Modjo River Bridge Project

Construction Methodology for Box Girder Precasting

Compiled by：

Checked by：

Approved by：

Modjo River Bridge Site Office

China Communications Construction Co., Ltd
July 2015

Table of Content

Construction Methodology for Precasted Box Girder...............................................2

1. General..................................................................................................................2
2. Construction Deployment.....................................................................................2
3. Box Girder Precasting Methodology.....................................................................2
3.1 Box Girder Precasting Procedure Chart..............................................................2
3.2 Precasting Yard Arrangement..............................................................................4
 3.3 Pedestal and Bottom Formwork..........................................................................4
3.4 Formwork Design and Manufacture...................................................................5
3.5 Reinforcement Manufacture................................................................................5
3.6 Installation and Removal of Formwork..............................................................6
3.7 Concrete Casing and Curing...............................................................................6
3.8 Prestressing Construction....................................................................................6
3.9 Anchorage Sealing at Ends of Beam...................................................................9
3.10 Girder Transportation and Storage....................................................................9
4.0 Quality Assurance Measurement.........................................................................9
5. Quality Defects And Control Measures During Box Girder Construction.........10
6. Arrangement of Equipment and Workforce........................................................12
7. Safety Technical Measures..................................................................................13
7.1 Safety Measures For Prestessing Tension Stress of Tendon.............................13
7.2 Safety Technical Measures For Moving Box Girder.........................................13
7.3 Others Safety Measures.....................................................................................13
Calculation of Gantry Crane...................................................................................14
Calculation for Railway Foundation of Gantry Crane............................................22
Bearing Capacity Calculation of Pedestal for Box Girder......................................23
Bearing Capacity Calculation of Pedestal For Beam Storage.................................26

Attachement:

Appendix I Process for Tension of Prestressed Steel

Appendix II Statistics of Precast Box Girder
Appendix III Arrangement of Precast Yard
Appendix IV Gantry Crane Design Drawing
Appendix V Design of Railway Foundation
Appendix VI Pedestal Design
Appendix VII Quality Inspection From

Construction Methodology for Precasted Box Girder

1. General

There is totally 1 new-built box girder bridges along the Modjo River Bridge project road with the
length of around 100m.
The superstructure of bridge is designed to be 25m-span precast box girder. The total amount of
precast box girder is 16 pieces. The detail information could be seen in following.
 Statistics of Precast Box Girders
Works Preparation
Steel bar testing

Bridge No. Station River (stream) Name Span No. of Box Girders
Material
Binding bottom and web
Steel bar manufacture steel bar Test
Proportion test
1 K0+607.775 Modjo 1-25m 12
Corrugated pipe
installation
Total Material preparation
12

2. Construction Deployment Inside formwork

installation Concrete mixing

The box girder shall be precasted uniformly and installed stage by stage. The precasting work will
be done with substructure construction simultaneously
Binding steel bar for to ensure the box girder precasting will not
affect the superstructure construction progress.
top slab

3. Box Girder Precasting Methodology

Outside and head
formwork installation
3.1 Box Girder Precasting Procedure Chart

Engineer
Inspection

Steel strand test Concrete casting

Test spacimen

Steel strand
Preparation curing

Steel strand Concrete spacimen reach the

installation design strength

tension record Tension calibration

Check elongation

Anchorage

Girder Transportation Consistency test

Grouting Record Grouting

Mortar sample
Test by engineer

Next box girde

3.2 Precasting Yard Arrangement
Mixture ratio test
The precast yard is located on right hand side at main alignment K13+500. We use the existing
Precast Yard & Concrete mixing Station for Box Girder Beams construction. The concrete mixing
plant, box girder precast yard, material storage, living house and office is arranged. The detail
arrangement could be seen in the appendix II.
There are 4 sets of formworks for Modjo River Bridge and 18 existing pedestals in precast yard. 12
pcs box girder for Modjo River Bridge will be stored in the girder storage area. Considering we
have enough formwork for Box Girder Beams, 12 box girders will be construction 1 piece 1 day,so
we will completed with 15 Days.
One underwater well, one tank with volume of 250m3, 2 cement store, one 160Kw generator, 2 set
of mixing plant and 6 concrete tank truck will be arranged in the precast yard. 2 set of drum mixer
will be worked for small member’s concrete casting.

