Presentación de PowerPoint - nspkjembatan.pu.go.idnspkjembatan.pu.go.id/public/uploads/elearning/15565247162._quality.pdf · poisson coefficient 0.3 specific weigth 378.5 kn/m materials

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DIREKTORAT JENDERAL BINA MARGA

SEMINAR ON EUROPEAN RESEARCH & DEVELOPMENT FOR STEEL FLYOVER TECHNOLOGY

QUALITY ASSURANCE / QUALITY CONTROL

QUALITY

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DESIGN BASIS - MATERIALS

STEEL QUALITY STANDARD

MINIMUM YIELD TENSILE COMPONENTS

STRENGTH (MPa) STRENGTH (MPa)

S355 UNE-EN 10025-2 355 470 to 630

ALL STEEL ELEMENTS BOTH

IN SUPERSTRUCTURE AND

IN SUBSTRUCTURE

BOLT TYPE QUALITY STANDARD TENSILE STRENGTH

(MPa)

HIGHT STRENGTH 10.9 UNE-EN ISO 898-1 1000

BOLTS UNE-EN 14399

STRUCTURAL BOLTS 6.8 UNE-EN ISO 898-1 600

UNE-EN 4017

STRUCTURAL STEEL

STRUCTURAL BOLTS, NUT AND WASHERS

Elasticity modulus 210000 Mpa

Transverse elasticity modulus 81000 Mpa

Coefficient of thermal expansion 12x10-6/⁰C

Poisson coefficient 0.3

Specific weigth 78.5 kN/m3

Materials

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STUDS SHEAR CONNECTORS

ANCHOR RODS

STUD SHEAR STANDARD

YIELD TENSILE ELONGATION (%)

CONNECTORS STRENGTH (MPa) STRENGTH (MPa)

TYPE SD1 UNE-EN ISO MINIMUM MINUMUM

MINIMUM 15% 13918:2008 350 450

ANCHOR ROD TYPE YIELD STRENGTH

(MPa)

TENSILE STRENGTH

(MPa)

THREADED BAR 950 1050

REBARS STANDARD QUALITY MINIMUM YIELD STRENGTH (MPa)

Ф6, Ф8, Ф10, Ф12, Ф16,

Ф20, Ф25, Ф32, Ф40 UNE 36065 EX or equivalent BS 4449:2005 B 500 SD

500

REINFORCEMENT BARS

Nominal diameter (mm) 6 8 10 12 16 20 25 32 40

Section (cm2) 0.282 0.503 0.785 1.131 2.01 3.14 4.91 8.04 12.57

Unitary Weigth (kg/m) 0.222 0.395 0.617 0.888 1.578 2.465 3.854 6.311 9.867

Materials

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CONCRETE

ELEMENT DESIGNATION - EC fck (Mpa)

PILES C30/37 30

PILES CAPS C30/37 30

PLINTHS C35/45 35

ABUTMENT WALLS C30/37 30

RETAINING WALLS C30/37 30

DECK SLAB C40/50 40

BLINDING CONCRETE C16/20 16

→ The compressive strength of each concrete element is related to the characteristic cylinder strength

→ The specific weight of reinforcement concrete is 25 kN/m3

ELEMENT QUALITY STANDARD QUALITY

TRAFFIC BARRIER S235JR & 275JR

UNE-EN 10025-2 HANDRAIL STEEL PIPE S235

POST STEEL PIPE S235

KNEERAIL STEEL PIPE S235

BOLTS 6.8 UNE-EN ISO 898-1

STEEL TRAFFIC BARRIER AND TUBULAR RAILING

Materials

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EXPANSION JOINTS

→ Expansion joints shall be reinforced elastomeric molded rubber joint system

→ Designed to be bolted to the structural deck and concrete abutments.

→ Elastomeric material shal be 100% virgin chloroprene (neoprene) or natural rubber with minimum durometer hardness 60+- 5 and

resistant to heat, oil and ozone

POT BEARINGS

Lower part (the pot) Steel S355JR

The piston or cover Steel S355JR

Elastomeric pad (Neoprene pad) Natural Rubber SH50⁰

The sliding components These are comprised of a sheet of cellular PTFE (*) slotted into the upper part of the piston and greased at

the assembly stage on which slides a stainless-steel plate connected to another steel plate higher up.

Guide Steel S355JR

Top plate Steel S355JR

(*) PTFE: Poly TetraFluoroEthylene or Teflon or similar

THE CONSTITUENT PARTS OF A POT BEARING (According to the Standard NF EN 1337-5)

Materials

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SURFACE PREPARATION – CORROSION PROTECTION

CONTACT SURFACES IN SLIP RESISTANCE CONNECTIONS

COAT MATERIAL MINIMUM DRY FILM

THICKNESS μ

Surface Preparation Blast Cleaning GRADE 21/2 (*) -----------------

1st Coat Zinc Phosphate, 75 μ

Blast Primer Quick Drying, Epoxy

2nd Coat Mio High Build, 150 μ

Undercoat Quick Drying, Epoxy

3rd Coat Polyurethne 75 μ

Gloss Finish

COAT MATERIAL MINIMUM DRY FILM

THICKNESS

Surface Preparation Blast Cleaning GRADE 21/2 (*) -----------------

1st Coat Zinc alkali silicate 50-80 μm

according to clause 8.4table 18 UNE -EN 1090-2 or equivalent

μ slip factor depends on the state on the contact surfaces in the friction interfaces. According to the above surface preparation its value is 0.4

(*) Standard UNE – EN 8501-1

Materials

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DESIGN MANUFACTURER SHOP DRAWINGS

ACCEPTANCE BY CENTUNION

MANUFACTURING CONTINUOUS

CHECK ACCEPTANCE BY

CENTUNION

SHIPPING QUALITY CONTROL

DOSSIER ACCEPTANCE BY

CENTUNION

QUALITY CONTROL

Before

2)DURING

3)AFTER

Quality control

Quality assurance GENERAL VIEW

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Before manufacturing

Design drawings

+

Technical Specifications

• Standards • Quality of materials • Tolerances…

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Manufacturers get feedback from CENTUNION until all shop drawings are according to our design drawings


Shop drawings

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Shop drawings

Hand railings

Panels

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Mill certificates of the

Raw Material

In accordance with Standards

Record in our data base

DOCUMENTS

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Cutting Drilling Welding

• Quality Control Plan • Inspection and Test Plan • Weld Procedures • Welders Homologation

DOCUMENTS

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Centunion.

