METODE KONSTRUKSI

MAIN SPAN

 Bored Pile
 Pile cap
 Pylon
 Steel Box Girder dan
Cable Stayed Installation
 Long Section of Approach Bridge and Main Bridge

TO SURABAYA TO MADURA

APPROACH BRIDGE CABLE STAY BRIDGE APPROACH BRIDGE

672 M 818 M 672 M

1 BORED PILE

Data teknis:
• Jumlah bored pile per
pylon adalah 56 titik
@ Dia. 2.4 m, L = 69 m
s/d 75 m
• Volume beton per titik
~ 340 m3
• Steel bar dirangkai di
stockyard
Construction Method | Bored Pile

Metode yang biasa digunakan untuk

pekerjaan bored pile dengan diameter
besar yang berada pada lingkungan laut,
adalah:

 Rotary Kelly Drilling Method with high

capacity hydraulical rigs

 Reversed Circulation Drill Method

Construction Method | Bored Pile
use Rotary Kelly Drilling Method
Alat yang digunakan:
 Pile driving barge 220 ft equipped with
crawler crane 150 ton, diesel hammer /
vibro hammer, bentonite plant, drilling
rig BG 30, genset, winch 8 x 25 ton,
container office etc
 Concreting barge 220 ft including
batching plant 60 m3 / hour.
 Transport barge to transport steel pile,
rebar etc
 Dumping barge 300 m3 to spoil
excavation material to shore or sea.
 Tug boat 800 hp and personnel boat.
Construction Method | Bored Pile
Sequence of Work
Remote Slurry Plant
STORAGE TREATMENT

Platform
(Jack-up or
Equivalent)

Soft Soil

Hard / Dense
Soil
Founding Soil

Installation of Casing
Excavation of the soil with
the drill bucket or auger,
stabilisation of the borehole
with slurry fluid
Cleaning the slurry with the
desander. Used slurry
cleaned/separated by
decanter
Installation of the
reinforcement auxiliary cage
by crane (using the drill rig
as illustrated is for special
cases only)
Pouring the concrete into the
bore hole through the tremie
pipe. Remove slurry by
pumping back to the tank
Casing installation (1/2)
Jack up barge
Rotary Drilling with Kelly - Equipment

Rock auger Rock auger

Core barrel
Bucket

Casing Shoe
Bucket
Drilling
Drilling in progress
Concreting
Construction Method | Bored Pile
use Reversed Circulation Drill Method

Bored Pile
use Reversed Circulation Drill Method
 PEKERJAAN PERSIAPAN PEMANCANGAN &
PENGEBORAN PONDASI BORED PILE (TAMPAK ATAS)

TAHAPAN PELAKSANAAN :
1. SURVEY PENDAHULUAN  PASANG PELAMPUNG DAN BENDERA
2. MOBILISASI CASING BORED PILE  PENYAMBUNGAN PADA PONTON SERVICE
3. MOBILISASI PONTON PANCANG  LEGO JANGKAR

1. 3.

PONTON
PANCANG

PONTON SERVICE
& CASING BORED PILE

P86 P87 P88 P89 P90 P91 P92 P93 P94 P95 P96 P97
2.
SITE PLAN
 PEKERJAAN PERSIAPAN BORED PILE
(TAMPAK ATAS)

TAHAPAN PELAKSANAAN :
4. PEMBUATAN PLATFORM
 PEMASANGAN PLATFORM SEBAGAI ACUAN PEMANCANGAN PIPA BAJA

PLATFORM
Construction Method | Bored Pile
use Reversed Circulation Drill Method
TAHAPAN PELAKSANAAN :

5. PEMASANGAN PIPA Ø 180 cm PADA POSISI

PLATFORM
Construction Method | Bored Pile
use Reversed Circulation Drill Method
TAHAPAN PELAKSANAAN :

5. PEMASANGAN PIPA
VIBRO
HAMMER
Ø 180 cm PADA
POSISI PLATFORM
6. PEMANCANGAN
DENGAN VIBRO
HAMMER
 PEKERJAAN PENGEBORAN BORED PILE
(TAMPAK DEPAN)

TAHAPAN PELAKSANAAN :
7. PENGANGKATAN MATA BOR PADA CASING BORED PILE
 PEKERJAAN PENGEBORAN BORED PILE
(TAMPAK DEPAN)