3.3 Pedestal and Bottom Formwork

3.3.1 Site Preparation
Clearing and grubbing shall be done for the precast yard. The soft and low area shall be replaced,
backfilled and compacted.
3.3.2 Pedestal for Box Girder
The precast yard shall be filled by 30cm scoria material and compacted. The foundation bearing
capacity shall be tested by central laboratory and 10cm C20 concrete shall be casted.
The Pedestal shall be casted by C20 concrete with dimension of 2600cm×95cm×25cm and arrange
steel bar by Ф12 with 20cm interval at base bottom. The ends of Pedestal will bear the weight of
box girder which is around 80T after tension of the girder. Therefore, the ends of Pedestal shall be
treated specially. The foundation of Pedestal within 250cm from ends shall be casted by C15
concrete with size of 200cm width and 20cm thickness and the reinforcement shall be put by Ф12
by 20cm interval.
3.3.3 Bottom Formwork
The steel plate with 6mm thickness shall be put on the Pedestal as the bottom formwork. 5# box
iron and rubble pipe for avoidance of mortar leakage during casting concrete shall be embedded on
both sides of Pedestal. The opening will be kept for rod and steel wire to be convenience of lifting.
3.3.4 Pedestal for beam storage
The Pedestal for beam storage adopt concrete enlarge foundation with length of 90m by 2 steps.
The dimension of upside step is 70cm ×40cm and the downside step is 200cm×40cm. The Pedestal
for beam storage will be casted by C20 concrete with Ф16 steel bar by 20cm intervals based on the
foundation of compacted scoria material.
3.3.5 Raiway foundation of gantry crane
The single wheel bear 25T for 100T gantry crane, therefore, the special treatment shall be done for
the railway foundation.
Treatment scheme: The first layer of concrete foundation with dimension 0.5m×0.2m shall be
casted by concrete with steel bar of 3 piece Ф12 and Ф6 stirrup by 30cm interval, which shall be
0.05m higher than original ground.
The dimension of second layer is 1.3m×0.4m and the third layer is 2.1m×0.4m. For the third layer,
the longitudinal steel bar of 7Ф12 andФ6 stirrup by 30cm interval shall be arranged at the top and
bottom of foundation.
After excavation of foundation, the foundation bearing capacity have been tested. The test result is
100Kpa. After considering actual conditions, the foundation shall be replaced by 40cm scoria and
compacted to improve the bearing capacity of concrete foundation before casting C25
reinforcement concrete.
The steel bar of Ф12 with 0.6 interval shall be put as the connection reinforcement for each layer.
The steel bar buried in the concrete shall be 10cm. the rubble stone with dimension not greater
14cm could be put between the second and third layer during concrete casting. Also, the rubble
concrete could be connection member for the second and third layer. The rubble stone shall be
washed before putting in the concrete. The detail design could be refer to the appendix.

3.4 Formwork Design and Manufacture

We have 4 sets of 25m box girder formwork totally. The formwork of side and middle girder is 2
sets for each, and 4 set of inside formwork totally.

3.5 Reinforcement Manufacture

The reinforcement shall be manufactured in the factory and bound on Pedestal.
The reinforcement for girder will be bound in 2 times. Firstly, bind the bottom and web
reinforcement, install the inside formwork and bind the top and flange slab.
The quality of all the reinforcement bar shall meet the requirement of specification and be tested
by laboratory.
The reinforcement shall be clean and any rust shall be removed. The length of reinforcement shall
be cut according to the design drawing. The longer steel bar shall be cut first and short one to
reduce the waste.
The weld or binding point for bearing reinforcement shall be at the weak point of inner force. The
distance between binding point shall be not less than 1.3 times of overlap length.
The reinforcement skeleton shall be binding on the bottom formwork and marked according to the
design drawing to ensure the good appearance. The diameter, amount, distance, dimension, binding
method, protection thickness shall be checked to satisfy the requirement of specification.
When the embedded member is designed, the reinforcement distance shall be adjusted, but the
reinforcement shall not be cut.
Bind the plastic cushion blocks and the cushion block made from mortar is forbidden to use to
ensure the protection thickness and good appearance of box girder.
The position of corrugated pipe shall be controlled by coordinate provided in the approved design
and the corrugated pipe shall be fixed to avoid any loose. The “#” shape of steel bar will be made
to fix corrugated pipe to weld with web reinforcement by 1.0m interval at the straight line and
0.5m interval for the curve section. The fix steel bar at negative moment shall be set with 0.5m
interval. The allowable difference of corrugate pipe shall not greater than ±5mm at the horizontal
direction and not greater than 5mm at longitudinal direction. The installation of corrugate pipe as
the key work procedure shall be controlled strictly.
During installation of anchor plate, the direction of grouting hole or air hole shall be up to avoid
blockage. The concrete near the anchor plate shall be vibrated tightly.
Reinforcement construction procedure:
Bind Underlayer and web reinforcement of bottom slab→locate and fix the corrugate
pipe→installation of uplayer reinforcement, auxiliary steel bar and embedded reinforcement.
The welding work is forbidden after location of corrugate pipe to avoid the puncture on corrugate
pipes.
The distance between reinforcement shall be controlled to ensure sufficient space for auxiliary
steel bar. The cushion block to ensure the protection layer shall satisfy the requirement of
specification.

3.6 Installation and Removal of Formwork

The formwork shall be checked before entrance of site construction. The surface of formwork shall
be clean and smooth without deformation and rust and all the dimension of formwork shall meet
the design requirement.
The steel formwork which is produced by factory shall be assembled tentatively after
transportation to the site. The deformation of formwork shall be adjusted and the joint point shall
be polished to avoid the mortar leakage. The formwork which could not satisfy the requirement
shall not be used for the construction.
The assembled formwork shall be clear without rust and the oil shall be painted.
The formwork will be fixed under the lifting of gantry crane after binding of reinforcement bar.
The formwork shall be strengthened after installation of all the reinforcement bar. For formwork,
the screw rod will be cross the reserved hole and fixed with the box iron. The slip bar will be
connected with formwork and ground anchor which is preembeded to avoid displacement and the
formwork could be adjusted through screw on slip bar.
The request for inspection by engineer shall be asked after formwork construction finished
according to the specification requirement.
After the concrete reached the demoulding strength, the formwork will be removed by gantry crane
under the assistance of manpower. The side formwork will be put both sides of girder and lifted
from girder space. The inside formwork will be removed sectionally by manpower from girder and
transported by gantry crane.

