CHINA-MALDIVES FRIENDSHIP BRIDGE

DETAILED DESIGN

VOLUME 3 OF 10 APPROACH BRIDGE

SECTION 1:PART 2- APPROACH BRIDGE SUBSTRUCTURE

CHINA RAILWAY MAJOR BRIDGE RECONNAISSANCE & DESIGN INSTITUTE CO., LTD.
CCCC SECOND HARBOUR ENGINEERING COMPANY LTD.
JANUARY 2017, WUHAN
 CHINA-MALDIVES FRIENDSHIP BRIDGE

DETAILED DESIGN

VOLUME 3 OF 10 APPROACH BRIDGE

SECTION 1:PART 2- APPROACH BRIDGE SUBSTRUCTURE

SUBSTRUCTURE DESIGNER:

DESIGN MANAGER:

DESIGN DIRECTOR:

DEPUTY CHIEF ENGINEER:

DEPUTY GENERAL MANAGER:

CHINA RAILWAY MAJOR BRIDGE RECONNAISSANCE & DESIGN INSTITUTE CO., LTD.
CCCC SECOND HARBOUR ENGINEERING COMPANY LTD.
JANUARY 2017, WUHAN
 DRAWING INDEX

VOLUME NO. CONTENT DWG. NO.

VOLUME 1 GENERAL DESIGN 15306-04-1101～

MAIN BRIDGE SUBSTRUCTURE (1) 15306-04-2101～

SECTION 1
MAIN BRIDGE SUBSTRUCTURE (2) 15306-04-2201～
VOLUME 2 MAIN BRIDGE
MAIN BRIDGE SUPERSTRUCTURE(1)
SECTION 2 15306-04-2301～
MAIN BRIDGE SUPERSTRUCTURE(2)

APPROACH BRIDGE SUBSTRUCTURE(1) 15306-04-3101～

SECTION 1
VOLUME 3 APPROACH BRIDGE APPROACH BRIDGE SUBSTRUCTURE(2) 15306-04-3201～

SECTION 2 APPROACH BRIDGE SUPERSTRUCTURE 15306-04-3301～

SECTION 1 SUBGRADE, PAVEMENT 15306-04-4101～

VOLUME 4 LINKING ROAD AND TRAFFIC ENGINEERING SECTION 2 ROUTE CROSSING 15306-04-4301～

SECTION 3 TRAFFIC ENGINEERING 15306-04-4501～

VOLUME 5 EMBANKMENT AND BREAKWATER 15306-04-5101～

VOLUME 6 BRIDGE AUXILIARY WORK AND ARCHITECTURAL DESIGN 15306-04-6101～

VOLUME 7 DURABILITY DESIGN

VOLUME 8 CONSTRUCTION SCHEME AND ORGANIZATION PLAN

VOLUME 9 BRIDGE OPERATION MANUAL

VOLUME10 ANNEX: BASIC INFORMATION AND RELATED DOCUMENTS

 PART 2 : DIRECTORY FOR SUBSTRUCTURE OF APPROACH BRIDGE
DRAWING DRAWING
NO. DRAWING TITLE NOS NO. DRAWING TITLE NOS
NUMBER NUMBER

1 INTRODUCTION 4 19

BOQ FOR SUBSTRUCTURE OF APPROACH

2 1 15306-04-3201 20
BRIDGE(2)

