Construction Method I Girder 25.7m at Longthanh - Daugiay Expressway

CONSTRUCTION METHOD
BEAM I25.7M
PACKAGE NO7- NORTH-SOUTH EXPRESSWAY CONSTRUCTION PROJECT
HO CHI MINH CITY DAU GIAY SECTION
Ho Chi Minh, Jan, 2014

Construction method of bearm I 25.7M
Pape 1
CHAPTER 1: GENERAL REGULATION

I. APPLIED CONDITION
This technical standard have written in order to support construction of pre-stressing reinforced
concrete girder post-tension full block;L25.7m, apply for Ba Dai bridge, package 7 - NORTHSOUTH EXPRESSWAY CONSTRUCTION PROJECT- HO CHI MINH CITY DAU GIAY
The girder is casted which depend on technical logic of concrete on site and formwork by steel.
Threaded hole for high strength tendon using spiral duct 60/67mm diameter.
High strength prestressing 12.7mm is executed in accordance with post-tension method when
strength of concrete is more than 40.5MPa ( is more than 90 % design strength)
1.1.
The introduceded items in bidding document

Items
Description
TCXDVN 389-07: Precast prestressted concrete products Technical requirement and acceptance
22TCN 247-98: Standard for Construction and acceptance of

prestressed reinforcement concrete beam.
ASTM C1077: Standard Practice for Laboratories Testing

Concrete and Concrete Aggregates for Use in Construction
ASTM A 421 91: Tiu chun li thp trn cho b tng d

ng lc/ bare mesh standard for prestressed concrete
ASTM 416 - 90a: 7 wires trand standard for prestressed

concrete
ASTM A722M-07: Uncovered high strength steel for the

concrete force
Item 7, section 07400-prestressed concrete
Comment
1.2. Construction sequence
Pape 2
Step 1:
Pape 3
Step 2:
Pape 4
II. ORGANIZATION CHART:

Site manager
Vo Van Quyet
(0913 198 029)
Site engineer
Nguyen Tien Ngoc
(0983 711 106)
Quality control - KCS

Nguyen Van Dat
(0979 590 615)
Cost Control Engineer

Nguyen Van Thanh
(0983 502 868)
Safety manager
Nguyen Truc Lam
(0932 152 778)
Chief of contruction group

Cao Quoc Thai
(0918 481 132)
Steel team
Formwork team
Concrete team
Pape 5
III. CONSTRUCTION SCHEDULE

Thi gian / Time
B c/
Casting bed
1
2
3
4
1
2
3
4
16
I-A
17
18
19
20
21
22
Thng 4/April
23
24
25
26
E-A
27
I-A
28
4
I-B
29
30
2
2
2
1
I-B
I-A
I-B
Loi dm/ Type girders
S lng / Quantity
Tng cng / Total
Nm 2014 / Years 2014
I-B
E-A
Thng 5/May
8
9
10
11
I-B
12
E-B
13
14
E-B
I-B
E-B
E-B
I-A
3
15
E-A
2
I-B
6
E-B
4
2
2
2
2
15
Ghi ch:
I-A: I girder, 25.7m, Internal girder type of two link slab.
E-A: I girder, 25.7m, External girder type of two link slab.
I-B: I girder, 25.7m, Internal girder type of one link slab, one expansion joint.
E-B: I girder 25.7m, External girder type of one link slab, one expansion joint.
Pape 6
CHAPTER II: MATERIAL

1. General requirement
- Contractor must submit all sample applied with concrete and test result to certify obey of the
technical introduction so that Consultance check.
- Contractor must use all approved material for preparing of concreted gradation design and trial
mixer to Consultance check.
- Dont transfer material to site when materials, gradation design and trial mixer have not had
approved consultance.
- The proposal for input materials would be listed as follow:

No
Materials
Source of material
Cement
Nghi Son Corp
admixture
Sika Ltd (Vietnam)
Manufactured sand
Tan Dong Hiep Quarry Binh Duong Province
Coarse aggregate
Tan Dong Hiep Quarry Binh Duong Province
Water
Factory water
Steel bars
Pomina Steel, Hoa Phat Steel
Stell plate (if any)
China
PC Strand
The Siam Industrial Wire Co., Ltd, ThaiLand
Remark
Guizhou Wire Rope(group) co., ltd , China

9
Achor
OVM Machinery Co.,Ltd, China
2. Prestressed reinforcement
Prestressed reinforcement of prestressing concrete girder must be reasonable with technical
standard as following:
- Use high strength cable 12.7mm low relaxation in accordance with ASTM A416-99 standard type
Grade 270 of equivalence.
- Some basic standard of high strength cable:

Pape 7
Type of
materia
Strand
Characteristics
Unit
Test method
(ASTM A416-2002)
Diameter tolerance
mm
ASTM A370
12.55-13.35
Cross section
mm2
ASTM A370
Min 98.7
Weight of Strand
kg/1000m
g/m
ASTM A370
Min 775
Diameter relation
between
center and outer wires
mm
ASTM A370
Min 0.0762
Yield strength
KN
ASTM A370
min 165.3
Breaking strength
KN
ASTM A370
Min 183.7
Elongation
ASTM A370
Min 3.5
Frequency
20 ton / 01 set
with consultant
or clients
witness
(ASTM A4162002)
3. Deformed reinforcement
Deformed reinforcement is plain round bar and deformed bar obeyed standard:
TCVN 1651-2008: Reinforcement for concrete
22TCN 272-05:
Type of
material
Reinforcement
( mechanical
properties )
Standard for bridge design
Criteria
(ASTM
A615-2004) Frequency
Test method
Gr60
Gr40
ASTM
50 ton / 3
Min 280 Min 420
A370
sets
(9 specimen)
ASTM
Min 420 Min 620
with
A370
consultant or
ASTM
Min 11 Min 8.0
clients
A370
witness
ASTM
No crack No crack
(TCVN
A370
1651-2008)
ASTM A370
6
ASTM A751
Characteristics
Unit
Yield strength
Mpa
Tensile strength
Mpa
Elongation
Bending strength
Permissible variation
in weight
Reinforcement Phosphorus content
( chemical
(P)
Pape 8
0.06
composition )
4. Wedges and Anchor
- Anchor used in design document is anchor EC5, is reasonable with requirement of 22TCN2672000 or equivalence.
- Used anchor have 12 holes 12.7 of manufacturers which is republic in Viet Nam.
5. Cement
- Used cement is PCB40.

- Mechanical properties of cement TCVN-6260-09
Criteria
Characteristics
Unit
Test method
Frequency
TCVN 6260 -09
Compressive strength
- 3 days
- 28 days
Setting time
- Initial set,not earlier than
- Final set, not later
MPa
TCVN 6016-95
min
TCVN 6017-96
18
40
45
420
than
Finesses:
- Retained content on sieve 0.09
mm, %
- Specific surface area , cm2/g
n nh th tch
Hm lng SO3
TCVN 4030-03
cm /g
mm
TCVN 6017-95
10
2800
10
TCVN 141 - 08
3.5
Giy chng
nhn kim tra
v phiu giao
hng cho mi
xe
- Packed cement have called name of manufacturers, kind of cement, kept in waterproofing store or
temporary store. The cement must be kept at dry place and floor is taller than existing ground. The
cement volumn in the store must be equivalence necessary concrete volumn for maximum structures.
Cement package should heaped, each heap dont exceed 8 packages and distance between packages
and wall is more than 1m.
- Cement due to trucks be stored in silos. All concrete porters work will be carried out so that the
cement contamination. The cement storage silos must be equipped with humidity control to keep dry
cement and anti-early hydration in the shed. The sheds have stairs and entrance to get the cement
samples from different heights from each silo to check.
6. Coarse aggregate
- Aggregate crushed stone for prestressed girder casting is limestone or crushed pebbles and.