3.7 Concrete Casing and Curing

The concrete casting shall be done at one time layer by layer according to the procedure from
bottom, web to the top slabs. The concrete will be filled in the hopper and lifted by gantry crane.
The concrete shall be casted from one side to another. The casting for bottom slab shall be done
firstly and then to the web slab by each casted layer around 30cm.
The concrete shall be mixed in the mixing plant, transported to the hopper by concrete tank truck
and lifted by gantry crane for casting. The free falling height of concrete shall not greater than
1.5m.
During concrete casting, the segregation of concrete shall not be happened and the vibration shall
be done sufficiently. The slump shall be controlled 12~13cm.
The top layer concrete shall be casted before initial setting of underlayer concrete. The penetrating
vibrator shall be used dominantly.
The concrete shall be vibrated properly. The insufficient and excessive vibration shall be avoided.
The signal of compaction is that the concrete ceases to fall down, no bubble burst out and the
surface becomes flat.
To ensure the operation of vibration, the concrete shall be vibrated from circumjacent to the center.
At last, the vibration on formwork shall be done for convenience of air to be expelled out.
The inside formwork shall be reinforced when installed and any fluctuate shall be forbidden during
concrete casting. Attention on any movement of inside formwork shall be paid. The casting work
shall be stopped and the correction shall be executed immediately if any movement of inside
formwork is happened.
The curing shall be done timely after concrete casting and the curing time shall not less than 14
days and the concrete strength shall reach to the 95% of the design strength.

3.8 Prestressing Construction

3.8.1 Construction Preparation
Build the prestressing steel strand cutting area and the cutting length of steel strand shall be
calculated as following:
Cutting length=duct length crossing by steel strand+ working anchor height + locating plate
thickness + jacking length + anchor height + reserved length.
Generally, reserved length shall be 15~20cm. The steel strand shall be marked after cutting. The
hard plastic pipe will be input the corrugate duct so that the corrugate pipe not be blocked.
3.8.2 Insert Steel Strand
The steel strand shall insert into corrugate pipe by manpower. The working length of steel strand
out of anchor plate shall satisfy the requirement of jacking tension and design.
3.8.3 Steel Strand Tension
After concrete strength reached the tensioning strength, the tension of steel strand could be started.
The calibration for jacking, oil gauge shall be done before operation of tension. The linear
regression formula shall be calculated according to the tension force and oil gauge value.
Tension work shall be done according to the design procedure and requirement. Adopt symmetrical
and simultaneous tension procedure and double control on tension force and length.
The difference of elongation rate between actual surveyed and theory value shall not be greater
than the value specified in the specification.
Tension procedure: 0→10%σcon（Initial stress）→20%σcon→100%σcon (Holding for 2min) →
anchoring.
The attention on tension shall be paid specially. The tension work shall be stopped If any abnormal
condition is happened. After tension, the steel strand could be cut by abrasive wheel cutting
machine from 5 cm of the anchorage.
The theoretical elongation ΔL (mm) of prestressing tendon shall be calculated according to the
formula (1)：
ΔL= ································（1）
where ： -------- Average tensioning force of prestressing tendon (N); the value could be
calculated according to the formula (2) .
L--------- Length of prestressing tendon(mm);
Ay-------- Cross-sectional area of prestressing tendon(mm2);
Ey-------- Elastic modulus of prestressing tendon(N/mm2).
Average tensioning force formula：
= ·····························（2）
Where：
Pp -- average tensioning force of prestressing tendon (N);
P -- Tensioning force of prestressing tendon at the tensioning end (N);
x -- duct length from the tensioning end to the calculated section (m);
θ -- included angle sum of tangent line from the tensioning end to the curved duct part of
calculated section (rad);
k -- friction influence coefficient of local deviation per 1m duct;
μ -- friction coefficient between the prestressing tendon and duct wall.

The calculation formula for tensioning force of prestressing tendon at the tensioning end
P=σk×Ag×n×b/1000·······················（3）
where ： σk----- tension control stress of prestressing tendon(Mpa), this parameter is provided by
design drawing;
Ag------ Cross-sectional area of single prestressing tendon (mm2);
n ------ Numbers of prestressing tendon at the same time (mm2);
b ------ overstretching factor, take 1.0 without overstretching.
The actual elongation ΔL (mm) of prestressing tendon may be calculated according to the formula
(4):
ΔL=ΔL1+ΔL2·······························（4）
Where,
ΔL1 -- Measured elongation value from the initial stress to the maximum tensioning force (mm);
ΔL2 -- Predicated elongation value below the initial stress (mm); the elongation value of adjacent
level may be used.
Tension Control point:
1 The tendon at the tension point shall be smooth and the intercross shall be forbidden.
2 Each hole on locating plate shall aim to the corresponding steel strand and anchorage circle to
ensure the locating plate to be close with the anchorage without joint.
3 When installation of jacking, the steel strand crossing the jacking, locating plate, anchorage
circle, anchorage plate shall be in the same line.
4 The tension on both ends shall be done symmetrically and simultaneously.
5 After operation of Initial stressing, make the record for all the tension process as the staring
data for calculation of actual elongation value.
6 Continue tension until the stress reached 100%σcon and holding 2 minute. compare the actual
and theory elongation value. If the difference is in the scope of ±6%, the tension satisfy the
requirement of specification, otherwise, stop the tension, analysis the reason and take the
measurement.
7 One side of steel strand shall be anchored firstly and then another side after reached the control
stress.
8 The outside of steel strand shall be cut and sealed after tension.
3.8.4 Grouting
The beam shall be move to the storage base after tension and the grouting shall be done as soon as
possible. The ratio of water and cement shall be controlled in the scope of 0.4~0.45. The bleeding
percentage shall not exceed 30% and 2% in 3 hours after mixing. The bleeding shall be absorbed
by mortar in 24hours. The mortar strength shall not less than the design requirement.
Grouting shall be done from downside to upside. The time between mortar mixing and grouting
shall not exceed 30 minutes. The mortar shall be stirred sustainedly before and during the grouting.
The grouting piston pump will be adopted and the maximum pressure shall satisfy the design
requirement.
The grouting work shall be done continuously until the thick mortar is drained out another side.
The consistency of mortar shall be tested until the mortar with same consistency is pressed out.
The pressure for mortar pumping shall be retained 0.5Mpa and hold above 2 minutes.
The following attention shall be taken:
1 Control the mixing proportion of material and the difference shall meet the requirement of
specification.
2 Grouting pipe shall select the high strength rubber pipe without crack under the maximum
pressure.
3 The mortar shall pass the 1.2mm sieve before grouting.
4 The grouting work shall be done in 30Min without any change of liquidity.
5 The structure concrete temperature shall not less than 5℃ in 48h.
6 3 groups of specimen for mortar shall be made with the dimension 70.7mm×70.7mm×70.7mm
under the 28days of standard curing and test pressure strength as the checking quality of
mortar.

