CONSTRUCTION OF BALANCE

CANTILEVER
SURAMADU APPROACH BRIDGE

1
02.10.07

CONSORTIUM OF INDONESIAN
CONTRACTOR

PLAN LAY OUT

Lokasi Jembatan
Suramadu

2
02.10.07

CONSORTIUM OF INDONESIAN
CONTRACTOR

TO SURABAYA

02.10.07

TO MADURA

APPROACH BRIDGE

CABLE STAY BRIDGE

APPROACH BRIDGE

672 M

818 M

672 M

44
38
36
40
42
45
41
37
39
43

BRIDGE DETAILS

BRIDGE ELEVATION

48
56
50
52
54
51
53
55 57
49

CONSORTIUM OF INDONESIAN
CONTRACTOR

A. DATA TEKNIS
1. Panjang Bentang : 672 m P37 ~ p45
2. Jumlah Pier :

8 Pier Sisi Surabaya

3. Pile Casing :

16 Pier x 18 ttk

: 288 Pile ( 1.800 mm)

35 Pile x 2 V-Pier : 70 Pile ( 2.200 mm)

4. Bored pile :
5. Pile Cap :

4
02.10.07

P37 ~ P40, P43+ P44

= 25.5 x 12 x 3 m

P41 + P42

= 25.5 x 16 x 3.5 m

P45 + P48

= 36.8 x 25.8 x 4.5 m

Bored Pile Sby Side

Pier
Length (m) Pile (nos)
P37
63.99
18
P38
71.99
18
P39
75.99
18
P40
80.99
18
P41
89.99
18
P42
93.99
18
P43
86.99
18
P44
90.99
18
Total
144
V-Pier
P45
80.99
35
P48
86.99
35
Total
70

CONSORTIUM OF INDONESIAN
CONTRACTOR

6.

7.

Pier Shaft & V-Pier :

Pier
P37
P38
P39
P40
P41
P42
P43
P44

Box Girder :
Length = 40 m
Height = 2.1 ~ 4.4 m (variatif)
Width = 14.7 m
Balance Cantilever Method :

5
02.10.07

Segment = 2 x 7 x 8 segment

Closure

Pier
P45
P48

Pier Shaft Sby Side

Height (m) Length (m) Width (m)
9.84
4.00
7.50
13.04
4.00
7.50
16.24
4.00
7.50
19.44
4.00
7.50
22.14
4.00
7.50
25.34
4.00
7.50
28.24
4.00
7.50
29.84
4.00
7.50
Total
V-Pier
Height (m) Length (m) Width (m)
37.80
36.70
9.00
37.80
36.70
9.00
Total

Unit
2
2
2
2
2
2
2
2
16
Unit
2
2
4

= 2 x 7 buah

CONSORTIUM OF INDONESIAN
CONTRACTOR

B. CONSTRUCTION METHOD
Super structure berupa double box
girder yang dilaksanakan secara
balance cantilever, cast in situ dengan
traveller form.

6
02.10.07

CONSORTIUM OF INDONESIAN
CONTRACTOR

1. Assembly Traveller

Traveller F/W
= 58.0 T
Traveller = 20.4 T

Form Work = 37.4 T

1. Traveller = 13,050 T

1. Outer + Inner + Bottom

= 31.5 T

2. Rail
Total

7,300 T

= 20,350 T

2. Beam + Penggantung
= 5.9 T

CONSORTIUM OF INDONESIAN
CONTRACTOR

Modul Utama + Truss + Rel

1. Modul ini yang akan memikul beton

segar s/d beton mengeras dan
dilakukan pekerjaan stressing.

Rear tie down

2. Rel diperlukan utk pergerakan

traveller setelah pengecoran.
CONSORTIUM OF INDONESIAN
CONTRACTOR

Rear levelling jack

Main Jack dg lock_nut

3. Setelah traveller duduk pada

main Jack j_1, traveller harus
dalam posisi horizontal.

4. Main hydraulic jack berfungsi

untuk mentransfer beban selama
pengecoran ke web. Dipakai 2
unit jack yang dipasang dibawah
main frame.

CONSORTIUM OF INDONESIAN
CONTRACTOR

Hanger traveller/rear tie down

5. Cantilever hanger, dipakai untuk

mendukung
form
work
selama
pergerakan traveller.
6. Vertical form hanger/penggantung
form work, dipakai untuk mengatur form
work dan memikul beban form work
selama pengecoran.
7. Angkur belakang / rear tie down,
dipakai untuk pengikat main frame/beam
selama pengecoran

CONSORTIUM OF INDONESIAN
CONTRACTOR

2. Pengoperasian Traveller

Pengecoran
Pergerakan
Bagian depan traveller
bertumpu pada Hyd. Jack j_1
Traveller bertumpu diatas rel
Pergerakan traveller
dilakukan dg hydraulic jack j_3

Bagian belakang traveller

diangkur ke beton lama dg stress
bar, elevasi diatur dg jack j_2

Outer F/W digantung dg high

tensile rebar

Rel tidak ada kontak dg

traveller

Inner F/W belum digerakkan.

