Highways Department Major Works Project Management Office

Contract No. HY/2009/19

Central - Wan Chai Bypass Tunnel (North Point
Section) and Island Eastern Corridor Link
Segment Launching for Bridgework
Date: Jan 2013

Contract No. HY/2009/19

Central Wan Chai Bypass Tunnel (North Point Section) and Island Eastern Corridor Link
Highways Department Major Works Project Management Office

Presentation Contents
Introduction
Segment Casting
Storage Yard in the Site
Delivery and Storage of Segments
Movement of Launching Girder

Contract No. HY/2009/19

Central Wan Chai Bypass Tunnel (North Point Section) and Island Eastern Corridor Link
Highways Department Major Works Project Management Office

Presentation Contents
Introduction
Contract Details
Overview of Contract Works
Bridge Arrangement
Segment Casting
Delivery and Storage of Segments
Bridge Segment Erection
Movement of Launching Girder

Contract No. HY/2009/19

Central Wan Chai Bypass Tunnel (North Point Section) and Island Eastern Corridor Link
Highways Department Major Works Project Management Office

Overview of Contract HY/2009/19 Works

HARBOUR GRAND
HONG KONG
CITY GARDEN
HARBOUR
HEIGHTS

VICTORIA
CENTRE

Noise
Enclosure

EXISTING IEC
HING FAT SLIP
ROAD

BOX CULVERT
U1
NEW IEC W/B
TUNNEL APPROACH
RAMP

EXISTING IEC E/B

TO BE
DEMOLISHED

NEW IEC E/B

BOX CULVERT
T1
IEC (Tunnel
Section)

Contract No. HY/2009/19

Central Wan Chai Bypass Tunnel (North Point Section) and Island Eastern Corridor Link
Highways Department Major Works Project Management Office

Bridge Arrangement in HY/2009/19

New Eastbound Bridge

to D2)
Bridg e D (D1
ge
Brid

Bridge D3

Brid ge F
(F

1 to F3)

Brid
ge

F5
Br
id

Bridge C (C1 to
C5)

F3)
Bridge F ( F1 to

City Garden

Harbour
Height

Victoria
Centre

ge
F

Existing Bridge
Precast Segments Bridges
Re-Construct Westbound Bridge

Provident Centre

Span length :

26.5m to 40.0m

Bridge types :

Precast Segments (Bridges D1 to D3, F1 to F3, C2 to C5)

U-beams (Bridges C1, E F4, F5)

Total nos. of segment :

653 segments

Total nos. of U-beam :

60 beams
5

Contract No. HY/2009/19

Central Wan Chai Bypass Tunnel (North Point Section) and Island Eastern Corridor Link
Highways Department Major Works Project Management Office

Presentation Contents
Introduction
Segment Casting
Typical Segments
Casting Yard
Segment Casting
Delivery and Storage of Segments
Bridge Segment Erection
Movement of Launching Girder

Contract No. HY/2009/19

Central Wan Chai Bypass Tunnel (North Point Section) and Island Eastern Corridor Link
Highways Department Major Works Project Management Office

Typical Segment Type

Type of Segments : Single and Twin Cell Segments

Contract No. HY/2009/19

Central Wan Chai Bypass Tunnel (North Point Section) and Island Eastern Corridor Link
Highways Department Major Works Project Management Office

Typical Segment Type

Segment Typical Detail

Span Distance

26.5m to 40.0m

Maximum Super-Elevation

3.7%

Maximum Gradient

4.86%

Minimum Horizontal Radius

350m

Maximum Segment Weight

150 tons

Department Major Works Project Management Office

Contract No. HY/2009/19 Central Wan ChaiHighways
Bypass
Tunnel (North Point
Section) and Island Eastern Corridor Link

Location of Fabrication Yard

Zhongshan,
China

Contract
HY/2009/19 Site
Precast Segment
Fabrication Yard

Hong Kong
Macau

Contract No. HY/2009/19

Central Wan Chai Bypass Tunnel (North Point Section) and Island Eastern Corridor Link
Highways Department Major Works Project Management Office

Fabrication Yard Layout

Area for Segment

Casting

10

Contract No. HY/2009/19

Central Wan Chai Bypass Tunnel (North Point Section) and Island Eastern Corridor Link
Highways Department Major Works Project Management Office

Casting Mould for Segments

3 nos. casting moulds in the casting yard
2 nos. for twin cells segments
1 nos. for single cell segment