3 LAYOUT OF APPROACH BRIDGE 4 15306-04-3202 21

ARRANGEMENTS FOR PIER AND FOUNDATION

4 1 15306-04-3203 22
OF PIER 1 TO 6
ARRANGEMENTS FOR PIER AND FOUNDATION
5 1 15306-04-3204 23
OF PIER 7 TO 9, 25, 26

6 COORDINATES FOR PILE OF PIER 1 TO 9, 25,26 1 15306-04-3205 24

TENDON LAYOUT FOR CAP BEAM OF PIER 1

7 2 15306-04-3206 25
TO9 ,25,26

8 R.C. DETAILS FOR CAP BEAM OF PIER 1 3 15306-04-3207 26

9 R.C. DETAILS FOR CAP BEAM OF PIER 2 TO 9 3 15306-04-3208 27

10 R.C. DETAILS FOR CAP BEAM OF PIER 25 3 15306-04-3209 28

11 R.C. DETAILS FOR CAP BEAM OF PIER26 3 15306-04-3210 29

R.C. DETAILS FOR LATERAL BLOCK OF CAP

12 1 15306-04-3211 30
BEAM OF PIER 1 TO 9, 25,26
POSITIONING REBAR FOR CAP BEAM
13 1 15306-04-3212 31
TENDONS OF PIER 1 TO 9, 25,26
REBAR UNDER ANCHOR FOR CAP BEAM
14 1 15306-04-3213 32
TENDONS OF PIER 1 TO 9, 25,26
R.C. DETAILS FOR PIER COLUMN OF PIER 1 TO
15 3 15306-04-3214 33
6
R.C. DETAILS FOR PIER COLUMN OF PIER 7 TO
16 3 15306-04-3215 34
9, 25,26

17 R.C. DETAILS FOR BORED PILE OF PIER 1 TO 6 3 15306-04-3216 35

R.C. DETAILS FOR BORED PILE OF PIER 7 TO 9,

18 3 15306-04-3217 36
25,26
 Introduction

1 Design Content 5 Main Material

Volume III-1 construction drawings (Volume III: approach bridge) of the Maldives-aid project, （1）Concrete

China-Maldives friendship bridge, indicate the approach bridge substructure (Ⅱ), including the High performance concrete for maritime work complying with “the Code for Design of Highway

substructure of pier 1-9#, 25# and 26#. The drawings mainly include: bridge general layout, pier and Reinforced Concrete and Prestressed Concrete Bridge and Culvert (JTG D62-2004) ” is to be

foundation general arrangement, cap beam tendon layout, pile foundation RC details, RC details for adopted.C35 tremie concrete for bored piles and C50 concrete for pier shaft and cap beam. The cement,

pier column and cap beam, etc. sand, stone, water and other materials used for concrete preparation, concrete mixture ratio, mixing,

transportation and concrete pouring shall be in strict subject to "Quality Control Standard of High

2 Main Design Reference Performance Concrete for Sea Port Engineering"（JTG/T F50-2011）.

All the materials and mixtures for concrete preparation shall be tested. The test method shall
（1）Bidding Document For “Engineering, Procurement And Construction (EPC)” Contract Of
comply with relevant provisions of the state and industry departments currently in effect. Technical
China-Maldives Friendship Bridge Published By Commerce Ministry(October, 2015） ；
requirements for durability of concrete are shown in table 1.
（2）Regulations On Administration Of Foreign Aid Project（Trail）
（Decree No.3 In 2015 By
Table1 Technical Requirements for Concrete
Commerce Ministry）；
56d chloride diffusion
（3）Engineering Feasibility Study Report For China-Maldives Friendship Bridge(June, 2015）； Concrete strength
Structure component Environment grade coefficient drcm
grade
（4）Conceptual Design For China-Maldives Friendship Bridge (July, 2015）； （10-12m2/s）
Pile D C35 4.0
（5）Technical Assignment Book For China-Maldives Friendship Bridge（July, 2015）
Pier column F C50 3.0
（6）"Letter on The Design Change of Part of The Pier Foundation [2016] NO. 533" (CCCC
Pier cap beam F C50 3.0
Second Harbour Engineering Company LTD.).
Note：①the standard curing temperature should be 27 ± 2 ° C；

②test method of chloride ion diffusion coefficient refer to "code for test method of ordinary concrete

3 The Main Design Standard and Refernence Code long-term performance and durability " (GB / T 50082).

The main design standard and code refer to design outline of china-maldives friendship bridge. （2）Reinforcement

