SDI Kuwait Causeway prj.(kusc)

SDI

For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project

05/01/2023

A BREAKING RECORDS

Strukuras DF International Co. LtdJanuary 9th, 2014

SDI’S EXPERTISE IN SHEIKH JABER CAUSEWAY PROJECT

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Contents

1. Project General Information 2. FSLM Equipment Introduction

• Design • Manufacturing• QA/QC• Factory Load Test• Painting& Packing• Spare Parts

3. On Site Services• On-site Assembly & Commissioning• 3 Times Modifications/Relocations of LG&T/P on Deck• 24 Months Maintenance

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1. Project General Information

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PROJECT LOCATION-Name of Project: FSLM Equipment Supply and Services for the Use of Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project – Main Link, in Kuwait-Client: Hyundai Engineering & Construction Co., Ltd.-Location: Kuwait/From Shuwaikh Port to Subiyah New Town

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CONDITION OF CONSTRUCTION:

Bridge NameDepth

(H) 2.5m 4.0m

Span(L) 35m 40m 45m 45m 60m30m or 31.14m

60m or 63.86m

Shuwaikh Port Br. 14 30 8

Shuwaikh Port I/C Br. 72

Shuwaikh Br. 202

South App. Br. 2 146

Main Br. 4 4

North App. Br. 4 300

Subiyah Br. 8 258

Sub Total 14 304 8 14 704 4 4

Total 326 726

(1) Bridge Information

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CONDITION OF CONSTRUCTION: (2) Minimum radius of Horizontal alignment :• H =2.5m PC Girder Bridges : R =1200m• H =4.0m PC Girder Bridges : R =25000m • Temporary Transport Road (18m width) at Subiyah Job Site : R=1200m• Temporary Access Ramp (30m ~ 45m width ) at Bay Island south : R=200m

(3) Maximum longitudinal slope:• H =2.5m PC Girder Bridges : S = 0.53%• Bridge with height 4.0m PC Girder : S = 0.02% • Temporary Transport Road at Subiyah Job Site : S = 2%• Temporary Access Ramp at Bay Island south : S = 2%

Bay Island south Temporary Access Road

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CHALLENGES

Since the 21st century, the bridge construction equipment and technology are developed rapidly, and kind of large-scaled bridge equipment had performed very important roles for the bridge construction in many large projects.

Around 2005, the worldwide famous Korea Incheon Bridge and China Hangzhou Bay bridge were built by adopting FSLM Method in turn, for which project the max.PC Box Girder to be erected is of 50m span, 1400t weight, meanwhile launching gantry had developed with a capacity suit for the erection of 50m, 1400t PC box girders.

And for the use of Kuwait Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project, the FSLM equipment we made are designed for the lifting and erection of up to 60m, 1800t PC box girders.

This shall be a new breaking record for FSLM bridge erection Construction, and also big challenges to develop such large-capacity full set of FSLM equipment and construction.


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China Hangzhou Bay Bridge- LG &T/P for erection of 50m&1400t PC Box Girder

Korea Incheon Bridge- LG &T/P for erection of 50m&1400t PC Box Girder

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CHALLENGES

Comparing to the Korea Incheon Bridge and China Hangzhou Bay bridge, the Kuwait Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project is not only to be built with a bigger span and weight (increased from 50m /1400t to 60m/1800t), but existing much more complicated construction conditions and requirements, which put forward much higher requirements and challenges for the full set of FSLM equipments.

Major Complicated and Special Construction Conditions:

a) Variable spans from 35m to 60m, with complicated and irregular span combinationsb) Existing Min. Curve Radius: 1200m bridge;c) Several times relocation and modifications over the sea are required for the L/G and

T/P; ..d) S-shaped access with 200m small curve radius are existed on the South Bay Island, the

Transporter on deck is required to carrying the PC box girders to be erected and LG for relocation to pass through for many times;

e) Many times construction for the first & last spans and variable spans;f) Existence of Widen flanged box-girder and construction of bridge with variable deck

width.


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SDI’s Working Scope In This Project

Design, Manufacture, DAP shipment of Full Set of FSLM Equipment to Subiyah Jobsite.

Site assembly & commissioning of All FSLM Equipment.

