•
•
communications and traction power
FUNDAMENTAL CONSTRAINT
Beams to be formed to suit final alignment geometry including
Architecture – Engineering – Urban Design – Transportation
–Marine D&C Contractor
, , super elevation (cant).
ROLE OF THE FINISHED PRODUCT
The beam carries practically all the E&M services as an
integral part of the beam and these are incorporated during casting
and interconnected during the installation process.
.
PLANNING & PRE-CONSTRUCTION WORKS
• Design philosophy : (i) minimal disruption to traffic during
construction.
. (iii) maximizing standardization in size for structural
members.
• - Precast post-tensioned concrete beams erected and
stitched together with in-situ concrete joints to form continuous
frames.
• Sub-structures : Cast in-situ concrete pile caps and piers.
• Non-typical situation (Obligatory Span) :
guideway beams at some location;
(ii) Long span superstructure may be adopted, e.g: major n ersec on
an ra way cross ng up o m;
(iii) Non-typical span arrangement where precast beam
transportation is difficult;
(iv) Single beam guideway structure near terminal station;
and
DESIGN CONCEPT OF GUIDEWAY STRUCTURES cont’d
• In certain circumstances, such as crossing existing railway
tracks, bridges or wide road below, special spanning
arrangements
sequences of construction may be adopted, in order to minimize
disruption to the flow of railway or road traffic. Extra long span
bridge supporting guideway beams may also be designed
for
not viable.
PROPOSED STEEL TRUSS BRIDGE FOR 50m SPAN CROSSING THE MAJOR
FLYOVER
• NOTE
RM 15 million.
500 000 extra for the 50 m
crossing.
• Wind load
• Temperature effects
• Seismic load
Design Loadings
, . .
Desi n Loadin s
• Live Loads
The guideway structure shall be designed to carry the axle
loads
the train supplier/ rolling stock.
• Train Vehicle Live Load (LL)
2/4/6/8 car modules with indicated axle load positioned
to
produce the maximum load patterns on the structures. The
with the rolling stock proposed for the monorail system. Each
axle load is generally ranging from 100kN to 135kN with
full
passenger load included.
Design Loadings
•
The dynamic impact factor for vertical load shall be generally
taken
as follow:
Concrete beam, I = 20/(50+L) ≤ 25%
Steel beam, I = 25/(50+L) ≤ 25%
where, L = length of span (m).
Centrifugal loads or longitudinal loads shall not be multiplied by
the
dynamic factor. The dynamic impact factor will be considered
for
su erstructure and iers onl . It shall not be a lied to iles
and
pilecaps.
•
Longitudinal loads from braking and traction shall be 18% and
20%
of live load per guideway respectively.
When a structure carries two guideways, both guideways shall
be
considered to be occupied simultaneously. Traction load shall
act
,
acting in the same direction to produce the worst loading
condition.
• un ng orce
Hunting or nosing force is caused by the lateral interaction of
the
train vehicle and the guideway (Snake motion of train).
Hunting
orce s a e o one s ng e ax e oa per car ac ng
perpendicularly to the track axis at center of bogie.
Design Loadings
The centrifugal force acting radially through the centre of gravity
of the
train at a curve track shall be computed from,
CF = V2 P / R g ≤ 0.17 P
where, R = radius of curvature m
g = acceleration due to gravity (m/s2)
P = train weight (kN)
When centrifugal and hunting forces can act simultaneously, only
the
larger forces need be considered. Centrifugal force need not
be
considered acting simultaneously with seismic load.
.
Structural
Element
Concret
, cu
Ec = Young’s modulus of elasticity of concrete
Poisson ratio of concrete shall be taken as 0.2.
reinforcement shall be 460 N/mm2, conforming to BS 4449. The
modulus of elasticity of steel reinforcement shall be taken
as 2.
Prestressing Strands
• restress ng stran s s a e o uncoate stress re eve ow
relaxation seven-ply strands conforming to ASTM A416 or
BS
5896. The minimum breaking strength per strand with
nominal
.
