Construction Methodology of Monorail Guide way Beams

CONSTRUCTION METHODOLOGY
OF MONORAIL GUIDEWAY BEAMS

Guideway Structure Construction Methodology

BEAM SEAT PREPARATION

PIER
PIER CAP

PILE CAP

CONSTRUCTION
FLEXIBILITY OF
GUIDEWAY STRUCTURE

BEAM LAUNCH READY

BEAM LAUNCHING

PILING
STITCHING

UNIQUE FUNCTION OF MONORAIL GUIDEWAY BEAMS

Sustain all design loads and design life

Running surface for vehicle
Accommodates system (E&M) requirements for signaling,
communications and traction power

FUNDAMENTAL CONSTRAINT

WB Group Of Company
Design &geometry
Construction
Beams to be formed to suit final alignment
including
horizontal & vertical curves,
curves gradients,
gradients transition curves and
super elevation (cant).

Architecture Engineering Urban Design Transportation Marine D&C

Contractor

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.
All these requirements call for a very high degree of quality assurance with big
impact on the riding comfort and reliability of the overall system; this
would affect the reputation of the system provider directly.
directly
6

PRESENTATION OVERVIEW
DESIGN CONCEPT OF GUIDEWAY STRUCTURE
PLANNING & PRE-CONSTRUCTION WORKS
TIMEFRAME,
TIMEFRAME MOULD DESIGN & PROCUREMENT
PRODUCTION & STORAGE
TRANSPORTATION & ERECTION
KEY SERVICES OFFERING

DESIGN CONCEPT OF GUIDEWAY STRUCTURES

Design philosophy :
(i) minimal disruption to traffic during construction.
(ii) minimal maintenance after completion.
completion
(iii) maximizing standardization in size for structural members.

Type of Super-structure
Super structure :
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.
Typical
T
i l arrangementt :
(i) Maximum 5 spans continuous beam without bearings.
(ii) Span ranges from 25m to 29m.

SOME CONCEPTUAL DRAWINGS

TYPICAL FRAME FOR STRAIGHT GUIDEWAY BEAM

DESIGN CONCEPT OF GUIDEWAY STRUCTURES

Non-typical situation (Obligatory Span) :

(i) Eccentric pier/portal frame will be required to support the

guideway beams at some location;
(ii) Long span superstructure may be adopted, e.g: major
intersection and railway crossing up to 60m;
(iii) Non-typical span arrangement where precast beam
transportation is difficult;
(iv) Single beam guideway structure near terminal station; and
(v) Curved guideway structure with the tightest radius of 50m.

DESIGN CONCEPT OF GUIDEWAY STRUCTURES (contd)

(
)

In certain circumstances, such as crossing existing railway tracks,

bridges or wide road below, special spanning arrangements
utilizing specially designed long span beams with extraordinary
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
locations where even the construction of the long span beams is
not viable.

The foundation system

y
generally
g
y adopts
p large
g diameter bored
piles, except at some places with special limitation or unsuitable
soil conditions where other foundation systems such as micropiles
may be used.

PROPOSED STEEL TRUSS BRIDGE FOR 50m SPAN

CROSSING THE MAJOR FLYOVER
NOTE
Base on KL construction rate
rate,
the above steel Truss will cost
RM 15 million.

VS

With the obligatory span

construction, it only cost RM
500,000 extra for the 50 m
crossing.

DESIGN
S G CRITERIAC
GUIDEWAY S
GU
STRUCTURES
UC U S
Design Loadings
The following loads and effects shall be considered in the design of
the guideway structures:
Dead load
Superimposed
S
i
dd
dead
d lload
d
Live load and its derivatives
Wind load
Temperature effects
Seismic load
Creep and shrinkage effects
Differential settlement
Erection loads

DESIGN CRITERIA- GUIDEWAY STRUCTURES (contd)

Design Loadings

Superimposed Dead Load (SDL)

Superimposed dead load shall include the weight of emergency
walkway, hanging sign boards, power rails and cable ducts.
Generally this value is around 4.0
Generally,
4 0 to 5.0
5 0 kN/m per beam

DESIGN CRITERIA- GUIDEWAY STRUCTURES (contd)

Design
g Loadings
g
Live Loads
The guideway structure shall be designed to carry the axle loads
of the monorail train. The axle load data is to be provided by
the train supplier/ rolling stock.
Train Vehicle Live Load (LL)
The design of the guideway structures take into consideration
2/4/6/8 car modules with indicated axle load positioned to
produce the maximum load patterns on the structures. The
arrangement of the train axle loads shall be in accordance
with the rolling stock proposed for the monorail system. Each
axle load is generally ranging from 100kN to 135kN with full
passenger
p
g load included.

