diap daelim construction plan for caisson fabricationsession 5... · diap daelim joint venture z...

DIAP DAELIMJoint Venture

Tuas TerminalConstructors



CONSTRUCTION PLANFOR CAISSON FABRICATION Tuas Terminal Phase 1 Reclamation, Wharf Construction and Dredging



1. General Information

2. Work Flow

2.1 Work Flow and Cycle Time Scheme

2.2. Site Utilization, Equipment and Manpower Plan

3. Method Statement

3.1 Base Slab Station

3.2 Slipform Station

3.3 Curing Station

4. QA/QC Plan

CONTENTS

CONSTRUCTION PLAN FOR CAISSON FABRICATION Tuas Terminal Phase 1 Reclamation, Wharf Construction and Dredging



1. General Information



Tuas TerminalConstructorsGeneral Information

CAISSON FABRICATION

This method statement describes the Fabrication of Caissons at the Caisson Fabrication Yard for the Tuas

Terminal Phase 1 Reclamation, Wharf Construction and Dredging Project.

The caissons will be fabricated in a land-based designated casting yard by using the Double Gantry Hydraulic

Slipform System.

The caissons will be casted following 3 lined up steps by using the automatic transfer system ; Individual Pushing

Caisson Carrier Vehicle System (IP-CCV) from base slab casting area to the floating dock (F/D, 22,000 ton).

[Fabrication Yard, 13th Feb. 2016 ] [Caisson A-Type Shape]



CAISSON FABRICATIONType of Caisson

Type Size (LxWxH, m) Cell Volume ( ) Weight (ton) Q’ty (EA) Remarks

A-Type 39.90 28.00 28.15 8 5 5,900 15,200 184

B-Type 29.90 28.00 28.15 6 5 4,600 11,700 7

C-Type 39.90 28.00 28.15 8 5 5,800 14,700 21 With IntegratedCulvert

D-Type 33.00 28.00 28.15 7 5 5,000 12,800 2 Corner Caisson

E-Type 36.05 28.00 28.15 8 5 5,500 14,100 2 Corner Caisson

F-Type 39.90 28.00 28.15 8 5 6,100 15,500 1 Corner Caisson

G-Type 31.06/12.86 28.00 28.15 6 5 3,500 8,800 1 Trapezoidal Caisson

H-Type 40.73/22.53 28.00 28.15 8 5 5,000 12,900 1 Trapezoidal Caisson

J-Type 36.85/30.91 28.00 28.15 8 5 5,300 13,600 2 Trapezoidal Caisson

K-Type 39.90 28.00 28.15 8 5 5,900 15,100 1 Connection to Corner Caisson

Total 222


Tuas TerminalConstructorsDrawings

CAISSON FABRICATION

A-Type Caisson (Total 184 EA)

39.90m 28.00m 28.15m

[Caisson A-Type Drawing]



CAISSON FABRICATION

Other Types (Total 38 EA)