3.9 Anchorage Sealing at Ends of Beam

The end surface of beam shall be roughened and washed by water. The formwork and
reinforcement mat shall be bound. Cast concrete as anchorage sealing and curing according to the
specification.

3.10 Girder Transportation and Storage

After tension, the box girder could be transported to the storage Pedestal by gantry crane and the
grouting could be operated on Pedestal. The production date and number shall be marked on the
girder after grouting.

4.0 Quality Assurance Measurement

To ensure the engineering quality, all the material, steel strand, anchorage shall been tested by
authorized department in China and issue the testing report.
Formwork: Assemble the formwork and check the joint and connection condition.
Reinforcement engineering: The protection layer shall be ensured when binding reinforcement
according to the design drawing and construction specification to improve the crack resistance of
concrete.
Make concrete proportion design and carefully organize the production, casting, curing work on
site.
The time for formwork removal shall be reasonable and the adjustment for formwork shall be done
timely. The appearance of concrete shall be smooth, straight and beauty.
Quality Management and Control Chart：
 Project Manager of Bridge
Branch

Deputy PM Chief Engineer

Engineering Business Laboratory

Department Department

Construction team

5. Quality Defects And Control Measures During Box Girder Construction

Reinforcement Formwork Concrete Tension Grouting Lifting
Team Team Team Team Team Team
（1） There are leakage, uncompacted, air hole and ripple of surface in joint between the bottom
and web slab
Cause analysis:
In addition of small reinforcement spacing and protection thickness, the mainly reason from
construction quality control perspective
QualityisControl
that imperfect construction process and poor coarse
aggregate gradation or unreasonable particle diameter. The coarse aggregate accumulate in
together at the bottom of the corrugated pipe. Then a layer of mortar may be emerged easily by
over-vibrating to concrete under corrugated pipe in order to ensure compaction of concrete. Part of
web of box girder is compacted insufficiently or have ripple of surface along corrugated pipe
direction.
Control measures:
The concrete shall be casted simultaneously with bottom, web and top slab with the full face skew
direction section circulation methodology. The slump and particle diameter of concrete under
corrugate pipe shall be controlled strictly. And the coarse aggregate shall pass the sieve, if
necessary.
（2） The camber of box girder is too big to construct bridge deck, particularly when the camber
of side box girder may be up to 4-5cm sometimes.
Cause analysis
Comparing with the middle girder, the side girder have more steel strand and have no negative
moment tensioned. After tension, the elastic modulus could not reach to the designed tension
strength due to the insufficient maturity, which cause the big camber of mid-span. The other reason
is that storage life is too long which results in the longer interval time from sagging moment
tension finishing to negative moment beginning.
Control measures:
The elasticity modulus and mixture ratio of concrete should be controlled strictly according to
design requirement; it should be tensioned and installed box girder in time to shorten the storage
life, the wet joint shall also be constructed to connect the girder with the whole bridge in time.
According to the shop drawing of box girder, the anti-camber can be set on pedestal.
（3） Circular and longitudinal direction bar could not be embedded for flange slab of box
girder or the hole of presress has not been constructed according to the shop drawing and
specification. It will be take some serious effect which affect the quality of wet joint and hole
of prestess.
Control measures
It should be regular inspection and strictly constructed for insert tendon according to the design
requirements, this tendon should be chiseled out in time when prefabricated have finished.
（4） The value of the tension stress for prestessing tendon is not exact, the different between
the actual elongation and the theoretical elongation is more than 6% requested by professional
standard.
Cause analysis
The value of the oil watch is not exact. The modulus of elasticity for steel is not exact when the
theoretical elongation was calculated. The modulus of elasticity should be come from the middle
value of experimentation although there are certificate of requirement standard. Because the range
value of modulus elasticity is big from the actual elongation to the theoretical elongation.
Control measures
The constructors that possess prestressing on construction site shall be stabilization, the controlling
of both stress and elongation should be adopted. The jack and oil watch shall be regular tested. If it
is found that there are some abnormity, the tensioning process shall be paused and continued after
the reasons have been detected. The steel will be checked with increasing frequency, it is better to
test to every bundle so that the value of the theoretical elongation will get adjusted in time
accordingly.
（5） The value of prestress lost increased as a result of mud-jacking process was delayed and
the tunnel cannot be filled fully.
Cause analysis
The reason is that sequence of construction is not arranged properly and grouting process was
delayed for long time. The steel strand is eroded by air and water which cause the prestress losing.
Control measures
According to the professional standard, it shall not exceed 14 days from tension and anchorage to
grouting in order to prevent erosion for steel. So the tunnel shall be grouting after tension as early
as possible.