DESIGN CRITERIA- GUIDEWAY STRUCTURES (contd)

Design Loadings

Dynamic Effect (I)

The dynamic impact factor for vertical load shall be generally taken
as follow:
Concrete beam,
Steel beam,
where,

I
I

=
=

20/(50+L)
25/(50+L)

length of span (m).

25%
25%

Centrifugal loads or longitudinal loads shall not be multiplied by the

dynamic factor. The dynamic impact factor will be considered for
superstructure
p
and p
piers only.
y It shall not be applied
pp
to p
piles and
pilecaps.

DESIGN CRITERIA- GUIDEWAY STRUCTURES

Design Loadings

Braking and Traction Loads (LF)

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
on one guideway and braking load acting on the other,
other with both
acting in the same direction to produce the worst loading condition.

Hunting
H
ti
Force
F
(HF)
Hunting or nosing force is caused by the lateral interaction of the
train vehicle and the guideway (Snake motion of train). Hunting
f
force
shall
h ll be
b 25% off one single
i l axle
l load
l d per car acting
ti
perpendicularly to the track axis at center of bogie.

DESIGN CRITERIA- GUIDEWAY STRUCTURES (contd)

Design Loadings

Centrifugal Force (CF)

The centrifugal force acting radially through the centre of gravity of the
train at a curve track shall be computed from,
CF
where,,

V2 P / R g

0.17 P

R
=
radius of curvature ((m))
g
=
acceleration due to gravity (m/s2)
P
=
train weight (kN)
V
=
train traveling
g speed
p
((m/s))
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.

Y
X
Z

Load 6<kN>

St uctu a Materials
Structural
ate a s
Concrete
The specified minimum 28-day compressive strengths of concrete
used for the various structural members are as follow:
Structural
Element
Guideway
beams
Piers
RC Portals
Pilecaps
Piles
where fcu
where,
fc
Ec

=
=
=

Concret
e Grade
60

fcu
N/mm2
60

fc
N/mm2
48

Ec
N/mm2
36000

45
45
35
35

45
45
35
35

36
36
28
28

32500
32500
29500
29500

cube compressive strength

cylindrical compressive strength
Youngs modulus of elasticity of concrete

Poisson ratio of concrete shall be taken as 0.2.

Structural
St
uctu a Materials
ate a s
Reinforcement
The minimum yield strength (fy) of high strength deformed steel
reinforcement shall be 460 N/mm2, conforming to BS 4449. The
modulus of elasticity of steel reinforcement shall be taken as
200kN/mm2.
Prestressing Strands
Prestressing
P t
i
strands
t d shall
h ll be
b off uncoated
t d stress
t
relieved
li
d low
l
relaxation seven-ply strands conforming to ASTM A416 or BS
5896. The minimum breaking strength per strand with nominal
area of 140mm2 shall be 260kN.
260kN The modulus of elasticity of
prestressing strands shall be taken as 195kN/mm2.

PRESENTATION OVERVIEW
DESIGN CONCEPT OF GUIDEWAY STRUCTURE
PLANNING & PRE-CONSTRUCTION
PRE CONSTRUCTION WORKS
CASTING YARD/MOULD DESIGN & PROCUREMENT
PRODUCTION & STORAGE
TRANSPORTATION & ERECTION
KEY SERVICES OFFERING

24

PLANNING AND PRE-CONSTRUCTION WORKS

PLANNING & PRE-CONSTRUCTION
(METHOD OF STATEMENT)

Beam
Technology Co.
Co.