F/W bawah diangkur ke beton

lama dg high tensile rebar

CONSORTIUM OF INDONESIAN
CONTRACTOR

CANTILEVER CONSTRUCTION DEVICE

LAUNCHING SEQUENCE

1.
2.
3.

6200

(2)

(2)

ASSEMBLE LEFT DEVICE AND RIGHT WITH

Z SHAPED CONNECTION
ANCHOR THE AUXILIARY TIE DOWN (2)
CASTING A SECTION WITH 4000 mm FOR
BOTH SIDES SIMULTANEOUSLY

CL

PIER

F1

F1

STEP 1

1.
2.
3.
4.
5.

4000
2

(2)
1
CL

AUXILIARY SUPPORT

STEP 2

PIER
AUXILIARY SUPPORT

F1

S5
4000
2

2.
3.
4.

5.

4000
1

S3 S4

3500

3500

FORWARD MOVEMENT OF RIGHT DEVICE BY

4000 mm INTO NEXT CASTING POSITION WITHOUT
MOVING LONG. GIRDER F1.
ROLL-OFF BEARING S3 IS NEWLY ANCHORED .
REAR ROLLER SUSPENSION S4 IS PUT FORWARD
AND ANCHORED.
FOLLOW THE PROCEDURE AS SOME AS
THE RIGHT DEVICE TO LAUNCHING THE LEFT
DEVICE
BOTH DEVICES ARE IN NEXT CASTING POSITION

CL

F1

STEP 3

4000
2

S4
4000
1

S4 S3

S5
4000
2

4000
1

4500

PIER

S5

F1

2600
1.

4000
1

3500

3500

SET UP THE LAUNCHING- RAIL WITH TIE DOWN 7

INSTALL AUXILIARY SUPPORT FOR BOTH DEVICES.
DISMANTLE THE Z SHAPED CONNECTION .
INSTALL THE TAIL PART OF RIGHT DEVICE FOR
LAUNCHING CONDITION.
AFTER INSTALLATION REMOVE THE AUXILARY
SUPPORT OF RIGHT DEVICE.

S5

S4 S3

S3 S4

S5

F1

S3
3500

3500

4000
1

S4 S3

4000
2

S5

CONSORTIUM OF INDONESIAN
CONTRACTOR

CANTILEVER CONSTRUCTION DEVICE

LAUNCHING SEQUENCE
4500

4500

CL

F1

PIER

S5

S4
4000
2

4000
3

1
2.
3.
4.

STEP 4

S3
4000
1

3500

3500

4000
1

4000
2

PIER

4000
4

S4
4000
3

F1

S3
4000
2
1.

STEP 5

S5

4000
3

4500

CL

S5

S4 S3

CASTING A SECTION WITH 4000mm FOR BOTH SIDES, SET UP LAUNCHING-RAIL WITH TIE DOWN 7.
MOVING FORWARD BOTH DEVICES BY 1000mm WITHOUT LONG F1.
FORWARD MOVEMENT OF BOTH DEVICES AND LONG, GIRDER F1 BY 3000 mm INTO NEXT CASTING POSITION
ROLL-OFF BEARING S3 IS NEWLY ANCHORED, THEN REAR - ROLLER S4 IS PUT FORWARD AND ANCHORED

4500

F1

F1

2.
3.

4000
1

3500

3500

4000
1

4000
2

4000
3

S4 S3

4000
4

S5

CASTING A SECTION WITH 4000mm FOR BOTH SIDES, MOVING FORWARD THE LAUNCHING-RAIL WITH TIE
DOWN 7 & 2
MOVING FORWARD BOTH DEVICES AND LONG. GIRDER F1, INTO NEXT CASTING POSITION.
ROLL-OFF BEARING S3 IS NEWLY ANCHORED , THEN REAR-ROLLER S4 IS PUT FORWARD AND ANCHORED

CONSORTIUM OF INDONESIAN
CONTRACTOR

Moving the cantilever

construction device into
the new concreting position

Chain Bloks
( 100kN )

Chain Bloks
( 100kN )