6. Arrangement of Equipment and Workforce

Main Equipments Table

No. Name number type
 1 Gantry Crane 1 100T
2 Gantry Crane 1 10T
3 Gantry Crane 1 5T
4 Mixing Plant 1 HZ120
5 Agitating Truck 3 8-10m3
6 Loader 1 ZL30
7 Form Vibrator 2 ZFZ1.5
8 Immersion Vibrator 10 ZH-50
9 Jacking 2 Ycw110
10 High pressure oil pump 2 ZB4-500
11 Mortar blender 1 HJ180
12 Generator 1 120KW
13 Steel extension machine 2 GT4-14
14 Bar cutter 2 GQ40T
15 Steel bar bender 2 GT-407
16 Electrical Welding Machine 4 BX1-500

Labor Schedule
No. Name Number No. Name Number
1 Formwork fixer 10 8 Quality supervisor 1
2 Steel fixer 10 9 technician 1
3 electrician 1 10 Safety man 1
4 repairman 1 11 Surveyor 2
5 Crane operator 1 12 lab assistant 2
6 Mixer Operator 10 13 Tension worker 4
7 Labour 30 total 74

7. Safety Technical Measures

7.1 Safety Measures for Prestessing Tension Stress of Tendon

7.1.1 Before tensioning, the platform and cross beam shall be inspected carefully, the process may
be carried out only after the inspection is qualified.
7.1.2 All the construction operation work must wear safety helmet. The operation brand shall be
hanged in the visible place of tension, and only related workers could be allowed to stay area of
tension.
7.1.3 The full time safety-personnel shall be deployed at site construction to tension the prestessed
tendon. Everyone is forbidden to stand behind jack.
7.1.4 The acting of the jack shall be paused when the elongation of the steel is measured.
7.1.5 The workers who operated the jack and measured value of elongation for steel should stand
at the side of jack according to the operation method. The workers are not allowed to leave when
the oil pump is working.
7.1.6 If any abnormity like the value of oil watch librate acutely, leaking oil, severing steel and so
on to be found, the tensioning process shall be paused and the reasons shall be detected.
7.1.7 The protection shall be ensured to keep the tension machine away from rainwater.

7.2 Safety Technical Measures for Moving Box Girder

1 Construction site must be unified command and presided with all works follow sequence by
specialist who should use signal or concise gestures to ensure division and cooperation
orderly.
2 The safety education should be strengthen for all employees to raise consciousness, personnel
and machines must have a good condition for safe operation with frequent checked and
maintain. Moreover some safety precautions (such as putting on helmet, hang the safety rope
and completes the peripheral protection) must be taken to ensure high quality and high
efficiency services for project.
3 Before the construction, the technical engineer should organize the technical personnel and
give the technical explanation to work teams to understand requirements and parameters of
craning girder.
4 Anyone is not allowed to stand under the box girder when the girder is lifted and installed.
5 Every machine will be checked before the process of girder lifting, otherwise the process of
crane must be paused.

7.3 Others Safety Measures

（1） The welding work shall follow the related regulations.
（2） It must have sufficient lighting if worked in the night, and anti-sliding measures should be
adopted in rainy time.
（3） Manage electricity according to the specification. Electric safety signs shall be set up on
site.
（4） Generator with attach facility of fire extinguisher should be installed on steady foundation,
and resistance value of attached grounded wire shall be less than 4Ω. Other wire must be
fastness and protected by an-creepage switch. Some combustible goods must keep away from
the generator.
（5） The distribution box must be protected by an-creepage switch. The door with lock and
waterproofing, the wire, switch and safety device should be arranged according to the
specification. The wire which has dilapidation is forbidden to use. The wire must be laid on
the insulating material.
（6） For the electrician and some special operation personnel, they shall be work with
certificate. The electricity wire is forbidden to connect promiscuously, and the obvious wire
must be found on the ground. All the wire shall be operated by the person in charge, and shall
not be used by others arbitrarily. Moreover, it should be set enough fire extinguishers in office
and site.
（7） A safety distance between air tank and acetylene tank must be assured that there are
enough distance. the pipe of these should be put orderliness and keep away from fire to ensure
safety.
（8） The construction field should be cleared when works finished, and materials or equipment
is laid orderliness. The wire and component of electricity must be installed according to
specification.