-
• Prepare Mould Setting & Casting Procedure,
• Prepare Mould Setting Data,
• Pre are Heav Lifts Methodolo StudiesPROCUREMENPROCUREMEN
Long Lead Time
Beam Casting Mould,
Temporary Works Equipment,
Pre-stressing System & Equipment,
• Erection Study ;
• An integrated between
design and construction
operations is essential since
or mistakes.
provide the basis of multi-
axle hydraulic platform
transporters to manoeuvre
The position and capacity of the
crane was driving influence for the
whole operation.
only made possible by the
extensive use of CAD, in order to
simulate every position of the
,
from site boundary conditions.
spans were cantilever beams,
tip since this would cause a
temporary sagg ng moment n
the beam – opposite to the hogging
resistance provided by the
Planning for Casting Yard
Precast Yard is required rational facilities and their arrangement
to increase
.
Mould Design
• Developing a mould system and a method of converting the al
ignment design into
Mould Design
• Since the guideway beam also forms the running surface for the
monorail, this
results in the warped concrete surfaces, which need to be properly
represented
by the formwork skin.
Casting Yard/Mould Design
Casting yard is constructed on ground which should be satisfied
prescribed
bearing capacity of ground. Especial ly foundation of gantry crane
and beam stock
area had heavy weight of guideway beams
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34
PLANNING & PRE-CONSTRUCTION WORKS
dimensionally different shapes of guideway
beams to get better understanding about
the beam geometry and to be able to
c ec ma ema ca ca cu a ons a er
on.
Mould setting using Programmable Logic Control (PLC).
Using third party software (Softdesk ®, Autocad Civil, etc)
to
into considerations of the effect due to super-elevations, radius
curvature and vertical alignments. The absolute jack
extension/compression coordinates will be reduced from the global
coordinates with reference to the local centerline of the
beam castin ard.
The individual beam will be numbered and the coordinated for the
respective jacks input into a PLC control to actuate the motorised
24 AC volts jacks into respective positions to form the beam. The
loop back to control the jack adjustments will be monitored using
linear laser measuring device. The final resting positions o t e
jac s wi e monitore on rea time. The Graphical User Interface will
be used to plot existing positions of the jacks verses the designed
positions using
PROJECTION
QA/QC Procedures - Beam Production Table – (Flow Chart)
The preparation of such flow chart requires the input from many
parties
including end users, system supplier, various teams as well as
perhaps those
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Production & Storage - Concrete Technology
of monorail so that there is no unevenness. The finish product
cannot be altered or modified or swapped.
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• Transportation and Erection
• With beams typically weighing anything from 35 tons to 185 tons
and up to 45
meter in length the selection of the equipment to be used and its
configuration
must also be worked out with specialist contractors and equipment
suppliers.
• The design of the interface between the beam and transporter is
crucial since
i t must accommodate the variable geometry, restraining forces
required
to stabilize the beam, together with the dynamic movements of
the
transporter as it negotiates the bends, gradients and junctions
along the route
from casting yard to the city
• It was imperative to design an interface that would not only
transmit the huge
loads into the transporter correctly and safely but also had to
ensure that
dynamic forces transmitted back into the beam were controlled
and
considered by the beam designer.
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KEY SERVICE OFFERING
• Setting up casting yard for the monorail guide way beam
production,
• Full guide way structures design, design and procurement .
• Provide Project Management for casting, E&M coordination,
transport and installation of guide way beams,
crane, concreting pump, bar cutting and bending machine, stressing
equipment, special trailer for transport and mobile crane for beam
installation,
• Provide construction engineering for transport route survey
including shop drawing and alignment data conversion,
• Provide all material for production of guide way beam , , ,
,
erection and holding brackets, torsion bearing and all accessories
and
“ ” directly and exclusively by the Company.
Notwithstanding the same, the information, materials and contents
provided by the Company in this presentation are provided on an "as
is" basis and are of a general nature and shall be subject to the
Shareholder’s obligation to take independent legal, financial or
other advise as the Shareholder shall deem necessary. The data and
analysis contained in this presentation may, however, be quoted
with proper acknowledgement of the Company.
Copyright © 2008 by Worthy Builders Sdn Bhd. All rights reserved.
No art of this resentation ma be re roduced stored in or introduced
into a retrieval s stem or transmitted in an form or b an
means (electronic, mechanical, photocopying, recording or
otherwise) without the prior written permission of the
Company.”