Type B

Length 29.90 m

Breadth 28.00 m

Depth 28.15 m

Weight 11,700 ton

Quantity 7 EA

Type C

Length 39.90 m

Breadth 28.00 m

Depth 28.15 m

Weight 14,900 ton

Quantity 21 EA

Type D

Length 33.00 m

Breadth 28.00 m

Depth 28.15 m

Weight 12,800 ton

Quantity 2 EA



CAISSON FABRICATION


Type E

Length 36.05 m

Breadth 28.00 m

Depth 28.15 m

Weight 14,100 ton

Quantity 2 EA

Type F

Length 39.90 m

Breadth 28.00 m

Depth 28.15 m

Weight 15,500 ton

Quantity 1 EA

Type G

Length 31.06m/12.86m

Breadth 28.00 m

Depth 28.15 m

Weight 8,800 ton

Quantity 1 EA



CAISSON FABRICATION


Type H


Breadth 28.00 m

Depth 28.15 m

Weight 12,900 ton

Quantity 1 EA

Type J


Breadth 28.00 m

Depth 28.15 m

Weight 13,600 ton

Quantity 2 EA

Type K

Length 39.90 m

Breadth 28.00 m

Depth 28.15 m

Weight 15,142 ton

Quantity 1 EA



2. Work Flow




2. Work Flow2.1 Work Flow and Cycle Time Scheme




CAISSON FABRICATIONWork Flow

SERVICE STATION BASE SLAB STATION SLIPFORM STATION CURING STATION LOADING ONTO F/D

1) General preparation

works

2) Material temporary

stockpiling

3) Miscellaneous works

1) Soffit form installation

2) Rebar installation

3) Side form installation

4) Concrete casting

1) Slipform setting

2) Rebar installation

3) Concrete casting

4) Slipform jacking up

5) Repetition

1) Corrosion protection

2) Safety platform

Installation

3) Rectification works

1) F/D berthing

2) F/D level setting

3) Caisson loading



CAISSON FABRICATIONCycle Time Scheme

Day Scope of work

Duration(Day) 5 10 15 20 25 30

Step 1BaseSlab

Rebar Installation 3.5

Form Work 1.0

Concrete Casting 0.5

Horizontal Rebar 1.0Formwork Removal

& Surface Treatment1.0

Curing 1.5

Transfer to Next Step 0.5

Sub-Total 9.0

Step 2Slipform

Setting (Jacking down,Clean shutter & Lifting rebar)

1.0

Rebar Installation & Casting 6.5

Sliform Removal & Curing 1.0

Transfer to Next Step 0.5

Sub-Total 9.0

Step 3Curing

Defects Rectification& Application of Silane

5.0

Curing 3.0

Transfer to the F/D 1.0

Sub-Total 9.0 Total 27 Days



CAISSON FABRICATIONCycle Time Scheme

No. Description Duration (Day)Lane 1 Lane 2

Q’ty (Cycle) Amount (Day) Q’ty (Cycle) Amount (Day)

1

Caisson Casting

1) 1st, 2nd 16 2 32 2 32

2) 3rd, 4th 12 2 24 2 24

3) 5th ~ 9 105 945 109 981

Sub-Total 109 1,001 113 1,037

2Form Change 12 7 84 5 60

Sub-Total 7 84 5 60

Total 1,085(36 Months)

1,097(36 Months)

Lane 1 Lane 2

Lane 1 : A, B, C, D,G, H, K Type Caissons

Lane 2 : A, C, E, F, J Type Caissons



2. Work Flow2.2. Site Utilization, Equipment and Manpower Plan




CAISSON FABRICATIONSite Utilization and Equipment Plan

Service Station

Base SlabStation

SlipformStation

Curing Station

Floating Dock

Classification Spec. Q’ty(EA) Description

Tower Crane 24 ton 2Base Slab Station : Form & Rebar Works

Curing Station : Repairing & Others

Mobile Crane 80 ton 1Base Slab Station : Form & Rebar Works

Curing Station : Repairing & Others

Boom Lift 30 m 1 Curing Station : Repairing & Others

Fork Lift 7 ton 3 Rebar Transportation

Pump Car 45 m 3 Base Slab Station : Concrete Casting

Water Jet800bar

2 For Cleaning

Rebar Bending Machine

Coil in bar

1 Rebar Cutting & Bending

Generator640kW

1 Stand by in Fabrication YardB/P


Tuas TerminalConstructorsManpower Plan (Indicative Only)

CAISSON FABRICATION

Classification Line – A(Man)

Line – B(Man)

Sub-Total(Man) Remark

General Manager 7 7

Shop Drawing 1 1

Safety / HR 6 6

Rebar Cut & Bending 46 46

Base Slab Station

Form Work 20 20 40

Rebar Work 36 36 72

Jack, Electric Operation 6 6 12

Slipform Station

Rebar Work 125 125 250

Concrete Casting Work 65 65 130

Jack Operation 11 11 22

Hoist Operation 20 20 40

Surface Treatment 4 4 8

Banksman 4 4 8

Curing StationSilane Painting 3 3 6

Surface Treatment 8 8 16

Heavy Equipment Operator

Forklift 3 3 6

Tower Crane 9 9

Crawler Crane 9 9

Total (Man) 689



3. Method Statement




3. Method Statement3.1 Base Slab Station



Tuas TerminalConstructorsBase Slab Station

CAISSON FABRICATION

Sofit Form Setting Vinyl Sheet Rebar Work

Side Form Setting Concrete Pumping Caisson Transfer



CAISSON FABRICATION

Base Slab Casting Plan

3 Pump Cars (Each 40 m3/h, 48 m Boom)

per Each Lane

Total 11 hours work (1,300 m3 3 Pump

Cars X 40 3/h X 11 hours) per Each Lane

9 Vibrators (3 EA X 3 Pump Cars) per

Each Lane

Concrete will be casted within 1 hour after

mixing for preventing construction joint

Wall Joint Section Exposed aggregates

with water jet for bonding

After removal the inner formwork, all

concrete defects will be rectified

Pum

p C

ar 1

Pum

p C

ar 2

Pum

p C

ar 3

[Base Slab Casting Sequence]