Calculation of Gantry Crane

1. Descriptions Of Crane Design

The crane will be used precast of knockdown box girded for 25m span, and tend toward as same
with longitudinal direction of the girder. A piece of girder shall be lifted by single-crane. The span
of crane is 33m in order to headroom of installing formwork, perforating prestressing tendon and
working for tension. The distance from point crane to ends of girder is 1m, and the ends of
crossbeam for crane is 5m.The height of crane is 8.485m due to the requirement of the height for
two piece girder will be laid together. Structure sketch of crane as follows,

Figure1 The profile of crane

Figure 2 Side View of Gantry Crane

2. Calculation of Internal Force For Crane Cross Beam

2.1 Structure Model of Crane
The cross beam withstand acting of the vertical force and gravity density which can be calculated
base on symmetrical acting.
Quantity Table Of Crossbeam
No. name unit Unit weight （kg） number Total weight（kg）
1 bailey piece 270 78 21060
2 Jack rod A piece 212.6 13 2764
3 Jack rod B piece 87.1 42 3659
4 Holding nut piece 0.691 408 282
5 Stiffening-effect piece 80 24 1920
6 bailey pin+ safety pin piece 3 180 540
7 Stiffening-effect bolt piece 2 48 96
8 P50 rail m 113.71 32 3646.8
Walk structures with
9 piece 1500 4 6000
diameter 400mm
10 5T windlass and sheave set 1000 2 2000
11 5T dynamic pulley tackle set 1000 1 1000
Total 42967.8

The weight of crossbeam is 43T according to upper table

So:
2.2 stress calculation
It is calculated base on symmetrical acting for deadweight of crossbeam and the curve bending
moment is parabola following shop drawing 4（a）which equation is Mq(x)= （1- . When
the girder lifted, the force with the two crane rope should be calculated as the centralized force
which the curve bending moment is parabola following shop drawing 4 （ b ） . Two bending
moment will effect together to be ascertained the position of max bending moment. It should be
compared the max stress with allowance of stress according to the max bending moment.
The weight of pulley tackle and top vehicle is 40KN, the weight of box girder is
750KNx1.05=787.5KN considering 5% superscale for 25m span box girder. The load of each rope
point for crane is P as follows considering the 20% concussion and safety coefficient.
P=(40*2+787.5)*1.2/2=520.5KN
C D
a b c
l

Chart 3 Sketch of rope point for crane

T1=T2=520.5KN a=5m b=23m c=5m l=33m

The crane of 25m span box girder lead bending moment as chart 3(b) for cross beam, the bending
moment equation should be constituted according to reference frame which based A point to origin
= = =520.5KN

= = =520.5KN
According to combination for bending moment:
M(x)=Mq(x)+Mt(x)
the site of max bending moment come from 5≤x≤28m section obviously. So,

It should order the formulae equal to 0 after derivative to an independent variable.

So. 178.37-10.81x=0
x=16.5m
The value of the X will be substitutd for upper equation, then =3988KNm
According to the table of code, allowable bond stress of 16Mn steel ， Sectional
resisting moment of mono-row and mono-layer enhance bailey truss
The max shearing force comes from the position of fulcrum; the allowable max shearing force is
the same as the value of mono-row and mono-layer bailey truss, so the value is [Q]=245.2kN
 <

2.3 Flexibility Calculation

According the table 3-5 in the page 59 for enchiridion of constructional Bailey bridge
Sectional inertia moment of mono-row and mono-layer enhance bailey truss: I=577434.4
elastic modulus of steel: E=2.1×1011MPa
The equation of flexibility calculation for the weight of crossbeam ，
Then: =1.30cm
it will get the equation of flexibility calculation with integral method for the centralized force.
……①
……②
It should be combined with the value of flexibility belong to T1 and T2 acting for crossbeam
It will get the max value of flexibility when X located nearby midspan. So flexibility value
calculated with X=16.5m.
Then: =520.5、a=5、b=23、l=33、x=16.5
So: =3.46cm
Then: =520.5、b=23、l=33、x=16.5
So: =2.28cm
f= + + =1.30+3.46+2.28=7.04cm
f/l=7.04/3300=1/469＜1/400
According to the calculation of bending moment, shearing force and flexibility, it is safety to crane
the 25m span box girder to use 6 layers bailey for crossbeam
2.4 Calculation For The Position Of Bailey Fulcrum
The position of fulcrum belong to ends of bailey which allowable resisting stress is 100KN,
considering the principia for enlarge 30% to allowable resisting stress in temporary project, the
allowable sustain stress can be calculated as follow formula.
[N]=100 kN×6 row×1.3=780 KN
According to the calculation above chapter :N=520.5KN，safety factor:i=780/520.5=1.5
It meets the requirement of design.
3 Calculation for The Crossbeam On The Vertical Post
3.1 The sketch under force acting as follows;

3.2 Calculation for Inner Force

The bending moment from self-weight can be ignored for the crossbeam
Axial force of crossbeam
The max shearing force
3.3 The calculation for size of crossbeam as follows

Chart 6 size for the crossbeam on the vertical post

Area
The inertial moment:

=768953125mm4
The flexural modulus

The area moment

The thickness of web plate

3.4 Calculation Of Strength
3.4.1 Flexural tensile stress

3.4.2 The shearing force

3.4.3 The calculation of stiffness

4 The calculation of the vertical post
The force on the vertical post is N=411.87KN.
4.1 The calculation for size as follows

4.2 The stability calculation of pole

Stability coefficient of axle load member adopt as per table：φ=0.847

The stability calculation of pole：

The wheel pressure calculation
5.1 work acting for crane：
5.1.1 The wheel pressure by working acting for crane

5.1.2 The wheel pressure by inertial force

5.1.3 The wheel pressure by wind power

The capsized moment calculation of crane by wind power
The working acting crane may meet instantaneous winds, and the wheel pressure of it is calculated
by follows formula

The pressure of wind power is calculated with follows formula when the construction of site was
delayed by abominable weather.

