] =85MPa which satisfied the requirements. 7 Construction Quantity Control According to the standard specifications for construction and maintenance of roads and bridges. 10,803.2 concrete. a)Casting of concrete cubes ‘The casting of concrete cubes shall be carried out in accordance with BS 1181:part 108:83 with a sttength requirement as specify in AASHTO T23 equivalent cylindrical specimen. b)Testing of conerete cubes ‘The testing of concrete specimen shall be carried out AASHTO T22 (ASTM C39), equivalent test with BS EN12390-3-2002, may be accepted according to the engineer's requirement, ¢) Slump Test The slump test shall be carried out in accordance with ASTM test designation C143/C143M.-05* or BS EN 12350-2-2000 or AASHTO T119-99 7.1. The control of Materials Source * Cement: to check the surface of the cement, if can not meet the requirements, not allowed to unloading, The strength, stability, such as setting time, standard consistency water can be tested by bulk supply Ultrafine mineral powder: activity index and fluidity ratio in bulk for testing, Fly ash: to test the fineness of fy ash, Sand: do Methylene blue test, fineness modulus, powder content, soil content, apparent density, bulk density and crush index detection. Rock: the approach of gravel content of silt and clay pieces first, other indicators such as grain size distributi n, apparent det , bulk density and crush index, etc. Admixture: do the cement slurry flow degree test for the admixture. The concrete slump and the expansion degree test is req ed when necessary, other test such as water reducing rate, exudation rate, when the air content, slump loss, such as the 15ratio of compressive strength is also required . Supervision for concrete at site a) The technician must stay at the site for supervise, adjust the concrete slump, ensure the completion of concrete pouring works. b) The pump truck drivers and truck mixer driver act as very important rolls for the concrete quality control 7.3. The preparing work before concrete pouring (1) Check the formwork Mainlly check formwork position, elevation, size, verticality degree, Formwork juncture, embedded component place and number and its supporting, Situation, clean the wood shavings and other waste materials in the formwork. Further, Please refer NO.FSDI-(S01)-CATIC-1356 for form setting details at site (I) Cheek the reinforcement Check stee! reinforcement brand, quantity, position, joint and embedded components materials, ete (TED) Check the materials, machinery and road Mainly check the varieties, specifications, quantity and quality of the Materials; the number of machines and tools, operation situation, and road Condition shall be checked also. (IV) Check the water and electricity supply Check the water and electricity supply, and also check the weather condition, (V) The conerete pouring Conerete should not drop in the form a greater distance than 1.5m ,teferd to clause 551.10.21 of project technical specifications Layer by layer to pour the concrete, height of each layer should be determined according to the structural characteristics, reinforcement density, and normal height is 1.25 times of vibrator function height, maximum not exceeding 500 mm, the layer thickness for the plate vibrator is 200 mm. ‘Turn on vibrators, quick insert inside the concrete, ensure that there is no bubbles, no 16obvious sinking on the concrete surface, pan pulp and surface formation on the surface level.Using vibrator should be insert fast & remove slowly, one area by one area vibrating, Conerete should be continuous until complete, There should have one person to check whether the formwork, reinforcement, reserved hole, embedded parts and other steel displaced/blocked or not, when pouring concrete. 1.4 The site concrete vibratory quality control Occur when one of the following occurs, it shows that conerete vibration has been finished: (1) Concrete surface to stop setting, or not have clear height change; (2) Nothave significant bubbles when vibrating, or no bubbles around the vibrator; G)The concrete surface is flat, floating pulp; (4) The edge part of the formwork has been full filled with concrete, 1.5 Thermal control of concrete This method does describe construction method for reinforcement, conerete or formworks in details, but it provides details in Thermal Control and Temperature Differential Method. Measures taken are detailedas follows: 7.8.1. Thermal Control Testing Frior to construction of capping beam, mock up testing is done. Dimensions, temperature of the thermal control specimen , layout of thermal control cables and detectors and testing time are conforming to Clause 551.10.6 of the Specifications. 1.5.2. Optimize the conerete mix design a) Select low heat portland cement approved by consultant and reduce cement quantity as much as possible subject to satisfying strength requirements; b) Well graded aggregates are used as coarse aggregate ©) The O~Smm quarry dust are used fine aggregates mixed with natural river sand, the silt content and dust amount is well controlled in course and fine aggregates so as to reduce ‘cement amount in general by trial mixes subject to satisfying the design strengths Adopt double admixing technology, i.e, adding fly ash and superplasticizer at the same time to reduce efficiently cement usage in unit concrete and postpone emerging of the temperature peak value. 7.53. Temperature reduction for materials, a) A shelter is established for the aggregate store to prevent from direct sunlight and sand and aggregates are flushed by water to reduce temperature, And the water content for batching in the plant is adjusted according to water content in wet aggregates. b) Water for batching will use the water approved only. If further reduction is required, ice cube can be added to the water. 7.54. Temperature reduction in Formwork and reinforcement 7Before placement of concrete, the formwork and reinforcement is flushed by water so that the temperature for formwork and reinforcement can be reduced on one hand and foreign matters can be cleared and removed therein on the other hand. 7.5.5. Cooling of the Machinery Before batching, proportioning machine and mixer are flushed by cold water. For the concrete mixer trucks, before loading conerete and when the trucks are waiting at site for conereging, they are parked at tree shades or sunshading places and watering is done to the conerete tank for cooling purpose. When the trucks are loaded with conerete, their engines cannot be turn off and the conerete tanks need rotating all the time. 7.5.6, Time for conereting. Time for conerete placement is preferred curing period when environment temperature is low during the day. For the batched concrete, placement should be done as soon as possible to prevent ial set of the concrete at high temperatures, 1.5.7. Conereting from one end to another Tor the concrete delivered to site already, temperature measured before placing into formwork which is required to be less than 32°C, Concrete placement is done from one end to another at thickness of 30~40cm for easy vibration to ensure concrete quality by making full use of concrete surface for heat dissipation. But the next hayer concreting should be completed before initial set of the previous layer to prevent cold cracks between layers. 7.5.8. Curing of the Concrete After concreting and final set, curing is done by specially-assigned person using gunnysacks or geotextile to cover the surfaces and carry out watering regularly . After removal of formwork, the lateral part is winding with gunnysacks to keep temperature and wetness. Gunnysacks or geotextile are to be kept wet during curing period. As for curing period, it should be done strictly as per the Specifications(7 days) and it should be extended when necessary, and the same is applicable to the removal of formworks. 8. Construction safety guarantee lark construction safety lines, vehicle speed below 20 km /h, set up warning signs at 18some important traffic intersection. Set up the work way, corridor, or some simple st Construction of electricity must be set up by a professional electrician in accordance inside of the column, with the requirements of operation standard. Safety staff must take in charge of the safety management of all the construction area. 9, Civilization construction and environmental protection measures ‘The construction site and transport roads are equipped with sprinkler, use sprinkler ‘maintenance the road regularly any dust caused by the construction. Pay attention to the construction noise at night, try to use low noise construction equipment. Do not use the mechanical equipment which can not meet the emissions standard. All the waste which is harm fall to the environment, such as abandon slag, construction waste, production waste, waste materials, etc., Can dump at a specified location for treatment 10.Measurement. ‘The measurement shall be determined in accordance with the clause 212.11 of Technical Specification and under pay items given below. Item Description Unit pe ~ | Structure elements (tie beams, pile caps, pier, pier head, ee abutment, approach slabs and parapat 551.009 | Wrought formwork a ‘Sqm 551.010 | Sawn formwork a Sqm 552.001 | Reinforcing steel bar oe Ke | 19