Second International Seminar on the Design & Construction

of the SECOND PENANG BRIDGE

CONSTRUCTION OF THE CABLESTAYED BRIDGE

Dr. Robin Sham, Global Long Span and Specialty Bridges Director, AECOM

Dr. Frank Fan, Associate, AECOM

Mr. Liu Yu Feng, Project Chief Engineer, Section 4, CHEC

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Second Penang Bridge in situ concrete cable-stayed

bridge

Presentation Title

January 29, 2013

Page 2

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Introduction
AECOM is consultant to China Harbour Engineering
Consultant (CHEC) in Second Penang Bridge
design,
specialist advice
construction supervision and
construction engineering.
In the construction of the cable-stayed bridge,
AECOM is responsible for construction engineering,
including erection analysis, geometry control and
temporary work design.

Page 3

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CONSTRUCTION ENGINEERING

Page 4

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Construction Engineering
Three Main Objectives:
1.To establish a methodology for the construction of the bridge which
does not cause overstress to any part of the permanent bridge
structure during construction

2.To safeguard structural adequacy, integrity and stability throughout

the erection stages including bridge completion
3.To achieve the reference states of the permanent works, including
the permanent load geometry and force distribution defined by the
Design

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General Arrangement

Page 6

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The Target Bridge Geometry

Target bridge geometry is determined for
the Reference Condition

1)under permanent loads only,

2)at a reference temperature of 30OC
3)at the time of 30 years after bridge completion

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The Target Bridge Geometry

Deck Segment Control Points
1)

Edge Beam: H2

2)

Slab: (H1 - 30mm thick asphalt)

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Stay Cable Force Distribution

The target stay cable forces at bridge completion

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Stress Limits during Construction BS5400

Prestressed concrete members
Tensile Stress Limit = 1 MPa

Compressive Stress Limit = 0.4 Fcu

ULS PM Interaction

Reinforced concrete members

No stress limits for serviceability limit state

DESIGN BRIEF, Revision 3, May 2010 specifies

Crack Width Limit =0.20 mm
ULS - PM Interaction

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Construction Manual provides the following data

1) Geometry Control Measures necessary for bridge construction

2) Pylon Setting-Out Coordinates of Control Points
3) Deck Setting-out (edge beams and deck slabs) - Coordinates of
Control Points
4) Stay Cables Setting-Out Coordinates of Control Points, cable
lengths, sags, initial and staged stay cable forces
5) Deck profiles at Various Stages Bridge Completion, 30 Years after
Bridge Completion and 120 Years after Bridge Completion
6) Stay Cable Forces at Various Stages Bridge Completion, 30 Years
after Bridge Completion and 120 Years after Bridge Completion

Page 11

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LOADS considered in Construction Analysis

1) Construction Loads including self-weight, equipments, form
traveller, etc

2) Wind Loads

Construction mean hourly wind speed = 25.175 m/s

Static wind forces drag, lift and moment

Wind buffeting effects (time history simulation)

3) Thermal Loads

uniform temperature 30C 10C

Differential temperature through depth and across width of deck girder

(ULS only)

Differential T between deck girder and stay cables (ULS only)

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Construction Loads
1) Form traveller and formwork on each side = 1655 kN
2) Construction equipment load = 50 kN at the tip of cantilever (cantilever
stressing platform)
3) Unbalanced a half segment weight = 1800 kN
4) Differential construction live loads = 5 kN/m on one side of cantilever

5) Differential dead load = one side of cantilever is heavier by 5%

6) Unbalanced weight due to loss of one form traveller = 1655 kN while
form traveller moves forwards
7) Other miscellaneous construction loads

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Load Combinations
Unbalanced Loads

Combination

Load
Factor

SW

EL

WL

1.0

1.0

1.0

(2)

1.0

1.0

(1)

1.15

1.15

1.15

1.15

(3)

1.15

1.15

(4)

1.15

1.15

(1)
SLS

TGL

Half Deck Diff. Dead Diff. Const

Diff. WL
Segment
Load
Live Load

Loss of
Form
Traveller

1.0

(2)
ULS

1.0

1.0

1.0

1.0

1.0

1.0

1.0

1.0

1.0

1.0

1.0

1.1

1.1
0.55

1.0

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1.0

MATERIAL PROPERTIES

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Material Properties Cube Compressive Strength, fcu

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Material Properties Elastic Modulus, Ec