The stress of capsized and pressure by wind power calculated for other parts of crane that have the
same barycenter and inertia stress as follows.
on top of vehicle structure:sizes;3*2m，two, The area aweather：
coefficient of area：
The stress of wind power：
The capsized moment by wind power of vehicle
the orbit of the vehicle: The area aweather：
coefficient of area：
The stress of wind power：
The capsized moment by wind power of vehicle

Crossbeam structure，The area aweather：

coefficient of area：
The stress of wind power：
The capsized moment by wind power of vehicle

the orbit of 5T dynamic pulley tackle， The area aweather：

coefficient of area：
The stress of wind power：
The capsized moment by wind power of vehicle

5T dynamic pulley tackle ,the area aweather：

coefficient of area：
The stress of wind power：
The capsized moment by wind power of vehicle

the vertical post, the area aweather：

coefficient of area：
The stress of wind power：
The capsized moment by wind power of vehicle

walking vehicle, the area aweather：

coefficient of area：
The stress of wind power：
The capsized moment by wind power of vehicle

The craned box girder The area aweather：

coefficient of area：
The stress of wind power：
The capsized moment by wind power of vehicle

5.1.4 The total capsized moment in working acting

The wheel pressure by wind power

The wheel pressure in working acting

The calculation of the wheel pressure
The diameter of the wheel for vehicle，E=2.1×105Mpa,l=70mm,R=200mm,p=244.96KN
Tangency stress

5.2 Relaxing acting for crane

The wheel pressure by relaxing acting for crane

The wheel pressure by wind power:

163703N=163.7KN
The wheel pressure by relaxing acting for crane:

The calculation of the wheel pressure：

tangency stress:

So, it is safety to adopt 400mm diameter according to the calculation.

6 Calculation of the steel wire rope
The allowable tension of the steel wire rope

where：K1—— safety factor of steel wire rope by pulley, K1=6

Sb—— rupture stress of steel wire rope，KN
Sb=αPg
where：α—— Imbalance coefficient of load between steel wire rope， Type 6×37 for steel wire
rope, thenα=0.82
Pg—— The total rupture stress of steel wire rope
According to the table in code, the value of Pg is 426.5KN if adopt the steel wire rope for the 26mm
diameter and 1700MPa tension
Sb=0.82×426.5=349.73KN
S=349.73/6=58.29KN
According to above calculation, the total load of signal crane position is 520.5KN, and is
apportioned by 10 groups steel wire rope .So every group steel wire rope must be supported
52.05KN, it is meet the requirements of design.
 Calculation for Railway Foundation of Gantry Crane

Railway foundation of gantry crane :The first layer of concrete foundation with dimension
0.5m×0.2m shall be casted by concrete with steel bar of 3 piece Ф12 and Ф6 stirrup by 30cm
interval, which shall be 0.05m higher than original ground. The dimension of second layer is
1.3m×0.4m and the third layer is 2.1m×0.4m. For the third layer, the longitudinal steel bar of 7Ф12
andФ6 stirrup by 30cm interval shall be arranged at the top and bottom of foundation.
According to the calculation of crane, the tangency stress is 803MPa, and diffuse by spreading
angleθto bed course pass 1m thickness of concrete layer, the value of the tangency stress is
decrease as the process.
The tangency stress will be distributed to the top of gravel layer through the spreading function of
1m concrete layer by spreading angle 45. If trapeziform distributing can be supposed on top of
gravel layer for diffused the tangency stress, then we can calculate according to the following
formula.
a×b×σ1＝[(b＋2×tanθ×h)×(a＋2×tanθ×h)] ×σ2
The final formula for affixation stress is following by predigestion.
σ2＝a×bσ1／ [(b＋2×tanθ×h1)×(a＋2×tanθ×h1)]
where：a—The length of rectangular concrete foundation; a＝30m；
b—The width of concrete top foundation; b＝0.5m；
h—Bed course thickness; h＝1m；
σ1—The average stress under the concrete
σ2—The average stress under bed course
θ—Pressure spreading angle for bed course can be adopted 45°
Variable replace by value
σ2＝30×0.5×803／((0.5＋2×tan45×1)×(30＋2×tan45×1))
＝150.56kpa
σ＝σ2＋r1×h1 (r1：Dead weight of concrete; 24KN／m3)
＝150.56＋24×1
＝174.56kpa
The bearing capacity of foundation is more than 200kpa, and meets the requirement after
replacement
It should be arranged some steel between the first layer and the third layer according the
conformation, in fact, The first layer of concrete foundation shall be casted by concrete with steel
bar of 3 piece Ф12 by 30cm interval.
A 实=3.14×62×3=339mm2
A=500×200=100000mm2
ρ=339/100000=0.34%＞0.21%，
The reinforcement ratio meets the requirement of code.
For the third layer, the longitudinal steel bar of 11Ф12 shall be arranged at the top and bottom of
foundation.
A 实=3.14×62×22=2487mm2
A=2100×400=840000mm2
ρ=2487/840000=0.30%＞0.21%.
The reinforcement ratio meets the requirement of code.

