CONSTRUCTION OF EXTENSION OF SOUTHERN EXPRESSWAY

FROM MATARA TO HAMBANTOTA

SECTION 1 FROM MATARA TO BELIATTA
CONTRACT NO: RDA/SEEP/CONTS1
(CH. 00+000 - 30+000 km)

METHOD STATEMENT OF SUPER STRUCTURE

CHINA NATIONAL AERO-TECHNOLOGY INTERNATIONAL

ENGINEERING CORPORATION.

Submitted Date: 20th January 2017

EXTENSTION OF SOUTHERN EXPRESSWAY FROM MATARA TO HAMBANTOTA

SECTION 1 FROM MATARA TO BELIATTA CH 0+000 TO 30+000 KM
Contract No: RDA/SEEP/CONT-S1
EMPLOYER

CONTRACTOR:

ROAD DEVELOPMENT AUTHORITY

CHINA NATIONAL AEROTECHNOLOGY INTERNATIONAL
ENGINEERING CORPORATION.

ENGINEER
CHINA RAILWAY FIRST SURVEY AND
DESIGN INSTITUTE GROUP CO.,LTD

File No:
METHOD STATEMENTOFSUPERSTRUCTURE

Revision No:
Sheet

INDEX
REVISION STATUS
CLAUSE

DESCRIPTION

0.0

INDEX

1.0

PAGE

AIM

2.0

SCOPE

3.0

REFERENCES

4.0

RESOURCE

50

5.0
6.0

DETAIL METHOD OF CARRYING

OUT METHOD STATEMENT
QUALITY ASSURANCE AND
QUALITY CONTROL MEASURES

7.0

HSE MEASURES

51

8.0

MEASUREMENT

54

PREPARED BY

Signature:

Date:

CHECKED BY

Signature:

Date:

APPROVED BY

Signature:

Date:

Content
1.0 Aim .................................................................................................................................................1
2.0 Scope ..............................................................................................................................................1
3.0 Reference ........................................................................................................................................1
4.0 Resource .........................................................................................................................................1
4.1 Responsibility of key staff..........................................................................................................1
4.2 Manpower...................................................................................................................................2
4.3 Equipment and Tools .................................................................................................................2
4.4 Material Preparation ...................................................................................................................3
4.5 Organization chart ......................................................................................................................3
5.0 Detailed method of carrying out method statement .......................................................................4
5.1 Construction technology ............................................................................................................4
5.2 Construction technology process ............................................................................................... 5
5.3 The construction method and operating points in each process ............................................6
5.3.1Construction technology process of End diaphragm,Mid diaphragm construction .............6
5.3.2.Reinforcement .....................................................................................................................7
5.3.3 .Formwork ...........................................................................................................................7
5.3.4 Casting and curing ...............................................................................................................8
5.3.5 Formwork removing ............................................................................................................9
5.3.6.Mid and End diaphragms reinforcement ...........................................................................10
5.3.7. Formwork for cast-in-place diaphragm at ends and middle .............................................11
5.3.8.Checking Calculation of Diaphragm Formwork ............................................................... 17
5.3.9. Safety railings, access arrangement, platforms, and working areas .................................19
5.4 Wet Joint ..................................................................................................................................21
5.4.1.Construction technology process of wet joint construction ..............................................21
5.4.2. Checking Calculation of Wet joint Formwork .................................................................23
5.5 Construction technology process of 40cm cantilever part of flange ........................................25
5.5.1.Construction technology process of 40cm cantilever part construction ........................... 25
5.5.2.Reinforcement for 40cm cantilever part............................................................................26
5.5.3.Formwork for 40cm cantilever part .................................................................................26
5.5.4.Casting and curing of 40cm cantilever part ......................................................................27
5.5.5. Formwork removing of 40cm cantilever part ..................................................................27
5.6.Cross beam ............................................................................................................................... 29
5.6.1.Construction technology process of Cross beam construction ..........................................29
5.6.2. Reinforcement ..................................................................................................................29
5.6.3. Formwork .........................................................................................................................30
5.6.4. Casting and curing ............................................................................................................33
5.6.5. Formwork removing .........................................................................................................33
5.7 .Tension of pre stressed steel of negative bending moment and grouting ............................... 34
5.7.1Construction technology process of tension of pre stressed steel of negative bending
moment and grouting .................................................................................................................34
5.7.2 Beam End Seal Anchor .....................................................................................................37
5.7.3 Safety railings, access arrangement, platforms, and working areas ..................................38
5.8.Guardrail...................................................................................................................................40
5.8.1 Construction technology process of guardrail construction ..............................................40
5.8.2. Preparation for reinforcement .......................................................................................... 40
5.8.3.Form installation for guardrail .......................................................................................... 41
5.8.4. Concreting of guardrail ....................................................................................................42
5.9. Bridge Deck Paving ................................................................................................................44

5.9.1.Construction technology process of bridge deck slab construction ..................................44

5.9.2.Work preparation...............................................................................................................45
5.9.3. Reinforcement for bridge deck slab .................................................................................45
5.9.4. Concrete work for bridge deck slab .................................................................................45
5.10 Technology of installation of expansion joint ........................................................................48
5.10.1 Construction technology process of bridge deck slab construction ................................ 48
6.0 Quality Assurance and Quality Control Measures .......................................................................51
6.1 The control of Materials Source ............................................................................................... 51
6.2 Control in Construction Process ............................................................................................... 51
7.0 HSE measures .............................................................................................................................. 51
7.1 Health measures .......................................................................................................................51
7.2 Safety Measures .......................................................................................................................52
7.2.1Principle of Safety First and Preventative Measures are always taken during the
construction of Cross beamdiaphragmwet joint ,bridge deck system and auxiliary
structures. Comprehensive treatment method is always maintained at the same time. .............52
7.2.2Safety measures of the construction staff ...........................................................................52
7.2.3Safety Measures for Machinery and Equipment. ............................................................... 52
7.2.4.Safety Measure for Electricity Used for Construction ......................................................53
7.2.5Firefighting measures at site. ............................................................................................. 53
7.3 Specific measures taken for environment protection. .............................................................. 53
7.3.1 Noise prevention ...............................................................................................................53
7.3.2 Rain water and waste water ............................................................................................... 53
7.3.3 Flying dusts .......................................................................................................................53
7.3.4 Solid wastes .......................................................................................................................54
7.3.5 Other environmental Issues .............................................................................................. 54
8.0. Measurement ............................................................................................................................... 54

1.0 Aim
This method statement specifies each and every construction activity of the whole process for cross
beamdiaphragmwet jointbridge deck system and auxiliary structure. The method statement
provides the details of the materials, the manpower, the machines, the equipment, the procedure and
relevant document related to these structures. During the whole process, the quality, safety and
environment shall have to be guaranteed and the final products shall have to conform to the design
drawings and technical specifications.

2.0 Scope
This method statement is applied to superstructures construction for cross beamdiaphragmwet
jointbridge deck system and auxiliary structure atviaduct from 0+000-30+000 including steps
fixing reinforcements, erecting formwork, casting concrete, curing tensioninggroutinganchor
seal.

3.0 Reference
The document be reference are appended as follows:
a) The relevant sections of Technical Specification which include;
b) ( Division 550) --- Structural concrete
c) (subdivision 553) --- Pre-stressed concrete members
d) ( Division 700) --- Materials
e) Approved Drawings
f) Workmanship of an experienced contractor
g) Technical instructions provided by the manufacturers for the equipment used in construction
h) Concrete proportion, cement and water proportion for grouting

4.0 Resource
4.1 Responsibility of key staff
Position

Responsibilities

Project Manager

Sets up the estimates, the budgets and the construction timetable for
the client and develops the construction strategy

Structure Engineer

To play a role of technical person for guiding the crafts, operatives and
subcontractor on construction site.
Check out the accuracy of work at regular interval of time in order to
get rid from the future related problems.
To make cost effective plans and procedures for the project. Should be
available at site during the operation.
To guide and work with planners, architects, sub-contractors,
engineers, construction managers and surveyors.
To survey the projects and come out with all requirements needed for
its proper completion.

