Doc No:

SIMPANG JAM Method Statement

Rev. No.: 0
FLY OVER
PROJECT Date :02-02-2017
Load Test for Form Traveller

Table of Contents

Section Description Page

1.0 General 2
2.0 Purpose 2
3.0 Loading Simulation on the Main Frames 3-5
4.0 Work Procedure for Load Test 6-8
5.0 Inspection & Evaluation 8

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 Doc No:
SIMPANG JAM Method Statement
Rev. No.: 0
FLY OVER
PROJECT Date :02-02-2017
Load Test for Form Traveller

1. General
DSI form traveler has been widely used in balanced cantilever bridge construction. It’s
effectivity, efficiency and adaptability has been tested through over 300 units of balanced
cantilever projects in Taiwan, Philippines, Malaysia, Vietnam, Indonesia, and some other parts
of Asia.
Under normal circumstances, DSI form traveler doesn’t require a load test. The traveler
configuration is derived based on the bridge design and the test is done on the jobsite by actual
pouring of concrete during construction.
However, upon request of the client, a load test can be done before installation. This test can be
carried out either on the ground at jobsite or at the work shop.

2. Purpose
The purpose of the load test is to prove that the form traveler can withstand the actual load
during construction. Deformation of the main frames shall also be checked during the test. This
document presents the simulation of the actual loading during construction into the load test and
the procedure on how the load test is to be carried out.

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 Doc No:
SIMPANG JAM Method Statement
Rev. No.: 0
FLY OVER
PROJECT :
Date :02-02-2017
Load Test for Form Traveller

3.0 Loading Simulation on the Main Frames

3.1 Worst Load Case

The maximum load case for Simpang Jam Fly Over is at segment 6 where the wet concrete
weighs 160 tons.

3.2 Actual Loading of the Form Traveler

In actual site condition, the concrete (160T)
( will be poured to the formwork which hangs at
the back from the previous concrete and at the front from the form traveler. The simplified
figure below shows how the concrete weight plus the weight of the formwork is shared
between the back and the front hanger
ha bars.

160T

0.5M 4.5 M
1.1M 82.13 tons
97.87 tons
6.1M

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 Doc No:
SIMPANG JAM Method Statement
Rev. No.: 0
FLY OVER
PROJECT Date :02-02-2017
Load Test for Form Traveller

Wc = weight of concrete
Wf = weight of all formwork
R1 = the load to be carried by the form traveler
R2 = the load to be carried by the previous concrete

Therefore, only the value of R1 will be used and simulated for the load test. Upon summation of
moment around the front and the back side of the formwork, the R1 & R2 will be calculated as
follows:

R1 = ( 160 x 2.75 + 20 x 3.05 ) / 6.1

= 82.13 Tons
R2 = ( 160 x 3.35 + 20 x 3.05 ) / 6.1
= 97.87 Tons

The form traveler for Simpang Jam Fly Over configuration is made up of 2 main frames.
Therefore, if the form traveler carries 82.13 tons of load, each main frame carries 41.065 Tons,
as shown in the figure below.

Figure.2

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 Doc No:
SIMPANG JAM Method Statement
Rev. No.: 0
FLY OVER
PROJECT :
Date :02-02-2017
Load Test for Form Traveller

3.3 Loading Simulation

The 41.065 Tons load will be applied to the main frame for the test. The idea is to put the 2
main frames of the form traveler facing each other and with the use of 1 hydraulic hollow
jacks, push the 2 frames towards each other, as shown below.

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 Doc No:
SIMPANG JAM Method Statement
Rev. No.: 0
FLY OVER
PROJECT Date :02-02-2017
Load Test for Form Traveller

4. Work Procedure for Load Test

4.1 Tools & Equipment
2 x form traveler main frame + anchor star + rear support + rear jacks
2 x back to back channel C250 , L=1.5m (stiffened)
6 x 32mm dia. PT bar, L=6m
1 x 100T hollow bar jack + hydraulic pump
1 x 25 ton mobile crane

4.2 Procedure
Preparation: (see Figure 4)
 Put the first main frame flat on the ground. Use timber support to make the frame perfectly
level.
 Put the second A-frame parallel but mirrored to the first one. Level the frame in the same
manner. The 2 frames must be at the same level. Make sure that the main jack support
blocks are connected together.
 Install the rear support for both frames and connect them together. Insert additional
shimming if needed to make the bottom chord of the frames parallel.
 Install the rear jack and anchor star for both frames and connect them together using the
rear PT bars.
 Install the back to back channel at the front of both frames and connect them together with
2 PT bars.

Load Test: (see Figure 5)

 Stress the rear jacks with 3 Tons jacking force. This will eliminate the slack on the rear
section of the frame and the slack between the rear supports.
 Install the hollow bar jacks at the front.
 Stress the hollow bar jacks simultaneously to initial force of 3 Tons. This will eliminate
the slack on the front section of the frames.
 Measure the initial distance between the 2 main frames. (marked as “X1” in Figure 5)

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 Doc No:
SIMPANG JAM Method Statement
Rev. No.: 0
FLY OVER
PROJECT :
Date :02-02-2017
Load Test for Form Traveller

 Continue stressing 5 Ton increment until the final

tressing the hollow jacks simultaneously by 5-Ton
force of 41.065 Tons is reached. Visual check must be done at the rear, center, and front
of the frames during stressing.
 Hold the force (41.065
41.065 Tons) for 15 minutes. Visual check shall be done once more
during this time.
 Measure the distance between the 2 frames. (marked as “X2” in Figure 5)
 Release the hollow jacks simultaneously back to zero.
 Dismantle the frames.

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 Doc No:
SIMPANG JAM Method Statement
Rev. No.: 0
FLY OVER
PROJECT :
Date :02-02-2017
Load Test for Form Traveller

5. Inspection & Evaluation

5.1 Visual check shall be done every after increment in stressing until the 15
15-minute hold time is
achieved. In case some evident failure on any part of the main frames is observed, the test shall
immediately stop.
5.2 After the initial and final distance between the 2 main frames has been recorded, the actual
average deformation of the frames shall be calculated as follows: Deformation = ( X1 – X2 ) / 2
This actual deformation shall be compared to the calculated theoretical value.

-End-