Design & Construction Experience On Concrete Bridge - AST - Senior Meeting - 21mar2016

Design & Construction Experience on Bridge/Elevated
Structure
Athasit Sirisonthi
B.Eng (Civil), M.Eng (Structural), Thammasat University
Senior Engineer/BIM Manager – Engineering Department, STECON
Lecturer – Department of Civil Engineering, Faculty of Engineering Thammasat University
COE Specialist – Civil Engineering
Professional Engineer No. 11491
stecon.ast@gmail.com
• Introduction to Bridge Design and Construction
• Experience in I-Girder Bridge/Elevated Structure
• Experience in Segmental Box-Girder Bridge/Elevated Structure
• Case Study: Ayutthaya Launcher accident
Introduction to Bridge Design and
Construction
Introduction to Bridge Design and Construction
• Bridge/Elevated Structure Characteristic
• Bridge/Elevated Construction Concept
Don Maung Tollway @ Lad prao SVB Airport Rail Link @ Soi Soon
Intersection Vijai
Bridge Superstructure: I-Girder with Deck slab
Bridge/Elevated Structures with I-Girder & Deck
slab on Superstructure type, the old school design
of bridge structure, this structure is use in many
construction project in Thailand such as;
- Don Muang Tollway
- Expressway Stage 3: Section S1
- Elevated Frontage Road NBIA Project
- Overpassed Bridge by DOH, DOR
- Highway Interchange by DOH, DOR
- Etc.
Bridge Superstructure: I-Girder Erection
Elevated Frontage Road NBIA Project – SV Joint Venture The 3rd Stage Expressway S1: Contract 1 - Vichitbhan Construction Co., Ltd.
The method of erection I-Girder, which suitable for project “Mobile Crane”
or “Launcher”
Bridge Superstructure: Deck slab construction
The 3rd Stage Expressway S1: Contract 1 - Vichitbhan Construction Co., Ltd. The 3rd Stage Expressway S1: Contract 1 - Vichitbhan Construction Co., Ltd.
The construction of bridge deck slab can be separated into 2 type, one is
composite deck slab with PC.Plank and the other one is Cast-In Placed slab
Bridge Superstructure: Box-Girder
Bridge/Elevated Structures with CIP. Box-Girder/PC. Box-
Girder on Superstructure type, the modern design of
bridge structure, this structure is use in many
construction project in Thailand such as;
- Expressway Stage 2
- BTS Elevated Structure
- Airport Rail Link
- MRT Purple Line/Blue Line
- Sri Rat Expressway
- Etc.
Bridge Superstructure: Cast-In Placed Box-Girder
Industrial Ring Road - STECON Industrial Ring Road - STECON
The method of construction Box Girder is separated into 2 type, one is by

using “Movable Scaffolding System” and the other one is “Conventional
Shoring”
Bridge Superstructure: PC. Segmental Box-Girder
SVB Airport Rail Link by Underslung Gantry – STECON & VSL SVB Airport Rail Link by Overhead Gantry - STECON
The Equipment that use to erection PC. Segmental Box Girder call
“Launcher” which can separated into 2 type, one is “USG: Underslung
Gantry” and the other one is “OHG: Over Head Gantry”
Experience in I-Girder Bridge/Elevated
Structure
Bridge Superstructure: I-Girder Production
The Elevated Frontage Road NBIA – SV Joint Venture

Experience in I-Girder Bridge/Elevated Structure
The 3rd stage expressway S1 Contract 1 - Vichitbhan Construction Co., Ltd.
S1 Project erection PC. I-Girder by

using modified existing Launcher
Don Maung Tollway - Diwidag
S1 Project: Launcher Modified for I-Girder Erection
Due to S1 Project construction
location cross over Bang-na
Intersection which have Bang-
na flyover cross the intersection
and all area of construction
have many traffic all time, VCB
make decision to use existing
Launching Truss as shown to
erection PC. I-Girder.
Before start of erection work
we need to recheck capacity,
strengthening and modified
equipment for work.
•Modified Main
•Structure
Girder •Load Test MG
•Create existing Design analysis/design
Investigate •Modified •Test sliding
drawing check as •Modified Modified Testing MG
Existing Launching system
•Test capacity of Existing Structure Launcher System and System
Launcher member/welding •Test Launching
Drawing •Prepare Drawing
•Modified sliding system
for Fabrication
system
•Check existing
CB condition
•Test Sliding
Assembly system Start •Check Girder
span
at Site •Test Launching Erection arrangement
system
•Check Sliding
beam elevation
Investigate existing Launching Truss -> Create as-built drawing -> Capacity test for member & welding
Structure analysis/design -> Modified Structure -> Prepare drawing for fabrication
Modified MG-Main Girder -> Modified Sliding System -> Modified Wagon System
Load test MG -> Test Wagon System -> Test Sliding System
Example for PC. I-Girder in curve span