Engineering
Consultants

Logistical Analysis of Alignment Geometry,

Define Mould Design,
Design
Development of the temporary works equipment,
Prepare Mould Setting & Casting Procedure,
Prepare Mould Setting Data,
Review Systems Inserts Data,

Long Lead Time

Prepare Technical Interface Procedure,

Define all Temporary Works & Equipments,

PROCUREMENT
Beam Casting Mould,

Prepare
epa e Heavy
ea y Lifts
ts Methodology
et odo ogy Stud
Studies,
es,
Prepare Transportation & Logistical Studies,
Prepare Erection Procedures,

Temporary Works Equipment,

Prepare Stitching of Joints Mould & Procedures.

Pre-stressing System & Equipment,

PRODUCTION

Reinforcement,

Prepare Shop Drawings,

Readyy Mix Concrete, etc.

Receive & Manage System Inserts,

QA/QC on Surface Finish,
Finish Inserts & Survey,
Survey etc.
etc

PLANNING AND PRE-CONSTRUCTION WORKS

Heavy and Over-dimension Transport Route study ;

Erection Study ;
Planning for Casting Yard ;

26

Heavy and Over-dimension Transport Route Study

27

An
integrated
between
design
and
construction
process for these types of
operations is essential since
there is no room for error
or mistakes.

A detail site topographical

survey was undertaken and
plotted electronically together
with building layout plans to
provide the basis of multiaxle hydraulic platform
transporters to manoeuvre
tight road junctions or a
constrained site access.

Erection Study (Crane Rigging Drawing)

The position and capacity of the
crane was driving influence for the
whole operation.
The planning of this operation was
only made possible by the
extensive use of CAD, in order to
simulate every position of the
transporter crane and beam so
transporter,
that clearance could be checked
from site boundary conditions.
The lifting position on the beam
were very important since the side
spans were cantilever beams,
which would not allow lifting at the
tip since this would cause a
t
temporary
sagging
i
momentt in
i
the beam opposite to the hogging
resistance
provided
by
the
permanent pre-stressing tendons.

28

Planning for Casting Yard

Precast Yard is required rational facilities and their arrangement to increase
production of guideway beam. It is necessary for the pre-caster to consider
construction schedule and quantity of the guideway beam.
beam

Mould Design

Developing a mould system and a method of converting the alignment design into
a series of mould setting information was one of the major technical challenges.

Mould Design

Since the guideway beam also forms the running surface for the monorail, this
p concrete surfaces, which need to be p
properly
p y represented
p
results in the warped
by the formwork skin.

Casting Yard/Mould Design

Casting yard is constructed on ground which should be satisfied prescribed
bearing capacity of ground. Especially foundation of gantry crane and beam stock
area had heavy weight of guideway beams

32

Casting Yard/Mould Design

Monorail Guideway Beam Casting Yard Facility

34

PRESENTATION OVERVIEW
DESIGN CONCEPT OF GUIDEWAY STRUCTURE
PLANNING & PRE-CONSTRUCTION WORKS
TIME FRAME,
FRAME MOULD DESIGN & PROCUREMENT
PRODUCTION & STORAGE
TRANSPORTATION & ERECTION
KEY SERVICES OFFERING

35

Production & Storage - Beam Production

The first step was to model threedimensionally different shapes of guideway

beams to get better understanding about
the beam geometry and to be able to
check
h k mathematical
th
ti l calculations
l l ti
l t
later
on.

Production & Storage - Mould Setting Data

Mould setting using Programmable Logic
Control (PLC).
Using third party software (Softdesk, Autocad Civil, etc) to
calculate the coordinates for the form work settings to take
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 casting
g yyard.
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 off the
h jacks
k willll be
b monitored
d on reall time.
The Graphical User Interface will be used to plot existing
positions of the jacks verses the designed positions using
visual line outputs instead of comparing a list of figures.
As compared to the existing manual methods, this
PLC interface
i
f
computer SCADA will
ill reduce
d
the
h risk
i k off
intermediate data extraction and input into
adjustments of the jacks by human errors. The casting
details and settings print out for the individual beams can be
obtained easily even with last minute changes to the
alignments
alignments.