Pape 9
- Test sample achieve more than 800kg/cm2 compressed strength at saturated status. Compression
strength of crushed stone is determinded by pressed method which its sample have demention 5x5x5
cm or circule sample 5cm, dont use weathered lava. Weight of stone is more than 2.8T/m3
- Maximum dimention of crushed stone is less than 3/ 4 reinforcement space and dont exceed 1/
3minimum length of
regulations in table :
structure. The coarse aggregates have reasonable dimention and obey

Coarse aggregate
Percentage of passing sieve
37.5 mm
100
25.0 mm
100
19.0 mm
90-100
12.5 mm
30-70
4.75 mm
0-10
7. Fine aggregate
- Fine aggregate content for Portland cememt concrete consist of sand and other inert materials
which are similar to characters, stiffness, durability. The fine aggregate must be pure, no impurities,
no clay, no organic and no harmful substances in accordance with AASHTO M6 standard.
- The fine aggregate must be homogeneous to deviation of minor modular between AASHTO M6
and representative sample used in mix amalgamate dont exceed 0.2 .
- The fine aggregate have reasonable content in accordance with parameters of following table :
Fine aggregate
Percentage of passing sieve
9.0 mm
100
4.75 mm
59-100
2.36 mm
80-100
1.18 mm
50-85
0.60 mm
25-60
0.30 mm
5-30
0.15 mm
2-10
8. Water : Accoding to TCXDVN - 302-04 specification
- Water course supplied by contractor for supervisor consult attached test result to certify required
guarantee water.
- Water for concrete have no impurities which are affect on nomal hydration of cement. Water have
no dirt, no oil will be used in concrete work.
Pape 10
- Water for concrete must achieve following parameters:
Ch tiu th nghim
Ch tiu nh gi
n v
Phng php th
pH value at 25oC
TCVN 2655-78
4 -12.5
Color
TCVN 4506-87
No color
Film of oil
TCVN 4506-87
Not detected
Dissolved solids
content
mg/L
TCVN 4506-87
200
Dissolve matter
mg/L
TCVN 4506-87
2,000
Chloride content
mg/L
APHA 4500
350
Sulfate content
mg/L
APHA 4500
600
Organic matter
content
mg/L
TCVN 4565-88
15
TCXDVN 302-04
Tn sut
Once every 6
month
(TCXDVN 302
-2004)
9. Admixture
- Plasticized admixture will be applied to improve workability of concrete. However, its dosage
depends on test process.
- We can apply Switzerlands plasticized admixture such as KAO, Bas, Sikament or
other
plasticized admixture, but it obey technical standard.

10. Lubricating materials
Form lubricating materials must obey following requirement.
- Suitable for use spray or scan equipment.

- Create a intermediate layer to prevent cohesion between the concrete and formwork.
- Easy destruction when move formwork, however it cant make any crack on the concrete surface.
- Do not make stainless steel formwork.
- We can apply some lubricating materials as following :
+ Separol Sika oil
Do not use any type of fuel oil and more dark oil achieved black soot impurities.
CHAPTER III: CREAT AND INSTALL FORMWORK

Pape 11
I. CREAT AND INSTALL FORMWORK

1. Holder of bottom formwork
- Bottom formwork put on fixed pedestal, the pedestal sink is not allowed too valuable to allow
deformation of beam formwork. Holder made of reinforced concrete emplacements casted in situ is
the reasonable distance to the bottom formwork is used. The foundation of the mound is compacted
and flipped gravel and sand.
- The embeded steel plate for supporting horizontal position turnbuckle of formwork during
vibration operation should ensure exactly so that no affect on the position of bottom formwork. In
case Turnbuckle against the bottom beam formwork are not available in the above steel pallets.
- The contractor must arrange casting-bed includes 4 sets of floor formwork and 1 set formwork of
beam I25,7m.
Structure of holder of bottom formwork
2. Install formwork
- The piece of formwork must be checked the size, warping, surface for treatments before
transporting to site and installing. The formwork, formwork bottom must be flat, straight. The sizes
have the reasonable required tolerance of the beam blade size.

Pape 12
- All joints between the pieces of formworks, the formwork and the bottom formwork, the
formwork of tip beam... must have elastomatric bearing or other material to prevent leakage of water
loss.
- The contact surface of the bottom formwork with its base (sleeper) should have rubber padding to
avoid shock and vibration enhancing while compaced operation.
- Form is located by turnbuckle, the position between formwork and bottom formwork by bolts or
located group.
- The contact surface of the bottom formwork must be lubricated by admixture or anti- stick
lubrication to its easy removing.
- Checking the dimention of formwork by steel measure. After satisfying technical requirement ,
further work (rebar layout, installation of formwork) shall be executed.
- After finished installation, if technical requirement satisfy , a center line will be marked along the
length of the bottom formwork to base and erect formwork in check.
General formwork
16kh x 1500 =24000
850
1475
1555
850
25700
200
200
1194
1500
1500
1610
1390
950 1013
1500
1500
1390
1610
1285 713 950
1390
1610
1500
1500
1194
Structure of formwork type 1

8150
500
500
500
500
500
500
500
400
500
500
500
500
500
500
500
550
200
Structure of formwork type 2

1620
200
400
400

Pape 13
1620
13kh x 500= 6500
400
200
- The criteria for formwork checking and method to carry out as followed (with allowable
tolerance) :
Activities
- Shape and dimension

- Flatness of steel plates.
- Tightness between
formwork panels
- Dimension deviation of
web thickness formwork
Equipment
Applied
standard
- Visual.
- Steel measurement
- Square ruler, spirit level
- Visual.
- Steel measurement
Flatness, smooth surface,

not curved or warped
Roughness of panels not exceed
3mm
Water-tightness to avoid laitance
leaking during casting and vibrating
- Visual.
- Steel measurement
- Formwork bottom flatness. - Visual.

- Cleaning inside formworks - Visual.
- Release agent.
- Visual.
- Squareness of end form

surface
- Visual
- Square ruler
Formworks after installation - Steel measurement
Requiremen
- 5mm.
TCVN 4453- - No water dripping at
bottom of formworks
1995
- No garbage, contamination, dust
inside formwork.
- Apply a uniform coat, the
thickness of the coat must be
homogenous to have the same
characteristics over the entire
formwork surface without dripping
- Not inclined 1% to the surface that
is perpendicular to the longitudinal
axis of the girder.
22TCN 247Conformity with Table 1
1998
Table 1 Allowable tolerance for completed installation formwork pre-stressed girder

No.
01
02
Deviation
(Tolerance according to formwork design)
Tolerance
allowable,
mm
Spacing between vertical supporting shores, inclined supporting shores,

anchorages and bracings in accordance to design
(a) For every linear meter
25
(b) For entire segment
75
Formwork panels surface, the junction of formwork panels, steel plate flatness of
bottom formwork, deviation bottom formwork from a straight line of girder
(a) For every linear meter
(b) For entire segment

- Side surface formwork
- Upper surface formwork
- Steel Plate surface of bottom formwork