Site Manager

Material Engineer
Surveyor

Safety Officer

Technical Officer
Supervisor
Foreman
Operators
Signal man

Provides statistical information for quality improvement by identifying

testing methods and samples.
Perform the check on control point traversing, leveling, topographical
survey, cross section and setting-out on the base of methodology and
the data.
Provides accurate survey data to calculation the work done quantity
Provides safety instruction for every working steps and should be
available at site before commencement of T-beam lifting operation.
Should be available at site during the operation.
To be a direct link between management and the work force and can be
most effective in developing job training, safety attitudes, safe working
methods and identifying unsafe acts.
For operating the machinery and equipment.
Issuing instruction for operators when lifting, transporting, erecting
formwork. The person should be qualified who involved the work.

4.2 Manpower
The major manpower used for construction are included, but not limited to the following.
Structural engineer
1 No
Safety Engineer
2 Nos
Technical officer /supervisor/foreman
2 Nos
Signal man
1 No
Operator
2 Nos
Electrician
1 Nos
Mechanic
1 No
Surveyor
1 No
Survey helper
2 Nos
Skilled labors
5 Nos
Notes: All above staff should be available at site during construction, especially safety officer.
The amount of manpower can vary according to site situation.

4.3 Equipment and Tools

The major equipment used for construction are included, but not limited to the following.
Concrete truck mixture
3 Nos.
Concrete batching plant
1 set
Reinforcing steel bending machine
4Nos
Reinforcing steel cutting machine
2Nos
Small cutting machine
2Nos
Chain blocks(5t)
4 sets
ProperVibrator
6 Nos
Survey machines include the total station, level machine etc.
2 set
Three roller paver
2Nos
Water tanker
2Nos
Finishing machine
2Nos
Electric welding machine
4Nos
Electric woodworking saws
4Nos
Derrick crane
2Nos
Trolley
6Nos
Restress tensioning device
4Sets
Grouting device
2Sets
2

Note: All mentioned equipment should be defect free and checked by safety officer, the amount of
equipment can vary according to site situation.

4.4 Material Preparation

The major materials used for cross beam diaphragm wet joint bridge deck system and
auxiliary structure include, but are not limited to the following:
a) Formwork-wood and steel
b) 1cm thickness bamboo plywood
c) Timber:10*10cm,(Sapu wood / Rambutan wood / Pine wood)
d) Timber:5*10cm,(Sapu wood / Rambutan wood / Pine wood)
e) Timber:10*20cm, (Sapu wood / Rambutan wood / Pine wood)
f) Reinforcing steel
g) Prestress tendon
All above-mentioned material shall meet the requirements as follows:
Material sample approved by engineer,
Necessary material stock pile at store and approved by engineer,
Use for the construction works.

4.5 Organization chart

Site manager

Structure engineer

Material engineer

Environment officer

Technical officer

Material technical

Safety officer

Supervisor

Helper

Quantity officer

Skill/unskilled labors
Figure No: 01
Note:
1. Contractors structural engineer, safety manager, safety officer should be available at site during
the operation.
2. Helper and operator should be competent to the operation.

5.0 Detailed method of carrying out method statement

5.1 Construction technology
The material of cross beam, diaphragmand wet joint are high-quality wood formwork or steel
formwork. Theformwork of guardrail is preformed steel formwork, reinforce/consolidation of
formwork is PVC drawbar and square timber according to actual site condition. Reinforcement
processing shall be carried out and situated in completed bridge deck, reinforcement shall be bind at
site. Concrete shall be firstly transported to the required place where is under the bridge deck by
concrete truck mixture, secondly the concrete shall be vertically lifted up to bridge deck by crane,
thirdly concrete shall be horizontally transported to needed place for casting, finally put concrete in
the formwork by concrete pump truck or manpower wheelbarrow. When concrete age gets to 5days
as well as the concrete strength reaches the 36Mpa of design, tension shall start, then grouting and
anchor seal.
The method and procedures for cross beamdiaphragmwet jointbridge deck system and
auxiliary structure will follow the steps below.
Note: The access arrangements, platforms, working areas and safety railings arrangement are shown
in the attached drawing.

5.2 Construction technology process

Installation of T girder

Mid diaphragm, end diaphragm,

construction

Wet joint construction and Edge

beam 40cm cantilever
construction

Cross beam construction

Negative moment tensioning

and anchorage seal grouting

Guardrail construction

Deck slab Construction

Expansion joint construction

Figure No: 02

5.3The construction method and operating points in each process

5.3.1Construction technology process of End diaphragm,Mid diaphragm construction

Reinforcement installation

N
Check

Y
Formwork installation

N
Check

Y
Cast concrete

Curing and remove formwork

Figure No: 03
Note:1.Four panels of end diaphragm if present to underside of infill slab-simultaneously
2.Four panels of midspan diaphragm to underside of infill slab-simultaneously
3.Four panels of 1st span diaphragm to underside of infill slab-simultaneously
4.Four panels of 2nd span diaphragm to underside of infill slab-simultaneously
5.Depending on the specific sequence for diaphragm, pier diaphragm (cross beam) up to top of
girder level

5.3.2.Reinforcement
a) Reinforcement fabrication work will be done at the steel fabrication yard and will deliver to the
site.Reinforcement shall be stocked under the shelter free from the exposure of sunshine and
rain, as well as from getting rusty due to the wetness with the bottom of mortar rubble.
b) Reinforcement will be assembled directly on the bottom f/w after the inspection of the
Engineers representative and before fixing the reinforcement the bottom formwork should be
cleaned and applied with formwork release agent.Loose scale, loose rust, dirt, paint, grease, oil
or others present on the reinforcement shall be removed by wire brushing. Position of the steel
bar is in accordance with the approved drawings.
c) Reinforcement bar will be joined by lapping to each other maintaining the lap length in
according to the approved drawing.
d) All the projected binding wire at the outer surface will be bent in to the cage to manage the
cover spacer.
e) As per design drawings, minimum concrete cover to reinforcement shall be 355mm.
f) Cover block of matching strength and with stainless steel wire should be provided to maintain
the design concrete cover as agreed with the engineer.
g) Upon completion in reinforcement binding, an internal check is done to ensure the work is in
accordance with quality requirements, after which only the consultant is to be informed for
formal joint check. Defects are to be rectified as pointed out by the consultant until satisfying
the design and specifications requirements.
Note: specification and detail drawings for the welding of reinforcement have will be submitted for
the approval.

5.3.3 .Formwork
The formworks will be steel formwork and wood formwork consist of lateral formwork, bottom
formwork, and ending formwork.
a) The formwork will be fixed only after the reinforcement work.
b) Formworks are connected with each other by bolt.
c) As shown on the sketch below, formwork shall be fabricated according to the dimensions of
the approved drawing.
d) And the formwork shall be coated with formwork release agent before installation.
e) Rubber mat or strips will be placed between the steel formwork to prevent leakage of sealing.
f) While the side formwork being installed, the bottom side and up side will be fixed by screwed
bar to control the width of formwork.

g) The level of the formwork can be adjusted by placing an adjustable u-jack at the bottom of the
formwork.
h) Draw bar will be utilized to tighten the two sides of the formworks.
i) Tie bar should be surly fastened before concrete.
j) Foam expansion agent shall be used to seal the holes where the reinforcement reaching out of
formwork or other possible slurry leakages.
After formworks being installed, the position, height, connects joints, alignment and the stability of
the supporting system will be checked by a competent worker with the Engineer.
The material of formwork for Cast-in-place continuous supported end is bamboo plywood or steel
formwork, the size and shape of it is in accordance with precast beam size and shape, which is
convenient for seal. The formwork should be firmly supported/fixed by short steel pipe and timber,
side formwork shall be fixed tight by opposite-tension screw which is covered by PVC hard plastic
pipe. The joint seam position of formwork shall be fixed by double-face glue tape to prevent
mortar leakage when vibrate the concrete.

