PENANG SECOND BRIDGE APPROACH SPANS
QUALITY OF SEGMENTAL BOX GIRDERS
SOLVING ISSUES DURING CONSTRUCTION
Julian Clarke General Manager Technical Buildcast Sdn Bhd 29 November 2012
PENANG SECOND BRIDGE QUALITY OF SBG SOLVING ISSUES DURING CONSTRUCTION
PULAU PINANG
PULAU JEREJAK
BCSB CASTING YARD
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PENANG SECOND BRIDGE QUALITY OF SBG SOLVING ISSUES DURING CONSTRUCTION
AERIAL VIEW OF THE CASTING YARD
PROJECT OWNER
GOVERNMENT OF MALAYSIA
PROJECT ORGANIZATION CHART
PACKAGE 2 APPROACH STRUCTURES
AUTHORITIES
MINISTRY OF WORKS
MALAYSIA HIGHWAY AUTHORITY
CONCESIONAIRE
JAMBATAN KEDUA SDN. BHD.
INDEPENDENT CHECK ENGINEER
ARUP JURURUNDING SDN. BHD.
PACKAGE 2
UEM BUILDERS BERHAD
SUPERSTRUCTURE DESIGNER RB Perunding
SITE SUPERVISION RB Perunding
SBG CASTING
BUILDCAST SDN BHD BCSB
SHOP DRAWING SUPPLIER
RB Perunding
PENANG SECOND BRIDGE QUALITY OF SBG SOLVING ISSUES DURING CONSTRUCTION
GENERAL OVERVIEW
Significant Specification Requirements
120 years design life Concrete Durability requirements RCPT: 1000 Coulombs at 28 days / 800 Coulombs at 56 days ISAT: 0.1 at 28 days
Strength Design 55MPa Target: 67.5MPa Early strength 15MPa for mould striking and 25MPa for lifting Current average 28-day strength: 90+MPa
Workability 550 650 mm Flow Table
36 degrees maximum fresh mix temperature
PENANG SECOND BRIDGE QUALITY OF SBG SOLVING ISSUES DURING CONSTRUCTION
TWIN DECK ARRANGEMENT
Expansion Joint adjacent to P1 pier segment
Typical Segments
Locator Segment
Deviator Segments
In-situ stitch joining P2 pier segments
Full six-span module arrangement
Direction of casting in the short-line moulds
PENANG SECOND BRIDGE QUALITY OF SBG SOLVING ISSUES DURING CONSTRUCTION
Three separate casting yards, each with one reinforcement cage jig per mould and serviced by one 20T gantry crane on rails per pair of moulds.
FINISHING BAYS
BP1 STORE WORK SHOP OFFICE
One reinforcement cutting shop (RCS) that processes all delivered stock length bars to cut bars for all three casting yards. Two segment storage yards (doublestacking) serviced by two 120 gantry cranes on rails and three straddle-carrier transporters. Note segments are also stored single-stacked on the general hardstanding areas. Total storage capacity is approximately 1000 segments.
Finishing bay area to the west end of Storage Yard B, of capacity eight spans, for finishing works and final inspection processing prior to delivery to UEMB jetty storage ready for shipment to the erection sites.
STORAGE YARD A
CANTEEN
OCY-1 7 Moulds OCY-2 8 Moulds
STORAGE YARD B
RCS
CCY 7 Moulds
PENANG SECOND BRIDGE QUALITY OF SBG SOLVING ISSUES DURING CONSTRUCTION SEGMENT TYPES
TYPICAL SEGMENT
DEVIATOR SEGMENT
LOCATOR SEGMENT
P1 EXPANSION JOINT SEGMENT
P2 PIER SEGMENT
PENANG SECOND BRIDGE QUALITY OF SBG SOLVING ISSUES DURING CONSTRUCTION
Typical Segment Casting Mould
Segment Storage Yard
PENANG SECOND BRIDGE QUALITY OF SBG SOLVING ISSUES DURING CONSTRUCTION
Span Finishing Bays
Jetty Storage Bays
PENANG SECOND BRIDGE QUALITY OF SBG SOLVING ISSUES DURING CONSTRUCTION
Summary of the Production and QA/QC Process The following summarises the production and QAQC processes carried out in the casting yard: Cut reinforcement is delivered to the appropriate bending areas at casting bay areas Bars are assembled into cages in the jigs first QC Pre-pour check
Cages are stored / transferred to the mould
Moulds prepared for casting second QC Pre-pour check Concrete poured subject to QC checks on every concrete batch Membrane and water-curing applied to unformed surfaces QC Post-pour check identify any quality issues
Segments used to match-cast and / or transferred to storage
Remedial works as required > QA/QC documentation and remedial works reviews and close-out Segments sent by spans in programme sequence to finishing bays QC final inspections
Finalise and close Birth Certificates (QAQC Departments of BCSB, RBP, UEMB and JKSB)
Send spans to erection jetty storage
PENANG SECOND BRIDGE QUALITY OF SBG SOLVING ISSUES DURING CONSTRUCTION
All segments are produced subject to strict quality control systems governed by the Project Quality Plan. This includes a Request For Inspection (RFI) process, specific Quality Control forms and the Inspection and Test Plan (ITP.)