Pape 14
03
Straight line formwork according to design
04
Overall length of form according to designed form (after fixing joint for girder span
12.5m)
05
Overall length of form according to designed form (after fixing joint for
girder span > 12.5m)
06
Length of segment form at end girder variable cross section (if any)
10
07
Thickness of two sidewalls formwork:
Width of side form of webs component
Hollow core horizontal direction position
08
Overall height of side forms: (after fixing joint) overall height of external form
09
Inclination of the end girder surface to the one which is perpendicular to its
longitudinal axis girder
10
Flatness of surface formwork end girder compared with straight line (unevenness)
1.5
11
Pre-stressing cable position according to design
12
Tie rod holes position for diaphragm according to design
13
Diaphragm position according to design
14
Formwork stability
15
Other tolerances as per specified design
0.3%
Ensure stable
and rigid
Not exceed
specified
design
3. Install vibrating system
- Vibrators arranged on the formwork. Ensure the correct distance from the radius of influence of
compactor type so that concrete is compacted the same over the whole beam length.
II.PROCESSING AND INSTALL DEFORMED REINFORCEMENT
1. Processing of deformed reinforcement
- Reinforcement shall be cut and bent in accordance with shape in the drawings. Error processing
according to ACI 315. The whole reinforcement must be cold-bent, unless approved otherwise. The
reinforcing steel in the concrete should not bend at the scene except indicated on the drawings and
approved the technical requirements.
- Hook dimensions and bending diameter must be measured in accordance with drawings. When
drawing dont dedicate, they must be applied with 5.10.2 of the TCN 272-05 22 "Standard bridge
design."
2. Install deformed reinforcement
- Reinforcement shall be installed in accordance with the shape and dimensions as indicated on the
drawings. The bars have cross section as regulation and shall be positioned in accordance with the
instructions on the drawing. The bar must be closely linked at the intersections to ensure no shape of
the reinforcement frame. The wire tip is inside of concrete and are not allowed to shoot to the
surface. The sleepers must be precast concrete and strength must be at least equivalent to the in-situ
Pape 15
concrete (45 MPa). The demention of sleepers must obey standards and are positioned correctly by
wires. These sleepers must be watertight before pouring concrete.
- The installation must be checked by supervision consultant and are not allowed for concreting
around the rebar Unapproved Consultant .
- At the time of concreting, reinforcement must be cleaned of rust, dust, oil, soil, or any mantle that
can destroy or reduce adhesion, concrete or in part concrete should also be cleaned that can be
deposited on it during the last concrete pour.
- The overlapping joints have dimentions as indicated on the drawings.If the ground is not
indicated, the length of overlapping joints is 35 times more than bar diameter.At the overlapping
joints, reinforcement must be installed and divided in accordance with specification for maintaining a
minimum distance to the concrete surface and the smallest distance between the bar has been pointed
out in this guide. Regulations for overlapping joints comply with Section 5.10.3 of 22TCN 272-05
"Standard bridge design."
- The welding joints is only used if the detailed drawings, or if approved supervision consultant.
The welded joints must comply with standard regulations of welded structures, reinforcement AWS
D1.4 of "South American Union" and the special provisions may be applied. reinforcement will be
welded if the chemical properties of the steel exceeds the percentage in the following table:
No
Chemical components
Percentage
Carbon
0,30
Mangan (MA)
1,50
Carbon equivalence
0,55
During the rebar work execution, the QA/QC procedure shall be control as follow
Activities
Inspection or
test method
Reinforcement
skin
Visual
Reinforcement
welding
Visual
Steel measurement
Cutting and
bending
Visual
Reinforcement
splicing
Steel measurement
Rebar
installation
Visual
Steel measurement

Pape 16
Standard
application
TCVN
4453-1995
QTSX
Requirement
Free from harmful flaws , free from
attachment of oil and no local necking
Smooth transition is required, burn
through, intermittent, local necking are
not permitted
Ensure the length and thickness of the
weld as per designed
Conform to table 2
Lap splicing length of main bar shall
not be less than :
250mm for tension bar and 200mm for
compression bar
Rebar installation are accurate
according to specification
Type of rebar, location and quantity are
accurate according to design
Time of
inspection
Prior to
fabrication
After
fabrication
and random
checking
During
fabrication
During
inspection
During
inspection
Spacer block
Visual
Steel measurement
TCVN
4453-1995
Concrete spacer blocks are

provided at regular intervals
not greater than 1m spacing (Closer
than 1m at the end)
Concrete cover thickness deviation
within a tolerance of 5mm
Completed
installation
reinforcement
Steel measurement
QTSX 2007
Conformity to table 3
During
installation
During
inspection
Table 2 - Dimension Tolerance of completed installation Reinforcement

Deviations
1. Dimension discrepancies by length of main bar
a) Every linear meter
b) Overall length
2. Deviation of pending position
3. Deviation of rebar length in mass concrete structure :
a) When the length is less than 10m
b) When the length is greater than 10m
4. Deviation of bending angle
5. Deviation of hook dimension
Where:
D: reinforcement diameter;
a: thickness of concrete cover
Allowable tolerance,
( mm )
5
20
20
+d
+ (d + 0.2a)
30
+a
Table 3 - Acceptable discrepancies of reinforcement after completed installation

Deviation
Allowable tolerance, mm
1. Spacing between main bars, anchor bars, water flow pipe (if any)
10
2. Spacing of PC bars
3. Discrepancies of spacing between fabric steel layers end of girder.

However, amount of stirrup, steel fabric should be accurate to
design
10
4. Local deviation of concrete cover thickness:

a) Design concrete cover thickness less than15mm
b) Design concrete cover thickness greater than 15mm
5. Measured dimension discrepancies of two symmetrical outer sides

(external edge) of steel box pile head.
6. Measured dimension discrepancies of two symmetrical inner sides
(internal edge) of sleeve (jointing end).
7. Stability and rigidity of steel frame after installation and
supporting
8. Other tolerances as per specified of design
Pape 17
-3 n 0
0 n +5
Ensure certainty and
rigidity.
Not exceed specified design
3. Fabrication and assembly of embedded structures in the beam
- After finish cradle plate and the cradle plate of bearing, straightedge is used to test the flat of steel
plate shall no bet exceeded 1 mm.
- Welding joint links steel plates with the anchor reinforcement to suit design requirements. Moving
position of anchor reinforcement dont exceed 2mm
- The cradle plates are installed exactly, not moved during pouring concrete. Engineer should be a
special attention to anchor positions and cradle plate of bearing because these details will affect on
the geometry, the bearing capacity of the beams and girders.
III. INSTALL DUCT
1. Processing of duct
- Pipe threading holes for high strength cable is ductt to ensure rigidity, not deformed in the process
of pouring concrete, resist better corrosion. Structure of the duct must ensure the requirements are as
follows:
- The diameter of the tubes is greater than the nominal diameter of at least 6mm, cross-sectional
area must be at least 2.5 times higher than the tendon area
- Ducts must be airtight, watertight and must have the required hardware design, fabricated from
galvanized steel sheets or other suitable materials.
2. Install duct
- To ensure exactly position of ducts should use located grids layout of along beam in accordance
with design document at the cross sections as shown in working drawing.
- Duct spacing can deviate 5mm from design drawing.

- Cap for edge of cable should be made to check usually the smoothness of the duct in the
concreting beams.

Pape 18

Pape 19
CHAPTER IV:TECHNOLOGY OF CONCRETE

I. MANUFACTURING THE MIX OF CONCRETE
1. Regulations of manufacturing the mix of concrete
- Selection components of the mix of concrete to cast PCI-Girder examines basical requirements :
+ Using meterials for construction which were experimented.
+ Strength must satisfy designal requirement 45 MPa
+ The shrinkage creep is small
+ The mollusk is good,no stratification when sustaining the stratification
- The ratio of mixing concrete must be experimented closely and approved by supervision about:
+ Amout of concrete
+ Ratio of N/X (Water/Concrete)
+ Slumps
+ Applied admixture
- In the materials of the concrete should not have gas and impurities chloride (NaCl, CaCl2)
- The concrete mixing materials such as water, cement, stone, sand all by weight. Precision of
quantitative material for 1 batch of concrete shall not exceed the following provisions:
+ The weighting instrument must be checked before casting each girder. Ensure accuracy while
using .
+ Concrete mixers must be selected according to the volume of concrete of one girder
(approximately 16.4m3) for a period not exceeding 2 hours.
+Laboratory staff must check the humidity of the aggregates to adjust the mixing ratio . Need
to check the humidity of the sand before casting each girder.
2. Checking concrete mixes
- The QA/QC procedure ding the pouring concrete shall be:
Activities
Mix design
Test
method
Standard
application
Indicated
on screen
of batching
plant
computer

Pape 20
TCVN
4453-1995
Requirement
Use of the correct concrete mix

design, no change W/C ratio
Quantities of the batched concrete
components are within the
acceptable
tolerances:
- Water, cement: 1%
- Aggregate and admixture: 3%
Frequency
First batch
Slump
Slump in
accordance
with TCVN
3106 1993
Samplin
TCVN 3105
-1993
Require slump 100 25 mm