Bearing Capacity Calculation of Pedestal for Box Girder

The Pedestal shall be casted by C20 concrete with dimension of 2600cm×95cm×25cm and arrange
steel bar by Ф12 with 20cm interval at base bottom. The precast yard shall be filled by 30cm scoria
material and compacted, and 10cm C20 concrete shall be casted. The ends of Pedestal shall be
treated specially. The foundation of Pedestal within 250cm from ends shall be casted by C15
concrete with size of 200cm width and 20cm thickness and the reinforcement shall be put by Ф12
by 20cm interval.
1. Parameter Calculation
1.1 The parameter of foundation soil
The foundation bearing capacity has been tested. The test result is 200Kpa
2. Parameters of load for 25m span side box girder
The ends and mid-span sections of 25m box girder

Ends sections of 25m box girder

The mid-span sections of 25m box girder

The area for ends of box girder Ad=1.31m2,and section girth Cd=11.76m
Concrete deadweight of the ends section for girder per meter is follows,1.3×26×1.31=44.28
kN/m ,which should consider the 1.3 of cast impact coefficient.
The area for mid span of box girder Ac=1.13m2, and section girth Cc=12.14m
Concrete deadweight of the mid-span section for girder per meter is follows,
1.3×26×1.13=38.19 kN/m 1.3×26×1.13=38.19 kN/m
the formwork deadweight of the ends section for girder per meter is follows,
0.75×11.76×1.0=8.82 kN/m
The formwork deadweight of the mid-span section for girder per meter is follows
0.75×12.14×1.0=9.11kN/m
Live load per meter for builder and equipments is follows,
3×1.2×1.0=3.6 kN/m, which is adopted by equal load and the value is 3kN/m2
The abutment deadweight per meter is follows, 25×0.25×0.95=5.94kN/m
2. The Calculation for Pedestal Foundation
The calculation for Pedestal foundation includes prefab moment and tension moment, the whole
foundation endure symmetrical load in the first moment, for the second moment, the working point
of girder have been moved to both of ends as a result of the arched for girder after the prestressing
tendon have tensioned, So the value of stress for Pedestal foundation should more than the value of
prefab moment.
1. Prefab moment
The counterpressure at the bottom of Pedestal foundation
The ends：Nd=44.28×1.0+8.82×1.0+3.6×1.0+5.94×1.0=62.64kN
Mid -span：Nc=38.19×1.0+9.11×1.0+3.6×1.0+5.94×1.0=56.84kN
The calculation of stress for foundation

The ends：σ1= = =31.32KPa＜200KPa

It meets the requirement of bearing capacity.

Mid -span：σ1= = =59.83KPa＜200KPa

It meets the requirement of bearing capacity.

2. Tension Moment
Loads for ends of box girder：N=（25×28.4+2.5×2×0.2×2）/2=356KN

The stress for foundation：σ= = =71.2KPa＜200KPa It meets the requirement of

bearing capacity
3. The calculation of steel
The reinforcement shall be put by Ф12 by 20cm interval in foundation of Pedestal
A 实=3.14×62×6=678mm2
 A=950×250=237500mm2
ρ=678/237500=0.30%＞0.21%，
The reinforcement ratio meets the requirement of code.
The foundation of Pedestal ends shall be enlarged treatment, and 10 bars shall be put by Ф12 by
20cm interval.
A 实=3.14×62×10=1130mm2
A=2000×200=400000mm2
ρ=1130/400000=0.30%＞0.21%
The reinforcement ratio meets the requirement of code.

Bearing Capacity Calculation of Pedestal For Beam Storage

The Pedestal for beam storage adopts concrete enlarge foundation with length of 90m by 2 steps.
The dimension of upside step is 70cm ×40cm and the downside step is 200cm×40cm. The Pedestal
for beam storage will be casted by C20 concrete with Ф16 steel bar by 20cm intervals based on the
foundation of compacted scoria material.
The bearing capacity of foundation is more than 200 KPa after test
The stress calculation of unitary Pedestal for beam storage; it should be calculated according to be
put 3 layers
The max volume for 25m span box girder according to shop drawing is 28.61m3
So the weight of 25m span box girder:26×28.61=743.86kN
The pressure of the Pedestal for beam by box girder is follows, N=743.86×3=2231.58kN
Considering the width of girder is 1 meter, so the stress at the bottom of girder is follows,

The stress at the bottom of the Pedestal for beam is follows,

σ2＝a×bσ1／ [(b＋2×tanθ×h1)×(a＋2×tanθ×h1)]
where: a—the length of rectangular concrete foundation, a＝90m；
b—the width of concrete top foundation, b＝0.7m；
h—bed course thickness, h＝0.8m；
σ1—The average stress on the top of the concrete；
σ2—The average stress under the concrete
θ— Pressure spreading angle for bed course can be adopted 58°
σ2＝90×0.7×0.128／((0.7＋2×tan58×0.8)×(90＋2×tan58×0.8))
＝27kpa
σ＝σ2＋r1×h1 (r1：Dead weight of concrete 24KN／m3)
＝27＋24×0.8
＝46.2kpa
So it meets the requirement of bearing capacity
It should be arranged some steel according the conformation
The Pedestal for beam storage will be arranged Ф16 steel bar by 20cm intervals based on the
foundation.
A 实=3.14×82×10=2010mm2
A=2000×400=800000mm2
ρ=2010/800000=0.30%＞0.21%，The reinforcement ratio meets the requirement of code.