5.3.4 Casting and curing

a) Rough chiseling shall be carried out at end part of beam before installing precast T Girder,
clean all laitance away from beam contact surface, so that fresh concrete and stone can be
revealed/observed directly, keep 2cm so that joint seam shapes well.
b) Beam installation shall accurately be in accordance with survey and design, in order to make
the width of cast-in-place structure be accurate.
c) Before casting cross beam,the duct of strand should be connected tightly for preventing
leakage. Strands should be cut and fixed into the duct.
d) Reinforcement, formwork shall be inspected and approved by the Consultant prior to
concrete casting
e) Method of vibrating
During the concreting a proper vibrator should be adopted.
f) The mix proportion should be approved by the Engineer
g) Concrete will be ready mixed at batching plant, transported by mix truck and lift by 1.0m3
hopper and directly poured into the formwork.
h) Concrete is discharged from chute and drop along the wing boards at both sides and
concrete is dropped along form surface as shown in the following diagram.
i) Concreteis completed by 30cm-50cm layer by layer.

Concreting
The method of placing concrete of each type of super structure element are as follow.
The concrete shall be transported where needed using pump car or closed bottom dump bucket
which is hanging by the crane. Concrete will be dropped in the forms layer by layer so that no
segregation will occur and no displacement of reinforcement will be caused. The superstructure
element greater than 1.5 meters shall be concreted using chutes, troughs or pipes under steep
slope conditions for avoidance of segregation. All the chutes, troughs or pipe shall be kept clean
& free of harden concrete by flushing with water after each run. Flushing water shall be
discharged outside the forms. (Aluminumchutes,troughs or pipe shall not be used)
Compaction
Concrete shall be compacted by the operation of approved mechanical vibrators within the
concrete and when required vibrating shall be supplemented by hand spading to assure proper
compacted,to force all course aggregate from the surface, to bring mortar against the forms to
produce a smooth finish. Vibration shall be off sufficient duration to accomplish compacted, but
shall not be prolonged to the point where segregation occurs and vibration shall not be used to
cause concrete to flow from point to point within form. The vibrators shall be manipulated in
such a manner that concrete is worked around reinforcement and imbedded features and into
angles of the form.
j)

Curing is done on time after casting finished. After removing the formwork. Cover with the
sackcloth to keep the concrete surface completely wet.

5.3.5 Formwork removing

Side and bottom formwork will be removed in sections after the compressive strength reached.
21Mpa of the requirement of specification: Division 550 (Table 551.8.7)

5.3.6.Mid and End diaphragms reinforcement

Reinforcement for continuous supported end diaphragm:

Figure No: 04
Reinforcement connection for simply supported end diaphragm:

Figure No: 05

10

Reinforcement connection of middle diaphragm:

Figure No: 06
As per the design drawings connect the reinforcement at ends and middle of diaphragm. the length
of welding shall meet the Specification requirement.
Note:The above wet joint reinforcement details of mid diaphragm and end diaphragm are indicating
only. It will be change according to the approved design drawing.
5.3.7. Formwork for cast-in-place diaphragm at ends and middle
The material of formworks for the cast-in-place diaphragm at ends and mid is wood formwork and
steel formwork.
Wood formwork
Side form shall be fixed/supported by opposite-pull screw and PVC hard plastic pipe, Bottom form
is on angle steel which is on 10*10*1cm steel plate of bridge deck wing plate and corner steel 10#
used for fixing formwork.Use 2 raw of16 screw support the bottom form, fix screw, keep form
and precast diaphragm closely attached with each other to prevent grouting leakage.
Steel formwork
side form shall be fixed/supported by opposite-pull screw and hard steel pipe, Bottom form is on
angle steel which is on 10*10cm timberof bridge deck wing plate, use 2 raw of16 screw support
the bottom form, fix screw, keep form and precast diaphragm closely attached with each other to
prevent grouting leakage

11

Steel Formwork-Mid Diaphragm

Figure No: 07

Figure No: 08
12

Wood Formwork- mid Diaphragm

Figure No: 09

Figure No: 10
13

Steel Formwork- End diaphragm

Figure No: 11

Figure No: 12

14

WoodFormwork-End Diaphragm

Figure No: 13

Figure No: 14
15

Figure No: 15

Figure No: 16

Figure No: 17

Figure No: 18

16

5.3.8.Checking Calculation of Diaphragm Formwork

1.General
Bamboo glued plate and rigid formwork will be applied as the formwork of diaphragm . while
bamboo glued plate will be applied as the bottom and side formwork of middle and end
diaphragm,10# channel bar framework will be used for the reinforcing of bottom formwork,
50x100mm and 100x100mm timber will be used for the reinforcing side formwork. For the Bottom
formwork of middle diaphragm, 10# channel bar will be applied longitudinally for the first layer,
and 100x100x10mm angle steel will be laid upon the channel bar. After this step is finished, the
bamboo glued plate will be laid upon angle steel. The specified dimensions are shown in the
drawing of diaphragm formwork.
2.Calculation of lateral pressure of web plate formwork
Lateral pressure caused by the new cast concrete is the main load for the vertical formwork.
Calculation of lateral pressure is performed as follows:
F 0.22 c t 0 1 2V 1 / 2

F cH
The smaller value is taken out of the two.
In the formula:
F---the maximum lateral pressure on the formwork from the fresh concreteKN/m2;
c--- gravity density of theconcretekN/m3and it is 26kN/m3 is taken here
t0---- initial setting time for fresh concrete (h) and it is actually 3 hours. In case of shortage in
testing documents, it is to adopt t0=200/(T+15) for calculations; suppose the concrete
temperature is 250C when pouring into form, i.e.,T=250C t0=5.
V---concrete pouring speed m/h, and it takes 2.5m/hhere;
H----total height from lateral pressure calculation location to the fresh surface top surface (m)
1---- the admixture affecting correction factorit is taking 1 without adding admixture while it is
taking 1.2 with retarder admixture.
2--- factor affecting concrete slump: when slump is less than 30mm, it is taking 0.85 while 1 is
taken when slump is 5090mm and 1.15 is taken when slump is 110150mm.
As per the design drawings, the width of the crossbeam is 50cm, height is 2m and length is 11.5m.
1.1
Calculation of lateral pressure for the form
F 0.22 c t 0 1 2V 1 / 2
=0.22*26*3*1*1.15 *2.5^0.5
=31.2kN/ m2
F c H =26x1.6=41.6kN/ m2
The smaller value is taken out of the two: F=31.2kN/ m2
The effectiveheight: h=F/rc=31.2/26=1.2
3.Calculation of cross brace strength
16 spiral bar will be applied as the cross brace with an interval of 550mm*500mm, of which the
vertical interval is500mm and longitudinal interval 550mm.
Calculation formula of cross brace strength:
FPA28083.1456268.8N
F31.210000.50.558580N
FF, therefore, it is compliance with the requirement.
4. Strength calculation of 10# channel bar of bottom of diaphragm
Concrete load of top plate is q18.51KN/
load caused by the vibrating of concrete q22KN/
Impact load caused by pouring of concrete q32KN/
17