3 Times Modification & Relocation of FSLM Launching Gantry and Transporter on Deck.

FSLM Equipment Buy-back unpon Completion of PC Girder Erection.

Full Set of FSLM Equipment, including: Launching Gantry(LG) Transporter On Deck (T/P on Deck) Transporter On Land (T/P on Land) Straddle Carrier at PC Yard(SC at PC Yard) Straddle Carrier at Jetty(SC at Jetty)

SDI1800 Launching Gantry DCY1800II Transporter On Deck

DCY1800II Transporter On Land

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1800Ton Straddle Carrier at PC Yard

1800Ton Straddle Carrier at Jetty

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Independent from SDI

Project Organization StructureHigh Rank Management

(SDI)

Project Manager

Design Manager

NDF design team

STK design check team

Korea KOSHA consultant

Fabrication manager

SDI fabrication Supervisor

NDF fabrication manager

Procurement manager

QA/QC Manager

QA/QC engineers

SDI internal QA/QC

3rd party NDT

Korean supervisor

A/S Manager

On-site assy.&commis

sioning

Equip.Modification Team

Onsite Maintenance

PM team office consultant team of experts

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2. FSLM Equipment Introduction

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Design

Working Environment

• Ambient temperature: 0 ℃ ～ +60℃• Wind Speed

under work : ≤20m/sec non-work : ≤42m/sec

• Equipped with lamps enough for Night Work

General Design Standard

1) Steel Structure 　　 All the Steel Structure conforms to European Design Codes: EN1990, Eurocode 0: Basis of Structural DesignEN1991, Eurocode 1: Actions on structures.EN1993, Eurocode 3: Design of steel structures.EN13001 : Cranes, General designEN13001-1: Cranes, General designEN13001-2: Cranes, General design

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Design

General Design Standard

2) Electrical and Hydraulic SystemsElectrical System: accordant with “CEI EN 60204.1” requirements, and Motor Protection Index is above IP55.The Design and assembly of the Hydraulic System follows ISO,UNI and CETOP relevant standards and requirements.

3) Safety and Test Criterions Safety: in accordance with EEC89/392 General Safety Criterion & Latest RegulationsTest: after completing the trial assembly, Load testing will be conducted (110% dynamic load; 125% statistic load)

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Design

Specification Data of the FSLM Equipment1) SDI1800 LG

• Equipment Type : Overhang type ( without under bridge)• Applicable Launching length : Variable PC Girder with 35m, 40m, 45m, 60m span• Minimum applicable radius : 1200m• Adaptable longitudinal gradient : 1% • Lifting capacity : 1800ton• Min. lifting height under the hanger : 12m • Lifting mode : Hoisted by 4 points with 3 points supporting system• Winch Trolley driving type : Chain pulling system ( long. running and side shift )• Winch Trolley running speed : 0~5m/min(full loading), 0~10m/min(unloading)• Lifting speed : 0~0.5m/min(full loading), 0~1m/min(unloading)• Launching Gantry forward speed: 0~10m/min

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Design

Specification Data of the FSLM Equipment2) DCY1800II Transporter on Deck

• Purpose of use : Feeding PC Girder to Launching Gantry for the erection.• Load capacity : 1800ton• Running mode : 4 sets trolleys, 2 sets trolleys to be operated synchronously• Driving mode : Hydraulic motor and reducer • Driving speed : 0~5km/h (full loading), 0~8km/h ( unloading)• Steering structure : Hydraulic cylinder driving shaft for steering• Braking Mode : Hydraulic system • Braking function : Driving brake, Parking brake, emergency brake• Tire type : Radial tire • Applicable Loading length : Variable PC Girder with 35m, 40m, 45m, 60m span• Minimum applicable radius : 200m (at Bay Island south ), 1200m(at Subiyah Job Site) • Adaptable gradient : 2% ( longitudinal), 3% (transversal)

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Design

Specification Data of the FSLM Equipment3) DCY1800ITransporter on Land

• Purpose of use : Transport PC Girder between Stock Yard and Jetty.• Load capacity : 1800ton• Running mode : 4 sets trolleys, 2 sets trolleys to be operated synchronously• Driving mode : Hydraulic motor and reducer • Driving speed : 0~5km/h (full loading), 0~8km/h ( unloading)• Steering structure : Hydraulic cylinder driving shaft for steering• Braking Mode : Hydraulic system • Braking function : Driving brake, Parking brake, emergency brake• Tire type : Radial tire • Applicable Loading length : Variable PC Girder of 35m, 40m, 45m, 60m and 63.5m span• Minimum applicable radius : 1200m(at Subiyah Job Site) • Adaptable gradient : 2% ( longitudinal), 3% (transversal)