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Material Properties Splitting Tensile Strength, fct

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CONSTRUCTION TOLERANCE

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Construction Tolerance - Specifications Section 22: In

Situ Segmental Construction
Deck Profile

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Construction Tolerance
Pylon Profile

Stay Cable Forces within 5%

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CONSTRUCTION METHOD AND

SEQUENCE
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Construction Sequence
Construction Drawing P2B/P1/VOL2-2/3001

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Construction Sequence

1) Transition Piers and Pylons P024, P025, P026, P027

2) Deck Segments 0 and 1 on falsework

3) Deck Segments 2 through 16 by Form Traveller (12-day

cycles)
4) Deck Segments SS18, SS17 side span closure
5) Deck Segments MS17, MS18
6) Deck Segment MS19 main span closure

7) Last tensioning of stay cables

8) Adjustment of stay cable forces as necessary

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Form traveller for cable-stayed bridge erection

Presentation Title

January 29, 2013

Page 25

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Typical Construction Cycle of One Deck Segment 12 days

Schematic Elevation of Form Traveller
On the 1st Day
1) Cast the edge beams of Deck
Segments N (N = 02 to 16).
On the 6th Day:
2) Stress the cantilever tendons in
the edge beams of Deck
Segments N upon the concrete
reaching 47MPa.

3) Stress the transverse tendons

N1, N3 in the diaphragms of
Deck Segment N-1.
4) Stress the transverse tendons
N2 in the diaphragms of Deck
Segment N-2.

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Typical Construction Cycle of One Deck Segment 12 days

On the 7th Day:

1st

5) Apply the first tensioning of Stay

Cables MN and SN on Deck
Segment N simultaneously.

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Typical Construction Cycle of One Deck Segment 12 days

On the 8th Day

6) Fold down all the formworks
(including edge beams, slabs
and diaphragms)
7) Connect launching system to the
front bogies and the launching
rails.

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Typical Construction Cycle of One Deck Segment 12 days

On the 8th Day

8) Launch the rail to Deck
Segments N.
9) Lower down the form traveller
and remove the high tension
bars.
10)Launch the form traveller to
Deck Segments N.

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Typical Construction Cycle of One Deck Segment 12 days

On the 9th Day:

2nd

11)Lift up the form traveller and

install the high tension bars.
12)Fold up the formworks and
install rebar cages (slabs and
diaphragms).
13)Apply the second tensioning of
Stay Cables MN and SN
simultaneously.
On the 10th Day:

14)Cast the slabs and diaphragms

of Deck Segments N on both
main and side spans
simultaneously.

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Typical Construction Cycle of One Deck Segment 12 days

On the 12th Day, for N = 02 to 15:

15)Apply the third tensioning of
Stay Cables MN and SN
simultaneously.

3rd

16)Fold up the formworks and

install rebar cages (edge
beams).
On the 15th Day, for N = 16

17)Stress the transverse tendons

N1, N3 in the diaphragms of
Deck Segment SS16.
18)Stress the transverse tendons
N2 in the diaphragms of Deck
Segment SS15.
19)Stress the transverse tendons
N2 in the diaphragms of Deck
Segment SS16.

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Deck Segments SS18 and SS17 (side span closure)

SS17 Side Span Closure

SS17 Side Span Closure

Current Design for Temporary Support

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Deck Segment MS17 12 days

Deck Segment MS18 22 days

MS18 Edge Beams

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Deck Segment MS18 22 days

MS18 East - Slab and Diaphragm

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Deck Segment MS18 22 days

MS18 West - Slab and Diaphragm

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Deck Segment MS19, Main Span Closure 7 days

MS19 Main Span Closure

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Main Span Closure

1. Position cantilever tips at the same level
2. Install counter-weights and
3. Jacking cantilever tips toward pylons
4. Install strongbacks

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Stage-by-Stage Construction

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CONSTRUCTION OF PYLONS

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Pylon Construction: Pre-camber and Setting-Out

Pre-camber values are given as the coordinates in the global coordinate
system:

X Longitudinal pre-camber of the pylon (Chainage)

Y Transverse pre-camber of the pylon (Center line of the bridge =
0.000, North is positive, South is negative)
Z Vertical pre-camber of the pylon (Elevation based upon Malaysia
NGVD)
The pylons are cast to pre-cambered profile:
1)
Leaning towards the transition piers for longitudinal (X) precamber
2)
Leaning inwards, towards the bridge centerline for transverse
(Y) pre-camber
3)