load caused by operation staff, equipment and piling materials q42KN/

so that the total load acted upon the formwork is q14.51KN/.
The linear load acted upon the 10# channel bar is q14.510.811.608KN/m, moment of inertia
of cross section I25.6cm4, moment of resistance of cross section W7.8cm and calculated span
L0.8m.
The strength of channel bar is calculated in accordance with the three-span continuous beam
calculation mode.
Calculation formula of strength:
qL/10W11.608100.8/107.810-6
95.24MPa215MPa, therefore, it is compliance with the requirement.
Calculation formula of rigidity:
WqL4/150EI=11.608100.84/1502.110510625.610-80.63mm
0.59mm3.2mm, therefore, it is compliance with the requirement.
5. Strength calculation of timber
Cross dimension of timber is 50100mm, center point internal of timber L0.5m, load acted upon
timber q 15.6KN/m, moment of inertia of cross section of timber I bh/12 416.67 cm4,
moment of resistance of cross section Wbh2/683.33cm.
Calculation formula of strength:
qL/10W15.6100.5/1083.3310-6
4.6MPa13MPa, therefore, it is compliance with the requirement.
Calculation formula of rigidity:
WqL4/150EI=15.2100.54/1509109416.6710-80.17mm
0.17mmL/1503.3mm, therefore, it is compliance with the requirement.
6. Strength calculation of timber
Cross dimension of timber is 100100mm, center point internal of timber L0.5m, load acted upon
timber q15.6KN/m, moment of inertia of cross section of timber Ibh/12833.33cm4, moment
of resistance of cross section Wbh2/6166.67cm.
Calculation formula of strength:
qL/10W15.6100.5/10166.6710-6
2.34MPa13MPa, therefore, it is compliance with the requirement.
Calculation formula of rigidity:
WqL4/150EI=15.6100.54/1509109833.3310-80.12mm
0.12mmL/1503.3mm, therefore, it is compliance with the requirement.
WqL4/150EI=20.8100.54/1509109416.6710-80.17mm
0.17mmL/1503.3mm, therefore, it is compliance with the requirement.
7. Strength calculation of the bamboo glued plate
The design value of bending strength of bamboo glued plate is 13MPa, thickness of it 15mm,
internal of timber used as formwork support L=0.3m, linear load acted upon the formwork q
15.2KN/m, moment of inertia of cross section of formwork Ibh/1214.063 cm4, moment of
resistance of cross section Wbh2/618.75 cm.
Calculation formula of strength:
qL/10W15.6100.3/1018.7510-6
7.49MPa13MPa, therefore, it is compliance with the requirement.
Calculation formula of rigidity:
WqL4/150EI=15.6100.34/1508.510914.06210-80.7mm
0.7mmL/1502mm, therefore, it is compliance with the requirement.
18

5.3.9. Safety railings, access arrangement, platforms, and working areas

Figure No: 19

Figure No: 20

19

Figure No: 21

Figure No: 22

20

5.4 Wet Joint

5.4.1.Construction technology process of wet joint construction

Bottom formwork installation

N
Check

Y
Reinforcement installation

N
Check

Y
Cast concrete

Curing and remove formwork

Figure No: 23
Note: After completing the construction of diaphragm, wet joint construction shall be start.
The form of wet joint is bamboo plywood of 1cm thick .Longitudinal dorsal bar is 5*10cmcross
dorsal bar is 10*10cm, space is 80cm, use two rows of screw to hang keel beneath the top plate,
cross arm timber is 10*10 square timber, each piece 122cm or 244cm, space is 80cm, tighten the
screw to make form and precast beam flange attach tightly to prevent grouting leakage.

21

As show in the picture:

Figure No: 24

Note:
1.
2.

Figure No: 25

16

mm bars are inserted through the 20mm dia PVC pipe, the hole shall be fill with
approved material .
When casting the wet joints, it leaves the 10cm dia hole (as mentioned in the following figure)
at the top tendon duct area for the stressing purpose. After finished the stressing procedure the
ducts will be casted.

22

Figure No: 26
When binding the rebar of wet joint, concrete chiseling shall be carried out at the precast flange,
bind the hoop reinforcement and lap joint reinforcement of precast beam together, the length of lap
joint shall meet the requirement of design and the Specification. After binding tightly, apply
longitudinal reinforcement.
It is C40 concrete that is used for cast-in-place continuous structure and wet joint, it shall be mixed
at batching plant, and transported by truck mixture,
When concreting, vibrator shall work uniformly, prevent the lack of or too much vibration, make
sure the connection between different layers.
When concrete reach its final setting, curing shall be carried out immediately to keep wet on surface
of concrete. If temperature goes too high, surface of concrete shall be covered. When remove the
form from concrete, shall pay attention to prevent hitting the surface of concrete which will cause
damage on concrete surface. When removal of form is completed, shall inform the Engineer to do
site inspection. Before the Engineers consent, the rectify shall not be done by contractor.
Professional safety officer shall be deployed beneath the bridge when form removal is ongoing, set
safety board and safety tape to prevent form falling accident.

5.4.2. Checking Calculation of Wet joint Formwork

23

1.General
Bamboo glued plate and rigid formwork will be applied as the formwork of wet joint . while
bamboo glued plate will be applied as the bottom of wet joint,100x100mm timber will be used for
the reinforcing bottom formwork. 100x100mm timber will be applied longitudinally for the first
layer, and 50x100mm timber will be laid upon the 100x100mm timber with a 300mm in transverse.
After this step is finished, the bamboo glued plate will be laid upon timber. The specified
dimensions are shown in the drawing of wet joint formwork.
2.loading
Unit weight of concrete: 26KN/m
a.Concrete load of wet joint is q15.2KN/
b.load caused by the vibrating of concrete q22KN/
c.impact load caused by pouring of concrete q32KN/
d.load caused by operation staff, equipment and piling materials q42KN/
The total load acted upon the formwork is q11.2KN/.
3.Calculation of cross brace strength
16 spiral bar will be applied as the cross brace with an interval of 800mm*800mm, of which the
transverse is 800mm and longitudinal interval 800mm.
Calculation formula of cross brace strength:
FPA28083.1456268.8N
F11.210000.80.87168N
FF, therefore, it is compliance with the requirement.
4. Strength calculation of 50x100mm of bottom of wet joint
The total load acted upon the formwork is q11.2KN/.
The linear load acted upon the 50x100mmtimber is q11.20.80.5695.1KN/m, moment of
inertia of cross section I416.66cm4, moment of resistance of cross section W83.33cm and
calculated span L0.8m. The strength of timber is calculated in accordance with the three-span
continuous beam calculation mode.
Calculation formula of strength:
qL/10W5.1100.8/1083.3310-6
3.9MPa13MPa, therefore, it is compliance with the requirement.
Calculation formula of rigidity:
WqL4/150EI=5.1100.84/1509109416.6610-80.37mm
0.37mmL/150=5.3mm, therefore, it is compliance with the requirement.
5. Strength calculation of timber
Cross dimension of timber is 100100mm, center point internal of timber L0.8m, load acted upon
timber q 8.96KN/m, moment of inertia of cross section of timber I bh/12 833.33 cm4,
moment of resistance of cross section Wbh2/6166.67cm.
Calculation formula of strength:
qL/10W8.96100.8/10166.6710-6
3.45MPa13MPa, therefore, it is compliance with the requirement.
Calculation formula of rigidity:
WqL4/150EI=8.96100.84/1509109833.3310-80.32mm
0.32mmL/1505.3mm, therefore, it is compliance with the requirement.
7. Strength calculation of the bamboo glued plate
The design value of bending strength of bamboo glued plate is 13MPa, thickness of it 15mm,
internal of timber used as formwork support L=0.55m, linear load acted upon the formwork q

24

6.16KN/m, moment of inertia of cross section of formwork Ibh/1215.46 cm4, moment of

resistance of cross section Wbh2/620.625 cm.
Calculation formula of strength:
qL/10W6.16100.55/1020.6310-6
9.03MPa13MPa, therefore, it is compliance with the requirement.
Calculation formula of rigidity:
WqL4/150EI=6.16100.554/1508.510915.4610-82.85mm
2.85L/1503.6mm, therefore, it is compliance with the requirement.