TAHAPAN PELAKSANAAN :
8. PENGEBORAN PADA PONDASI BORED PILE
Osterberg Cell Test
The Osterberg Cell
2 PILE CAP
Data Teknis
Volume 1 pile cap = 9.996,56 m3 ~ 10.000 m3
Steel bar dan floating steel formwork dibuat di
stockyard
Alat yang digunakan:
 Floating steel formwork
 2 buah Floating Concrete Batching Plant Kapasitas 60
m3/jam yang dilengkapi dengan water tank
 4 buah ponton 220 ft kapasitas 1800 ton
 Ponton service 180 ft kapasitas 1500 ton
 8 buah Concrete pump kapasitas 15 m3/jam
 Crawler crane
 Alat bantu
Instalasi Floating Steel
Formwork
Setting Floating Steel
Formwork
Penulangan Pile Cap
Pengecoran Pile Cap
 3 PYLON
Structure Geometry of Pylon
 Pylon leg shoe
 Lower pylon leg
 Lower strut
 Middle pylon leg
 Middle strut
 Upper pylon leg
 Upper strut
Pekerjaan lower pylon leg, middle pylon leg
dan upper pylon leg dilakukan secara
segmental @ 4 m menggunakan climbing
form.
Pekerjaan pada pylon terdiri dari:
 Pekerjaan penulangan
 Pekerjaan formwork
 Pekerjaan pengecoran
 Pekerjaan stressing
Alat yang digunakan:
• Tower crane
• Climbing Form dengan tinggi per segmen adalah
4m
• Stiffening framework
• 1 buah Floating Concrete Batching Plant
Kapasitas 60 m3/jam
• 2 buah Ponton 220 ft kapasitas 1800 ton
• Ponton service 180 ft kapasitas 1500 ton
• Alat bantu
Reference of pylons construction (1/4)
Reference of Pylon Construction (2/4)
3 Steel Box Girder dan Cable Stayed Installation

Alat yang digunakan per pylon:

• Ponton service 180 ft kapasitas 1500 ton
• 4 set Lifting Device
• 2 unit Scaffoldings
• 2 unit Temporary piers
• Alat bantu
Note:
• Pada instalasi cable stayed diperlukan counterweight
(cast iron dan concrete ballast)~3500 ton ---> krn
ketidaksimetrian main bridge
CONSTRUCTION METHODE
Of

MAIN BRIDGE
 STAGE ONE
1. Construct the pylons and end piers
2. Set up brackets above lower-strut of pylon
3. Suspend in place No. 0 segments of main girder by floating ship and fix the
segments to the pylons by temporary connection device
4. Suspend in place No. 1 segments of main girder, and post-tension No. 1
cable for the first time.

 
 STAGE TWO
1. Set up lifting equipment on the bridge deck.
2. Ferry No. 2 segment of main girder to appropriate lifting place, suspend in place No. 2
segments of main girder by the lifting equipment on the bridge deck.
3. Post-tension No. 2 cables for the first time.
4. Set forth the lifting equipment, suspend in place the prefabricated concrete slab of
bridge deck above No. 1 and No. 2 segments of main girder, cast and seam concrete.

5. Post-tension No. 1 cable for the second time.

 
 STAGE THREE
1. Remove brackets above lower-strut of pylon
2. Repeat construction sequences 2 ~ 4 in Stage Two
3. At the same time, commence construction of temporary support piers (which are 132 m
away from the eqicenter of near pylons). The construction of temporary support piers
must be finished before the erection of No. 12 segment of main girder.

4. Erect the falsework on main girder in the region of black cable, and suspend in place the
main girder in this region by floating ship. Complete the placement of first-stage
counterweight.

132 m 132 m
 STAGE FOUR
1. Repeat the erection of bridge deck symmetrically until the enclosure of side span,
uninstall the lifting equipment in the bridge deck of side span.
2. Continue to erect bridge deck in the center span and post-tension the stay cables
symmetrically until it reach at the closure position of the center span.
3. Suspend in place the main girder of bridge deck at the closure position of the center span
the whole bridge is closed.
4. Uninstall the lifting equipment on the bridge deck of center span, complete the
construction of remain slab of bridge deck.


