IABSE Conference - Weimar 2007

Presentation Contents

• Introduction to the Project and the Key Organisations

• Role of the Contractors Checking Engineer (CCE)
• Construction photographs of the checked components
• Conclusions

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Project Details Project Details

• Project Statistics
• Total construction cost of €1.1 billion
• 52 month construction period
• Completion date of October 2009

Crossing length 12.3 km • Contractors Checking Engineer (CCE) Role

• Halcrow – Arup – Dasan JV
• Halcrow lead consultant
Cable Stayed Bridge Approach Bridges Low Level Viaduct
• Period of service March 2005 to March 2007 (ongoing)
• 1480m total length • 1778m total length • 8400m total length
• 800m main span • 145m span lengths • 50m span lengths
• 74m high navigation
clearance

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 Project Organisation Role of the Contractor’s Checking Engineer
Korean Expressway
IBC – 51% AMEC and 49% the
City of Incheon Joint Venture INPUTS
Corporation (KEC) SCJV – Samsung, Daelim, Daewoo,
Hanjin, Hanwha, Kumho and GS • Independent Design Check of the Permanent Works
Incheon Bridge • Independent Design Review of the Temporary Works
Company Ltd AMEC
(Concessionaire) (Project
• Review Technical Notes produced by others
Management)
Samsung • Provide Technical Assistance to the Contractor
Construction Contractors Design Supervisor
Joint Venture Designers (DS)
(SCJV) Seoyeong-Chodai-Cowi Yooshin-Mott MacDonald DELIVERABLES
(Design and
Build Contractor) Construction • Design Check Certificates (DCC) for permanent works
Supervisor (CS)
Halcrow (lead) Yooshin • Design Review Certificates (DRC) for temporary works
Contractors
Checking Arup Contractual Relationship • Design Review Certificates (DRC) for technical reports
Engineer Line of Communication
Dasan

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Role of the Contractor’s Checking Engineer Role of the Contractor’s Checking Engineer
Halcrow (lead) Arup Dasan
General CCE Management, Technical Technical Advice, Construction Alignment, Expansion Joints, • Design Standards
Advice, Construction Advice, Advice, Seismic survey and Barriers, Surfacing, Drainage,
Seismic survey and hazard hazard, Pile load test Lighting
• 2 key documents
Cable Stayed Bridge Analysis (Support), Analysis, Deck, Aerodynamics
Geotechnics, Substructure,
Pylons, Aerodynamics
• Project Performance Requirements (PPR)
Viaduct Analysis, Geotechnics,
Substructure, Superstructure
- Written by the Ministry of Construction and Transportation
• Concessionaire’s Supplementary Requirements (CSR)
Approach Bridge Analysis, Geotechnics,
Substructure, Superstructure - Written by Incheon Bridge Company Ltd (IBC)

Ship Impact Protection Layout, finite element • AASHTO LRFD (3rd Edition) & Korean Bridge Design Standards
modelling, model test
• Interpretation of LRFD required – new document
Scour Protection Scour protection design, model
test • CCE produced many Technical Notes

Toll Plaza Bridges Earthworks, Substructure,

• Design Manual produced by SCJV
Superstructure

Temporary Works Overview Overview Design review

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Role of the Contractor’s Checking Engineer Role of the Contractor’s Checking Engineer
• Approach Bridge Design Check

• Cable Stayed Bridge Design Check • 145m long spans by balanced cantilever construction
• Built in pier tops – no bearings apart from end spans
• 1480m long with 800m main span
• Design tools – LARSA, stage construction & time dependent effects
• 33.4m wide steel orthotropic deck
• REPUTE – non-linear analysis of pile groups in multiple soil strata
• Pylon – reinforced concrete hollow section in diamond configuration
• Camber curves checked for casting yard segment alignment
• Design tools – TDV RM2000, Oasys GSA, LARSA
• Sub-structure certified for construction before deck checked
• Fast track design & check – 12 weeks to start of piling
• Interaction with the Designer – agree loads before detailing re-bar • Low Level Viaduct Design Check
• Wind buffeting analysis, response spectrum seismic analysis • 50m spans built by the span-by-span method
• pre-tensioned 1400 tonne units erected by floating crane
• Majority of sub-structure on pile bents
• Represented the majority of the crossing

