沉管隧道施工課件講義（純英文PPT54頁）

1、Busan-Geoje Fixed Link Project2009. 06. Immersed Tunnel SegmentPrecasting forGeoje -doKadeok-do - CONTENT-. Project Overview. Location. Facts and figures. Element Production . Warping, Towing and Mooring. Immersion Works. General background items Busan-Geoje Fixed Link Project 2 Roadway lanes in eac

2、h direction : L=8.2Km, B=20.5m Immersed tunnel : 3.7km 2 x Cable stayed bridge : 1.6km 4 x Approach bridges : 1.9km 2 x Bored tunnels : 1.0km 2004.12.10 2010.12.09 (Construction: 6years, Concession : 40years) Start point : Yuhori, Jangmockmyun, Kyungnam, Geojesi GK Fixed Link Corporation Yooshin Eng

3、ineering Corporation Project nameKey dataLocationConcessionaireConstruction PeriodContractorSupervisor COWI in JV with 5 Korean consultantsDesignerProject cost End point : Chunsungdong, Gaduckdo, Kangseogu, Busansi Total project cost : $1.4Bil. (based on December 1999 prices) Government subsidy : $0

4、.4Bil. Private investment : $1Bil. Project Overview: 44.6%: 21.3%: 13.6%: 8.0%: 5.7%: 5.3%: 1.5% DAEWOO E&C DAELIM DOOSAN Industrial Development SK Engineering & Construction KDC HANIL WONHA ConstructionKosungTongyeongiGeojeSinhyunMasanChangwonJinhaeBusanDaejeon-Tongyeong HighwayAnjeong Yard(Immerse

5、d Tunnel Elements & Bridge Substructure)Obi Yard(Bridge Superstructure)Immersed tunnel and Cable stayed bridgesGeoje IslandOverall Project L=8.2kmCable Stayed Bridges & bored tunnels L=4.5kmImmersed Tunnel L=3.7km. LocationTemporary Mooring Area (37Km from Gaduk)Gaduk IslandNaval baseProject section

6、Birds eye viewThree Pylon cable stayed bridgeTwo Pylon cable stayed bridgeImmersed Tunnel (3.7KM)Main span : 230M / Navigation clearance: 36M / Pylon Height : 102MMain span : 475M / Navigation clearance: 52M / Pylon Height : 156MGeoje IslandGaduk Island. Facts and Figures (Segments / Elements) Quant

7、ity: 18 No.(3.24km) Length : 180m (8x22.5m segments)Weight : approximately 54,000t Width : 26.46m, Length : 22.50m, Height : 9.97mRebar: 430t/seg. (E1,2) & 330t/seg (E3,4)Concrete : 2,264/segmentStrand : 132 t/elementSteel cast-in items : 1,100 t/elementS1S2S3S4S5S6S7S822.5M180M26.46mElementShear Ke

8、yShear Key Typical Cross sectionBallast ConcreteBallast ConcreteShear KeyPRIMARY ENDSECONDARY END Elevation9.97mt=0.58mt=1.35mt=1.33mt=1.33mArea of Yard(329m 870m)Site officeDock Gate(Floating)Dry DockMooringAreaLocation : Anjeong National Industrial Kyungnam TongyeongKey data : Overall area approx.

9、 250,000 m Dry dock volume 100,000 m ItemDry Dock Element productionArea for bridge substructureBridge Caisson constructionT. T. P constructionBridge Pier constructionSizeL = 474m, W = 145m ( EL = -11.15 )W = 26.46 28.46m, H = 9.97m, L=180mL = 268 m, W = 50 mQuantity118 1H = 1034 m ( 1,1409,800ton )

10、234 ton 72 ton8,600H = 1437 m ( 1,2603,500ton )22CommentMax. 5 elements at one time 8 complete, 5 70% completeCompleted Artificial island now completedSubstantially completedMooring areaL=556m, W=217m1Max. 6 elements at one time Overview . Anjeong Pre-Casting Yard OverviewLocation : Obi Industrial c

11、omplexes , Kyungnam Area : Approx. 130,000 mItemSuperstructure work areaApproach bridge spansPre-cast deck panels for cable-stayed bridgesSize L = 250m, W = 100m, Total : 140000M1Spans lengths from 49 90 mW = 10.35 12.35 m , L = 4 mQuantity1 30 702Comments8 spans placedStarts soon Element protection

12、 worksCore-Loc 12Ton, Accropode 25, 35, 50 Ton5,473Substantially completed . Obi Pre-Casting yardItemCaissonPierDesign11 11 Completed11 4 Being built 1 5 Not started - 2 ItemCaissonPierDesign1211 Completed12EABeing built 1 3 Not started - 8 . Cable stayed bridge 2 Pylon Bridge 3 Pylon Bridge Western

13、 Portal (Jungjuk island) Eastern Portal (Gaduk island) 1. Dredging and foundations2. Immersing and backfilling3. Internal works in the elements4. Cut & Cover tunnel construction - East : 170m - West : 170m. Immersed Tunnel. Element ProductionSet plywood on support slab Erect rebar access platforms,