37

3D BEAM MODELLING

3D BEAM FROM
ISOMETRIC
PROJECTION DERIVED
DIRECTLY FROM
ALIGNMENT
PARAMETERS

ISOMETRIC PROJECTION OF GUIDEWAY

BEAM

3D BEAM MODELLING FROM ISOMETRIC

PROJECTION

VIEW FROM SOUTH-WEST

VIEW FROM BOTTOM & RIGHT

3D VIEW FROM END

SECTION

SECTIONAL SLICING OF BEAM CORRESPONDING TO

MOULD FRAME

TYPICAL SLICED SECTION OF BEAM

SECTIONS DERIVED FROM SLICING

SECTIONS CORRESPONDS TO
JACK POINTS IN THE MOULD

PLAN VIEW OF JACK POINTS

BOGIE/SOFFIT SETUP
& TYPICAL SLICED SECTION

TYPICAL SECTION FOR SETTING

OUT AT THE JACK POINTS

GUIDEWAY BEAMS ISOMETRIC PROJECTION

ANOTHER VIEW OF THE SAME

VIEW FROM TYPICAL IPs

VIEW FROM TYPICAL IPs

REALIZATION
PRESENTING.

3D
MODELLING OF
THE SAME

PLAN VIEW
IP 32A

IP 33A

AERIAL VIEW

VIEW FROM IP 33A TO 32A

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
with previous experience through project, research and further study.
59

QA/QC Procedures - Beam Production Table

60

QA/QC Procedures - Beam Production Table

61

QA/QC Procedures - Beam Production Table

62

QA/QC Procedures - Beam Production Table

63

QA/QC Procedures - Beam Production Table

64

QA/QC Procedures - Beam Production Table

65

QA/QC Procedures - Beam Production Table

66

QA/QC Procedures - Beam Production Table

67

QA/QC Procedures - Beam Production Table

68

QA/QC Procedures - Beam Production Table

69

QA/QC Procedures - Beam Production Table

70

QA/QC Procedures - Beam Production Table

71

Production and Storage

72

Production & Storage - Concrete Technology

The bearing surface of guideway beam shall be finished by becoming a run side
of monorail so that there is no unevenness. The finish product cannot be
altered or modified or swapped.

73

PRESENTATION OVERVIEW
DESIGN CONCEPT OF GUIDEWAY STRUCTURE
PLANNING & PRE-CONSTRUCTION
PRE CONSTRUCTION WORKS
CASTING YARD/MOULD DESIGN & PROCUREMENT
PRODUCTION & STORAGE
TRANSPORTATION & ERECTION
KEY SERVICES OFFERING

74

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
it 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
y
forces transmitted back into the beam were controlled and
considered by the beam designer.

Transportation & Erection - Beam Transport

76

Transportation & Erection - Beam Transport

77

Transportation & Erection - Beam Erection

78

Beam St
B
Stability
bilit
and Adjustment

83

Monorail Beam Stability and Stitching

85

PRESENTATION OVERVIEW
DESIGN CONCEPT OF GUIDEWAY STRUCTURE
PLANNING & PRE-CONSTRUCTION
PRE CONSTRUCTION WORKS
CASTING YARD/MOULD DESIGN & PROCUREMENT
PRODUCTION & STORAGE
TRANSPORTATION & ERECTION
KEY SERVICES OFFERING

88

KEY SERVICE OFFERING

Setting up casting yard for the monorail guide way beam
production,
Full guide way structures design, design and procurement
of guide way beam moulds including mould vehicle.
vehicle
Provide Project Management for casting, E&M coordination,
transport and installation of guide way beams,
Provide full set of casting yard equipment including gantry
crane, concreting pump, bar cutting and bending machine,
stressing equipment, special trailer for transport and mobile
crane for beam installation,
Provide construction engineering for
f transport route survey
including shop drawing and alignment data conversion,
Provide all material for production of guide way beam
including grade 60 concrete,
concrete rebar,
rebar strand,
strand finger plate,
plate
erection and holding brackets, torsion bearing and all
accessories and
Provide design for temporary structure for beam installation
i l di traffic
including
t ffi control
t l and
d personall protection
t ti equipment.
i
t

Thank you
Worthy
Worthy Builders Sdn Bhd (the Company)
Company ) has taken reasonable care to ensure the accuracy of information materials and content given
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 Shareholders 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 part of this presentation may be reproduced, stored in or introduced into a retrieval system, or transmitted in any form, or by any means
(electronic, mechanical, photocopying, recording or otherwise) without the prior written permission of the Company.

FOR ENQUIRIES PLEASE CONTACT:

Ir. Lee C. M
T +606-6783306 / +6019-3833015

E wbcmlee@gmail.com