5.5 Construction technology process of 40cm cantilever part of flange

5.5.1.Construction technology process of 40cm cantilever part construction
Bottom formwork installation

N
Check

Y
Reinforcement installation

N
Check

Y
Side Formwork Installation

Cast concrete

Curing and remove formwork

Figure No: 27
25

Note: 400mm edge cantilever part has to be cast before the pier cross beam is cast and stressed
5.5.2.Reinforcement for 40cm cantilever part
a) Reinforcement fabrication work will be done at the steel fabrication yard and will deliver to the
site.Reinforcement shall be stocked under the shelter free from the exposure of sunshine and
rain, as well as from getting rusty due to the wetness with the bottom of mortar rubble.
b) Reinforcement will be assembled directly on the bottom f/w after the inspection of the
Engineers representative and before fixing the reinforcement the bottom formwork should be
cleaned and applied with formwork release agent.Loose scale, loose rust, dirt, paint, grease, oil
or others present on the reinforcement shall be removed by wire brushing. Position of the steel
bar is in accordance with the approved drawings.
c) Reinforcement bar will be joined by lapping to each other maintaining the lap length in
according to the approved drawing.
d) All the projected binding wire at the outer surface will be bent in to the cage to manage the
cover spacer.
e) As perDesign drawings, minimum concrete cover to reinforcement shall be 355mm.
f) Cover block should be provided to maintain the design concrete cover as agreed with the
engineer.
g) Upon completion in reinforcement binding , an internal check is done to ensure the work is in
accordance with quality requirements, after which only the consultant is to be informed for
formal joint check. Defects are to be rectified as pointed out by the consultant until satisfying
the design and specifications requirements
h) Reinforcement bar, which belongs to the deck, guard wall, should be fixed before concrete
i) Pipe of drain should be embedded according to the approved design drawing.
5.5.3.Formwork for 40cm cantilever part
The formwork for guardrail will be fixed only after the reinforcement work.
a) Formworks are connected with each other by bolt.
b) As shown on the sketch below, formwork shall be fabricated according to the dimensions of
the approved drawing.
c) And the formwork shall be coated with formwork release agent before installation.
d) Rubber mat or strips will be placed between the steel formwork to prevent leakage of sealing.
e) While the side formwork being installed, the bottom side and up side will be fixed by screwed
bar to control the width of formwork.
f) The level of the formwork can be adjusted by placing an adjustable u-jack at the bottom of the
formwork.
g) Draw bar will be utilized to tighten the two sides of the formworks.
h) Tie bar should be surly fastened before concrete.
26

i) Foam expansion agent shall be used to seal the holes where the reinforcement reaching out of
formwork or other possible slurry leakages on concreted faces.

After formworks being installed, the position, height, connects joints, alignment and the stability of
the supporting system will be checked by the specified worker with the Engineer
5.5.4.Casting and curing of 40cm cantilever part
a) Rough chiseling shall be carried out at end part of beam before installing precast T Girder,
clean all laitance away from beam contact surface, so that fresh concrete and stone can be
revealed/observed directly, keep 2cm so that joint seam shapes well.
b) Before 40cm cantilever part the duct for drain should be keep and reinforcement, formwork
shall be inspected and approved by the Consultant prior to concrete casting.
c) Method of vibrating
During the concreting a proper vibrator should be adopted.
d) The mix proportion should be approved by the Engineer
e) Concrete will be ready mixed at batching plant, transported by mix truck and lift by 1.0m3
hopper and directly poured into the formwork.
f) Concrete is discharged from chute and drop along the wing boards at both sides and
concrete is dropped along form surface.
g) Concreteis completed by 30cm-50cm layer by layer
h) Curing is done on time after casting finished
5.5.5. Formwork removing of 40cm cantilever part
Side and bottom formwork will be removed in sections after the compressive strength reached.
21Mpa of the requirement of specification: Division 550 (Table 551.8.7)

27

Steel formwork-40cm cantilever part of flange

Figure No: 28
When casting the 40cm cantilever part, it should be embedded the drainage pipe as mention below.
Note: The following drains details are indicate only. The drainage details will be according to the
approved design drawing

Figure No: 29

28

5.6.Cross beam
5.6.1.Construction technology process of Cross beam construction
Reinforcement installation

N
Check

Y
Formwork installation

N
Check

Y
Cast concrete

Curing and remove formwork

Figure No: 30
5.6.2. Reinforcement
All the reinforcement work shall be carried out according to 5.3.2
When carry out the reinforcement installation, the reinforcement of Cast-in-place cross beam shall
be matched one-to-one with the reserved reinforcement of precast beam, single-face welding or
double-face welding will be applied to it, the minimum length of welding shall be according to the
specification or the details of approved drawings, and should be high-quality /fully welding. If the
length of lap joint of reserved main reinforcement is not enough for welding, an additional rebar
shall be used for rod welding. Other reserved rebar shall be straightening and bind with lap joint,
the length of lap joint shall be in accordance with design. Pay attention to theembedded
reinforcement of guardrail.

29

Reinforcement connection is shown as follows:

Figure No: 31

Figure No: 32
When reinforcement installation is complete, connect the negative bending flat corrugated pipe
according to the actual site condition, pay attention to the wrapping and sealing of joint position.
First put steel strand through pipe duct, second repeatedly twitch the steel strand before initial set of
concrete to prevent adhesive of Slurry.
5.6.3. Formwork
All the formwork shall be carried out according to the 5.3.3
Cross beam formwork is shown as follows

30

Steel formwork-Cross beam

Figure No: 33

Figure No: 34
Checking Calculation of cross beam
Due to small quantity of concrete volume in diaphragm and large quantity of concrete volume in
crossbeams, this calculation is based on crossbeams as the example. The formwork for the
diaphragm conforms to requirements in case formwork for crossbeams conforms to requirements.
31

1. Calculation of lateral pressure

Calculation of lateral pressure is performed as follows:
F 0.22 c t 0 1 2V 1 / 2

F cH
The smaller value is taken out of the two.
In the formula:
F---the maximum lateral pressure on the formwork from the fresh concreteKN/m2;
c--- gravity density of theconcretekN/m3and it is 26kN/m3 is taken here
t0---- initial setting time for fresh concrete (h) and it is actually 3 hours. In case of shortage in
testing documents, it is to adopt t0=200/(T+15) for calculations; suppose the concrete
temperature is 250C when pouring into form, i.e,T=250C t0=5.
V---concrete pouring speed m/h, and it takes 2.5m/hhere;
H----total height from lateral pressure calculation location to the fresh surface top surface (m)
1---- the admixture affecting correction factorit is taking 1 without adding admixture while it is
taking 1.2 with retarder admixture.
2--- factor affecting concrete slump: when slump is less than 30mm, it is taking 0.85 while 1 is
taken when slump is 5090mm and 1.15 is taken when slump is 110150mm.
As per the design drawings, the width of the crossbeam is 50cm, height is 2m and length is 11.5m.
2.Calculation of lateral pressure for the form
F 0.22 c t 0 1 2V 1 / 2
=0.22*26*3*1*1.15 *2.5^0.5
=31.2kN/ m2
F c H =25x2=50 kN/ m2
The smaller value is taken out of the two: F=31.2kN/ m2
The effectiveheight: h=F/rc=331.2/26=1.2
The standard value of horizontal load generate by pouring concrete: 4.0 kN/ m2
Considering above, the lateral pressure of the concrete is 31.2KN/m2, less than the design value of
60KN/m2.
2 Calculation of vertical pressure
F= rc x h=26x2=52KN/m2
3. Calculation of form
Construction height of the form is 2m. The face plate is made of steel plate, which is 1500mm long,
600mm wide and 3mm thick. The back side is made of squared steel plate with rib. The entire
thickness of form is 5cm. On the form, D16 bars are installed with interval of 500mm x700mm.
Checking calculation of form strength
Line load on the face plate q1 ql =52x1=52N/mm
2
Maximum bending moment of face plate M max q1l 10
=52x1500x1500/10=11.7x106Nmm
1
2
Section factor of face plate W bh 6 = 6 x600x502=250x103mm3