- Checking slump at batching plant
- Checking at casting yard
Visual
Compressive
strength
According
to ASTM C39
or TCVN 31181993
1 girder / set
(12 specimens
)
TCVN
4453- 1995
Follow as sampling standard
TCVN
4453-1995
No segregation
Slump follow as design
Each casting
To ensure a homogenous material

and the most compact with out
honeycomb
- It could be realized through
theres no more air bubbles rising
on the surface and surface starts of
bleeding
- When using the needle vibrator
the spacing between 2 points of
vibration should not be more than
1.5 times of vibrator radius action
(the diameter of needle action
circles specified in supplier
catalogues), Placing neddle
approximate 10 cm in previous
layer to ensure a better
homogeneity for layers group
Each casting
Concrete
placing
Consolidation
Each mixer
truck

Pape 21
TCVN
4453-1995
TCVN
4453-1995
Reach required compressive

strength R3>Fc = 40.5MPa
1 girder/ set
(12 specimens
)
Curing
concrete
visual
TCVN 391
2007
Cover the concrete surface with

moist burlap as soon as the
concrete surface has hardened
sufficiently to prevent damage and
keep the concrete moist at all times
by adding water at least once
every 2 hours.
Curing is carried out by using a
sprayer with a nozzle to apply the
water over entire the concrete
surface for at least every 3 times a
day.
Required curing period for 3 days.
Each product
3. Dilivery concrete mixes
- Cast in-situ in place beam should arrangement casting-bed reasonablely for the dilivery concrete
is easy.
- Concrete is delivered from mix plant to site by special vehicle.

II. PLACING AND COMPACTING
1. Preparation before placing concrete
Before placing girders concrete checking the following issues :
- Based on the laboratory report, the proportion of concrete mixes is provided by experiment, again
check out at the site whether qualities of meterials are qualified. Is the quantity of materials enough
for placing 1 girder.
- Checking the weighting instruments if they are fit and edited.

- Checking the operational status of equipment in the chain,the situation of supplying electricity and
priventive plans(crane,agitating truck,compactor).
- Quality
control of formwork (hardness,clean,lubrication,tolerance of size,vibration

system).checking the tightness of formwork,tighness of the bolts and turnbucke linked to
formwork ;
- Checking the operation of vibration system..Examining and treatment abilities which may hinder
the effects of vibration.l
- Checking bars :Diameter of bar,distance of bar,position of anchor steel and the steel anchor pillow
- Checking tendon ducts(diameter,position,located system,drainage and air holes in the ducts)
- Checking safety plans,arrangement of manpower.
- Seizing the weather to work against rain and wind.
- Arrangement of lighting in case of placing concrete at night ;
Pape 22
- Examining procedures of nspectment.

2.
Placing and compacting
Concrete is placed at the batching plant of contactor and transported to the location of casting
girder by special vehicles,then placed into girder by funnel of placing concrete
During placing concrete notes:
- Concrete shall not have a free fall more than 1.5m

- Concrete shall be devided 3 layers, one layer less than 50cm.
- Concrete must be placed continously,discontinuous time when placing is not over 45min, time
placement 1 girder is not over 2 hours
- Compacting is a important stage,to ensure quality of concrete need to arrange compactors full of
type capacity.
+ Side vibrator (according to designation of formwork)
+ Using 2 pocker vibators 35 -70 to compact the bottom of girder.
- Operating time of the concussion outside for each concrete layer is 90 seconds. Signs to stop
concussions are: concrete is not sunk, cement surface has water and does appear bubbles anymore.
- During placement concrete must often check formwork,if there is deformation must suspend and
repair,if any leak of ciments water,must seal.Checking tendon ducts by threader.
- At position of cross beam before placing concrete, formwork shall be puttied by Sika Atisol F and
then the position would be puttied by pressure water injection to clear sureface cover depth 3mm.
- Finally placement concrete, sureface would be puttied by Sika Atisol C and then the position
would be puttied by pressure water injection to clear sureface cover depth 3mm.
- Placing concrete the tendon ducts need closed wood to protect.

Pape 23
100
3.
Curing
- After placing at least 10 hours concrete must be covered and watered,if it is hot,windy after 2-3
hours covering uncoveref surface of girder by water retention materials (sacks ,sand).The curing of
concrete is done by nozzle,wet-spray entire the day.The spraying time is more in hot days.Signs of
making well this work is the concrete does not dry out
- Water for curing concrete is the water that is used for mixing concrete.
- Concretes strength when removing side formwork 40.4Mpa(about 1 days after placing
concrete).Avoiding clefting the edge of girder and crackling localy when removing formwork
- After removing formwork must check the surface of the body of girder and set the inspectment
report.
III. EQUIPMENTS AND INSTRUMENTS
The proposal of equipment and manpower shall be prepared at follow:
No
01
Item
Code
Quantity
Hoist formwork , girder,

transport girder
Gantry crane 80 Ton

Pape 24
01
Mark
Formwork
02
Side Formwork
01
Bottom Formwork
04
Production girder
03
Batching plant 60m3/h
01
Agitating truck 6m3
02
Electric generator >200KVA
02
Vibrating compactor (attach

interior formwork)
18
02 Backup
Vibrator cylinder
04
02 Backup
Rope chopper
02
Bending apparatus
02
Hydraulic jack 60 ton
02
Gas cutter
04
Cooling plant
01
Stressed cable
04
05
Turnbuckle
02
Gauge
02
Testing
Gradienter
01
Test cylinder (D15x30cm)
18
Slump Cone
02
List of manpower construction PCI 25.7 girder

No
Situation
Description
Quatity
Foreman
Managing the work
Skilled worker(1)
Fabrication and Installation re-bar
Skilled worker(2)
Placing concrete,jack,clinical beam
Worker
CHAPTER V :STRESSING HIGH INTENSITY STRAND

I. ANCHORAGE
Pape 25
Note
1. Technical requirements of anchorage
- Using only a type of anchorage in a girder.

- Anchorage must reach technical requirements by experiments,is used.
- The destructive force of anchorage is equal to 0.9 strands destructive force.
- Type of used anchorage have attached certification.
- Checking the accuracy of round anchorage and pin anchorage as table 2.
Table 2
No
Allowable Tolerance as installing anchorage+high

intensity strands
Allowable quantity
mm
Tolerance of anchorages size

- For height
- For diameter
- For stepper
The distance between anchorages plane
(L + 50)
L length controlled of tendon
(L-10)
Movement of tendons length
30
Movement distance among tendons
10
Warping of the plane at the tip of jack
Movement of the value of tensioning pressure
5%
Movement of elongation of each tendon
6%
Movement of reserve camper.
Difference of total elongation is not over
1/100
5%
2. Preparation of installation high intensity tendon

III.1.Preparation before creating PC
- Examining the deflect of girder,if effecting to load capacity must repair.

- Checking concretes strength,if 90% of design strength is achieved,tensioning is permitted
to be execution.
- Checking technical certificate of high intensity tendon.

- Checking technical certificate of the top of anchorage.
Pape 26
- Checking tolerance when installing high intensity tendon(table 2).

- Checking and editing jack,pressure gauge shall be used(checking periodically).
- Determination coefficient friction of jack and anchorage loop.
- Checking hole for high strength steel bunch(cleaness,through passage).
- Checking practice on operation safety.
III.2.Manufacturing and installation high strength steel bunch
- Using high strength steel bunch type 12.7mm.In 1 girder,only use 1 type of ship,produced
according to a specification.
- Using mechanical method to cut high strength steek bunch,forbit to use electric arc welding
machine for cutting,the physical properties of PC tendon will lose.
- PC tendons need to be protected from rust due to airs humidity.While dilivery,moving the
tendon,distance between supporting points 4m.Not sticky oil and soil.The tendon is not scraped and
deformed.
- Prior to passing through anchors ring into tendon for preparation of stressing high strength steel
bunch,need to clean soil and protective grease layer in the tendon and anchors loop.For anchor
pin,prior to pressing the anchor need to be got rid of grease until having a absolutely clean dry
surface.
3. Stressing of PC tendon
3.1. Prestressing jack
- Prior to using must experiment to test jack and check the combination of hydraulic jack,hydraulic
pump and pressure gauge.
- Using 2 hydraulic jacks to stress 12.7mm tendon from 2 directions of girder.