Higher than the theoretical elevation for vertical (Z) pre-camber

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Control Points for Pylon Segment

24 Segments Per Pylon
2 Control Points for Each Segment Pour, One at Each End Face
CL PYLON AND CONTROL POINTS

CL PYLON AND CONTROL POINTS

CONTROL POINT 22
EL=96.280
CONTROL POINT 21
EL=93.820

CONTROL POINT

CONTROL POINT 20
EL=89.320

CONTROL POINT 19
EL=84.820

CONTROL POINT 18
EL=80.320

CONTROL POINT 17
EL=75.820

CONTROL POINT 16
EL=71.320

CONTROL POINT 15
EL=66.820

SECTION D-D

CONTROL POINT 14
EL=62.320

CONTROL POINT 13

EL=57.820

CONTROL POINT 12
EL=53.320

CONTROL POINT 11
EL=48.820

CONTROL POINT 10
EL=44.320

CONTROL POINT 09
EL=39.820

CL OF BRIDGE

CONTROL POINT

CONTROL POINT 08
EL=35.320

MAIN SPAN

SIDE SPAN

CONTROL POINT 07
EL=30.820

CONTROL POINT 06
EL=26.320

CONTROL POINT 05
EL=21.820

CONTROL POINT 04
EL=17.320

CONTROL POINT 03
EL=12.820

CONTROL POINT 02
EL=8.320

CONTROL POINT 01
EL=2.680

PILECAP TOP LEVEL

ELEVATION VIEW A-A

ELEVATION VIEW B-B

SECTION E-E

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Pre-camber at Control Points of Pylon P25S

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Stress Envelopes for Pylon P025N

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Pylon Construction

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Transition Pier 027

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Pylon 026

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Cable Saddle

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Cable Saddle

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CONSTRUCTION OF DECK
SEGMENTS
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Deck Segment Construction: Pre-camber and Setting-Out

Deck segment pour in two stages: edge beam pour followed by diaphragm and slab
pour
1. Edge Beams
For setting-out of edge beams, the control points along the fascia lines of the
deck segments are used. The coordinates of the control points incorporating
pre-camber are expressed as:
1) X = Chainage at ends of edge beam segments + X pre-

camber
2) Y = +/- 17,300mm + Y pre-camber
3) Z = Elevation H2 + Z pre-camber

Note: The Z coordinate at Control Point H2 has to include an additional

deformation of form traveller under the self-weight of edge beams. The data is
provided by the construction team.
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Pre-camber Edge Beams at Control Point H2

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Edge Beams Profile at Various Stages

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Stress Envelope Edge Beams

Tensile Stress Limit = 1 MPa
Compressive Stress Limit = 0.4 Fcu = 0.4 (55) = 22 MPa

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Deck Segment Construction: Pre-camber and Setting-Out

2. Slabs
For setting-out of slab and diaphragm, control points along the center
line of the deck are used. The coordinates of the control points are:

1) X = Chainage at ends of slab segments + X pre-camber

2) Y = 0 mm + Y pre-camber

3) Z = Elevation H1 30mm asphalt thickness + Z pre-camber

Note: The Z coordinate at Control Point (H1-30mm) has to include an
additional deformation of formwork under the self-weight of deck slab.
The data is provided by the construction team.
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Pre-camber Slabs at Control Point (H1-30mm)

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Slab Profiles at Various Stages

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Stress Envelope Slabs

No stress limit under SLS.
Crack Width limit = 0.20 mm (Design Brief)

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Form Traveller

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Tie-arch concept in form traveller design and fabrication

Presentation Title

January 29, 2013

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Deck Segments 0 and 1

erection on falsework

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Typical deck segment

erection with form
traveller

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INSTALLATION OF STAY CABLES

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Stay Cables Construction

Control Points
Deck Anchorage: TLA1, TLA2
Pylon Saddle: TP1, TP2

TP1

TP2

TLA1

TLA2

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Stay Cables Installation

Control Point Coordinates for Northwest Side Span
Northwest Side Span - Prior To Tensioning of Stay Cables
Stay No

S01
S02
S03
S04
S05
S06
S07
S08
S09
S10
S11
S12
S13
S14
S15
S16
S17
S18

Control Point TLA1-Deck

X(m)
1965.417
1959.414
1953.411
1947.408
1941.405
1935.403
1929.402
1923.401
1917.400
1911.399
1905.397
1899.397
1893.396
1887.393
1881.391
1875.389
1871.402
1867.407