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Design

Specification Data of the FSLM Equipment4) Straddle Carrier PC Yard

• Purpose of use : Carry PC Girder out from casting bed• Type of PC Girder : Variable ( 35m, 40m, 45m, 60m, 63.5m and hybrid girder)• Lifting capacity : 2uints x 900ton• Synchronized operation of two units• Leg Span : 45m • Minimum lifting height under the hanger : 18m• Minimum height under the main girder : 20m • Driving mode : hydraulic motor and reducer • Braking Mode : hydraulic system• Operation mode : Remote control and cabin• Running speed : 3km/h(full loading), 6km/h(unloading)• Lifting speed : 0~0.5m/min(full loading), 0~1.5m/min(unloading)• Tire type : Radial tire

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Design

Specification Data of the FSLM Equipment5) Straddle Carrier at Jetty (Subiyah Temporary Jetty)

• Purpose of use : Shipping of PC Girder• Type of PC Girder : Variable ( 35m, 40m, 45m, 60m, 63.5m and hybrid girder)• Lifting capacity : 2uints x 900ton• Synchronized operation of two units• Leg Span : 45m • Minimum lifting height under the hanger : 18m• Minimum height under the main girder : 20m • Driving mode : Hydraulic motor and reducer • Braking Mode : Hydraulic system• Operation mode : Remote control and cabin• Running speed : 3km/h(full loading), 6km/h(unloading)• Lifting speed : 0~0.5m/min(full loading), 0~1.5m/min(unloading)• Tire type : Radial tire

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1. Control to the Construction Loads– the Biggest Difficulty , the Key to Overall Proposal

Control to the Construction load of the LG and T/P on deck is the most difficult point for this project and it determines the success of overall construction proposal.

For the bridge, the construction load(deadweight of LG and T/P) is far bigger than the running loads on the bridge from vehicles after construction completion. Bridge design should consider and check the construction loads are satisfying the bearing capacities of the PC girder and Piers/Abutment.

The Construction Loads are quite difficult to control mainly due to below factors:

a) Self weight of the LG is quite big, almost equal to the weight of one piece of the PC Girderb) The relative bigger construction loads on the bridge deck must be reacted around the area

near the pier caps.c) The LG and T/P on deck is designed to satisfy the construction loads for the erection of 60

spans, and also has to meet that requirements for the erection of 40mspans.d) Construction loads caused by relocation of the LG&T/P, the erections of the first, last and

variable spans.e) Impact caused by erection the widened flanged box-girder and construction of bridge with

variable deck width.

Design Challenges – Launching Gantry

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1. Control to the Construction Loads– the Biggest Difficulty , the Key to Overall Proposal

We had taken below measures to control the construction loads for reducing the impact tobridge piers and the PC girders:

a) Optimize the design proposal and construction procedures, and make the loadsb) concentrating on the pier caps or above the web areas/cross walls of the PC girders. c) Arrange the supporting positions of each legs of LG properly longitudinally or

transversally to distribute the concentrated loads.d) To avoid any bigger concentrated loads may occurred to the erected deck during LG

launching operations.e) Through the transporter on deck to transmit and distribute the loads onto 4 pieces of

erected PC girders. f) Modify and shorten the main girder when to erect the smaller spans


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2. Girder Erection at Small Curve Radius – 1200m

Through side-shit the main supports/legs to realize deflection adjustment during LG

launching operation.

The key is to control and realize the legs supports on the pier caps and bridge deck.

And Main Girder of the LG is required to rotate horizontally and position during launching

operation, this also raises high requirements for the design of LG mechanisms.


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3. Girder Erection at Variable SpansThe no.2# leg, no.3# leg and no.4# leg are longitudinally movable along the main girder, this is the basic requirements to realize girder erections for the variable spans.There are variable spans(30m, 40m, 45m and 60m) in the project, how to arrange LG supports/legs reasonable to satisfy the requirements of girder feeding and erection, and meanwhile to ensure the construction loads to be approved by bridge designer? This is another key and difficult points for LG Design.