Stress M max W =11.7x106/250x103=46.8N/mm2< f m =215 N/mm2

Requirements are met.
32

In the equation, f m --steel anti-bending strength design value is 215 N/mm2

4. Calculation of split screw
Split screw is made of D16 screw, with vertical interval of 700mm and horizontal interval of
500mm.
Empirical formula of Split screw is N A f
N--- Design value of tensile force which the Split screw bears. Normally it is the lateral pressure of
concrete.
A--- Net cross section area of Split screwmm2A=200mm2
f -- Tensile strength design value of Split screw f 320 N/mm2
NN=1*31.2KN
Af=200 mm2x320 N/mm2=64KN>48KN
Therefore, requirements are met.
5.6.4. Casting and curing
All the casting and curing work shall be carried out as per the 5.3.4
5.6.5. Formwork removing
All the casting and curing work shall be carried out as per the 5.3.5

33

5.7 .Tension of pre stressed steel of negative bending moment and grouting
5.7.1Construction technology process of tension of pre stressed steel of negative bending
moment and grouting
Let the strengthen of mid diaphragm, end
diaphragm cross beam at concrete strength
36Mpa or 5 days after concreting

Request

Tensioning

Request

Grouting

Engineer supervision

Engineer supervision

Anchorage seal
reinforcement installation

N
Check

Y
Formwork installation

N
Check

Y
Cast concrete

Curing, remove formwork

Figure No: 35
Note: 1.After cross beam construction, the stressing and grouting procedure of top tendon shall
start.
2.All references to the strength of concrete relevant to top tendon stressing should refer to
site cured cube.
34

Stressing sequence
1.The longitudinal tension sequence of T-girder and casting sequence for cross beam

Figure No: 36

3
2
1
2
3

3.Stressing strands first in T3 and T4 in a symmetrical manner,then stressing strands in T1 and T2

then in the same way

Figure No: 37
35

4.Single line tension sequence

Figure No: 38
Note:1.stressing procedure is mention as ,,
2.The stressing record sheet will be submitted for the approval.
When cast-in-place concretestrength reaches 36Mpa of design and age reaches 5days, start tension
of prestressed steel of negative bending moment. Use OVM-YDC240QX 24tons jacks for singlepiece and single-end tension, one by one, first tension for long steel (T3 and T4), second tension for
short steel (T1 and T2), middle steel goes first, left and right steel go second.
Before install work anchor, first check flat anchor and asperities around, clean them, then install
work anchor, then install clip, fix tightly, then install jack and work anchor, work anchor and clip
should be waxing for the convenience of making rectify and removal.
When tension, pay attention to pre-stress control, elongation check. Efficacy checking and matching
for jack and oil meter to guarantee the correct relationship of tensioning force and oil pressure for
the purpose of controlling the stress. Classification for tension amount and take elongation,
classification is shown as follow:
020%coninitial stressAmount of elongation50%conAmount of elongation100%
conAmount of elongationoil back to 0.5MPaAmount of elongation.
Actual Amount of elongation X compare with theory Amount of elongation average the
difference is within6%X6%.
The tension control stress of negative bending moment and theoretical extension value as follows:

When Prestress rebar tension anchor fix/seal is complete, duct grouting shall be carried out.
36

Mix design which has been approved by the Engineer shall be used, before grouting, clean duct,
make it dry, clean again, grouting.
Continuation method shall be used for making/mixing cement grout. Grouting pump shall be used,
consistence of cement grouting shall be in accordance with Specification design requirement.When
grouting, start from lowest position, it shall be slow, uniform, continuous going in same duct,
complete in one time. When out coming grout reaches the same consistence with the incoming
grout, use valve to seal the grout outgoing place, again start press grouting machine until the
pressure is measured reaches 0.7Mpa.
Note: Grouting is done within 10 days after tensioning.
In order to guarantee corrugated pipe is fully grouted, grouting inlet position shall be sealed. All
valves shall be sealed until the initial setting of cement grouting.
Each time when grouting is complete, clean water shall be used to clean mixture machine and
grouting pump, clean them again at the end of a work day.
When mix grout, each time randomly make grouting standard testing cube(50mm*50mm*50mm),
Total cube should be 9 pieces. Send the cube to lab for standard curing, in order to test the 28-day
strength. When grouting, make grouting record and pay attention to the safety.
5.7.2 Beam End Seal Anchor
When tension and grouting are complete, seal anchor work shall start. Precast T girder beam end
seal anchor work shall be complete before lifting the precast beam in position.
Negative bending moment seal anchor shall be complete before prepared hole of wet joint
concreting.
Check chiseling, make sure chiseling fully, clean chiseling concrete surface. As per the design
requirement install, bind and weld the reinforcement of sealing anchor,
When reinforcement installation is complete, formwork installation/erection starts. The material of
formwork of anchor sealing is high-quality bamboo plywood, all connection seam of the formwork
shall be fixed by double-face glue tape to prevent leakage which will influence the look of concrete.
And provide supporting to avoid any break causing the concrete. Formwork top open level shall be
5cm higher than anchor seal level, in order to make it convenient to be casting fully.When
formworks are removed, cut and clean the concrete smoothly by manpower.
Seal Anchor concreting shall be done by manuallyand compaction shall be done by hand spading as
it is in under the flange.
When concrete initially set, curing work shall start immediately and it shall keep not less than 7
days. When doing curing, firstly apply water on concrete surface, secondly use geotextile to cover
concrete surface, or apply curing agent, tomake sure the surface of concrete always keeps wet.

37

5.7.3 Safety railings, access arrangement, platforms, and working areas

Figure No: 39

Figure
38 No: 40

Figure No: 41

Figure No: 42
39

5.8.Guardrail
5.8.1 Construction technology process of guardrail construction
Reinforcement installation

N
Check

Y
Dowel bar and joint filler

Formwork installation

N
Check
Y
Casting concrete

Curing and remove formwork

Figure No: 43
Note: After stressing and grouting procedure of top tendon, the guard rail construction shall start.

5.8.2. Preparation for reinforcement

Deploy worker to chiseling on beam head and flange, chisel away cement mortar and
unconsolidated layer, use water to wash it, and make concrete surface clean.
In order to make beam top elevation is accordance with design, before starting the guardrail
construction.
Before installing reinforcement, beam surface shall be cleaned, chiseling laitance away, use water to
wash it clean. Then, according to the set up data, by running a line position and elevate the
40

reinforcement accurately. According to the drawing, bind the reinforcement, control the quality
according to the bridge specification. When construction is ongoing, pay attention to the controlling
of reinforcement top elevation and shape.
Installation of reinforcement protective cover. Cushion block of protective cover is made by
concrete, it is 35mm thick, set in quincuncial shape, bind and fix concrete block on reinforcement,
to prevent the position change of protective block when install form.
5.8.3.Form installation for guardrail
Size of form shall be infirmity with design, with enough strength and rigidity, and convenient to be
remove.
Template trial: rail body form is standard type steel form; different pieces shall be connected with
flange plate bolt. When forms are transported to position, experimental installation shall be started
to check the whole effect, rectify, then start to formally use the form.
Form installation: use self-made gantry to lift and install form. Both inside and outside form shall
attach concrete bottom base and be supported and fixed by stay bolts, at both bottom and top two
stay bolts shall be set, 80cm distance. Check the form when installation is completed, such as size,
position, support point and elevation. If there are any defect observed rectification shall be carried
out. The form shall take waterproof measurement to prevent leakage.
When concrete is ongoing, shall arrange people to observe and check support of the form. If any
defect is observed the rectification shall be carried out.
Note: Location of joint in guard rail will arrange as per the approved design drawing.
Installation of Guardrail form.