Geom etric Data For Erection 1st stage Geom etric Data For Erection 2nd stage
PG. Elevation No. of No. of Span %grade No. of Max. Length Min. Length Diff. of PG. Elevation No. of No. of Span %grade No. of Max. Length Min. Length Diff. of
STA. STA.
(m ) MLP Span Length (m ) To up STA. Girder of Girder of Girder Girder Length (m ) MLP Span Length (m ) To up STA. Girder of Girder of Girder Girder Length
4+ 102.000 27.604 1 1 30.000 1.467 14 29.922 27.334 2.588 3+ 812.000 21.84 1 1 25.000 2.000 14 23.627 22.267 1.360
4+ 132.000 28.044 2 2 28.000 1.050 13 27.532 26.014 1.518 3+ 837.000 22.34 2 2 30.000 2.000 14 29.342 27.710 1.632
4+ 160.000 28.338 3 3 30.000 0.637 13 31.001 26.202 4.799 3+ 867.000 22.94 3 3 30.000 2.000 14 29.383 27.710 1.673
4+ 190.000 28.529 4 4 20.000 0.275 12 20.493 17.681 2.812 3+ 897.000 23.54 4 4 30.000 2.000 11 28.986 27.710 1.276
4+ 210.000 28.584 5 5 30.000 -0.077 15 29.893 28.206 1.687 3+ 927.000 24.14 5 5 25.000 2.000 11 24.430 23.367 1.063
4+ 240.000 28.561 6 6 30.000 -0.507 14 29.891 28.252 1.639 3+ 952.000 24.64 6 6 30.000 2.000 14 29.536 27.917 1.619
4+ 270.000 28.409 7 7 27.000 -0.915 14 26.789 25.324 1.465 3+ 982.000 25.24 7 7 30.000 2.000 14 29.536 27.904 1.632
4+ 297.000 28.162 8 8 30.000 -1.320 13 29.835 28.261 1.574 4+ 12.000 25.84 8 8 30.000 2.000 14 29.536 27.904 1.632
4+ 327.000 27.766 9 9 30.000 -1.750 13 29.581 28.407 1.174 4+ 42.000 26.44 9 9 30.000 2.000 14 29.408 28.102 1.306
4+ 72.000 27.04 10 30.000 1.880 14 29.408 28.103 1.305
4+ 357.000 27.241 10 10 30.000 -2.177 12 29.248 28.641 0.607
4+ 387.000 26.588 11 11 30.000 -2.607 12 28.988 28.857 0.131
4+ 417.000 25.806 12 12 28.775 -2.961 11 27.675 27.675 0.000
4+ 445.775 24.954 13 13 28.775 -2.999 11 27.675 27.675 0.000
4+ 474.550 24.091 14 14 30.000 -3.000 11 28.913 27.887 1.026
4+ 504.550 23.191 15 30.000 -3.000 11 29.050 28.749 0.301
Sum m ary
Total Erection span by Luancher 23 spans

Maximum girder Length 31.001 m
Minimum girder Length 17.681 m
Maimum Different Girder Length 4.799 m
S1 Geometric data for Erection PC. I-Girder