14、Fix bottom slab & lower wall rebar Install steel cast-in items Dismantle inner access platforms Move formwork launching girder, Install inner formsFix upper wall & top slab rebar and install steel cast-in itemsDismantle rebar access platforms, Inspect rebar etc. Erect stop end and outer formsDo fina

15、l inspection and prepare for placing concrete Place concrete (24hr) and Cure (5 days)Repetitive workInner FormOuter FormRain ShelterLaunching Girder Formwork System (Kumkang Doka). Element Production Set plywood, Erect rebar access platforms, Fix bottom slab & lower wall rebarRebar work platformBott

16、om plywood. Element Production Move Launching Girder and Set Inner Form. Element Production Fix upper wall & top slab rebar, Install steel cast-in items, Erect stop end and outer forms, prepare for concreting. Element Production Concrete placing and curingConcrete placing (24 hours continuous workin

17、g) Quantity : 2,264/seg Equipment - Concrete pump with 32m boom : 4 active, 2 standby - Static concrete pumps : 2 - Concrete truck mixers : 13 - Batching Plant (210/hr) : 2 Curing in formwork : Winter 5 7 days, Summer 4 days (3)Concrete constituentDetailsStrength35 MPaSlag Cement 319kg/Water145kg/Ad

18、dictiveFly ash 83kg/Silica Fume12kg/AdmixtureSilk road, EcontaxHigh-performance water reducing agent. Element Production Cross section Injectable Water StopShear KeyShear KeyShear KeyP.T. ductsShear KeyOmega Anchor Plate Quantity : 32 tendons / element (28 19strand + 4 31 strand) Weight : 132Tonnes

19、/ element Strand : 7 wire x 15.24mm diameter Duct : 110mm or 140mmManufacturerTrelleborgMaterialSBRService life100yearsLength (L)66mPurpose : It is cast in to each side of the segment joints and is the first barrier against water ingress. It can accommodate movement due to temperature, shrinkage, cr

20、eep and earthquake. Element ProductionDuctBearing plateStrandWedgeAnchor headGrout inlet OMEGA SEALManufacturerTrelleborg BakkerSizeOS 240-40MaterialSBRService life100yearsPurpose : Second barrier against water ingress and can accommodate movement due to temperature, shrinkage, creep and earthquake.

21、 . Element Production Post Tensioning & Grouting. Element Production GINA GASKET Storing Loading Unloading. Element Production“GINA GASKET”410mm360mm GINA GASKETManufacturerYokohamaSizeM34MaterialNRDurability100yearsPurpose : Installed on the primary end of one element to form a watertight seal agai

22、nst the steel front plate of the secondary end of the adjacent element at the immersion joint. It can accommodate movement due to temperature, shrinkage, creep, earthquake. Element Production Ballast Tank, pipe-work and pump layout Ballast Tank(6 / element) Size : 20.25 9.1 5.0m Capacity : 920 each

23、Main pump(2 No.) Flow rate : 1,000t/hr (110kw) Sub pump(1No.) Flow rate : 200t/hr (19kw). Element Production Temporary Steel Bulkhead Assembly. Element ProductionPore filling1st (green) coat of Polyurea Primer & surface pore filling2nd (grey) coat of Polyurea Polyurea waterproofing membrane to outer

24、 walls and upper haunch Waterproofing membrane required by Government Audit. Element Production15 . Warping Towing and Mooring Flooding the dry dock and preparing for towingRemoving vertical sealsMoving Floating Gate(29.215.015.35m)2 valves 1000mm100T crane15 . Warping Towing and Mooring Warping out

25、2600HP Tug 15 Towing. Warping, Towing and Mooring Towing and MooringSecuring in mooring areaE1, E2, E3 & E4 in mooring area. Warping, Towing and MooringJungjuk approach (255m) Immersed Tunnel (3,239m)Gaduk approach (170m) Reclamation for artificial island with sea defence works Cut & Cover Tunnel (2

26、1.25m x 8 segments = 170m) Approach Ramp (85m) Ventilation system Earthworks and sea defence works Cut & Cover Tunnel (21.25m x 8 segments = 170m) Ventilation system Soft ground improvement Dredging and foundation work 18 No. Towing, Mooring, Immersing Backfilling and Protection work Inside finishin

27、g work Plan & Elevation of Tunnel1st Element18th ElementJungju IslandGaduk Island13Th ElementDepth: about 50m(M.S.L-Bottom level of Element). Immersion Works Foundation GroundSectionBasic designDetail designThe presentWest sectionSCP + PreloadingSCP + PreloadingSCP + PreloadingMain section-CDMCDMEas

28、t sectionRubble foundationRubble foundationRubble foundationGround improvement at main section - Basic design: limited ground improvement plan (displacement, SCP) at exposed part of start/end point - Addition of ground improvement plan (CDM) to increase the safety for long-term settlement at general

29、 sectionMain sectionWest sectionEast sectionBusan GeojeDefinition - Immersed tunnel foundation consists of foundation ground and BED transferring load of element to foundation ground - Immersed tunnel method is a concept that the self-weight of element is offset by using buoyancy , so that load tran