Figure No: 44
41

Figure No: 45
5.8.4. Concreting of guardrail
Concrete truck mixture or concrete pump truck shall be used for casting which shall be cast layer by
layer from bottom to top as per the requirement of the Specification and the Engineer.
Porker vibrator shall be used for vibration. In order to ensure new concrete layer and previous
concrete layer are connected well, vibrator shall not touch form when working. In order to prevent
hole, it shall be quick plug and slow pull so that the concrete will be dense.
When concrete is ongoing, shall arrange people to observe and check support of the form. If any
defect is observed the rectification shall be carried out. Make concrete test sample as per the
Specification.
When concrete is completed and the strength reach the requirement of Specification, remove form,
cover geotextile and linen, then watering and keep concrete surface wet, concrete curing shall not
less than 7days.
The concrete of guardrail shall be divided to two times, first time, concrete 40cm of Cantilever part
of flange, second time, complete the whole guardrail concrete.

42

As shown in the picture:

Figure No: 46

Figure No: 47
Note: The reinforcement of the deck slab and the guard rail will arrange as per the approved design
drawing.
43

5.9. Bridge Deck Paving

5.9.1.Construction technology process of bridge deck slab construction
Reinforcement installation

N
Check

Y
Left and right side elevation
control belt formwork
installation

N
Check

Y
First cast 500mm elevation
control belt

Curing and remove formwork

After 5 day casting, cast middle

section of deck slab

Curing
Figure No: 48

Note:1. 100mm deck slab to 1stspan to say 2000mm from any internal pier.
2. Deck slab to 2ndspan ending with the section over the completed pier diaphragm.
44

5.9.2.Work preparation
Before bridge deck paving, full survey shall be carried out for bridge deck top elevation, each 5m
one cross section, each cross section shall include not less than 3 point, to make thickness of paving
is enough. Before the installation of bridge deck steel net, fully chiseling beam to clean oil, scum,
laitance and other object, then use high-pressure water gun to clean surface, ensure the attach
between bridge deck pavement and base surface.
5.9.3. Reinforcement for bridge deck slab
The paving position of ridge deck steel shall be in conformity with design, especially that the
thickness of protective layer shall be enough. The Reinforcement net of bridge deck concrete
pavement shall be vertically supported by reinforcement pier made of 12 reinforcement, distance
80x80cm, support reinforcement and paving reinforcement shall be connected by welding, bridge
deck paving reinforcement shall be flat; Bridge deck paving reinforcement shall be breaking only at
expansion joint, and shall be fully set at bridge deck continuous structure. The binding location of
bridge deck reinforcement net shall be accurate and uniform; reinforcement binding shall be in
conformity with design
5.9.4. Concrete work for bridge deck slab
Concrete elevation control belt
Install form at the inside bottom of guardrail, as per the survey of elevation control belt, use
concrete as same as the one used for bridge deck paving, concrete elevation guardrail side width
100cm. When the top surface of elevation control belt floating is ongoing, pay attention to the
bridge deck transverse slope. Concrete elevation control belt shall depend on the bridge deck paving
design, discrepancy shall be controlled within 5mm, as the rail of three rolling vibration beam,
then paving layer shall be all concrete at one time.
Concrete elevation control belt:

45

Figure No: 49

Figure No: 50
Note: First cast the 500mm wide cast-in-situ concrete area as Elevation control Belt in both edge
as mention above figure by maintaining design slope for the purpose of control finish level of
100mm deck slab. Three roller drum is used for level the finish surface
.
46

Concreting
Within the contract section, C40 concrete shall be used for all bridge deck paving, thickness is
10cm, Concrete truck mixture, concrete pump and three roll vibration beam shall be used for
construction.
When Reinforcement net binding is completed, installation of three rollers shall be commenced on
concrete elevation belt, then concreting.
The concrete of bridge deck paving shall be made by batching plant of automatically quantity
survey, transported by concrete truck mixture, paved by concrete pump, vibrated by three-roller
vibration beam and poker vibrator, leveling by three-roller drum.

Technological process:
concrete mixing, transportation, paving vibration by poker vibrator, plate
vibratorslurryleveling by three-roller static placing for 3 hours ( depend on environment
temperature, concrete slumps.etc ) plaster galling and scuffingkerfswatering and curing
filling and seaming finished product protection
Static placing for 3 hours(depend on environment temperature, concrete slumps.etc ) to keep
concrete stay in critical initial setting period, then start manual plaster. Skilled worker shall be
deployed, it is prohibited to work directly on surface of concrete, the work stage that can bear many
people and move conveniently shall be specially made, when stage is moving it is prohibited to
touch and damage concrete surface.
In order to keep roughness on surface of bridge deck, when plaster is finished, use finger to press on
it, when 2mm deep depression can be observed then it is the best time for galling and scuffing, use
plastic sweep for galling, horizontally, uniformly, depth shall be 12mm.
When compressive strength of concrete reaches 510Map, kerfing (joint cutting)shall begin, it is
prohibited to delay, otherwise concrete surface cracks. It is also prohibited to be untimely,
otherwise sawtooth print will occur. Before kerfing, electricity resources, water resources, and
cutting machine shall be checked.
When concrete galling successfully shaped up, it shall be covered by geotextile and water-retention
material. At the beginning of curing period, dont use too much water, sprayer can be used. When
concrete is final setting, soaking can be used for curing. Curing will be more than 7days.

47

5.10 Technology of installation of expansion joint

5.10.1 Construction technology process of bridge deck slab construction

Cleaning

Expansion joint installation

Formwork installation

N
Check

Y
Cast concrete

Curing and remove formwork

Figure No: 51
a) Preparation for construction
All expansion tool, accessory material, equipment for expansion joint construction shall be
transported to site before the start of construction.
b) Clean
The joint surface shall be cleaned, chiseling laitance away, in order to make firm connection
between new concrete and beam body.
Air compressor or high-pressure water gun shall be used to clean concrete scrap and dust. Check the
length, width and depth in conformity with the design drawings.
48

c)Setting-Out
As per the requirement of design, at reserved installation area for expansion equipment, mark
accurately the edge position of joint, and draw the line, then installing the equipment as per the
design drawings and Specification.
d)Expansion Joint Installation
Check the reserved reinforcement, and make it flat and uniform. According to the actual dimension
of reserved reinforcement, make detailed statement method of expansion joint body.
If there is no reserved rebar in notch or the location of reserved rebar is not correct, insert rebar
shall be used to increase the strength. The location, type, amount, fix depth, pull resistance, etc. all
need to be in conformity with design.
When fixing the connecting rebar and reinforcement rebar, they shall not higher than road pavement,
concrete protective layer shall be remained more than 2.5cm. following details are further clarity.

Figure No: 52

49

Gap setting details are as follow

Figure No: 53

Figure No: 54
50

e) Installation of Form And Rubber Water-Proof Belt

As per the requirement of design, install formwork between the angle steel and beam end at both
sides of structure joint, use iron wire to bind and fix formwork firmly(the type of iron wire is
No.14). Mortar (or linen) shall be used to fill the gap ( joint) of different forms. Ensure the
strength and density when concreting.
Installation of expansion rubber water-proof belt. Install the belt on the socket of angle steel in the
mid of bracket.
f) Concreting with grade 50
Before concreting, recheck the formwork, to prevent the form expanding and leakage.
The concrete will be mixed by batching plant, transported by truck mixture, put concrete in notch
from two side of it gradually, use internal vibrator to vibrate uniformly, quick plug and slow pull.
When concrete complete and initial set starts, concrete shall be covered by blanket or straw,
regularly watering and curing, keep wet. During the curing, vehicle and people are prohibited to
enter the construction area to prevent concrete surface damage.

6.0 Quality Assurance and Quality Control Measures

6.1 The control of Materials Source
a) Formwork: implement construction as per Section 551.8.2 in Technical Specifications for
complete check to ensure there is no quality issue.
b) Reinforcement: check the length, dimensions and shape to confirm it is matching with design
demands and it is not seriously corroded.
c) Concrete: implement construction as per Section 551.4.2 in Technical Specifications.

