C:\Users\David Moloney\Desktop\Road Bridge 182 Infographic

Bridge Deck Construction - Insitu with void formers & post-tensioned

David Moloney 22th Dec 2010

Step 1 - Falsework, Soffit Formwork & Bearings Step 2 - Fix Reinforcement Step 3 - Fix Ducts for stressing Step 4 - Fix Stop ends & Anchor Coens
Spiroflex 85 mm dia tubing & vent pipes
Vent Pipe Duct Profile curved
Anchor Anchor

Abutment Abutment Pier Abutment .

Pier Longitudinal Deck Section Duct

Walkway & Working Platform Grout Tube

Abutment Block
Wedges Coen
Falsework is the temporary scaffold system used to support the Formwork aka shuttering is the casing used to contain Strands
formwork to the deck soffit. concrete during placement and hardening Anchorage for Strand Tendon .

Sequence for Walls Pours Abutments davmol

C2 Bottom Adapt shutters Adapt shutters Alternatively done after Concreting

A2 Bottom C4 Bottom C6 Bottom Step 5 - Push in Stressing Strand Step 6 - Fix void Formers Step 7 - Pour Deck Step 8 - Pour Parapet Upstands
C2 Top A4 Bottom A6 Bottom Strand Dispenser & Pusher Material - Expanded polystyrene formers & metal fixings Concrete pumps 32 m boom x 2 nr
A2 Top C4 Top C6 Top Strand 15.2 mm dia high tensile Used to reduce the deadweight of the structure. 420 m3 of concrete or 61 loads, pump 8 loads per hour
A4 Top A6 Top Speed 40 to 60 m per minute
Typically 20 nr. strands per Tendon

Bridge 182 - Deck Pour Methodology

Materials
C 50 Slump 125 +/- 25

Concrete Volume 1,200 cu. M.

Approx 50m long x 24m wide x 1 m deep Step 9 - Stress deck & Erect Railing Step 10 - Strike Falsework & Formwork Step 11 - Grout Tendons Step 12 - Waterproof Deck
Plant Paths & Rubbing Strips
Batching Plants on Site. Located @ NDA Per Hour Asphalt to carriageway
2# Liebherr Betomix 2.25 outputs 60 cu m per hour each 100 cu m Jack 350 tonne multi stand & Hydraulic Pump. Grouting provides:- Grout Mixer & Pump
1# Turkish plant outputs 60 cu m per hour each 50 cu m Strand extensions are measured during loading. 1. Corrosion protection to the strands.
Concrete Pumps 2. A bond between the strands and the surrounding concrete.
Positioned on either side of deck, will be moved once during pour. Span centres lift during stressing.
42m Boom capacity 50 cu m per hour
42m Boom capacity 50 cu m per hour 100 cu m.
Duration; 12 hours
Lorries Capacity 8 cu m per load Note: the tendon profile lies in the bottom of the deck in the
Cycle time Load travel discharge & return to bataching plant = 60 minutes mid-span region and rises to the top of the deck over the
100 cu m per hour divided by Lorry 8 cm per hour = 13 lorries
supports. When the tendons are stressed the deck is
compressed in those regions where the load causes tensile
Vibrating Equipment 6 # 50mm dimeter Electrical internal poker vibrators
stress. Precompressing the tensile zones of the deck reduces
Concrete Finishing Equipment Levelled by Shovels & rakes Aluminium Screed by Hand cracking to produce more durable concrete deck.
Curing Equipment By liquid membrane using mechanical sprayer

Deck Construction Sequence

Erect Falsework
Step 1 Hot Weather Concrete
Erect
Step 2 Soffit Formwork
Fix3 Bridge bearings
Step Specification requirements
Erect
Step 4 Formwork for Cantilever Ribs Max Placement Temperature 32*C
Fix5 Bottom matt of reinforcement & cages
Step Max Core Temperature 65*C
Fix6 ducts for tensioning
Step Maximum differential temperature 20*C
Fix7 stop ends and anchors for tensioning
Step

Fix8 void formers

Step Actions to ensure above
Pour
Step 9 deck & contilever ribs Flaked ice is used in mix to control temperature
Push
Step 10 in stressing strand Pour in evening in hot weather
Stress
Step 11 deck Proper Curing
Grout
Step 12 tendons
Pour
Step 13 parapet walls
Pour
Step 14 curved Masking Fascia
Strike
Step 15 Falsework

Deck Pour 1,400 m3 5am to 9pm 4# pumps Step 16 Other Works Trial Deck Section
Joints, Paths, Rubbing Strips, Surfacing, Railing, Painting
Pumps Capacity 42m boom 60m3 per hour 35m boom 40m3 per hour