Girder

Skema Pergerakan Traveler Antar Pier

C
L Of Pier

C
L Of Pier
C
L Of Pier

80000

80000

CONSORTIUM OF INDONESIAN
CONTRACTOR

Skema Pergerakan Traveler Antar Pier

Elevation
C
L Of Pier

C
L Of Pier

C
L Of Pier

Plan
Bearing

80.000

80.000
CONSORTIUM
OF INDONESIAN
CONTRACTOR

Skema Pergerakan Traveler

80000

80000

CONSORTIUM OF INDONESIAN
CONTRACTOR

SEQUENCE OF CONCRETING
BOX GIRDER
STEP 1

CONCRETE ( STEP 1 )
BOX GIRDER ( TYPICAL SECTION )

STEP 2

CONCRETE ( STEP 2 )
CONCRETE ( STEP 1 )
BOX GIRDER ( TYPICAL SECTION )
CONCRETE ( STEP 3 ) STEP 3
CONCRETE ( STEP 2 )
CONCRETE ( STEP 1 )
BOX GIRDER ( TYPICAL SECTION )

CONSORTIUM OF INDONESIAN
CONTRACTOR

4. Cycle time pengecoran

No

DESCRIPTION

Duration

Strip form work & Advance rail

0.5

Advance traveller + setting outer F/W

0.5

Install bottom+web rebar & ducting

1.5

Setting inner F/W

0.5

Install top rebar & ducting

1.5

Concrete pouring

0.5

Curing

Install strand and wedges

Stressing

19
02.10.07

Days
1

Bisa diperpendek

0.5

CONSORTIUM OF INDONESIAN
CONTRACTOR

5. Sequence stressing

Cantilever
Cantileverstressing
stressing

Tes
Testekan
tekanbeton
beton>>85
85%%

Stressing
Stressing75
75%%UTS
UTS

Urutan
Urutan
pekerjaan
pekerjaan
stressing
stressing

Transversal
Transversalstressing
stressing

Stressing
Stressing40-50
40-50%%UTS
UTS

Continuity
Continuitystressing
stressing

closure
CCororclosure

20
02.10.07

CONSORTIUM OF INDONESIAN
CONTRACTOR

Tampang Tendon

1.

Tendon cantilever

1515.24 mm(top) + 1915.24 mm (web)

2. Tendon transversal
3-515.24 mm

3. Tendon longitudinal
1915.24 mm

21
02.10.07

CONSORTIUM OF INDONESIAN
CONTRACTOR

Lay out kabel

ELEVATION FOR WEB TENDONS

1

1
0

1
1

1
2

1
3

1
4

1
5

1
6

1
7

1
8

1
9

2
0

1
6

1
7

1
8

1
9

2
0

ELEVATION FOR TOP AND BOTTOM TENDONS

1

PLAN OF TOP PLATE

02.10.07

NOTE :
- FOR TOP =
- FOR BOTTOM =

1
0

1
1

1
2

1
3

1
4

1
5

PLAN OF TOP PLATE

CONSORTIUM OF INDONESIAN
CONTRACTOR

Ilustrasi Lay out kabel

ELEVATION FOR WEB TENDONS

Pier 36

Pier 38

P.3
7

ELEVATION FOR TOP AND BOTTOM TENDONS

Pier 36

Pier 38

P.3
7

PLAN OF TOP PLATE

PLAN OF TOP PLATE

P.3
7

Pier 36

PLAN OF BOTTOM PLATE

02.10.07

PLAN OF TOP PLATE

Pier 38

PLAN OF BOTTOM PLATE

NOTE :
- FOR TOP =
- FOR BOTTOM =

PLAN OF BOTTOM PLATE

CONSORTIUM OF INDONESIAN
CONTRACTOR

6. Deflection control

Setting traveller form

3
4
5

24
02.10.07

Install rebar

Compare
prechamber
analysis

Pengecoran segmen
Pekerjaan stressing

Pergerakan traveller

CONSORTIUM OF INDONESIAN
CONTRACTOR

25
02.10.07

CONSORTIUM OF INDONESIAN
CONTRACTOR

4. Closure

A
Segmen penutup antar span

Closure
Selama pelaksanaan
terlindungi thd muai

Selama pelaksanaan terlindungi terhadap

susut

D
F/W memakai traveller / profil
26
02.10.07

CONSORTIUM OF INDONESIAN
CONTRACTOR

2.

1.

Desain Temporary Angkur untuk Pier

Head
Temporary angkur difungsikan untuk
menahan posisi Piertable tetap stabil saat
pengecoran segmen girder.

Desain Temporary Lock untuk Closure

Temporary Lock ini diperuntukkan untuk
menahan pemuaian dan penyusutan beton
pada pelaksanaan closure.

27
02.10.07

CONSORTIUM OF INDONESIAN
CONTRACTOR

Traveller yang sudah

terpasang diatas pier table

CONSORTIUM OF INDONESIAN
CONTRACTOR

29
02.10.07

CONSORTIUM OF INDONESIAN
CONTRACTOR