6.2 Control in Construction Process

a) Fixing position for the reinforcement and formwork must be done as per the design drawings.
The forms shall be cleaned of all debris immediately prior to placing concrete, and surfaces not
oil treated shall be wetted.
b) Concrete must be properly casted to avoid quality defects,Sampling and testing should be
performed by the Contractor and under engineers supervising
c) Vibrating: Concrete shall be compacted by the operation of approved mechanical vibrators
within the concrete.Vibration shall be of sufficient duration to accomplish compacted but shall
not be prolonged to the point where segregation occurs. Vibration shall not be used to cause
concrete to flow from point to point within forms.

7.0 HSE measures

7.1 Health measures
1. Healthy employees able to normally carry out work are employed for construction activities;
2. Before construction, the personal safety equipment are checked to be adequate and staff with
inadequate equipment must be supplemented;
3. Provide a good working environment to minimize dust, noises and toxic airs so as to minimize
the harmful factors to human health. If it is impossible to remove these hazards thoroughly, working
hours are to be reduced and working way is to be changed as preventive measures.
4. Avoid sunstroke in high temperatures by minimizing construction during mid-noon high
temperature period. The site is allocated with medicines and heat reducing devices;
51

5. Dining hall, washroom and toilets are established for hygiene purpose.
Set up first aid boxes and regularly supply medicines at site.
6. People with acrophobia, heart diseases, high blood pressure, epilepsy and anemia, or the old
weak people, are not allowed to perform height operations.

7.2 Safety Measures

7.2.1Principle of Safety First and Preventative Measures are always taken during the
construction of Cross beam diaphragm wet joint ,bridge deck system and auxiliary
structures. Comprehensive treatment method is always maintained at the same time.
7.2.2Safety measures of the construction staff
All staff, administrators, visitors, surveying staff and supervising staff involved in operations are
required to wear safety helmets, safety shoes and safety jackets. Slippers are prohibited at the
construction site.
All operators for must be licensed for performing the assigned work.
These who plan to go high platforms must wear safety belts.For height platforms which have staff
often to work for construction purpose must be stabilized in establishment, and stairs, guardrails and
safety nets must be provided in accordance with safety requirements
Fixing and removal of forms shall have to follow the required procedure strictly as commanded by
specially assigned personnel. Standing under the form is prohibited to avoid any injuries caused by
overturning of form.
Non authorized personnel not involved in construction are not allowed to enter construction site.
No personnel is allowed to stand under the cranes in lifting or running operations and no one is
allowed to go up or down using lifting hook.
When carrying out work, all construction personnel must be clear with their own division of labor,
the staff and designation must be fixed for fixed machineries and all personnel should properly
follow instructions of the technical staff and the commanding staff.
Meanwhile, management staffs correct management shall have to be followed.
Site commanding staff must use signal flag for commanding purpose, and all oral instructions from
the commanding staff must be clear and movements must be standard and specific.

7.2.3Safety Measures for Machinery and Equipment.

All machinery and equipment must be checked and maintained by necessary testing by specially
appointed personnel to guarantee the good working conditions.
All skilled labors are required to attend the professional training to understand and master the
operational procedure and technical points to avoid improper operations.
Regular safety checks are done for the height operational facilities, machinery and equipment and
barricade for warning purpose is established at the height operation area.
Materials piled at height platforms are to be stabilized safely and tools are placed inside toolboxes
and passing of materials should be safe, reliable while prohibiting throwing.
Machineries are maintained periodically and machineries are clean, greased, tightened, adjusted and
corrosion free before, during and after using. Overrunning of machinery is prohibited, repairs
during operation and running in broken conditions are not allowed.
Safety course shall be attended by drivers and driving without licenses or drunk driving is
prohibited absolutely.
Before concrete construction, batching plant, power supply cables and lifting components are
checked to be in proper working conditions.
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7.2.4.Safety Measure for Electricity Used for Construction

1. Wiring and equipment fixing follow strictly relevant regulations and they are properly earthed.
2. Disqualified gas or electricity equipment are prohibited in use.
Site lighting: cable insulation is maintained well for lighting and wires cannot be dragged randomly
on ground or tied to the false work. Metal cover for lighting must be connected to null line.
3. Management in electricity use: installations, repairs and removal of temporary electricity is done
by professional electricians who is licensed. Switches are water proof and safety stable and earth
leakage protective device is provided. All are to be checked regularly.
4. Cables for all cranes shall have to be checked before use and disqualified cables are not allowed
in use.
7.2.5Firefighting measures at site.
1. Electricity use is carefully managed at site to prevent any electricity fire disaster. Firefighting
equipment is provided nearby the work sheds and store houses and regular checks are carried out.
2. Welding and cutting operations shall be minimum 10m from the oxygen and acetylene cylinders
and minimum 30m are maintained from flammable and explosive materials.
3. During lifting by gantry crane, no one is allowed to stand within the lifting radius and signalman
is appointed for commanding the operations. Adequate lighting is provided during nighttime
operations.

7.3 Specific measures taken for environment protection.

Measures for environment protection must follow regulations of EMP
7.3.1 Noise prevention
Source of noises
When the gantry crane moves along the rails;
Other equipment such as loader, concrete truck mixer and mobile cranes are at site for
construction.
Measures taken for prevention purpose:
Maximally use the low noise machineries and equipment for operation, and all machineries
and equipment are to be maintained and serviced regularly using proper greases for smooth
operations to minimize noises;
Educate the construction site workers to minimize human noises during construction
7.3.2 Rain water and waste water
Sources of rain water and waste water.
Ground rain water by rainfalls.
Water from water bowser when watering for dust mitigation.
Water from washing construction machineries.
Measures taken for prevention purposes:
Hardening the road surface area by concrete taking into consideration of flow direction and
slope so that water can be drained off to the drains at both sides;
Wash area is established close to sedimentation basin so that the waste water from washing
tools and machineries is drained off to the sedimentation basin punctually.
7.3.3 Flying dusts
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 Sources of flying dust

The major reason for flying dust is due to the vehicles passing through the access road,
causing flying dusts.
Measures taken for dust mitigation:
The ground is to be cleaned and cleared regularly to keep it clean;
Watering is carried out in sunny weather to minimize the dust by water bowsers;
Fine particles are covered with canvas to prevent dusts
7.3.4 Solid wastes
A solid waste tank is built in the beam yard and the location for girder erection for the loader to
collect the solid waste generated from construction, and the solid waste is stockpiled at the tank and
cleared and disposed at the designated place.
7.3.5 Other environmental Issues
Rain shelters are built for the storage area for reinforcements so that the rusts can be prevented to
pollute the ground from rain water corrosion.
All fuels and chemicals should be stored in warehouse properly and used carefully to avoid flowing
into nearby water sources.
It is prohibited to burn the linoleums, rubbers, plastics, leathers, weeds and other poisonous and
harmful smokes and gaseous substances.
Machineries and equipment should be maintained well for smooth operation to minimize exhaust
emissions.

8.0. Measurement
The measurement shall be determined in accordance with the clause 551 of technical specification
and under pay items given below.
551

551.009

Structure Concrete
Class 40/20 concrete
Decks,crossbeam,and diaphragms
Class 30/20 concrete
Parapet
Formwork
Wrought formwork

551.010

Sawn formwork

552

Reinforcing steel

552.001

Reinforcing steel bar

562

Preformed Elastomeric Joint Sealer

562.002

Expansion joint

600.002

Bridge Drainage Pipe PVC 200mm

P.V.C.pipe 75mm dia
P.V.C.pipe 110mm dia (on Bridge)

Steel Dowel 25mm

Nr

551.001
551.002

600.006
600.008

Cu.m
Cu.m
Sq.m
Sq.m
Kg

54

m
m