- Tensioning sequence is 1-2-3-4-5.

Pape 27
3.2. Process of stressing of PC tendon

Preparation
- Prior to stressing of PC tendon using paint (thin line)to draw 2 lines to watch for the reserve
camper and horizontal deformation of girder during stressing of PC tendon
+ Baseline 1 :placed horizontaly to belly of girder,defined the correct elevation by automatic
level at 5 points :at 2 bearings,at 1/2L,at 2 points which their distance to midpoint 6.25m each
side. This standard line to measure the reserve camper.
+ Baseline 2 : at the upper side of girder(center line of girder) also located at 5 positions as
on.This baseline to measure horizontal deformation of girders axis due to prestressing.
- Process of stressing of PC tendon is carried out as follows :

1- Stressing tendon to force 0.2Pk then mark 2 heads of tendon (behind jack zone) to measure
elongation
2- Continue stressing to classes of force:0.5Pk;0.8Pk;Pk(Pk is close force anchor)
3- Stressing over 5%:1.05 Pk unchanged in 5 minutes
4- Lower to close force anchor Pk
5- Closing anchor with force Pk according to design(the value of force corresponding to
jacks gauge shall be experimented specifically with the jack used to stress)
Pk is design tension of 1 tendon (Pk=951 KN)

Pape 28
- Measurement elongation
Corresponding to each class of force during stressing,need to measure elongation of
tendon to compare with calculating value.
Elongation is calculated by formula:
P Ln
Ltt=
Ap E h
In that:
Ln:Tendons length calculated by distance of 2 heads of anchor(mm)
Ap:Area of 1 tendon(mm2)
Eh:Elastic module of steel(N/mm2) defined by experiments
P.Close force anchor according to design(N)
Measuring elongation when stressing tendon
Lk = 1 + 2
In that:
1 : Actual elongation measured at jack 1,jack 2.
2 : Theoretical elongation when stressing to 0.2Pk.
- Measuring elongation need to use metre with its accuracy 0.1mm

- Marking for measurement of elongation using white paint has thin line 1mm

Pape 29
TABLE CALCULATION OF TOTAL ELONGATION I GIRDER 25.7M

1. Coordinate of center pretressing cable I25.7m:
Coordinate of prestressing cable:

(mm)
B 1
B 2
B 3
B 4
B 5
Points
X
Y
Z
Y
Z
Y
Z
Y
Z
Y
Z
1
12700
0
1185
0
945
0
705
0
465
0
225
2
12500
0
1159.5
0
923.3
0
687.1
0
453.9
0
220.8
3
12000
0
1095.6
0
868.9
0
642.3
0
426.3
0
210.3
4
11700
0
1057.3
0
836.3
0
615.4
0
409.7
0
204
5
11000
0
969.3
0
761.3
0
553.3
0
371.8
0
190.3
6
10000
0
854.8
0
663
0
472
0
322
0
172
7
9000
0
749.7
0
574.1
0
398.5
0
277
0
155.5
8
8000
0
656.4
0
494.5
0
332.7
20.1
236.7
20.1
140.7
9
7000
0
574
0
424.3
0
274.6
41
201.1
41
127.6
10
6000
0
502.6
0
363.5
0
224.3
61.8
170.3
61.8
116.3
11
5000
0
442.3
0
312
0
181.8
82.7
144.3
82.7
106.8
12
4000
0
392.8
0
269.9
0
146.9
101.8
122.9
101.8
98.9
13
3000
0
354.4
0
237.1
0
119.8
101.8
106.3
101.8
92.8
14
2000
0
327
0
213.7
0
100.5
101.8
94.5
101.8
85.9
15
1000
0
310.5
0
199.7
0
88.9
101.8
87.4
101.8
85.9
Pape 7
16
0
0
305
0
195
0
85
101.8
85
101.8
85
1. Total elongation of cable number 1:

1.Force befor seating (Lc cng u dm) :
Pk=
2.Modulus of Elasticity (Moun n hi) :
E=
3.Area of strand tendon (Din tch b cp) :
Fc=
703.13 mm2
4.Friction coefficient (H s ma st) :
0.2 1/rad
5.Wobble coefficient (H s ma st lc) :
K=
P= Pk*(1-e-(K*x+*a))
Pi
x
li
Lk
202.41 KN/mm2
6.6E-07 1/m
(22TCN 27205)
li=(Pi+Pi+1)*Li/(2*Fc*E)
Tng gi tr tuyt i ca gc chuyn tnh t u kch gn nht n im ang xt (rad)
ng sut trong cp DUL ti mi on im ang xt (Mpa)
Chiu di b cp DUL o t u kch n im ang xt
dn di ca mi on
Chiu di cp cng ko
Point No.
(im)
Crossbeam cable 1
951.00 KN
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Distance
from jacking
end (K/C t
im cng
ti im
ang xt)
m
0.00
0.00
0.20
0.71
1.01
1.71
2.72
3.73
4.73
5.73
6.74
7.74
8.74
9.74
10.74
11.74
12.74
Segment Length
(Chiu di 2 im
cnh nhau)
Angula
r
change
(Gc
chuyn)
Pi
li
KN
0.00
0.00
0.00
0.06
0.08
0.45
2.55
4.31
6.52
8.56
10.62
12.70
14.72
16.79
18.84
20.87
22.91
KN
951.00
951.00
951.00
950.94
950.86
950.41
947.87
943.56
937.04
928.48
917.86
905.16
890.45
873.66
854.82
833.95
811.03
mm
0
0.0
1.3
3.4
2.0
4.7
6.7
6.7
6.6
6.6
6.5
6.4
6.3
6.2
6.1
5.9
5.8
162.56
m
Degree
0.00
0.00
0.00
0.00
0.20
0.00
0.50
0.02
0.30
0.02
0.71
0.13
1.01
0.77
1.01
1.30
1.00
1.97
1.00
2.59
1.00
3.22
1.00
3.85
1.00
4.47
1.00
5.10
1.00
5.73
1.00
6.35
1.00
6.98
Total Elongation (Tng dn di)

Pape 7

Pk=
E=
Fc=
703.13 mm2
0.2 1/rad
K=
P= Pk*(1-e-(K*x+*a))
951.00 KN
202.41 KN/mm2
6.6E-07 1/m
(22TCN 27205)

Pi ng sut trong cp DUL ti mi on im ang xt (Mpa)
x
li dn di ca mi on
Lk Chiu di cp cng ko
Crossbeam cable 2
Point No.
(im)
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Distance
Angular
from
Segment
change
jacking end
Length (Chiu
(Gc
(K/C t
di 2 im cnh chuyn)
im cng
nhau)
ti im
ang xt)
m
m
Degree
0.00
0.00
0.00
0.00
0.00
0.00
0.20
0.20
0.00
0.70
0.50
0.02
1.01
0.30
0.02
1.71
0.70
0.11
2.71
1.00
0.61
3.72
1.00
1.15
4.72
1.00
1.68
5.72
1.00
2.21
6.73
1.00
2.75
7.73
1.00
3.28
8.73
1.00
3.82
9.73
1.00
4.35
10.73
1.00
4.89
11.73
1.00
5.42
12.73
1.00
5.96

Pape 8
Pi
li
KN
0.00
0.00
0.00
0.06
0.08
0.37
2.03
3.80
5.55
7.31
9.08
10.83
12.59
14.33
16.09
17.84
19.58
KN
951.00
951.00
951.00
950.94
950.86
950.49
948.46
944.66
939.11
931.80
922.72
911.89
899.31
884.98
868.89
851.04
831.46
mm
0
0.0
1.3
3.4
2.0
4.7
6.7
6.7
6.6
6.6
6.5
6.5
6.4
6.3
6.2
6.0
5.9
163.55