Geom etric Data For Erection VICHITBHAN CONSTRUCTION CO., LTD.
No. Elev. % CB Height of Sliding Beam at Support No. <Elev. At LT is Datum > Elev.
STA. of at LT CF Length No. 1 No. 2 No. 3 No. 4 No. 5 No. 6 No. 7 No. 8 No. 9 No. 10 No. 11 No. 12 No. 13 No. 14 No. 15 No. 16 at RT
MLP (m ) (m ) 0.75 3.75 6.75 9.75 12.75 15.75 18.75 21.75 24.75 27.75 30.75 33.75 36.75 39.75 42.75 45.75 (m )
4+ 474.550 1 23.485 -2.500 26.400 0.019 0.094 0.169 0.244 0.319 0.394 0.469 0.544 0.619 0.660
4+ 445.775 2 24.380 -2.500 26.400 0.019 0.094 0.169 0.244 0.319 0.394 0.469 0.544 0.619 0.660
4+ 417.000 3 25.329 -2.500 34.000 0.019 0.094 0.169 0.244 0.319 0.394 0.469 0.544 0.619 0.694 0.769 0.844 0.850
4+ 387.000 4 26.071 -2.500 34.000 0.019 0.094 0.169 0.244 0.319 0.394 0.469 0.544 0.619 0.694 0.769 0.844 0.850
4+ 357.000 5 26.802 -2.787 34.000 0.021 0.105 0.188 0.272 0.355 0.439 0.523 0.606 0.690 0.773 0.857 0.941 0.948
4+ 327.000 6 27.688 -4.573 34.336 0.034 0.171 0.309 0.446 0.583 0.720 0.857 0.995 1.132 1.269 1.406 1.543 1.570
4+ 297.000 7 28.206 -4.800 35.968 0.036 0.180 0.324 0.468 0.612 0.756 0.900 1.044 1.188 1.332 1.476 1.620 1.726
4+ 270.000 8 28.512 -4.800 37.150 0.036 0.180 0.324 0.468 0.612 0.756 0.900 1.044 1.188 1.332 1.476 1.620 1.764 1.783
4+ 240.000 9 28.684 -4.800 37.300 0.036 0.180 0.324 0.468 0.612 0.756 0.900 1.044 1.188 1.332 1.476 1.620 1.764 1.790
4+ 210.000 10 28.709 -4.800 37.682 0.036 0.180 0.324 0.468 0.612 0.756 0.900 1.044 1.188 1.332 1.476 1.620 1.764 1.809
4+ 190.000 11 28.338 -4.807 30.398 0.036 0.180 0.324 0.469 0.613 0.757 0.901 1.046 1.190 1.334 1.478 1.461
4+ 160.000 12 28.216 -4.800 31.400 0.036 0.180 0.324 0.468 0.612 0.756 0.900 1.044 1.188 1.332 1.476 1.620 1.507
4+ 132.000 13 27.935 -4.800 32.800 0.036 0.180 0.324 0.468 0.612 0.756 0.900 1.044 1.188 1.332 1.476 1.620 1.574
4+ 102.000 14 27.549 -4.800 33.400 0.036 0.180 0.324 0.468 0.612 0.756 0.900 1.044 1.188 1.332 1.476 1.620 1.603
4+ 72.000 15 27.047 -4.800 33.400 0.036 0.180 0.324 0.468 0.612 0.756 0.900 1.044 1.188 1.332 1.476 1.620 1.603
4+ 42.000 16 26.479 -4.800 33.400 0.036 0.180 0.324 0.468 0.612 0.756 0.900 1.044 1.188 1.332 1.476 1.620 1.603
4+ 12.000 17 25.879 -4.800 33.400 0.036 0.180 0.324 0.468 0.612 0.756 0.900 1.044 1.188 1.332 1.476 1.620 1.603
3+ 982.000 18 25.279 -4.800 33.400 0.036 0.180 0.324 0.468 0.612 0.756 0.900 1.044 1.188 1.332 1.476 1.620 1.603
3+ 952.000 19 24.667 -4.800 35.020 0.036 0.180 0.324 0.468 0.612 0.756 0.900 1.044 1.188 1.332 1.476 1.620 1.764 1.681
3+ 927.000 20 24.135 -4.800 26.400 0.036 0.180 0.324 0.468 0.612 0.756 0.900 1.044 1.188 1.267
3+ 897.000 21 23.929 -4.800 38.481 0.036 0.180 0.324 0.468 0.612 0.756 0.900 1.044 1.188 1.332 1.476 1.620 1.764 1.847
3+ 867.000 22 23.310 -4.800 33.400 0.036 0.180 0.324 0.468 0.612 0.756 0.900 1.044 1.188 1.332 1.476 1.620 1.603
3+ 837.000 23 23.228 -4.800 44.100 0.036 0.180 0.324 0.468 0.612 0.756 0.900 1.044 1.188 1.332 1.476 1.620 1.764 1.908 2.052 2.196 2.117
S1 Geometric data for Erection PC. I-Girder