Design Challenges - Launching Gantry

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4. The First Span and the Last Span Girder Erection

For Girder Erection of the first span or the last span, it is not just a simple operations to

support the LG Legs onto the abutment or roadbed.

How to arrange the main supports/legs and transmit the construction loads?

How to design the leg structure to satisfy the supporting requirements?

How to launch the LG in position and ready for Girder erection? Etc.

All the requirements should be considered during the design stage.

Design Challenges - Launching Gantry

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5. Assy. and Relocation/Modification over the Marine Area The LG & T/P on deck shall be assy. On deck oversea. And due to the construction and Girder erection requirements of the North &

South Bay Islands, the LG& T/P on deck are required to relocated/modified on the marine for 3 times.

Design Challenges - LG＆ T/P on Deck

Erection of 1 span by LG

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5. Assy. and Relocation/Modification over the Marine Area

Thus the working conditions as below for the assy., modification/relocation worksare required to be considered, i.e.:

• Assy. and dismantling of the LG and T/P by Floating Crane on the deck;• LG transported by T/P for relocation;• Transportation of the main parts and or the LG and T/P by marine barges.


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The last spans near the South Bay Island and North Bay Island are designed to bewidened PC box girders, distance from the center to the web flange of the box girders are increasing from 8.5m to 11.8m gradually. And no.4# leg of the LG is required to satisfy the requirements to support and launching at these area.


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7. S- shaped Access of 200m Curve Radius at South Bay Island

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The T/P on deck carrying the PC Girder or the whole LG is required to pass through this area.

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8. Variable Bridge Width/ Center Distance Launching Gantry and Transporter shall be suitable to pass Shuwaikh Port Bridge

where the lateral center distance of the deck are changed from 19m to 18m around STA 103+352.(Pier P077 to P076),accordingly the pier center distance are changed from 18.872m to 17.782m.

.


P(077)Pier P(076) Pier

1900

0

1800

0

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8. Variable Bridge Width/ Center Distance

When the Transporter carrying with heavy load is passing through this area, the lateral center distance between two trolleys is required to be adjusted to suitable the change from 19m to 18m(center distance of the deck), to ensure that center of the Transporter is in line with the deck center , and wheel loads be symmetrical reacting on deck.

.


19000 18000

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8. Variable Bridge Width/ Center Distance

When the LG is launching through and operating at this area, the transversal distance of each legs/supports are required to be adjusted continuously to satisfy the supporting requirements of each leg and proper load transmission.

.


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9. Other Key Design Points

Synchronous control of 2 units Straddle Carriers of one set

Synchronous Control technology of 4 trolleys of the Transporter

Equipment Reliability and Safety Design

Design to ensure reliability of equipment Mechanism, Electric System and

Hydraulic System under high temperature ambient.

Other Design Challenges - SC＆ T/P

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9. Other Key Design Points

4 transporters to work simultaneously on bridge deck or embankment with small radius is a technical challenge.We carried out tests on 4 transporters’ simultaneous control and succeed. Please see a short video.

Other Design Challenges - SC＆ T/P

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Strong Design Capacity - A joint design team with over 50 experienced engineers from NDF and STK are participated in the project.

Design input

Design

Design CheckCompliance with European

Standards

NDF

NDF+SDI

Strukturas AS

Consultant team

Design Capacity

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3-dimension design modelFinite Element Method for Structure Calculation

Design Capacity

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Finite Element Method for Structure Calculation

Design Capacity

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Design Capacity

Currently, the detailed design of all the FLSM equipment is near completion,. and through continuous realizable design, optimization and effective communication with client , almost all the design challenges have been overcame successfully and approved by bridge designer and client.

And Straddle Carrier at PC yard has been put into fabrication since Feb.10th, 2014.

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Manufacturing

Manufacturing Capacity

SDI carries out most equipment fabrication and almost all factory acceptance testing at the workshops of it’s major shareholder, Zhengzhou New Dafang Heavy Industry Science & Technology Co.,Ltd. (NDF).

NDF’s headquarters and main workshopsoccupy 254,000 square meters of land.