CAISSON FABRICATION

Individual Pushing Caisson Carrier Vehicle System (IP-CCV)

84 EA (6 Lines X 14 Rows) per Each Lane

Lifting Capacity : 21,000 ton

(250 ton X 84 EA)

Pushing Capacity : 2,100 ton

Horizontal Speed : 10 m/h

Min. Base Slab Strength : 11 MPa

Soffit Form

Steel Track and Track Slab

Base Slab

Step 0

[Concept of the IP-CCV]



CAISSON FABRICATION




(250 ton X 84 EA)





Base Slab

LiftingStep 1




CAISSON FABRICATION




(250 ton X 84 EA)





Base Slab

Pushing

Step 2




CAISSON FABRICATION




(250 ton X 84 EA)





Base Slab

Step 3Descending




CAISSON FABRICATION




(250 ton X 84 EA)





Base Slab

Step 3

Pulling Back




3. Method Statement3.2 Slipform Station



Tuas TerminalConstructorsSlipform Station

CAISSON FABRICATION

Slipform System

Working DeckConcrete Vibration, Installation of Horizontal Rebar

Upper Deck Storing of Rebar, Installation of Vertical Rebar, Operation of winches

Hanging DeckSurface Treatment, Inspection

Upper Deck

Hanging Deck

Working Deck



CAISSON FABRICATION

Setting of Slipform Slipform & Base Slab Docking Rebar Work

Slipforming (Casting) Corbel Installation Dowel Bar



CAISSON FABRICATION

Jack Up System

36 EA X 42 ton (1,512 ton) Rod Climbing

Jacks per Each Lane

Total Load = 1,059 ton (70%)

Live Load = 541 ton

Dead Load = 581 ton per Each LaneSlipform

Jack Up System

Lane 12 EA X 18 Set

Hydraulic Jacks

Lane 22 EA X 18 Set

Hydraulic Jacks

[Arrangement of Hydraulic Jacks] [Concept of Grip Jaw Climbing]



CAISSON FABRICATION

Concrete Supply

Mixer Trucks Concrete Hopper

Hopper Lifting with Winch Positioning

at Upper Deck Hole Using Plastic Tube

16 Vibrators per Each Lane

10 ~ 20 cm/h Climbing Rate

Sufficient Supply Ability

Plastic Tube

HopperOn-Site

B/P

Desc. Calculation

B/PCapacity

Spec. : 240 m3/hOperating Ratio : 80% (Assumption)

Supply Quantity : 192 m3/h

CaissonCasting(Max.)

Lane 1 : 20 cm/h x 171.4 m2 = 34.3 m3/hLane 2 : 20 cm/h x 171.4 m2 = 34.3 m3/h

Requirement Quantity : 68.6 m3/h (38%)

[Concept of Concrete Supply]



CAISSON FABRICATION

Rebar Work Plan

Cut & Bend Gantry Tower Rolling Up

Temporary Storage on the Upper Deck

Fabrication

Horizontal Supply : Rebar Slide Guide

Spacer Installation at Yoke Leg

The Upper Deck Stability (Please Refer

Details Below)

Vertical Rebar Supply

Horizontal Rebar Supply

RebarSlideGuide

Concrete coverdepth = 50~75mm

Space

Rebar Moving Roller

Vertical direction : 2 ton × 6 bundle × 6 column = 72 tonHorizontal direction : 2 ton × 4 bundle × 9 row = 72 ton

Total = 144 ton(67%)

* Capacity of the upper deck for storage of rebar is 216 ton

[Rebar Storage Plan]

[Rebar Supply Plan]



CAISSON FABRICATION

Corbel Installation

Slipform Climbing and Concrete Casting

H-Beam Installation

Bracket Installation and Positioning

Hatch Removal

Corbel Form and Tie Installation

Rebar Fabrication


Corbel Form and Bracket Dismantling

[Concept of Corbel Installation]