Segments are all prepared and cast to an individual and unique Shop Drawing package. Supervision is provided by BPJV production managers and supervisors, production engineers and QAQC engineers. All operations are overseen by the resident Site Supervision consultant team. Any defects in the segments are generally detected at the post-pour inspection, others within the storage areas and some at the finishing bays. Depending on the severity of the defect or imperfection, the Site Supervision teams raise a Non Conformance Report (NCR) or a Site Observation Report (SOR). JKSB also carry out independent quality reviews and raise correspondence to UEMB accordingly. Segment defects are generally remediated at the transfer bays or in the storage yards prior to transfer to the finishing bays, using the Request For Inspection (RFI) system. Once segments have been transferred to the finishing bays and passed a final inspection process each segment is awarded a Birth Certificate (on a full span arrangement), which is signed by the Supervision Consultant and JKSB. The full span is then transferred to the UEMB jetty storage facility to await transfer to the bridge site for erection. Segment quality is monitored on a continuous basis, with reviews of SOR or NCR frequency and responsibility. Quality issues are discussed at regular coordination meetings to discuss keep the production teams aware of the current status, and specific and general cases reviewed with a view to eliminate poor practice or other defect source.
PENANG SECOND BRIDGE QUALITY OF SBG SOLVING ISSUES DURING CONSTRUCTION
PENANG SECOND BRIDGE QUALITY OF SBG SOLVING ISSUES DURING CONSTRUCTION
MATRIX FOR BIWEEKLY SPAN DELIVERY COORDINATION MEETING
SPAN ID SEGMENT NO TYPE 1 2 SOR / NCR REF. NO. OCY 1 CCY Nature of Defects LOC. STATUS REMARKS
3
4 5 6 SOR 798 822 Crack at top slab (0.3mm width) OCY1 Suspected segregation on the soffit of bottom slab S1 cast on 24/5/12 S14 cast on 28/8/12
7
N 192 8 9 10 11 12 13 14 All 1 2 3 4 5 6 7 OCY 2 S 192 8 9 10 11 12 13 14 All OCY 1 OCY 2 SOR
S1 cast on 26/4/12
on 4/9/12
S14 cast
PENANG SECOND BRIDGE QUALITY OF SBG SOLVING ISSUES DURING CONSTRUCTION
8000 7000 6000 5000 4000 3000 2000 1000 Jul- Au Se Oct No De Jan Fe Ma Apr Ma Jun Jul- Au Se Oct No De Jan Fe Ma Apr Ma Jun Jul- Au Se Oct 0 Cumulative SBG Cast
Monthly Cast
Casting of the segments commenced in July 2010, initially with the typical span segments and subsequently the pier segments. The rate of segment casting remained low until the end of 2011 when production increased to over 400 segments per month.
100.00% 90.00% 80.00% 70.00%
P2B APPROACH SPANS SEGMENT PRECASTING RATE OF SOR/NCR INCIDENCE AGAINST CUMULATIVE SEGMENT CASTING
SOR
NCR
60.00%
50.00% 40.00% 30.00% 20.00% 10.00% 0.00%
It is of note that, although production increased, the rate of SOR and NCR incidence (against cumulative number of segments cast) generally decreased.
It is stressed that incidence of serious defects is relatively low.