30、sferred to ground can be reduced. Immersion WorksLocking FillCrushed stone ,below 75mmBackfillRubble, below 300mmArmour Protection0.251.0T(Underwater) Protection workMain part Start / End part Geoje directionBusan direction. Immersion WorksFoundation pavement (Gravel Bed)Outfit installation / Elemen

31、t Towing and ImmersingOutfit dismantlementLocking / BackfillProtection and In-tunnel work. Immersion WorksPlan of PavementCross section of pavementTremie pipie at end Concept of foundation pavement Equipment for foundation pavmentNationality : KoreaCompany: Eunsung foundationSize : Hull : 613511m Po

32、ntoon : 617.54.5m,(2EA) 2074.5m(2EA) Tremie pipe : diameter- 1572mm,19T Length- 0 -39m Construction depth : 49mConstruction ability : 3,500 4,000 m3/dayMeasuring a Elevation by measurement installed on the groundL2, distance from top of tremie to eco-soundL3, distance from surface of pavement to eco

33、-soundHow to measureElevation 21-2-3. Immersion Works15 Installation of Outfit and Preparation of transportationPRIMARY ENDSECONDARY END Pulling Jack(150T) . Immersion Works Installation of Outfit and Preparation for transportation E P S (External Lifting & Positioning System) and Pontoon settingEqu

34、ipment : PontoonNationality : In-country Company: Sungbo Development Winch Yuyoung Development, Hull DaekyungjoseonSize : Width - 42.15m,Length 36.0m Height 9.0m, Weight About 1,400t. Immersion Works Installation of equipment and preparation for transportationEquipment: E P SNationality : KoreaCompa

35、ny : Daekyungjosun, Yuyoung Development, Keosung TechSize : Vertical Jack(800T) 2EA a set(Total 4EA) Horizontal Jack(200T) 2EA a set(Total 8EA). Immersion Works Preparation for immersion120m. Immersion Works Preparation for immersion. Immersion Works Immersing. Immersion Works Immersing. Immersion W

36、orks Immersing. Immersion WorksGRAVEL BEDBallast TankPumpView of Immersion JointBallast Tank( Stage 1 )( Stage 2 ). Immersion WorksBallast Tank( Stage 3 )“DETAIL”View of Immersion Joint. Immersion Works Now some general bits and pieces of information that may be useful laterNationality : Netherlands

37、Company : Van Oord (HAM-316)Size : 8,473m3Max. depth : 47mCapacity : 16,00020,000m3/day Trailer Suction Dredger Gravel BedNationality : Korea Company : DONG-A Geological Engineering (Trial works) Suckjung, Eunsung Foundations (Main works)Size : LEADER : 85.0 m VIBRO-HAMMER : V-55000 Casing : bottom

38、1,232 / top 812 mm*74.0m Belt Conveyor : 300 /hr Construction depth : 12m Construction capacity : 400 m/day CDM & SCP Principal equipmentNationality : KoreaCompany : Eunsung foundationSize : Hull : 613511m Pontoon : 617.54.5m,(2EA) 2074.5m(2EA) Tremmie pipe : diameter- 1572mm,19T Length- 0 -39m Dept

39、h : 49mCapacity : 3,500 4,000 m3/day Principal Equipment for ImmersionEquipmentSizeQuantityRemarksEPS-2 setsInstalled on segments. 2 &7EPS (Vertical Jack)800T42/ EPS setEPS (Horizontal Jack)200T84/ EPS setPulling Jack150T2Installed at Primary EndPontoon42.5369mWeight:1,400T2 setsInstalled at segment

40、s 2 & 7Tugboat3,200HP22,600HP2Anchor handling boat2,500HP1Sampan350HP2Winch60T10For control of element 35T8For control of pontoon OrganizationField teamSupport teamPC- YardCable stayed bridgeImmersed tunnelDesignProject controlManagement4637361214811934154Ground improvement : Mixing cement and water

41、 - Injecting using specific agitation machine - Establishing a round PileCDM (Cement Deep Mixing)C D M1,000 4EA112,093mConstruction period 2006.12.23 2007. 5.30Design standardDesign strength8/W/C0.8Cement175/SCP (Sand Compaction Pile)S C P2,00061,972mConstruction period1,60030,302mTotal92,274m2006.

42、8.15 2007. 6.30Trial mixCharacteristics of fresh concreteCompressive & Tensile strengthChloride Diffusion co-efficient DCL ?10-12/sFree of thermal cracksEndYESNoNOYesTraditional approach Duracrete approachRequirements of Slump, compressive strength, air content etc. Consider proportions of constitue

43、nts Grading of sand, maximum size of coarse Aggregate, W/C etcTrial Mix Evaluation of performance(Workability, Compressive strength)NotOKEndOKTraditional mix design (Focus on strength)GK Project Durable mix designGK Project (Focus on durability)(Chloride diffusion Control of thermal cracks) Mix design of Durable concreteImmersion/ Locking FillStabilization of tunnel element Stage 1 - After checking the alignment of element, overweight is increased : 6% (Net 2,700t