1st Twin Cell Segment

Mould

2nd Twin Cell Segment

Mould

Single Cell Segment

Mould

11

Contract No. HY/2009/19

Central Wan Chai Bypass Tunnel (North Point Section) and Island Eastern Corridor Link

Segment Casting Procedure

Step 1 - Fabrication of Reinforcement Cage

Step 3 - Cleaning Steel Mould

Highways Department Major Works Project Management Office

Step 2 - Matching & Geometric Adjustment

of Match Cast Segment

Step 4- Placing Reinforcement Cage to

Segment Mould

12

Contract No. HY/2009/19

Central Wan Chai Bypass Tunnel (North Point Section) and Island Eastern Corridor Link

Segment Casting Procedure

Step 5 - Installing Internal Formwork

Step 7 - Demoulding

Highways Department Major Works Project Management Office

Step 6 - Pouring Concrete

Step 8 - Completed Segment

Contract No. HY/2009/19

Central Wan Chai Bypass Tunnel (North Point Section) and Island Eastern Corridor Link
Highways Department Major Works Project Management Office

Presentation Contents
Introduction
Segment Casting
Delivery and Storage of Segments
Delivery Route
Unloading Point
Storage Yard
Bridge Segment Erection
Movement of Launching Girder

14

Department Major Works Project Management Office

Contract No. HY/2009/19 Central Wan ChaiHighways
Bypass
Tunnel (North Point
Section) and Island Eastern Corridor Link

Delivery Route to the Site

Zhongshan,
China

Contract
HY/2009/19 Site
Precast Segment
Fabrication Yard

Hong Kong
Macau

Precast segments deliver to site by barge

15

Department Major Works Project Management Office

Contract No. HY/2009/19 Central Wan ChaiHighways
Bypass
Tunnel (North Point
Section) and Island Eastern Corridor Link

Precast Segment Unloading Point on Site

PORTION III
PORTION VII

16

Contract No. HY/2009/19

Central Wan Chai Bypass Tunnel (North Point Section) and Island Eastern Corridor Link
Highways Department Major Works Project Management Office

Storage Yard Arrangement

Segment Storage
(Max. Capacity = 20 Segments)

Front View
Side View
Stacking Arrangement
Segment Barge

Unloading
Derrick

Bridge Loading
Area
(After
completion of
Bridge D3)

17

Contract No. HY/2009/19

Central Wan Chai Bypass Tunnel (North Point Section) and Island Eastern Corridor Link

Lifting Equipments at Storage Yard

Highways Department Major Works Project Management Office

Truck for Transporting Segment

(Example Photo)
Portal Crane

Unloading Derrick

Contract No. HY/2009/19

Central Wan Chai Bypass Tunnel (North Point Section) and Island Eastern Corridor Link
Highways Department Major Works Project Management Office

Presentation Contents
Introduction
Segment Casting
Delivery and Storage of Segments
Bridge Segment Erection
Launching Girder
Main Support and Lifting Beam
Install Bearing and Segment at Piers by Crawl Cranes
Segment Erection by Launching Girder
Movement of Launching Girder

19

Contract No. HY/2009/19

Central Wan Chai Bypass Tunnel (North Point Section) and Island Eastern Corridor Link
Highways Department Major Works Project Management Office

Launching Girder Configuration

FRONT LEG (FL)
MASTER
WINCH (MW02)

REAR LEG
(RL)

MAIN SUPPORT
(MS2)

MASTER
WINCH
(MW01)

MAIN TRUSS
MAIN SUPPORT
(MS1)

MAIN SUPPORT
(MS3)

General Specification
Dimension (L x W x H)

103.44m x 8.4m x7.5m

Max. Lifting Capacity

160 T

Max. Hanging Capacity

700 T (7 segments)

Fabrication

Wuhu, China

20

Contract No. HY/2009/19

Central Wan Chai Bypass Tunnel (North Point Section) and Island Eastern Corridor Link
Highways Department Major Works Project Management Office

Launching Girder Main Support

Rotation Table for

Truss Rotation

Jack for adjustment

of transverse
movement

Jack for launching

forward of main
truss

Main Beam Unit

Section

Elevation
Jack for adjustment of
crossfall and longitudinal fall
of segment

Contract No. HY/2009/19

Central Wan Chai Bypass Tunnel (North Point Section) and Island Eastern Corridor Link

Launching Girder Main Support

Highways Department Major Works Project Management Office

Jack for adjustment for

crossfall and longitudinal
fall of segment
Jack for adjustment
of transverse
movement

Main Beam Unit of

Main Support

Contract No. HY/2009/19

Central Wan Chai Bypass Tunnel (North Point Section) and Island Eastern Corridor Link
Highways Department Major Works Project Management Office