Pk=
E=
Fc=
703.13 mm2
0.2 1/rad
K=
P= Pk*(1-e-(K*x+*a))
Pi
x
li
Lk
202.41 KN/mm2
6.6E-07 1/m
(22TCN 27205)
dn di ca mi on
Chiu di cp cng ko
Point No.
(im)
Crossbeam cable 3
951.00 KN
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Distance
from jacking
end (K/C t
im cng
ti im
ang xt)
m
0.00
0.00
0.20
0.70
1.00
1.71
2.71
3.71
4.71
5.72
6.72
7.72
8.72
9.72
10.72
11.72
12.72
Segment Length
(Chiu di 2 im
cnh nhau)
Angula
r
change
(Gc
chuyn)
Pi
li
KN
0.00
0.00
0.00
0.02
0.03
0.21
1.61
3.08
4.54
5.99
7.46
8.92
10.35
11.82
13.28
14.73
16.17
KN
951.00
951.00
951.00
950.98
950.95
950.74
949.12
946.04
941.51
935.52
928.06
919.14
908.78
896.96
883.68
868.95
852.79
mm
0
0.0
1.3
3.4
2.0
4.7
6.7
6.7
6.6
6.6
6.6
6.5
6.4
6.3
6.3
6.2
6.0
164.63
m
Degree
0.00
0.00
0.00
0.00
0.20
0.00
0.50
0.01
0.30
0.01
0.70
0.06
1.00
0.49
1.00
0.93
1.00
1.37
1.00
1.81
1.00
2.25
1.00
2.70
1.00
3.13
1.00
3.58
1.00
4.03
1.00
4.47
1.00
4.91

Pape 9

Pk=
E=
Fc=
703.13 mm2
0.2 1/rad
K=
P= Pk*(1-e-(K*x+*a))
Pi
x
li
Lk
202.41 KN/mm2
6.6E-07 1/m
(22TCN 27205)
dn di ca mi on
Chiu di cp cng ko
Point No.
(im)
Crossbeam cable 4
951.00 KN
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Distance
from jacking
end (K/C t
im cng
ti im
ang xt)
m
0.00
0.00
0.20
0.70
1.00
1.70
2.70
3.70
4.71
5.71
6.71
7.71
8.71
9.71
10.71
11.71
12.71
Segment Length
(Chiu di 2 im
cnh nhau)
Angula
r
change
(Gc
chuyn)
Pi
li
KN
0.00
0.00
0.00
0.06
0.08
0.31
1.13
2.04
2.93
3.82
4.73
5.64
6.51
7.42
8.32
9.21
10.09
KN
951.00
951.00
951.00
950.94
950.86
950.55
949.42
947.38
944.44
940.62
935.89
930.25
923.74
916.32
908.00
898.79
888.70
mm
0
0.0
1.3
3.3
2.0
4.7
6.7
6.7
6.7
6.6
6.6
6.6
6.5
6.5
6.4
6.3
6.3
166.36
m
Degree
0.00
0.00
0.00
0.00
0.20
0.00
0.50
0.02
0.30
0.02
0.70
0.09
1.00
0.34
1.00
0.62
1.00
0.88
1.00
1.15
1.00
1.43
1.00
1.70
1.00
1.97
1.00
2.24
1.00
2.52
1.00
2.79
1.00
3.05

Pape 10
5. Total elongation of cable number 5
Pk=
E=
Fc=
703.13 mm2
0.2 1/rad
K=
P= Pk*(1-e-(K*x+*a))
Pi
x
li
Lk
202.41 KN/mm2
6.6E-07 1/m
(22TCN 27205)
dn di ca mi on
Chiu di cp cng ko
Point No.
(im)
Crossbeam cable 5
951.00 KN
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Distance
from jacking
end (K/C t
im cng
ti im
ang xt)
m
0.00
0.00
0.20
0.70
1.00
1.70
2.70
3.70
4.70
5.70
6.70
7.70
8.70
9.70
10.70
11.70
12.70
Segment Length
(Chiu di 2 im
cnh nhau)
Angula
r
change
(Gc
chuyn)
Pi
li
KN
0.00
0.00
0.00
0.00
0.00
0.27
0.51
0.86
1.18
1.50
1.85
2.19
2.49
2.84
2.99
4.30
4.47
KN
951.00
951.00
951.00
951.00
951.00
950.73
950.21
949.35
948.17
946.67
944.82
942.63
940.14
937.30
934.32
930.02
925.55
mm
0
0.0
1.3
3.3
2.0
4.7
6.7
6.7
6.7
6.7
6.6
6.6
6.6
6.6
6.6
6.5
6.5
168.35
m
Degree
0.00
0.00
0.00
0.00
0.20
0.00
0.50
0.00
0.30
0.00
0.70
0.08
1.00
0.15
1.00
0.26
1.00
0.36
1.00
0.45
1.00
0.56
1.00
0.66
1.00
0.75
1.00
0.85
1.00
0.90
1.00
1.29
1.00
1.35

Pape 11
4. Measurement the reserve camper and horizontal deformation of girder

4.1. Measurement the reserve camper
After finishing stressing tendon need to measure the accuracy of the reserve camper at the posit
ion 1/2L and 2 positions are far from midpoint each side 6.25 m.The position of the reserve camper
need to be marked to follow.
- Prior to inspectment of girder used need to measure again the accuracy of the reserve camper
again.
4.2. Watching for the hozirontal deformation of girder due to stressing irregularly
- After finishing stressing tendon need to watch for the horizontal deformation of girder at center
line axis marked on the baseline 2 (according to 3.2)
- After placing mortar ciment and putting girder used need to measure again the horizontal
deviation of girder in comparison to girders axis.
- Measurement the horizontal using the theodolite and steel ruler

5. Technical requirements of progress of prestressing of PC tendon
5.1. Requirement of geometry of tendon
When beginning to stress center hole and anchor jack must be adjusted on the same axis to avoid
when stressing anchor jack makes steel pull of.Installing anchor must arrange tendons equally,not
obliquely,not curly
5.2. Requirement of amount and quality
In one tendon not falling off more than 1 thread. In a girder the number of lagging or cut strand
no more than 2. Power losses due to the lagging strand (or off) causes shall be added when stressing
the last tendon. If the anchor does not meet the requirements will not be used.
5.3. Requirement of position of putting jack
Position of putting jack indicated in the scheme, in the anchor seat and hydraulic jacks,
concrete surfaces (metal)need to be flat and perpendicular to the tendon. The anchor and jack keep in
place during the pulling.
5.4. Requirement of watching for index
Carrying out stressing by hydraulic jack, need to check the value of force on the gauge with the
accuracy 5%, the value of elongation is measured from 0 with the accuracy 1mm
5.5. Checking jack and pressure gauge
Jack and pressure gauge used in stressing tendon must ensure the honest feedback, exactly
actual force which tendon receive.So they must be examined periodically about the followings:
- Deformation the calibrating equation between the value on pressure gauge and tensioning
force of jack
- When stressing tendon must note the serial number of jack and the serial number of gauge must
unite on test.Not using gauge and jack which are not experimented together.
Pape 12
+ In the following case the pressure gauge must be celibrated or repaired:

+ The sewing does not come back to number 0
+ The accuracy exceed over domain permitted or has errors
+ Over time written on inspection stamps

Pape 13
CHAPTER VI : PUMPING CIMENT MORTAR AND

PLACING CONCRETE SEALING HEAD OF GIRDER
I. PUMPING CIMENT MORTAR
1. General requirement
The porpose of pumping ciment mortar sealing threaded holes of tendon is to protect PC steel
not be rusty and ensure the cohension between steel and concrete.Mortar must ensure the following
requirements:
- There is no aggressive substances oxidize reinforcement

- Ensure the viscosity while pumping
- No sedimentation,few shrinkage
- Ensure design strength 45 Mpa and no shrinkage
2. Mortars components
- Mortars components consist of ciment,water and and swelling additive (not using the quick
freeze additives)
- Ciment is PCB 40 (has content of clorua and sunfat is not over 3%)
- Water:Using water for placing concrete ensuring specifications
- The ratio N/X = 0.34-0.38 (when no additive is not over 0.4; when having additive is not over
0.38).
3. Experiment of mortar at laboratory
Experiment at lab comply correctly standard used in the project.However need to define some
norms for construction:
- Experiment of mobility-the mobility on demand is 14-20 seconds