Y(m)
16.500
16.499
16.499
16.499
16.499
16.499
16.499
16.499
16.499
16.499
16.499
16.499
16.499
16.499
16.499
16.499
16.500
16.500

Z(m)
31.516
31.411
31.309
31.203
31.094
30.979
30.859
30.726
30.592
30.452
30.307
30.157
30.005
29.866
29.731
29.599
29.724
29.637

Control Point TP1-Pylon

X(m)
1979.338
1979.327
1979.321
1979.316
1979.311
1979.307
1979.303
1979.299
1979.296
1979.293
1979.289
1979.287
1979.284
1979.280
1979.275
1979.269
1979.392
1979.401

Y(m)
16.500
16.497
16.497
16.496
16.496
16.496
16.495
16.495
16.495
16.494
16.494
16.494
16.493
16.493
16.492
16.492
16.491
16.491

Z(m)
48.422
52.186
54.892
57.524
60.116
62.683
65.235
67.776
70.309
72.836
75.359
77.877
80.394
82.907
85.419
87.929
90.427
92.921

Chord
Length
(m)
21.899
28.777
35.036
41.363
47.740
54.154
60.596
67.061
73.542
80.037
86.543
93.057
99.579
106.096
112.616
119.137
123.881
128.638

Control Point TLA1'-Deck

X'(m)
1965.417
1959.413
1953.409
1947.405
1941.402
1935.400
1929.398
1923.396
1917.395
1911.393
1905.391
1899.390
1893.388
1887.385
1881.382
1875.379
1871.392
1867.398

Y'(m)
16.500
16.500
16.500
16.500
16.500
16.500
16.500
16.500
16.500
16.500
16.500
16.500
16.500
16.500
16.500
16.500
16.500
16.500

Z'(m)
31.512
31.419
31.324
31.227
31.127
31.022
30.911
30.788
30.660
30.526
30.387
30.244
30.098
29.967
29.841
29.720
29.714
29.632

Northwest Side Span - After Tensioning of Stay Cables

Unstrained
Total
Chord Elongation
Control Point TP1'-Pylon
Length
Length
Length
L
Lu
L = L + Lu
X'(m)
Y'(m)
Z'(m)
(m)
(m)
(m)
(m)
1979.337
16.498
48.420
21.901
0.044
21.857
21.901
1979.327
16.497
52.186
28.772
0.026
28.747
28.773
1979.321
16.497
54.892
35.027
0.033
34.994
35.027
1979.316
16.496
57.524
41.350
0.036
41.315
41.351
1979.311
16.496
60.116
47.722
0.043
47.680
47.723
1979.307
16.496
62.683
54.132
0.051
54.082
54.133
1979.303
16.495
65.235
60.570
0.059
60.513
60.571
1979.299
16.495
67.776
67.031
0.052
66.982
67.035
1979.296
16.495
70.309
73.510
0.058
73.456
73.514
1979.293
16.494
72.836
80.003
0.065
79.943
80.008
1979.289
16.494
75.359
86.507
0.072
86.442
86.513
1979.287
16.494
77.877
93.019
0.078
92.948
93.027
1979.284
16.493
80.394
99.537
0.085
99.462
99.547
1979.279
16.493
82.907 106.053
0.091
105.972
106.064
1979.275
16.492
85.419 112.569
0.101
112.481
112.582
1979.269
16.492
87.929 119.086
0.104
118.997
119.101
1979.326
16.491
90.425 123.837
0.097
123.761
123.858
1979.339
16.491
92.919 128.593
0.108
128.506
128.614

X Chainage
Y Transverse Direction (North Positive; South Negative)
Z Elevation (Relative To Malaysia NGVD)

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Sag
(m)
0.014
0.055
0.076
0.117
0.149
0.184
0.223
0.341
0.401
0.464
0.533
0.606
0.685
0.768
0.833
0.953
1.149
1.156

Stay Cable Forces Comparison at Bridge Completion

Stay No.