Facilities include : Workshop area is over 80,000 square meters;includes 3 Steel Structure shops, 3

machining shops, 2 final assembly shops. Loading test fields are over 45,000 square meters.

Annual manufacturingcapacity: Over100sets of large-scaled bridge building equipment. Annual steel processing capacity: over 50,000 tons.

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Factory Workshop Annual Capacity DF Heavy Industry 86,500m2 12,000tons Liuye 26,000m2 30,000 tonsDongfang metal structure 20,000m2 50,000 tonsHangxiao steel structure 51,440m2 Over 24,000tonsZhongkai-changjian 40,500m2 12,000 tons

Manufacturing


SDI also has several affiliated and long-term cooperating workshops for fabrication. The major affiliated / partner workshops are:

DF Heavy Industry(subsidiary of NDF) Liuye Dongfang metal structure Hangxiao Zhongkai – Changjian

Steel Processing Workshop Area and Annual Capacity

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Manufacturing


As the workload of each factory is changing time to time, and its capacity available to SDI for this project is also changing time to time.

Refer to the real-time steel structure fabricating capacity available to SDI, the major affiliated / partner workshops to be involved to the project are:

DF Heavy Industry(subsidiary of NDF) Liuye Dongfang metal structure Hangxiao Zhongkai - Changjian

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Manufacturing

Manufacturing Arrangement & LocationFSLM Equip. Item Manufacturing FactorySC at PC Yard Steel Structure of MG&Supports, etc Liuye

Machining Parts, Running System, Winch Trolleys

NDF

Purchased Parts Delivered to NDF

FAT(load test) NDF

SC at Jetty Steel Structure of MG&Supports, etc Dongfang/or Hangxiao(spare)

Machining Parts, Running System, Winch Trolleys

NDF


FAT(load test) NDF

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Manufacturing

Manufacturing Arrangement & FactoriesFSLM Equip. Item Manufacturing FactoryT/P on Land Main Frame/Steel Structure Dongfang

All Other Parts NDF


FAT(load test) NDF

T/P on Deck Main Frame Dongfang

All Other Parts NDF


FAT(load test) NDF

L/G Steel Structure of MG&Supports,etc. Liuye

All Other Parts NDF


FAT(load test) NDF

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Detailed Manufacturing and Assembly Schedule

Manufacturing

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QA/QC Control

Design Quality Control

1st controlDesign Quality is subjected to NDF’s design quality control system, as mentioned in SDI Introduction.

2nd controlFully Independent Design Check will be carried out by Strukturas for this project to ensure compliance with relevant Euro codes.

3rd controlEquipment experts from outside of SDI, NDF AND Strukturas are invited to review and comment.

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QA/QC Control

Design Quality Control

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QA/QC Control

SDI QUALITY CONTROL PLAN

SDI’s QA/QC DEPARTMENTMonitoring

3rd PARTY NDT

Information

INSPECTION AND TEST PLAN (ITP)

WORKSHOP INTERNAL QA/QC

AS-BUILT DOCUMENTATION

Clinet’s Superintendent

Supervision&Cooperation

Manufacturing Quality ControlBelow Control Plan shall be followed to ensure the Manufacturing Quality

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Manufacturing Quality Control Steel Fabrication Quality Control Plan, covers the following items:

- Material (Purchase, Receipt, Marking, Checking & Testing)- Welding (Qualifications, Procedures, Inspection)- NDT (Operator Qualification, Extent of Testing, Repair Welding, Dimensional Survey)- Surface Preparation (Shot Blasting, Visual Inspection, Temperature / Dew Point /

Humidity Readings)- Trial Assembly (After all welding has been completed)- AS Built Documentation (Quality Documentation to be supplied to Client)

QA/QC Control

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QA/QC Control

Purchased Parts Quality Control Besided conform to the RFQ of HDEC and requirements, all purchased parts shall beof the reliable ones and be appoved by client/HDEC before P.O.

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Each one nos of each kind of FSLM equipment as below shall be tested and accepted by client before EXW.