The construction specificationcan refer to construction technique standard. HPB300、HRB400 rebar have been employed in the structure design, HPB300 rebar shall comply

with the requirements in “Steel Application for Reinforcement Concrete:Hot-Rolling Plain Round Bar
4 Coordinate and Elevation System
（GB 1499.1-2008）”. HRB400 reinforcement bar shall comply with the requirements stipulated in
The plane coordinate system and the elevation system are both adopt local systems of Maldives.
“(GB1499.2-2007) Steel for The Reinforcement of Concrete-Ribbed Bars”. As per the durability

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overall plan of the bridge, it is recommended to use epoxy-coated steel complying with (GBT (excluding block) in the transverse direction of bridge, with bidirectional 2.5% cross slope on the top

25826-2010) Epoxy-coated steel for the reinforcement of concrete in pier column and cap beam of pier surface. Lateral block is arranged in the middle of cap beam. The height at the cantilever end of cap

1to 9, 25,26 on the splash zone. beam is 1.8m, the under edge of the cap beam is arranged to tangent to pier with round fillet R=250cm.

Plain round bar HPB300 is expressed as "" in the document and ribbed bar HRB400 is The cap beam adopts C50 marine durability concrete.

expressed as "". 2 strands of Φs15.2-12 and 6 strands of Φs15.2-15 prestressed strand are used for the cap beam

Ribbed bars (HRB400) with a diameter not less than 25mm are subject to mechanical splicing; with two batches of tensioning. Tension the first batch of prestressed strand when concrete strength

the performance of mechanical coupler shall meet the requirements stipulated in Technical Code for reached 90% of the design strength, tension the second batch of prestressed strand after erection of I

rebar mechanical splicing (JGJ107-2010). The coupler is of Grade I. Reinforced couplers shall be beam. The control stress under anchor is 1339Mpa.

arranged at positions with smaller stress of the component in interlace. The connector distribution rate Double-column piers are adopted. Pier column sections are rectangular with rounded (R=30cm),

at the same cross section shall be no greater than 50%; in addition, special attention shall be paid to which plane dimension is 1.6m × 1.6m for pier 1 to 6, 1.6m (transverse direction of bridge) × 2.0m

ensure protection layer thickness of each type of reinforcement bar. Lap and tie joint can be adopted on (longitudinal direction of bridge) for pier 7 to 9,25,26. The pier column is of C50 marine durability

ribbed bar (HRB400) with a diameter less than 25mm. The lap length and spacing of rebar shall concrete.

comply with the requirements in “Code for Design of Highway Reinforced Concrete and Prestressed The pier column of 1 to 6 base on a bored pile of diameter 2.0m, the center distance between two

Concrete Bridge and Culverts（JTG D62-2004）”.. piles is 9m. The pier column of 7 to 9,25,26 base on a bored pile of diameter 2.2m, the center distance

（3）Tendon, anchorage and duct between two piles is 9m. The concrete, 2m below the pile top, is C50 marine durability concrete.

Low relaxation prestressed steel strand with a nominal diameter of 15.2mm, fpk=1860MPa and The pile is of C35 marine tremie concrete.

Ep=1.95*105MPa is to be used. The technical standard shall comply with the requirements stipulated 7 Construction Attentions
in "Steel Strand for Prestressed Concrete "(GB/T5224-2014).
The bridge construction technology, material requirements and quality should not only be in
Prestressed anchorage, clamping piece and coupler shall comply with relevant regulations of
accordance with the relevant provisions of the“Technical Specifications for Construction of Highway
"Prestressed anchorage, clamping piece and connector" (GB/T 14370-2007) and "Applied technology
Bridges and Culverts” JTG/T F50-2011, but also pay special attention to the following matters:
specification of prestressed anchorage, clamping piece and connector "(JGJ 85-2010).
7.1 Construction of Bored Pile foundation
Embedded duct of prestressed steel strand shall be plastic corrugated pipe complying with the
（1）Bored pile is adopted for all the approach bridge foundation, The detailed requirements
requirements stipulated in "Plastic bellows for prestressed concrete bridge" (JT/T 529-2016). Duct
didn’t specify in the drawings, the contractor shall decide the diameter, thickness of wall, and bury
adopts vacuum aided grouting technique. The detailed information of specific technical requirements is
depth, etc. by itself according to actual site conditions and relevant Standards & Codes.
as shown in relevant technical standards.
（2）During drilling, contractor shall compare the actual soil conditions with the adjacent
6 Development of Substructures borehole log. If there is obvious difference between them, influencing the bearing capacity of the pile,