Assembly at Site -> Start Erection

Experience in Box-Girder Bridge/Elevated
Structure
Experience in Box-Girder Bridge/Elevated Structure
Construction of Precast Segmental Box-Girder Span by Span Erection
Precast Segmental Box-Girder: Segment Production
The segments for erection viaduct
has produced by Short-Line Casting
Method that need the method of
Calculation to control alignment
and profile of bridge structure call
“Geometry Control”
STECON has developed “Geometry
Control Software” for use to
control our production of precast
segmental box-girder erection,
STEC-GM can generate Setting Out
data for match cast segment and
recheck As-casted Data for erection
and control error of production in
limitation of specification and
practice code. It can show casted
span in 3 Dimensional and show
N,E,Z of As-Casted span compare to
Span Layout
Precast Segmental Box-Girder: Bridge/Elevated Characteristic
The span layout of Segment Viaduct
bridge is consist of engineering data
(N,E, Elevation) and aesthetic of
alignment data that should be
conform to viaduct shape, Limit of
Substructure condition, segment Mold
configuration, philosophy of Geometry
control and Limit condition of Erection
gantry
This above paragraph shown that
viaduct type precast segmental box-
girder must have concentrate and
understand in bridge/elevated
characteristic to much
The engineering knowledge will be
solve in technical problem that will
effect to project construction, do
anything by do not understand will be
loss in many way…
Precast Segmental Box-Girder: Launcher design concept
Design process workflow of “Launcher” for Study Bridge/Elevated Structure
erection works in every project of STECON characteristic, Alignment, Profile
and Concept of Span Layout
as shown.
Structural analysis, design and detail of
fabrication drawing by STECON engineer will
be done and send to 3rd Party design firm to Draft concept of Erection
check before start fabrication. Kinematic for Typical span
arrangement
The report of 3rd Party check will be
considering into in depth of structural
engineering such as review analysis by FEM:
Finite Element Model, Local failure analysis, Design Correction/Comment Model “Launcher” as concept
kinematic for analysis and
Stability analysis, Dynamic analysis of Free design (And it Accessories)
vibration response due to Launcher self
weight, Joint connection capacity check,
deflection check and Safety Factor check at
each stage. Prepare drawing for
3rd Party Engineer review/ MG detail check
Fabrication and detailing
After report review and comment, Launcher check MG and comment
fabrication sequence
Fabrication will be start and witness by
Engineering Team & Launching Operation
Fabrication Launcher and its

accessories
Example of Calculation detail

• Design Criteria
• Load Case calculation

• Section properties
• Joint Connection

• Erection stage
• Launching stage

• Summary analysis result
• Design of MG

• Check concentrate Load
• Design support
Example of 3rd Party check

• FEM analysis check
• Dynamic response
Precast Segmental Box-Girder: Launcher Accessories
RS - Roller Support LCB – Lower Cross Beam LSU - Lowering Span Unit
PB - Pier Bracket WF - Winch Frame

Precast Segmental Box-Girder: Accessories design
RS – Roller Support Calculation

• Design Criteria
• STR Model and Load Case
Precast Segmental Box-Girder: Accessories design
LCB – Lower Cross Beam

• Load Case and Combination
• STR Model and Analysis
Precast Segmental Box-Girder: Launcher Documents
Before Launcher Operation ESS will
finished all Engineering Document
as follows;
• Design Calculation & Drawing
• Assembly Method
• Launching Kinematic
• Construction stage check of
substructure
• Load transfer calculation
• Launcher Method and Load Test
Result
All document will be submit to CSC,
STECON QA/QC team, Launching
Operation Team to do as design
procedure from ESS Team
Precast Segmental Box-Girder: Launcher Documents
Precast Segmental Box-Girder: Launcher – Assembly
Precast Segmental Box-Girder: Launcher - Kinematic
Precast Segmental Box-Girder: Erection Load Transfer
Precast Segmental Box-Girder: Launcher – Load Test
Deflection measurement at each Load Step of Gantry A & Gantry B
Precast Segmental Box-Girder: Launcher Operation
When start operating Launcher STECON has process to check and corrective missing and human error of erection works by using 3
separated team with witness point of work to cross check and review process of works before 3 main step of erection works
Check before erection Check before Launching Check before sliding

Precast Segmental Box-Girder: Launcher Operation
Launching Span Alignment & Profile check Concrete wet joint
Erection Post-Tensioned works