- Checking the sedimentation
- Experiment of shrinkage after 24 hours;the volume of shrinkage is not over 2%
- Experiment of the setting time, starting 3h finishing 24h
4. Experiment of mortar at the site
Prior to pumping mortar 24h making some experiments at the site to check the flow and
sedimentation, the result of viscosity does not exceed its in lab 3 seconds, but are in 14-20 seconds,
sedimentation is not over 2%.If the result is not attained must change the quatity of water 1-2 litre
for 100kg of ciment.
5. Purpose of checking quality of mortar pumping
Experiment of checking viscosity and sedimentation input (in the barrel) and output (input making
3 experiments for 1 ton of ciment, output making 1 experiment for 1 duct). The result of experiment
Pape 14
must ensure tolerance 13-25s.Not over 2 %,if the result is not attained stopping pumping mortar and
adjust components
6. Production mortar
- Ensure making weight correctly, error of ciment, water is not over 1%.Having net to filter ciment
before giving it into mixer and filter mortar before taking out (suburd of filtering 2mm)
- Mortar must be mixed continuously.Not mixing by hand, the time for mixing at least 4 minutes.
- Mortar has been mixed must be pumped into horizontal system with separated time is not over 20
minutes.If mortar has not been pumped as a result of problem , before pumping must check the flow
7. Technology of pumping mortar
Checking head of input pipe , output pipe ( the vent 10mm the grout hole 15mm).Pumping
mortar need to be done early after stressing of PC tendon.Sequence of pumping:
- Sealing the head of anchor by ciment mortar has strength as girders concrete, after sealing the
head of anchor 48 hours , carrying out pumping mortar, aimed at keeping pressure of pumping does
not leak out.
- Prior to pumping need to pump water into pipe to clean pipe and reinforcement.This cleaning
must be done until the output water is clear.
The mortar pump must have pressure not over 1.5 MPa.In the pump hole has valve.After full of
mortar in the hole keep the machine in some time.Pumping mortar with pressure 0.4-0.8 MPa (at
least 5 minutes with pressure 0.7 MPa) close valve (Note:After removing valve, clean it at once.
- To avoid mortar of upper hole flow down the under hole makes pipe jammed while pumping, need
to pump the under hole firstly, then upper hole.
- Pumping mortar must be done regularly and continuously, so having the reserve equipment is
essential.
- While pumping mortar is clumping make pipe jammed or another reason must pump water from
the reserve direction to clean then pump again.
II.PLACING CONCRETE SEALING HEAD OF GIRDER
- After pumping mortar completely need to place cocncrete sealing head of girder to seal the anchor
- Concrete sealing head of girder must link to girders concrete well, must create roughness the
contact surface after pumping mortar 24 hours (not touching the reinforcement, provide lagging
anchor
- When sealing head of girder must ensure size of it and total length of girder as design
- Class of concrete sealing head of girder is as good as girders concrete.
- Not welding reinforcement sealign head of girder into anchor.
- After placing concrete sealing head of girder completely, must be maintained according to
specifications as maintenance concretes girder
Pape 15
- Strength removing formwork must be more 45Mpa.

- The engineer of contractor need to check the progress of placing concrete ensurign specifications
as: class of concrete, making roughness, welding reinforcement, size of formwork, concrete vibrator,
maintenance.

Pape 16
CHAPTER VII : ACCEPTANCE AND BEAM LAUNCHING

I. REGULATION ABOUT BEAM ACCEPTANCE
1.
General regulations
After each of the following segment, necessarily acceptance of the quality control department
and recorded in the diary of each slab beams:
- The installation of formwork, installation of reinforcement.

- Inspection and testing of materials, weighing instruments for use in the manufacture of beams,
concreting equipment.
- Strength of concrete at stages: high strength tendon tension; specification strength at 28 days.
- Quality checking of beam before pre-stressed tension.
- Checking the installation of high strength tendon and anchor.
- Tension process: Force parameter on pressure clock, elongation corresponding
- Shape of beam after stretching: camber, horizontal deviation.
- Check the cement grouting.
- Check the concrete sealing head of beam
- Shape of beam after finishing : camber, geometry, surface of beams

Pape 17
2.
Standard quality control of beam I 25.7m are shown as following diagram :

Work Item to be inspected
Construction tearm
for Beam
Engineer
Site Manager
QC. Engineer
Bridge Engineer
Internal inspection
No
No
Inspection
by engineer
Next work items
3.
Check size of beam
After pre-stressed tension and beam finishing (Placing concrete sealing head of girder), beam
deflection and camber of the beams, the cross-sectional dimensions of the beam should be measured
in the sections.
- Beam deflection and camber of the beams should measured at 5 sections :at bearing, at mid beam,
position where is distance each side 6.25m
- Geometric dimensions measured in the sections include: the dimention of bottom beam, beam
web, beam height, length, width
- After finishing the fabrication process, the girders shall be stored at the storage yard. The final
inspection for finished product shall be:
Activities
Surface
appearance
Shape and
defects of
production
Test method
Visual
Standard
application
TCXDVN
389-2007
Visual

Pape 18
Requirement
Flatness, Smooth surface, no convexity
or concavity point greater than 5mm
- Any rebar protruding beyond the
concrete surface except stirrups shall
not be permitted
- Concrete surface needs to be
Homologous color
-Small spalling (total surface area
Frequency
Each produc
During
inspection
not exceed 50 cm2) which may occur

during formwork removal process or
transportation without detrimental
effect on the structure capacity of the
member needs to be repaired using nonshrinkage grout with same or even
better grade concrete in oder to restore
its structure strength
- In case cracks appear on surface not
exceed 0.1mm. it is necessary to be
repaired by cement grout
4.
Beam Acceptance
- Beams made the project criteria considered valid application and acceptance to use
II. TRANSPORTING AND ERECTION
- When the cement mortar and concrete girder tipped ensure 40.4Mpa about strength are allowed
to lift off the tank.
- System of beam mark:

- All girder would be paint by number, include three marks to povide information about type of
girder, day of casting
Area 1
Span
Area 2
Girder number
Area 3
Cating bed
- Example to rename of girder at position span 1, cast in bed F2 ,It would be had the name
S1-G02R-F2.
- The bottom area would be paint day of casting.

S1-G02R-F2
16/4/2014
- After approved Supervision Consultant in accordance with regulation, beams will be transported
into scenery, installed on the piers and abutment according to submitted method.

Pape 19
CHAPTER VIII : ENSURING SAFETY WORK

I. ENSURING SAFETY WORK
- Before starting work with every shift of drill, all members working on site must understand the
following issues to do the job effectively and not cause an accident or any consequence
1. Work safety:
1.1. General work.
Safety is always our first attention on the field and applies the following measures:
- Establish an organization of work safety, which has network of safety staves and operates
effectively
- Maintain a barrier between the construction site and the surrounding area. Ensure smooth flow,
and installing traffic signs around.
- All workers on site have to learn work safety rules before joining the construction, wear helmet
for protection, wear uniforms, shoes and safety glasses when needed.
- Strictly abide by the regime of periodical inspection on the safety work.

- Use the right kind of worker, mechanic should have operating certificates.
- The used equipment and machinery must be calibration, machines must have history and license
to use according to the Law of labor union.
- On site must be equip a medicine cabinets, construction leader must have contracts with the city
hospital on transporting an emergency for accidents (if any).
- Electricity network for construction was definitely fixed on the column; the power distribution
cabinets and other electrical equipment have Automat, earth connection and distance to the ground at
least 1.2 m. Ensure lighting system to have sufficient light at night during the construction.
- At the site office where the phone table is located, must show the needful phone number such as
emergency, police, fire, etc.
- Have measures to disseminate and educate site safety rules for technical staff and workers, draw
slogans such as: "Safety is friend, an accident is enemy", etc. to constantly remind people who
participate on site.
- Not allow the unauthorized people can join in site.