The pier adopts double-column piers with prestressed concrete T-type cap beam, the full shall inform the designer immediately for adjusting the pile length.

prestressed concrete inverted T-type cap beam is 2.5m width in the longitudinal direction and 18.7m （3）The deviation of the pile after completion shall be less than 1/100, the deviation of bored pile

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top center shall not larger than 5cm, and the borehole diameter shall not less than the design pile (9) The mud should be properly handled during construction of bored piles to avoid pollution.

diameter. The borehole should be timely cleaned after drilling completion, and the thickness of 7.2 The Construction of Shaft Column and Cap Beam
sediment shall not exceede 10cm before casting the tremie concrete. With secondary pile hole cleaning （1）As the pier shaft and cap beam have great influence on the appearance of bridge, the

before the pouring of concrete, to avoid sediment thickness affect the bearing capacity of pile. construction formwork shall be smooth and have good water permeability to ensure that the concrete

（4）Reinforcement cage can be machined in segments, and extended in length during installation, of pier shaft and cap beam is smooth outside with compacted inside.

for the fabrication of rebar, shall follow the current codes and specifications. The mechanical coupler （2）The interface between fresh and hardened concrete shall be roughened and cleaned at

should be tested on construction site to ensure it satisfied the requirements of current code and construction joint to ensure effective combination between concrete.

specifications. （3）The concrete of pier shaft shall be poured within two weeks aftter the completion of piles.

(5) The reinforcement cage should be fixed, and the deviation of the center of the reinforcement Effective measures shall be taken to decrease the hydration heat of concrete. In order to avoid crack on

cage and the borehole should not be more than 5cm. And due measures shall be adopted to prevent the the pier shaft, the curing shall be strengthened.

reinforcement cage float-up during casting concrete. The construction process shall meet the relevant （4）After the pouring of cap beam, effective measures shall be taken to block both sides of

requirements specified in the Standards & Codes. prestressed pipe to prevent chloride deposition. The interval between strand penetration and

（6）Steel tubes for sonic-testing are installed for each pile, the construction methodology shall prestressed tension shall not exceed 12 hours. When the concrete strength of cap beam reaches 90%

meet the requirements specified in relevant standards. To prevent slurry leakage, plugging pipe of design strength, the first batch of tendons are tensioned. After the erection of I girder, the other

incident, acoustic pipe connection must be reliable, sheathed threaded joints should be adopted, the tendons are tensioned. The tension of prestressed tendons follows the principle: intermediate first and

pressure performance (external pressure) of sonic test tube wall and joints should not less than 5.0 later on both sides with symmetrical tension. The tension of prestressed tendons is controlled by

MPa, the joints can bear 4.5 MPa external pressure under the condition of 3KN axial tensile. The tension force and elongation, mainly by tension force. The control stress under anchor is 1339Mpa.

contractor should take measures to protect the sonic test tube in the installation of reinforcement cage The error between actual stretching elongation and theoretical calculation shall be controlled within

and pouring concrete, each steel pipe should be grouted after the sonic-testing. 5%.