Case Study: Ayutthaya Launcher accident
Case Study: Ayutthaya Launcher accident 5 Jan 2016
• Owner: Department of Rural Road (DOR)
• Designer/CSC: Span Co., Ltd.
• Contractor: Prayoonwisawa Co., Ltd.
• Bridge Characteristics: Precast Segmental Box Girder,
span by span construction at Bridge approach (30-40m span
length) and Balance Cantilever Bridge, C.I.P. cross over Chao
Phraya River
• Viaduct Construction: Viaduct erection by using Overhead

Erection Gantry (Double A-Frame Launching Gantry)
• Accidence case: Erection Gantry has collapse and slide to

crash with home that close to ROW
❖ Erection Gantry (MG) failure?
❖ Erection accessories failure?
❖ Method/Sequence mistake?
Ayutthaya Launcher accident: Failure investigation
Accidence information : By Site
investigation with COE and EIT on 6 JAN 2016,
Contractor and CSC inform as follow
• Contractor has start erection viaduct S7

(span between P7-P8), when lifting
segment No. 8 up to position, the bracket
support at P7 has subsiding and its grow
to collapse mode
• Erection Gantry has sliding down to right
hand side (Look fwd to river) and crash
with pier segment wing after that it fall
down to crash with home close to ROW
• This erection method and sequence has
been use for 3 spans before New Year
Holiday
Between span
Pier 7 – River Pier Pier 8 – Land Pier
Bracket system – assumption of failure cause stecon.ast@gmail.com

From site observe we found
that many stress bar in use has
damage and wrong keeping
Lacking knowledge and working
practice both contractor and
consultant
Stress Bar & Pipe have failure by shear behavior
Bracket design concept:

Stress bar will carry Moment due to P*e that convert to couple force moment acting on bracket, Top bar will be in tension and bottom bar will in
compression
Shaft will be high grade of steel structure we propose S45C that consist of high carbon which make S45C is to hard but not ductile, suitable for
resisting on shear failure behavior
• Use 75% of Fu, PT Bar Grade 835/1030 to limit tensile stress that will occur to PT bar, consider to FS. of PT bar when 100% of capacity = (1/0.75 ) *1.3 =1.73 Ductile failure
• For shear design the limit of shear stress that occur to shaft is 40% of Fy, consider to FS. of Shaft when 100% of capacity = (1/0.4)/0.5 *1.3 = 6.5 Brittle failure
Failure assumption:
Select Pipe to use as Shear Pin is the 1st assumption that make Erection Gantry collapse and fall down, Area to resisting shear stress is to less when
compare to S45C shaft as ESS design.
The 2nd is knowledge and practice in using of PT Bar/Stressing Bar, High tensile bar has many condition to use and design, it should be educated
Engineer/Supervisor/Foreman that will be take care it when designer use PT bar as connection material.
The last one is design philosophy of bracket shape, the load transfer from shaft to concrete bearing when concrete shape underneath is taper shape,
it will be decrease FS. Of structure.
Compare to STECON works @ Korat
Thank you
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Design & Construction Experience on Bridge/Elevated

Industrial Ring Road - STECON Industrial Ring Road - STECON

The method of construction Box Girder is separated into 2 type, one is by

The Elevated Frontage Road NBIA – SV Joint Venture

The 3rd stage expressway S1 Contract 1 - Vichitbhan Construction Co., Ltd.

S1 Project erection PC. I-Girder by

Example for PC. I-Girder in curve span

Total Erection span by Luancher 23 spans

S1 Geometric data for Erection PC. I-Girder

S1 Geometric data for Erection PC. I-Girder

Assembly at Site -> Start Erection

Construction of Precast Segmental Box-Girder Span by Span Erection

Fabrication Launcher and its

Example of Calculation detail

Example of Calculation detail

Example of Calculation detail

Example of Calculation detail

Example of Calculation detail

Example of 3rd Party check

PB - Pier Bracket WF - Winch Frame

RS – Roller Support Calculation

LCB – Lower Cross Beam

Deflection measurement at each Load Step of Gantry A & Gantry B

Check before erection Check before Launching Check before sliding

Launching Span Alignment & Profile check Concrete wet joint

Erection Post-Tensioned works

• Viaduct Construction: Viaduct erection by using Overhead

• Accidence case: Erection Gantry has collapse and slide to

• Contractor has start erection viaduct S7

Pier 7 – River Pier Pier 8 – Land Pier

Bracket system – assumption of failure cause stecon.ast@gmail.com

Stress Bar & Pipe have failure by shear behavior

Bracket design concept:

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