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Role of the Contractor’s Checking Engineer Role of the Contractor’s Checking Engineer

• Temporary Works • Technical Reports for Review

• Major Temporary Works (MTW) • Probabilistic Seismic Hazard Assessment
- 2km long temporary jetty • Oceanographic Investigations
- temporary back span piers for the CSB • Ground Investigations
- temporary struts to prop the inclined pylon legs • Pile Load Tests
- self-launching overhead gantry for the viaduct
• Wind Tunnel Testing
• Temporary Works (TW) • Ship Impact Protection Test Programme and Results
• Method Statements (MS) • Scour Test Report
• Independent design check for MTW’s
• Independent design review for TW’s and MS’s

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 Pile Cage Prefabrication
• Pile reinforcement cages
fabricated in 12m lengths
• Link reinforcement rolled onto
the pile cage
• Up to 3.0m diameter piles
Construction Yard Activities • Accurate assembly allows the
used of threaded couplers to
join cages

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Balanced Cantilever Deck Segments Viaduct Deck Spans (50m)

• Target 1 span every 2 days

• Short bed match casting
• 3 stage fabrication
• Reinforcement stage 1
• Internal formwork + complete reinforcement
• External formwork + stressing + concreting
• Longitudinally and transversely pre-tensioned
• 1400t each

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 Site Construction Yard
Reinforcement storage Approach Bridge deck Deep Water Piles
precast segment
Concrete batching cutting and bending fabrication
plant
Site offices and staff
accommodation

50m viaduct deck precasting

shed (1 unit every 2 days)

50m viaduct deck storage

and loading area • Piles constructed in upto 25m
Prefabricated pile deep water
reinforcement cage Approach Bridge pier-
storage head segment • Permanent steel casing to rock
precasting level
CSB pylon precast
cross-beams • Pile diameters between 1.8m and
3.0m

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Shallow Water Piles Pilecaps

• Pilecap precast formwork up to 1650t
lifted using 3000t floating crane
• Precast formwork sealed onto steel
pile casings - dry working area for
fabrication of pilecap reinforcement
• Temporary pilecap working enclosure
(upto 70mx25m in plan)

• 2km long steel temporary access

trestle
• Driven steel piles
• Access for construction of piles
and cross beams

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 Viaduct Deck
Pilecaps • 1500t viaduct deck units
brought out to deep water
using 3000t floating crane
• Temporary enclosure for pilecap
concreting and curing • Loaded onto multi-wheel
carrier
• Low level viaducts consist of pile bent
and in-situ cross beam below deck • Multi-wheel carrier moves
level deck unit out to launching
girder operating in shallow
water area inaccessible to
floating crane
• Units lifted onto bearings
using launching gantry

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Viaduct Deck Viaduct Deck Construction

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Viaduct Deck
Approach Bridge Balanced Cantilevers

• Precast pier head segments erected

using 3000t floating crane
• Precast deck segments lifted from barges
using derrick cranes erected on the
cantilever

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Approach Bridge Balanced Cantilevers Approach Bridge Balanced Cantilevers

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Approach Bridge Balanced Cantilevers Approach Bridge Balanced Cantilevers

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Approach Bridge Balanced Cantilevers Approach Bridge Balanced Cantilevers

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 Approach Bridge Balanced Cantilevers Approach Bridge Balanced Cantilevers

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Approach Bridge Balanced Cantilevers Cable Stayed Bridge

80m 260m 800m 260m 80m
tie-down span back span Main span back span tie-down span

• 225m high pylons

erected using self
climbing jump formwork
• Backspan erected with
80m long large segments
supported on temporary
piers
• Mainspan cantilevered out
in 15m segments

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Pylon Construction Pylon Construction

• Precast, post tensioned

crossbeams
• In-situ connection to pylon
legs

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Incheon Bridge Project

The role of the Contractor’s Checking Engineer
19-21 September 2007

Dr Innes Flett – Chief Bridges Engineer, Halcrow

Matt Carter – Associate, Arup
Andrew Yeoward – Director, Halcrow Asia Pacific
Naeem Hussain – Director, Arup
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