PENANG SECOND BRIDGE QUALITY OF SBG SOLVING ISSUES DURING CONSTRUCTION
QUALITY ISSUES DURING PRECASTING OPERATIONS During segment production various types of quality issues have occurred to some segments. Generally these have been physical defects in the hardened concrete, of varying degrees of severity. The root causes include; poor fresh concrete consistency or workability, poor workmanship a combination of the above Defect Category List referred to on the NCR and SOR documents. structural defects >> NCR, requiring specific remedial works procedures non-structural defects >> SORs, for which standard remedial works procedures are applied.
All remedial works are inspected by the Site Supervision teams at various stages, and are only closed out on final closure of the specific RFI. No Birth Certificate may be issued without the segment, including any defect remedial works, being in compliance with the Specification.
In cases where defects are deemed to be totally unacceptable, the segment affected has been rejected outright.
PENANG SECOND BRIDGE QUALITY OF SBG SOLVING ISSUES DURING CONSTRUCTION
PENANG SECOND BRIDGE QUALITY OF SBG SOLVING ISSUES DURING CONSTRUCTION
Quality issues at the precast yard include:
Honeycombing Shear key and section edge concrete spalling
Cold joints (apparent)
Cracks to formed and unformed surfaces Misalignment of PT tendon ducts Incorrect PT cast-in items Blow holes on inclined formed surfaces
Concrete section dimensional variations exceeding specified tolerances
Grout loss from mould joints Formed surface discolorations and blemishes Displaced reinforcement couplers with reduced cover
PENANG SECOND BRIDGE QUALITY OF SBG SOLVING ISSUES DURING CONSTRUCTION
Selected Example for Discussion:
Honeycombing At internal webs and lower haunches or bottom slab soffits, often at deviator segments Delays to concrete truck delivery, Concrete quality inconsistency and poor workability, Poor vibration and incorrect layering of concrete as the pour rises up the webs Smaller cases occur at match faces in the vicinity of internal ducts and at grout leaks at mould joints Remedial works for the more severe cases improved with improved procedures, supervision and application methods. Ultrasound Pulse Velocity (UPV) testing and MP4 accelerometer standard cube strength, RCPT and ISAT testing to confirm the structural integrity and durability compliance. Improvements to the concrete consistency and delivery, Introduction of variable truck load sizes against location in the segment, Improved placement and compaction practices
have significantly reduced the incidence and severity of honeycomb issues.
PENANG SECOND BRIDGE QUALITY OF SBG SOLVING ISSUES DURING CONSTRUCTION
PENANG SECOND BRIDGE QUALITY OF SBG SOLVING ISSUES DURING CONSTRUCTION
Actions by BCSB on Quality Issues
Proactive :
Improvements to: concrete consistency quality and supply casting and finishing practices
Reactive:
Development of appropriate remedial works procedures and practices Specific testing using cores, UPV and MP4 >> increased confidence that the remedial works are sound both structurally and for durability
BCSB, RBP design office and Site Supervision, JKSB and ICE have worked together to address the various issues
PENANG SECOND BRIDGE QUALITY OF SBG SOLVING ISSUES DURING CONSTRUCTION
Quality issues experienced at the bridge site include: Spalling of concrete during PT stressing Design / construction development to minimise a particular quality issue Example of Continuous Improvement
PENANG SECOND BRIDGE QUALITY OF SBG SOLVING ISSUES DURING CONSTRUCTION
Pier segment diaphragm cracks during stressing works Design / construction development to minimise a particular quality issue Example of on-going Continuous Improvement
PENANG SECOND BRIDGE QUALITY OF SBG SOLVING ISSUES DURING CONSTRUCTION
Incorrect PT cast-in items QC System Issue Systems improved to eliminate production quality issues
PENANG SECOND BRIDGE QUALITY OF SBG SOLVING ISSUES DURING CONSTRUCTION
Actions instigated by BCSB 1. A back-check of all the shop drawing packages for segments cast to that date plus those in preparation was carried out. This identified that one other package had incorporated an incorrect drawing that would have had similar consequences to those of S109 as above.
2.
A modified system of shop drawing package preparation and schedule was developed which includes a rigorous double-check and random triple-check of the packages by successively senior QC staff plus a review by the RBP Site Supervision team.
3.
A modified QC site check system to ensure that the shop drawing details were being correctly installed as per the design requirements.
PENANG SECOND BRIDGE QUALITY OF SBG SOLVING ISSUES DURING CONSTRUCTION
END OF PRESENTATION THANK YOU