Launching Girder Main Support

Main Truss

Jack for launching

forward of main
truss girder

Contract No. HY/2009/19

Central Wan Chai Bypass Tunnel (North Point Section) and Island Eastern Corridor Link
Highways Department Major Works Project Management Office

Launching Girder Lifting Beam

Jack for adjustment
of crossfall of
segment

Strings hung from

Master Winch

Jack for adjustment

of longitudinal fall of
segment

Pin joint for

connecting with
hanger beam

Jack for adjustment

of longitudinal fall of
segment

Section

Plan

Elevation

Contract No. HY/2009/19

Central Wan Chai Bypass Tunnel (North Point Section) and Island Eastern Corridor Link
Highways Department Major Works Project Management Office

Launching Girder Hanger Beam for Segment Erection

40mm High Strength
Bar

For Single-Cell Arrangement

Pin joint for

connecting with
lifting beam of
master winch

Section

40mm High Strength

Bar

For Twin-Cells Arrangement

Contract No. HY/2009/19

Central Wan Chai Bypass Tunnel (North Point Section) and Island Eastern Corridor Link
Highways Department Major Works Project Management Office

Launching Girder Hanger Beam for Hanging Segment at End Span

1. Erect the segment by master winches
2. Hang and fix the segment by 50 High Strength Bar
3. Release the master winches after fixing with high strength bar
4. Repeat 1 to 3 for the rest of the segment at end span

Main Truss of
Launching Girder

Hanger Beam

Hung From the Main

Truss of Launching
Girder

50mm High Strength

Bar

Hanger Beam

Elevation
Section

Contract No. HY/2009/19

Central Wan Chai Bypass Tunnel (North Point Section) and Island Eastern Corridor Link
Highways Department Major Works Project Management Office

Before Segment Erection

1. Installing the bearing and temporary hydraulic jacks on the piers

Temporary
Hydraulic
Jacks

Bearing
s

(Example Photo)

Temporary Hydraulic
Jack

Adjusting Jack

Bearing

27

Contract No. HY/2009/19

Central Wan Chai Bypass Tunnel (North Point Section) and Island Eastern Corridor Link
Highways Department Major Works Project Management Office

Before Segment Erection

2. Erect MJ and pier segments at the piers by cranes

MJ Segments

Pier
Segments

28

Contract No. HY/2009/19

Central Wan Chai Bypass Tunnel (North Point Section) and Island Eastern Corridor Link
Highways Department Major Works Project Management Office

Before Segment Erection

3. Fix the MJ and pier segments at the piers

Fixed by high
strength bars

At Movement Joint Pier

Fixed by Nailing

At Intermediate Pier

29

Contract No. HY/2009/19

Central Wan Chai Bypass Tunnel (North Point Section) and Island Eastern Corridor Link
Highways Department Major Works Project Management Office

Before Segment Erection

4. Install launching girder on the erected pier/MJ segments:. Install main support main truss girder master winches on main truss girder

3. Install Master
Winches

2. Install Main Truss

Girder

1. Install Main
Support on erected
segment

1. Install Main
Support on erected
segment

30

Contract No. HY/2009/19

Central Wan Chai Bypass Tunnel (North Point Section) and Island Eastern Corridor Link
Highways Department Major Works Project Management Office

Before Segment Erection

5. Proceed the load test of the launching girder (trial lifting Master Winches)
Additional
. Lift the heaviest segment plus extra10% of SWL (160T)
weight by
concrete block
. Visual check of launching girder after lifting
. Lower the loaded segment after satisfaction by RPE

Load test at the

middle of the span

Example Photo of Load Test of Master Winch

Load test at the

other span

Contract No. HY/2009/19

Central Wan Chai Bypass Tunnel (North Point Section) and Island Eastern Corridor Link
Highways Department Major Works Project Management Office

Before Segment Erection

6. Proceed the load test of the launching girder (Trial Launching)
. Launch the main truss forward/backward for the short distance
. Without any load on Master Winches during trial launching

Launch main truss

forward/backward

7. The certificate of launching girder issued by RPE once the load test is
satisfactory.

Contract No. HY/2009/19

Central Wan Chai Bypass Tunnel (North Point Section) and Island Eastern Corridor Link
Highways Department Major Works Project Management Office

Segment Erection Methods

Types of Segment Erections Methods

Segment Erection at Pier

(Balanced-Cantilever Erection)

At End Span Erection

(Hanging Erection)