(7) As the pile foundation is located in the coral reef geology, post grouting for pile base is （5）After the tendons are tensioned, the pipe shall be grouted densely in time and the

needed because of uncertainty of the soil mechanical properties. The grouting tube for pile base should interval time shall not exceed 12 hours. The grade of cement paste shall be not less than M50. And

be reserved during pile foundation construction. then the sealing anchor concrete is poured. The grade of concrete is C50. Cement paste and sealing

（8）The pile base grouting is controlled by grouting volume and pressure, mainly by grouting anchor concrete materials shall meet the relevant regulation in article 7.9 of “Technical Specifications

volume. The calcultion of grouting volume refers to related requirements for gravelly soil in appendix for Construction of Highway Bridges and Culverts” （JTG_TF50-2011）.

N "key technology for post grouting" of "Code for Design of Ground Base and Foundation of Highway （6）The lifting of precast beam should follow the principle: from the centre line of bridge to both

Bridges and Culverts"（JTGD63-2007）. The maximun control pressure of grouting shall be 6 ～ sides and symmetrical construction. The bridge deck should also follow the principle as above.

8Mpa. The slurry strength grade shall be one grade higher than the pile concrete design strength at （7）The contractor should provide the construction load and its position to designer for

least. The slurry fluidity shall be less than 18s. checking the security of structure. The construction could not proceed until the approval of the

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designer. （9）The contractors shall take feasible wind protection measures to ensure the security during

construction.

（10）If there are abrupt slope and steep shore, the disturbance of rock around shall be decreased
8 Others in construction. If the nature rock aroud or the rock disturbed in construction are found to be unstable,

（1）The contractors shall have a careful study and overall consideration on the design documents. it shall be reported to the management department in time. The construction could not be continued

The coordinates, elevation, reinforcement details and related dimensions of structure shall be checked until some measures are taken.

carefully. Once the problem is found, it should be reported to the design company.The construction （11）The contractors shall take necessary measures to ensure the security of construction and

could not start until the problem is solved. workers during construction of whole bridge.

（2）The contractors shall make detailed construction organization plans and feasible construction （12）Other specific construction requirements refer to other volumns. And the requirements not

schemes, and carry out strictly after approval to ensure the quality of bridge and security in included shall meet “Technical Specification for Construction of Highway Bridge and Culverts”

construction. (JTG/T F50-2011) and “Quality Inspection and Evaluation Standards for Highway Engineering” (JTG

（3）The contractors shall take notice of the relationship between members and related design F80/1-2004).

documents to ensure the accuracy of pre-embedded parts and avoid missing.

（4）The contractors shall communicated with the relevant part of Maldives in time to ensure the

aviation safety during the construction with large construction machinery within the liminted height for

aviation.

（5）The contractors shall take feasible construction methods to prevent pollution and protect

local natural ecological environment.

（6）The hydrological condition at project location is complex.The influence of ocean current and

wave shall be taken into consideration adequately during construction of foundation and superstructure.

An emergency plan is necessary for construction security.

（7）The contractors shall monitor the ocean current, wave condition, construction platform,

stress and deformation of bridge and build early warning mechanism to ensure the construction

security in the whole period.

（8）When the substructure is under construction, the contractors shall make calculations for

temporary structures. The calculations focus on the influence to major structure caused by external

load such as cofferdams, jacket platform and ship’s temporary stop. The auxiliary measures shall be

taken to ensure the security of major structures in construction.

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1 -7 9 3 23
2 24
-1 0 -2
5 -8 -3 7 2 3 -0
-2 6 0 -6 9 -3 10 23
5
3 -9 1 -4 4 -2
6
-2
1 -0 23 12 12 11 5
-2 8 -6 4 2 -0
0 7 -3 -2
5 -8 -4 -4 6 5 3
0 2 0 -2
8 -1 -3 -3 -3
4 6 0
-2 7 -5 -3 9 -3 0 -1
2
4 -6 8 9 -3
3 -1 8 -4 1 - -3
-1 2 1 -4 9 3 -3 -1
9 0 7 3
3 -6 -4 -4 1 -3 1 3
5 -5 3 -4 3 4
3 -1 9
2 7 -2
-2 8 -5 -4 6
4 7 -5 8 -3 -1
4 -1 1 -4 -3 5
-1 1 -8 1 4 1
9 4 8
-4 -3