CAISSON FABRICATION

Corbel Installation

Hatch


Slip Form


H-Beam Installation


Hatch Removal


Rebar Fabrication





CAISSON FABRICATION

Corbel Installation

Bracket Installation

H-Beam 100 x 100

Hatch Removal


Slip Form


H-Beam Installation


Hatch Removal


Rebar Fabrication





CAISSON FABRICATION

Corbel Installation

H-Beam 100 x 100


Slip Form

Corbel Form

Tie Slipform Climbing and Concrete Casting

H-Beam Installation


Hatch Removal


Rebar Fabrication





CAISSON FABRICATION

Corbel Installation

H-Beam 100 x 100


Slip Form

Tie

Rebar


H-Beam Installation


Hatch Removal


Rebar Fabrication





CAISSON FABRICATION

Corbel Installation


Slip Form


H-Beam Installation


Hatch Removal


Rebar Fabrication





CAISSON FABRICATION

Corbel Installation

Form and Bracket

Dismantling



H-Beam Installation


Hatch Removal


Rebar Fabrication





CAISSON FABRICATION

Corbel Installation



H-Beam Installation


Hatch Removal


Rebar Fabrication





3. Method Statement3.3 Curing Station



Tuas TerminalConstructorsCuring Station

CAISSON FABRICATION

Silane Application Safety Platform Installation Loading onto F/D

Rectification Works



Proposed Suppliers (Waiting Approval)

Curing Station

CAISSON FABRICATION

Silane Application

All Concrete Surfaces above -1.0m CD

Approximately 930,000 m2

Silane Requirement

AkyltriethoxysilaneContent (%) 98 %

Nitrite Content (%) < 1 %

Chloride Content (ppm) <= 20 ppm

Specific Gravity 0.88

Viscosity (mPa s ) 0.95 mPa s

Application2 Layers coat applications

>= 300ml/m2 per coat>= 18 min. Interval

Spray Equipment 4 + 1 set (backup) planning, <= 70 kPa

Acceptance Criteria(PyGC Test) Minimum 0.05%

Warranty Contractor and supplier jointly guarantee for 10 years

BASF South East Asia Pte Ltd (Germany)

Dow Corning Singapore Pte Ltd (USA)

KCC Singapore Pte Ltd (South Korea)

Evonik South East Asia Pte Ltd (Germany)

[Silane Application Plan]



4. QA/QC Plan



Tuas TerminalConstructorsQA/QC Plan

CAISSON FABRICATION

Base Slab Station

No. Description Acceptance Criteria Frequency DDJV Sub-Con

SO Rep.

3rd Party

1 RebarRebar shall be in accordance with Shop DrawingsSpacer bars, Supporting stools, and distance pieces to be inspected and approved by SO Rep.

3 visual inspections R R A

2 FormworkFormwork fixed in accordance to Shop DrawingsForms shall be cleaned and wettedConcrete cover 50 mm

Simultaneous visual inspection with the last rebar inspection

R R A

3Concrete

Temperature Monitoring

Temperature shall not exceed 70 CTemperature differential not exceed 20 C

Once for the second base slab casting

R A R

4Removal of Form Bolts (D-Cones)

Bolt holes shall be completely filled with approved sealing material Bolts shall not be placed within 50mm of any RebarScrew spacer cones between the bolt and formwork shall be removed promptly

For every form bolt (plastic cone) used during fabrication

R R A

5

Concrete Surface (Post-Casting) for Exposed Aggregate,

Laitance, Defect

Surface finish by screeding within tolerance of 3mm of true level and gradeEnsure that exposed aggregate surfaces are adequately preparedLaitance will be removedDefects will be patched with approved material under the permission of the SO Rep.

All concrete surfaces to be inspected for each base slab

R R A

6Movement of

Caisson

Prior approval from SO Rep.Concrete Cubes strength should be at least 10 MPa at 1.5 days

Every each caisson R R A

[R : Responsible, A : Approval]



CAISSON FABRICATION

Slipform Station


SO Rep.

3rd Party

1 Rebar

Rebar shall be in accordance with Shop DrawingsSpacer Bars, Supporting Stools, and distance pieces to be inspected and approved by SO Rep.Rebar verticality check with bubble level instrument

1 visual inspection for every 1.0 m

R R A

2 Formwork

Formwork fixed in accordance to Shop DrawingsForms shall be cleaned and wettedConcrete cover

1) Caisson External Face of Front Wall = 75 mm 2) Caisson External and Internal Wall = 50 mm

Simultaneous visual inspection for every 1.0 m

R R A

3

Concrete Surface (Post-Casting) for Exposed Aggregate,

Laitance, Defect

Surface Finish by screeding within tolerance of 3mm of true level and gradeEnsure that exposed aggregate surfaces are adequately preparedLaitance will be removedDefects will be patched with approved material under the permission of the SO Rep.