33

Contract No. HY/2009/19

Central Wan Chai Bypass Tunnel (North Point Section) and Island Eastern Corridor Link
Highways Department Major Works Project Management Office

Typical Segment Erection at Pier

Temporary Prestress Bars

to connect during each pair
segment erection prior to
the permanent stressing

Temporary
Prestress Bars to
be removed

Permanent Prestressing to carry

out at each pair segment
erection

Design check for permanent structure (e.g. pier) due to segment erection is
required.
34

Contract No. HY/2009/19

Central Wan Chai Bypass Tunnel (North Point Section) and Island Eastern Corridor Link
Highways Department Major Works Project Management Office

Typical Segment Erection at End Span

1 2 3 4 5

Temporary Prestress Bars

to connect the segment
prior to the permanent
stressing

Temporary
Prestress Bars and
Supports to be
removed

6 7

Construct Stitch
Joint

As-constructed
Segment
Cantilever

Permanent Prestressing to carry

out after the completion of
stitch joint

Design check for permanent structure (e.g. pier) due to segment erection is
required.
35

Contract No. HY/2009/19

Central Wan Chai Bypass Tunnel (North Point Section) and Island Eastern Corridor Link
Highways Department Major Works Project Management Office

Segment Erection Applying Glue for Joining Segments

Apply epoxy glue on segment face before joining segment
Amount of epoxy glue in accordance with the manufacturers recommendation
Curing time: 4 8 hrs (initial); 2 7 days (final)

Mixing epoxy glue

Applying epoxy on segment face

Contract No. HY/2009/19

Central Wan Chai Bypass Tunnel (North Point Section) and Island Eastern Corridor Link
Highways Department Major Works Project Management Office

Segment Erection Applying Glue for Joining Segments

PHYSICAL AND CHEMICAL PROPERTYES

Specification

30

50

Density

1685kg/m3

1685kg/m3

Pot time

>35 minutes

>20 minutes

Open time

>60 minutes

>60 minutes

Compressive strength @ 24 hours

>65MPa

>70MPa

Compressive strength @7 days

>80MPa

>80MPa

Contract No. HY/2009/19

Central Wan Chai Bypass Tunnel (North Point Section) and Island Eastern Corridor Link
Highways Department Major Works Project Management Office

Segment Erection - Temporary Prestressing

Segment held by high strength MaCalloy Bars (36mm dia., UTS =1030N/mm2)
Each bar is stressed to the specified force by hydraulic jack.(524KN or 598KN)
During application of epoxy glue, a minimum average compressive stress of 0.2
N/mm2 across the whole section shall be achieved.
To be removed after completion of permanent prestressing.

Steel blister at
bridge deck

Bar is stressed by
Hydraulic Jack

Temporary
Prestressing Bar

At Bridge Deck (Example

Photo)

Bar is stressed
by Hydraulic
Jack

Temporary
Prestressing Bar

Inside the Bridge Deck

(Example Photo)

Contract No. HY/2009/19

Central Wan Chai Bypass Tunnel (North Point Section) and Island Eastern Corridor Link
Highways Department Major Works Project Management Office

Temporary Prestressing General Arrangement

Steel Blisters

Prestressing bars

Prestressing bars

Concrete Blisters

Elevation
Steel Blisters

Recess Hole for

Temp Prestress
Concrete Blisters

For Twin Cell Segment

Recess Hole for

Temp Prestress

For Single Cell Segment

39

Contract No. HY/2009/19

Central Wan Chai Bypass Tunnel (North Point Section) and Island Eastern Corridor Link
Highways Department Major Works Project Management Office

Stitch Joint Construction

Construct between the cantilever and end span or between two cantilevers.
Adjust the vertical and horizontal alignment of the erected cantilever tips

Stitch Joint
Stitch Formwork

40

Contract No. HY/2009/19

Central Wan Chai Bypass Tunnel (North Point Section) and Island Eastern Corridor Link
Highways Department Major Works Project Management Office

Permanent Prestressing
Thread strand through the tendon duct
Apply prestressing force gradually until required stressing force is attained.
(Min=784KN ,Max=4312KN)
Release the pressure, allow the wedge to draw-in and lock strand

Installing Hydraulic Jack

(Example Photo)

Stressing Prestressing Strand

(Example Photo)
41

Contract No. HY/2009/19

Central Wan Chai Bypass Tunnel (North Point Section) and Island Eastern Corridor Link
Highways Department Major Works Project Management Office

Permanent Prestressing
Platform for workers of prestressing work (for balanced cantilever segment
erection only)
It is hung under the main truss of launching girder
Main Truss of
launching girder