FAT (Load Test )for:

SDI1800 Launching Gantry DCY1800II Transporter On Deck DCY1800I Transporter On Land Straddle Carrier at PC Yard Straddle Carrier at Jetty

FAT Criteria:

Load Test shall be carried out on completion of assembly in the factory:

110% dynamic load; 125% static load

Factory Acceptence Test

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FAT/ load tests for the FSLM equipment on completion of assembly shall be carried out at below testing yards in NDF, SDI’s Main factory.


20,000m2 15,000m2

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General Plan and layout of loading tests


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Loading test capacity up to 2000 ton: SIMULATE CONCRETE BEAM OF 60M

We prepared 60m MSS main girder used as main beam structure in loading test.

We prepared 2000 ton concrete blocks used as load for in loading test.


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General tests plan of straddle carriers


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General tests plan of transporters


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General tests plan of launching Gantry


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Painting:Steel shall be pretreated before cutting-off;Painting after Blasting in accordance with outdoor working Requirements:

Blasting comply with Sweden SA2 standards The first coat: inorganic zinc coating, 60 microns thick.

Intermediate coat: epoxy paint, 60 microns thick. Min. total painting thickness = 120 microns

Study on “good paint for 60 Celsius degree” is carried out.

Painting and Packing

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Packing : Oversized structure parts of the equipment shall be shipped in bulk after sound and reliable packing, e.g. below figs .

MG500 GC to Korea

SDI has experience to pack and ship bridge building equipment to Korea, Taiwan, Middle East, Russia.

We tried and found out the ways to reduce damages to the least!


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Standard-sized structure and fragile parts are to be loaded and well fixed into 40’OT containers to ensure no damages during long-sea voyage

Fragile parts like motors, reducers and cylinders are to be well packed into boxes before loading and fixing in 40’OT containers to ensure no damages during long-sea voyage


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Spare Parts :

Additional Repair Parts as property of SDI shall also be delivered to site to ensuretimely repairs under warranty and emergency repairs out of warranty if any.

We have considered and listed some necessary spare parts to be supplied together with the equipment.

Repair Parts :

Spare Parts and Repair Parts

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Section 3 – On Site Services

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To complete the assembly, commissioning and modification works of FSLM equipment supplied in a safety, high-quality and scheduled manner, a professional management team(dispatched in batches, about 60 staffs in total) with high professional level, rich construction experience shall be launched. And adequate technical workers and qualified construction equipments will also be put in the project.

Assembly &Commissioning of FSLM equipment

Assembly of all FSLM equipment and conducting commissioning as below:

Erection of 3 span (6 number of PC Girder) of Subiyah Bridge by Launching Gantry and Transporter on Deck.

Transportation of 6 number of PC girder by Transporter on Land from PC Yard to Subiyah Jetty Lifting and stock of 6 number of PC girder by Straddle Carrier at PC Yard from PC Factory to PC

Yard. Lifting and unloading of 6 number of PC girder on the transportation barge by Straddle

Carrier at Jetty.

On-site Assembly & Commissioning

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Assembly Plan for equipment’s first site assembly

On-site Assembly and Commissioning

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3 times modifications of FSLM equipment:

① Transportation of L/G and T/P from Subiyah bridge to Shuwaikh r Bridge after the completion of PC Girder erection of Subiyah Bridge, including erection of 2 spans of Shuwaikh Birdge after modification.

② Transportation of L/G and T/P from Shuwaikh r Bridge to Bay Island South arera after the completion of PC Girder erection of Shuwaikh r Bridge .

③ Transportation of L/G and T/P from Bay Island South arera to Bay Island North arera.

3 times Modifications

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More detail plan has to be made according to site condition and construction demand.

LG and T/P on deck Relocation Plan

3 times Modifications

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We shall mobilize and operate an experienced and professional maintenance team at site to maintain the FSLM Equipment for the required duration -24 months warranty.

Maintenance team shall consist of: one supervisor, one electrician and two mechanics (Hydraulic and mechanic)

Our maintenance team shall provide any required maintenance and repair work under warranty and technical assistance to Client /equipment operators.

24 month maintenance

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CONTACT US FOR MORE INFORMATION:www.sdi-intl.com

[email protected]@163.com

Tel: 0086 (0)371 55635362

We are glad to provide you our best service.

Thanks for your time!

SDI Kuwait Causeway prj.(kusc)

Engineering

Transcript of SDI Kuwait Causeway prj.(kusc)