- All workers working on the barge should have lifebuoys.
1.2. Safety in construction

Pape 20
- All workers working on construction sites must be trained about safety in bored pile constructing,
and sign a written commitment not to cause labor accidents.
- On site, everyone must be fully equipped with needful labor protection such as helmet, shoes,
boots, gloves, protective clothing, safety strap, welding glasses, etc consistent with their job
undertaken.
- Beginning and after work shift, workers are required to operate the inspection and maintenance of
the important position of machinery, equipment such as pulleys, winches, cables, check all bolts
screw truss, crane hook, drilling, the circuit breaker cabinet, welding machine, welding wire, check
oil, cooling water of the equipment .etc.
- The shift people absolutely obey the orders of the technical staff or shift leader.
- When repair of electrical appliances, machinery .etc must install dangerous sign, or arrange guard.
Who are unauthorized do not allow standing under when the repairs are on higher. After finished,
must clean all equipment, check carefully before switching on or operating machines (to avoid the
forgotten instruments will fall down when the motor is working can cause danger)
2. Fire protection:
- Site engineer shall be responsible for the fire safety conditions in sector under his charge.
- Establish professional fire fighting teams with members selected from construction workers. This
force is organized to study the basic professional training of the fire protection.
- Before construction works, the site manager and representatives of companies plan to work with
the project management to implement protection supplies and flammable equipment for fire
protection.
- Construction organization supplies and installs fire extinguisher in the site offices, warehouses and
dangerous places such as where to welding, boiler cutting etc.
- No worker can bring flammable substance into the site, no cooking on site.
- In site office must be show the phone numbers of fire extinguish organization for contacting.
- Observe the regulations and technical procedures to ensure the safety of the power.
- Flammable materials must be managed carefully, clearly assigned responsibilities, with specific
rule.
- The commander of fire protection regularly inspects safety equipment and equipped facilities.
3. Ensure regional transport:
- The transportation shall be reasonable, avoid peak hours so as not to cause traffic jams.
- The direction for moving excavated and waste materials will be carefully prepared
- All ways out and enter into the site will be install site signs,traffic signs and traffic instructor when
large vehicles arrive and go out of the site.
Pape 21
- Workers will clean up the waste materials dropped on the road in process of go in and out of site.
4. Hygiene
Problems of environmental hygiene are essential. We will apply the following specific measures:
- Waste water is put into manholes to deposit dirt before discharge to the common area drainage
system.
- Trucks carrying soil, waste materials must be sealed. Soil and waste materials must be poured at
the prescribed place.
- Regularly cleaning, use water trucks to spray the area moist and clean road construction.
- The temporary area must be ensure of hygiene and be removed immediately after handing over
the project.
- The construction equipment and machinery are in order to ensure in good conditions for prevent
noise, emission levels in the limit. Equipment and machinery are licensed for operating and traffic.
- During the construction process must be canvas covered against the dust and noise reduction.
When constructing at night should pay special attention to minimize possible noise.
5. Hazad and treament
5.1.1. Wastewater treatment.
- Wastewater must treatmented by small tank for grount overflow from drilling hole and by pond
for grount overflow from soil during transportation process of soil to dumping ground.
5.1.2. Working Under Raining
- During construction, all activities concerning to electrical work shall be stopped if raining.
- All electric boxes shall be protected by roof to prevent water from entering inside. If concrete
work is being carried out and it rains, activities shall be continued as usual with the plastic covers for
the concrete hooper and concrete mixing trucks.
5.1.3. Tremie Pipe Getting Stuck
- Removing & cleaning inside tremie pipe from bored hole if it is stucked.
- Re-installation the tremie pipe up to level higher than the stopping level of concrete 30cm.
- Starting concrete again same with beginning up to 1m height then tremie pipe will be connected
and make it down 13m. After that, concrete work can be continued until the new concrete level
which is higher than designated one 2m.
5.1.4. Broken Drilling Machine
- Repairing work for broken machine will be carried out immediately by a mechanics.
5.1.5. Diameter and vertical of the bored pile dont meet requierement.

Pape 22
- Using crane to cut the part of soil jutted out by means of moving bucket according to diameter. If
the vertical of drilling hole dose not meet requirement, rotate bucket to cut soil jutted out on the wall
of drilling hole.
- Use casing have length 6m, diameter 1.2m, thickness 12mm to move free in drilling hole.
6.
SECURITY AT SITE
6.1.1. Security system
- The security at site will carry out by 3 security officers assign to present 24/24 h always on site by
shift. They have responsibility to ensure security in the whole of construction site, the commanding
unit, and the construction teams. To ensure safety for all the finishing works. Protect, preserver all
material, equipment in construction site.
- This security team will co-ordinate with the security team of Client, police, and the resident
security team combine to ensure security at around construction area.
6.1.2. The managed security method for the person in construction site
- Crease the detail regulation applied in the construction site and disseminate to whole staff and
worker that participated in construction site.
- Manage the manpower source that enter/out of site: To issue the ID construction card (to
discriminate between the officer and worker of sub-contractor by the different color in the card)
- Assign the working area: to clearly discriminate the scope of working area for each construction
team under the inspection of engineer in charge for construction. Prevent to make chaotic to cause of
not order in site.
- Fence line and lighting: install the fence line and install the light system for sufficient of light for
prevent all of illegal person from outside enter inside the construction area.
- Relation with local authority: All of engineer staff, worker, security officer that stay in
construction site have to register temporary reside with local authority according to Government
Regulation

Pape 23

Construction Method I Girder 25.7m at Longthanh - Daugiay Expressway

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CONSTRUCTION METHOD

Ho Chi Minh, Jan, 2014

CHAPTER 1: GENERAL REGULATION

The introduceded items in bidding document

22TCN 247-98: Standard for Construction and acceptance of

ASTM C1077: Standard Practice for Laboratories Testing

ASTM A 421 91: Tiu chun li thp trn cho b tng d

ASTM 416 - 90a: 7 wires trand standard for prestressed

ASTM A722M-07: Uncovered high strength steel for the

Item 7, section 07400-prestressed concrete

1.2. Construction sequence

Construction method of bearm I 25.7M

Construction method of bearm I 25.7M

Construction method of bearm I 25.7M

II. ORGANIZATION CHART:

Quality control - KCS

Cost Control Engineer

Chief of contruction group

Construction method of bearm I 25.7M

III. CONSTRUCTION SCHEDULE

Tng cng / Total

Nm 2014 / Years 2014

Construction method of bearm I 25.7M

CHAPTER II: MATERIAL

- The proposal for input materials would be listed as follow:

Nghi Son Corp

Sika Ltd (Vietnam)

Tan Dong Hiep Quarry Binh Duong Province

Tan Dong Hiep Quarry Binh Duong Province

Pomina Steel, Hoa Phat Steel

Stell plate (if any)

The Siam Industrial Wire Co., Ltd, ThaiLand

Guizhou Wire Rope(group) co., ltd , China

OVM Machinery Co.,Ltd, China

- Some basic standard of high strength cable:

Construction method of bearm I 25.7M

Standard for bridge design

- Used cement is PCB40.

Construction method of bearm I 25.7M

structure. The coarse aggregates have reasonable dimention and obey

Percentage of passing sieve

Percentage of passing sieve

8. Water : Accoding to TCXDVN - 302-04 specification

- Water for concrete must achieve following parameters:

- We can apply Switzerlands plasticized admixture such as KAO, Bas, Sikament or

plasticized admixture, but it obey technical standard.

- Suitable for use spray or scan equipment.

CHAPTER III: CREAT AND INSTALL FORMWORK

I. CREAT AND INSTALL FORMWORK

Construction method of bearm I 25.7M

1285 713 950

Structure of formwork type 1

Structure of formwork type 2

Construction method of bearm I 25.7M

13kh x 500= 6500

- Shape and dimension

Flatness, smooth surface,

- Formwork bottom flatness. - Visual.

- Squareness of end form

Formworks after installation - Steel measurement

Table 1 Allowable tolerance for completed installation formwork pre-stressed girder

Spacing between vertical supporting shores, inclined supporting shores,

(b) For entire segment