Winch for
hanging
hydraulic
jack

Section

Stressing
platform

Erection

Contract No. HY/2009/19

Central Wan Chai Bypass Tunnel (North Point Section) and Island Eastern Corridor Link
Highways Department Major Works Project Management Office

Grouting Tendon Duct after Permanent Prestress

1. Cut the excess strand
2. Check clearance of duct and leakage check
3. Pump the grout into the duct
4. Seal all outlet vents

Completed cutting excess strand

(Example Photo)

Pumping grout into the duct

(Example Photo)

Completed grouting
(Example Photo)
43

Contract No. HY/2009/19

Central Wan Chai Bypass Tunnel (North Point Section) and Island Eastern Corridor Link
Highways Department Major Works Project Management Office

Presentation Contents
Introduction
Segment Casting
Storage Yard in the Site
Bridge Segment Erection
Movement of Launching Girder
Forward Launching
Forward Launching in Curve Section
Typhoon Anchors
General Erection Sequence

44

Contract No. HY/2009/19

Central Wan Chai Bypass Tunnel (North Point Section) and Island Eastern Corridor Link
Highways Department Major Works Project Management Office

Launching Girder Forward Launching

Assemble
LG onLG
pier
D8,9,10 as
Launch
to D9,10,11
shown

Repeat steps before to

Launch LG to D10,11,12

Engage RL,move MS to the positon

LG
forward
MS again
LG forward
until reach
segments
ofasLaunch
Tshown
spanLaunch
by
Install segments
of endInstall
span Move
Erect
segments
of TD11
as shown.
pair
span

Erect temporary prop and

MJ
Erect
pier segments
segment
at D11
Move
MSFLtoon
D11
Erect
T Erectof
engage
it of
Move
MSErect
onto
segments
end

span
D12

segment at D12
span

Erect external
tendons

Cast the
stitch
Pier
D8

Cast the
stitch

Cast the
stitch
Pier
D9

Pier
D10

Cast the
stitch
Pier
D11

Pier
D12

Contract No. HY/2009/19

Central Wan Chai Bypass Tunnel (North Point Section) and Island Eastern Corridor Link
Highways Department Major Works Project Management Office

Launching Girder Forward Launching in Curve Section

1. Shift and rotate the main truss transversely by hydraulic jack on main truss

Main Truss
Main Support

2. Launch the main truss forward to the designated position

Main Truss
Main Support

46

Contract No. HY/2009/19

Central Wan Chai Bypass Tunnel (North Point Section) and Island Eastern Corridor Link
Highways Department Major Works Project Management Office

Launching Girder Forward Launching in Curve Section

1. Main truss will not extend to existing bridge.

Main Support

Main Truss

Edge of Existing
Bridge

47

Contract No. HY/2009/19

Central Wan Chai Bypass Tunnel (North Point Section) and Island Eastern Corridor Link
Highways Department Major Works Project Management Office

Launching Girder Forward Launching in Curve Section

1. Supporting beam will not extend to existing bridge.

300mm

Pier
F8

48

Contract No. HY/2009/19

Central Wan Chai Bypass Tunnel (North Point Section) and Island Eastern Corridor Link
Highways Department Major Works Project Management Office

Launching Girder Typhoon Anchorage Operation

40 HIGH-STENGTH PT BAR
(PRELOADED TO 700KN
EACH)

40 HIGH-STENGTH PT BAR
(PRELOADED TO 700KN
EACH)

49

Contract No. HY/2009/19

Central Wan Chai Bypass Tunnel (North Point Section) and Island Eastern Corridor Link
Highways Department Major Works Project Management Office

Segment Erection Sequence

Bridges

Sequence

Duration (Approx.)

New Eastbound Bridge

Pier D8 to Pier F8 > Pier D8 to Pier D1

206 Days

Re-Construct Westbound Bridge

(Towards Causeway Bay Direction)

Pier 28 to Pier 43 > Pier 28 to Pier 22

187 Days

Re-Construct Westbound Bridge

(Connect to Approach Ramp)

Abutment D12 to Pier F8 >

Abutment D12 to Pier F3

100 Days

New Eastbound Bridge

Pier
D8

Pier
D1

Pier
22

Abut
D12

Pier
F3

Pier
28

Re-construct Westbound Bridge

(Towards Causeway Bay Direction)

Pier
F8

Pier
43
Re-construct Westbound Bridge
(Connect to Approach Ramp)

Highways Department Major Works Project Management Office

THE END

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