Inspected for every 1.0 m of concrete deposited

R R A

4Spraying of

Curing Compound

Spraying of approved curing compound for concrete surfaces above -1.0m CDTop and Side Surfaces of concrete to be kept moist for a period of four days after the concrete is placed

Outer surfaces to be sprayed for every 1.0 m

5Movement of

Caisson

Prior approval from SO Rep.Concrete Cubes strength (Slab sample) should be at least 40 MPa at 10 days





CAISSON FABRICATION

Curing Station


SO Rep.

3rd Party

1Concrete Surface (Caisson Cells)

Surface Finish by screeding within tolerance of 3mm of true level and gradeLaitance will be removedDefects will be patched with approved material. No repair of any concrete surface will be allowed without the permission of the SO Rep.

All surfaces of concrete for all caisson cells

R R A

2Final Dimension

Checking

Dimensions of Caissons will be surveyed; Tolerance for Formworks and Concrete Surface Finishes:

1) Variation in cross-sectional dimensions : +/- 6mm 2) Departure from alignment : +/- 6mm per 6m 3) Finished surface level of deck slab : +/- 3 mm

Verticality of Caisson Walls are surveyed;


3Post-SilaneApplication

Concrete Testing

Area of coring to be marked by SO Rep. to be tested for depth of penetration The test core shall be assigned an identification number

1 EA / 500 mm2 of concrete surface applied with Silane

R R A R

4Marking of

Caisson LabelClear and legible markings





THANK YOU !



Tuas TerminalConstructorsRectification Works

CAISSON FABRICATION

Damage Cases Rectification Works

Re-cast Concrete Structure

Erect temporary propsHacking with pneumatic toolsBonding agent material coating at the edge of existing concreteErect formworks Casting (G40 concrete with waterproofing admixture)

Concrete Repair- Formwork Grouting

Cut and hack around at demarcated honeycomb area Erect formworks Install inlet and outlet (25mmØ UPVC pipe , 600mm c/c)Grouting (Sika Grout 215)

Concrete Hand Patch Repair (for area < 0.5m2 at depth < 20mm)

Cut around demarcated honeycomb area Apply one coat of bonding agent (Sika Monotop – 610MY)Casting the cement mortar (Sika Monotop – R)

Crack Repair (for width < 0.05mm)

Clean the cracksSeal the surfaces (epoxy or polyester or other proper material)If Extremely high injection pressures V cut depth of 13 mm and width of 20 mmInstall the entry and venting portsEpoxy injection

Repair of Damage with exposed Steel Reinforcement

With a jack hammer, cut out 2 cm deep in 90 angle the perimeter of breakingClean the surfaceMixing : Non-shrink mortar (or micro concrete), fiber reinforced and polymer modified powderInfill the mixing material and curing



Measures for Temperature Control (Minimizing Heat of Hydration)

Preliminary Analysis & Mock-up Test and Plan of Temperature Monitoring

Temperature Control on Base Slab

CAISSON FABRICATION

PBFC (Low Heat Cement)will be used

Optimizing Content of Cementat Mix Design

Precooling Aggregateusing Shelter

Type of CementComposition of Cement

Relevant StandardOPC GGBS

PBFCfor Base Slab

30% 70% BS EN 146

Specification of

Concrete

W/C(%)

S/a(%)

Unit Weight (kg/m3)

WC (PBFC)

S G AD1 AD2OPC GGBS

G50 PBFC S3 36.0 46.1 155 129 301 812 950 0.96 5.29

Analysis ofHeat of Hydration

Mock-up Test forTemperature Monitoring

Plan ofTemperature Monitoring

100

400

400

100 Thermocouple

100

275

275

100



Further Measures for Temperature Control

This method is to adopted if original measures can not satisfy the requirement:

Temperature Control on Base Slab

CAISSON FABRICATION

Spraying Water on the Aggregate(only for Granite) Change the Placing Time

Change the Componentof PBFC

Cooling the Mixing Waterwith ICE



Specifications

This method statement is prepared according to the following specifications:

Codes and standards (BSI – DIN – ICE – ISO …)

Criteria

CAISSON FABRICATION

Document Number Document Title

30/06.C18 PART BTECHNICAL SPECIFICATION

Chapter 8. CAISSON CONSTRUCTION TO ENGINEER'S DESIGN

30/06.C18 PART BTECHNICAL SPECIFICATION

Chapter 9. STRUCTURAL WORKS

Singapore Standard (SS)

SS EN 1992-1-1:2004 Eurocode 2

Design of concrete structures

British Standard(BSI)

BS 4449 Steel for the reinforcement of concrete.

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