DATA2015-12-06 Ashghal Presentation 2

Leighton Qatar – Al Jaber Engineering JV


NEW ORBITAL HIGHWAY CONTRACT 3



Junction 7

2*5 (2+3) Main Bridges:

700m total length, 16 spans,

2 Ramp Bridges:1 450m total

length,35 spans,



2 Ramp Bridges:780m total

length,18 spans,

Junction 8



2*6 (3+3) Main Bridges:620m total

length, 16 spans,


length,34 spans,

Junction 9


Junction 10

2 *1 Main Bridges:260m total

length,8 spans,


length, 33 spans,


Junction 11

2 *2 (3+3) Main Bridges:520m total length,

16 spans,


Ramp Bridges Typical DetailsPlan, Elevation and Cross section of typical module (Junction 7)

Constant width (13.60m) and constant depth (2.60m) for

all ramp bridge boxesWeight between 55 & 87tons


Main Bridges Typical Details

Segments stitched together transversely to create varying widths required for each Main

Bridge

Constant width (7,00m) and constant depth (2.35m) for all

main bridge boxesWeight between 48 & 69 tons

Plan, Elevation and Cross section of typical module (Junction 9)


Precast Yard Location


Precast Yard Decomposition

PROD

UCTI

ON D

IREC

TION

REBAR AREA

CASTING AREA

FINISHING AREASTORAGE AREA


Stage of Precasting

oRebar – Cage Assembly

oSegment Casting & Curing

oSegment Finishing

oSegment Storage


WHAT IS NEEDED?

• Materials

• Manpower

Special Team for Civil & PT Works

• Rebar & Formwork Shop Drawing

• Equipment:

Gantry Crane 100t 3uTower Crane 8,2t @ 40m 2uRegar Jig 8u* 3 linesRebar-Cage Lifting Beam

Segment Steel Skeleton


Segment Casting & Curing

1. Rebar – Cage Positioning in Casting cell

2. Adjustment cover, insert, opening PT items,

3. Close Formwork,

4. Order & Delivery of Concrete,

5. Concrete placement,

6. Curing Compound:a) 12 hours water curing,b) After 12 hours Application of

Curing Compound application,

7. Stripping Formwork after12 hours – shift mash-cast segment with manipulator,

8. After 36hours lifting Segment,


Segment Finishing

1. Curing Compound application on Segment Bottom Slab,

2. Segment Finishing,

3. Segment lifting,


Segment Storage

1. Segment Storage, 2 layers,

2. Storage 28days,

3. Segment Lifting to trailer for erection site,


Precast Yard – Moulds & Production Rate

Moulds

•Ramp Bridges: 1 434 Segments No. of Moulds = 8

6 Field Segments + 1 Pier + 1 Expansion JointFor all Casting Cells the installation & commissioning are done

•Main Bridges: 846 Segments No of Moulds = 5

2 Field Segment + 1 Deviator + 1 Pier + 1 Expansion Joint 1 Field Segment casting cell Installation & commissioning done

The other casting cells the installation is ongoing

Production Rate:

•Field and Deviator segment = 1 segment per mould per day 9 Segments/Day •Pier and Expansion Joint = 1 segment per mould every 2 days 2 Segments/Day

Transportation of Segments:

•Ramp Bridges: 6 Trucks * 2 trips/ day by 2 shifts 24 Segments/Day

•Main Bridges: 6 Trucks * 2 trips / day 12 Segments/Day


Erection Segments – Ramps Bridges

Segments are transported one by one to site and lifted to their final position.

This erection process will involve:

1.Lifting the segment off the transport truck using special equipment or crane to place them to their

final position in the superstructure.

2.Temporarily hanging or supporting the segment from temporary works

3.Once all the segments are in the final position, they are joined and post-stressed to form the

permanent monolithic superstructure

For NOH Contract 3 - The most effective method to construct the ramps with precast segments is to use the:

Span by Span Method with an Underslung Launching Gantry

The first launching girder is under delivery at Ramp Bridges Junction 8The second are under fabrication delivery planned before the end of this year

.


Erection Sequence – Ramps Bridges

Launching Gantry

Underslung

Precast segments

Typical span by span erection with Underslung Launching Gantry

And crawler cranes 2 units of 220tnsSupplier of Crawler Crane AERTSSEN

Production Rate: 2,5 days by span


Erection Sequence – Ramps Bridges


Erection Sequence – Main Bridges

Segment placement by use of crawler cranes of 200 tons

Main Bridge Erection works on Falsework

Production Rate: 5 days by line


Erection Sequence – Main Bridges

Erection over Salwa Road with 2 x Portals



Thank you for your Thank you for your attentionattention

Documents

DATA2015-12-06 Ashghal Presentation 2