Resulting Cable Forces (kN)

Design Cable Forces (kN)

S18
S17
S16
S15
S14
S13
S12
S11
S10
S09
S08
S07
S06
S05
S04
S03
S02
S01
M01
M02
M03
M04
M05
M06
M07
M08
M09
M10
M11
M12
M13
M14
M15
M16
M17
M18
Total

5379
3540
3781
4091
4205
4322
4254
4342
4386
4425
4473
4613
5190
5471
5756
5670
6037
6108
4984
3482
3772
4143
4328
4444
4346
4464
4510
4495
4916
4983
5055
5232
5201
5463
5868
5901
171633

5397
3539
3791
4111
4226
4339
4271
4363
4411
4455
4511
4657
5235
5512
5785
5580
6043
6115
5065
3496
3786
4157
4336
4445
4343
4457
4503
4493
4917
4986
5059
5238
5210
5478
5895
5938
172143

Differences= (ResultDesign)/Design (kN)

-0.3%
0.0%
-0.3%
-0.5%
-0.5%
-0.4%
-0.4%
-0.5%
-0.6%
-0.7%
-0.8%
-0.9%
-0.9%
-0.7%
-0.5%
1.6%
-0.1%
-0.1%
-1.6%
-0.4%
-0.4%
-0.3%
-0.2%
0.0%
0.1%
0.2%
0.2%
0.0%
0.0%
-0.1%
-0.1%
-0.1%
-0.2%
-0.3%
-0.5%
-0.6%
-0.3%

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< 5%, OK
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On-Site Stay Cable Installation

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SITE SURVEY PROCEDURE

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Site Survey Procedure

Setting-out is based on bridge profiles (deck and pylons) as modified by
the pre-cambers provided in the Construction Manual. However,
adjustments will be necessary for:
1) site temperature is different
2) construction loadings are not the same as the loads planned
3) correction for any deviations from theoretical profiles from earlier
construction stages
4) foundation settlement
5) falsework deflection and settlement
The survey procedures include generally:

1) pre-pour survey and setting-out

2) post-pour survey
and require geometry, temperature, wind direction and speed, weather
condition and construction load mapping surveys.

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Pylon Survey
Pre-Pour Survey
CHEC to measure site temperature, wind direction/speed
AECOM to provide setting-out information at Control Points

Post-Pour Survey
CHEC to measure site temperature, wind direction/speed, pylon concrete temperature,
control point coordinates, foundation settlement

AECOM to establish pylon alignment at Control Points, to update/adjust finite element

model as needed
REFERENCE POINT

Control Point

REFERENCE POINT

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Deck Segment Survey

Pre-Pour Survey

CHEC to measure site temperature, wind direction/speed, construction

load map
AECOM to provide setting-out information at Control Points (coordinates
and/or break angles)
Post-Pour Survey
CHEC to measure site temperature, wind direction/speed, deck concrete
temperature, control point coordinates
AECOM to establish deck alignment at Control Points (H1-30mm) for
slabs and H2 for edge beams, to update/adjust the finite element model as
needed

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Stay Cable Survey

Pre-Tensioning Survey

CHEC to measure site temperature, wind direction/speed, construction load map

AECOM to provide setting-out information at Control Points - saddles (TP1, TP2)
and bearing plates (TLA1, TLA2)
Post-Tensioning Survey
CHEC to measure site temperature, wind direction/speed, stay cable temperature,
as-built stay cable forces, Provide lift-off forces as requested

AECOM to establish stay cable force distribution, to update/adjust the finite

element model as needed

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Survey Methods
3D coordinates measured by Total Station, GPS, or other equipments with precision to a
few mm
3D coordinates shall be converted to the global coordinates system
The survey results are checked by construction team before transferring to construction
engineering team on the same day

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Wind Monitoring
Typical Locations of Anemometers on Pylons
Stationary and Moveable

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Temperature Monitoring
900

900

1200

900
96.280

22

One temperature sensor on each

face at every three segments

1000

1200

95.280

21

1000

900

19

2000

4000

20

18

1000

17
16
15

400

2200

400

3000
14

SECTION D-D
13
12

93600

11

2000

10
9

CL OF BRIDGE

35.320

35.320

30.320

2000

6000

2.5%

2.5%

2000

32.64

32.64

150 KICKER

PILECAP TOP LEVEL

150 KICKER

Pylon

Tower Crane

1
2.680

400

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2200~4200
3000~5000

ELEVATION VIEW

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400

Temperature Monitoring
Deck

Stay Cables

Temperature Sensors

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Temperature Monitoring

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Foundation Settlement

Total Station or GPS

Sensors on Pile Caps

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THANK YOU

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