 STAGE FIVE
1. Uninstall the temporary support piers
2. Uninstall the falsework of main girder in the region of back cables
3. Remove the temporary connection between pylons and bridge deck
 STAGE SIX
1. Place the second-stage counterweight at the bridge deck in the region of
back cables.
2. Construct the bridge accessories
3. Paint the steel structures with anticorosive material
4. Complete the proof-test of bridge loading, open the traffic
Temporary piers, scaffolding and counterweight

BENTANG TEPI BENTANG TENGAH

 Approach Bridge
Major work:
• Bored pile
• Pile cap
• Pier shaft
• Concrete Box Girder
 Bored Pile dan Pile Cap

Metode pelaksanaan bored pile dan pile cap

pada approach bridge seperti pada pelaksanaan
bored pile dan pile cap pada main bridge
 Pier Shaft
Data Teknis:
PILE CAP & PIER WORKS
SEQUENCE
1. Installing steel box for formwork, thickness 10mm
2. Pump the water outside formwork
3. Pouring sealing concrete, thickness 1 m
4. Installing steel bar of pile cap
5. Pouring concrete of pile cap
6. Installing climbing form
7. Installing 1st steel bar of pier
8. Pouring 1st segment of pier concrete
9. Move up climbing form
10. Pouring 2nd segment of pier concrete
11. Installing 2nd steel bar of pier, etc

HWL
Sequence of Pier Shaft (1/2)

I II III
 Sequence of Pier Shaft (2/2)

IV V VI VII
V PIER WORKS
SEQUENCE

HWL
Alat yang digunakan:
• 1 buah Floating concrete batching plant kapasitas 60 m3/jam
• 2 buah Ponton 220 ft kapasitas 1800 ton
• Ponton service 180 ft kapasitas 1500 ton
• Crawler crane kapasitas 25 ton
• 2 buah Concrete pump kapasitas 15 m3/jam
• Climbing formwork dengan tinggi per modul 3 m
• Alat bantu
 Concrete Box Girder

Metode yang digunakan adalah cast in situ dengan sistem balanced

cantilever method
Pelaksanaan:
• Pier segment/table dan instalasi traveller diperkirakan 2 bulan
• Masing-masing tipikal segment diperkirakan 7 hari
• Closure segment dan dismantling traveller diperkirakan 2 minggu
• Total waktu yang dibutuhkan per span ~ 120 hari
BALANCED CANTILEVER METHOD
 Principle

Constructing bridge by succession of segments

Each cast segment carrying next segment

Completed segment as starting base

Self-supporting by prestressed tendon

 Advantage

Elimination of piers and falsework

Reduction in number of forms

Improvements in workmanship

Suitable for curved section

 Application – Span Length

Span length list

Construction of prestressed concrete bridges

Spans (metres)

0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180

Prefabricated beams

Contilever

Incrementally launching

Advance shoring

Optimum range

Normal range

Exceptional range
Data teknis:
Setiap span approach bridge terdiri dari 1 pier segmen/table (di atas pier shaft), 20
tipikal segmen @ 3.5 m dan 2 closure segmen @ 1 m.
Alat yang digunakan:
 4 Set (8 buah) Carriage Form Traveller (CFT)
Total CFT yang digunakan untuk Approach Bridge adalah 8 set
 Floating Concrete Batching Plant Kapasitas 60 m3/ jam
 Ponton 220 ft kapasitas 1800 ton
 Concrete pump dengan kapasitas 15 m3/ jam
 Alat bantu
PIER TABLE WORKS
INSTALLING FORMWORK
INSTALING STEEL REINFORCEMENT
CONCRETE WORK
REMOVAL FORMWORK

FEEDER BARGE
BATCHING BARGE BACK FOR RELOADING
FROM STOCK YARD

HWL 38 L. 156 3. WB
BOX GIRDER WORKS
INSTALLING FORM TRAVELER

FORM TRAVELER

HWL 38 L. 1563. WB
BOX GIRDER WORKS
CONCRETE WORK

BATCHING BARGE
38 HWL
 GIRDER WORKS
SEQUENCE

80 m
10 BOXES @ 3,5 m PIER TABLE 10 BOXES @ 3,5 m
7 8 9 10
3 4 5 6
5 4 3 2 1 1 2
10 9 8 7 6
CLOSURED
CLOSURED

HWL 38
Formtraveller
Piertable Construction (I)
Terima Kasih