Design Drawings

Technical Specifications

Workshop.

Shop drawings

Technical Documents

Acceptance by

CENTUNION


• Feedback and checking of shop drawings before manufacturing activities

• Mill certificates

• Inspection and test plan according to our Specifications

• Welding procedures and welders Homologation

YES NO

Summarazing…

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Manufacturing

Main

Manufacturers

Steel Structure

Bolts, Nuts and Washers

Panels

Hand railing

Trapezoidal steel

formwork

Pot bearings

Expansion Joints

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Raw Material

Cutting and drilling

Welding

Painting or Galvanizing

Packing

Manufacturing

Steel Structure Profiles

Steel Structure Plates

Steel Structure

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• Stockpiled in good conditions

• Assign an internal code associated to the mill certificate

• Traceability

Manufacturing

Raw Material

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Raw Material


Welding


Packing

Manufacturing



Steel Structure

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Manufacturing

• Computer-aided manufacturing machines

• From shop drawings Geometry High precision


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Manufacturing

Result of cutting and drilling

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Dimensional control

Manufacturing

• Check main dimensions

• Check position of the drills

• Check diameter of the drills

Guarantee geometry of

pieces is according to

drawings

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Raw Material


Welding


Packing

Manufacturing



Steel Structure

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Assembly of Main girders

Manufacturing

• Specific Area just for this process

• Length = 10 m • Put the web and Flange in

position

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Welding

Manufacturing

• Welders Homologation • Welding procedures • Final result depends on the execution of

the welds • High Qualified workers

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Manufacturing

MAGNETIC PARTICLE TEST

• Detect superficial defects

ULTRASONIC TEST

• Detect internal defects

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Raw Material


Welding


Packing

Manufacturing



Steel Structure

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Manufacturing

Painting

• Preparation of the surface (Abrasive blasting)

• 1st: Prime Coat

• 2nd: Intermediate Coat

• 3rd: Final Coat

• Drying time

• Control total thickness

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Manufacturing

Painting

• Rajagiriya: RAL 9003 - White • Ganemulla & Polgahawela:

RAL 7001 - Gray

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Manufacturing

Hot Dip Galvanizing Process

- Pieces are sinked in a tank full of liquid zinc

- Chemical reaction: zinc coat

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Marking

Manufacturing

• Centunion gives a Mark to every piece

• Makes easy to identify pieces

Stamping Painting

• 100 -> S275 • 200 -> S355 • 300 -> S460

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Raw Material


Welding


Packing

Manufacturing



Steel Structure

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Manufacturing Packing before delivery to Port

• Bundles • Boxes

Steel profiles for the bundles.

Guarantee safety of materials during transport

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Manufacturing

Main

Manufacturers

Steel Structure

Bolts, Nuts and Washers

Panels

Hand railing

Trapezoidal steel

formwork

Pot bearings

Expansion Joints

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Manufacturing

Panels Trapezoidal steel formwork

Hand railing

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• Raw material – S355 Deck panels

– S275 Pedestrian panels

– S235 Hand railing

– S275 Trapezoidal Steel Formwork

• Cutting and drilling

• Welding: very important to avoid camber in panels for assembly

Manufacturing

• Visual inspection and Dye Penetrant inspection of welds

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Manufacturing

Pre-assembly panels and hand railing

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• Galvanizing • Anti-skid surface treatment: traffic and pedestrian panels

Blasting

Primer Coat

First layer of resin

Second layer of

resin

Sand aggregates

Manufacturing

Appropiate weather conditions

Adherence of coats

Friction

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Packing before delivery to port

Manufacturing

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Manufacturing Pot bearings

• Individual design

• Movement Free/Fixed

• Delivered in boxes

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Manufacturing Expansion Joints

Free Abutment

Fixed Abutment

• Allows more displacement (Elongations produced by

temperature variations)

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Manufacturing

Expansion Joints

Free abutment expansión joint Fixed abutment expansión joint

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Manufacturing

Bolts Nuts and Washers

Bolts EN 14399-4 10.9 M24 Bolts EN 14399-4 10.9 M20 Bolts EN 4017 6.8 M20 Nuts 14399-4 Washers 14399-5/6/9

Prestressed bolt connections (work by friction) High strength bolts Different geometries(length, diameter…)

Standards

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Manufacturing

Raw Material

Cold Stamping

Heat treatment

Blasting

Galvanizing

Passivate

Bolts Manufacturing Process

SHAPE

IMPROVE MECHANICAL CHARACTERISTICS

CLEAR SURFACE

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Trial Assembly

• Recreate real topography

• Check that all pieces fit well

• Check there are not pieces under stress

There is a Trial Assembly that takes place at the workshop

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Aligned holes

Trial Assembly

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Checking exceptional geometry for pier

Trial Assembly

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Trial Assembly

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Trial Assembly

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Topographic Control

• Check the coordinates X,Y & Z of certain points

• Measure difference between theoretical and real coordinates

• Check that this difference is under tolerances

• Report of topographic control

Trial Assembly