COST PROPOSAL FOR DESIGN AND MAJOR

EQUIPMENT SUPPLY

PROJECT : Bach Dang Cable Stayed Bridge project

(Option 1)

2016. 1. 28.
Bach Dang Cable Stayed Bridge project

1. DESIGN CONCEPT OF UNDERSLUNG FORMTRAVELLER

The self-launching UFT is designed for in-situ casting of the segment by free cantilevering method.
During casting of segment, the UFT are supported by permanent stays in front through the pre-
casted cable anchorage and stress bar which is tie downed to the front longitudinal girder and by
hanger bar anchored to previously casted segment at the rear through C Frame.
During launching operation, the UFT are supported by two hanger frames (front, rear) rolling on
previously cast deck.
A hydraulic jack and spreader beam which were hanged to the deck casted by stress bar for
vertical longitudinal adjustment for camber.
Prior to launching of the UFT and when the required concrete strength is achieved, side and edge
forms are stripped. The UFT is then lowered to required level hence stripping all the soffit forms.
The UFT will be equipped with hydraulic equipments for lowering/lifting and launching operations.
We have many options of UFT type to be applied to the design but the UFT type is basically
decided depending upon the stiffness of the superstructure and construction methodology.
Considering the above, the self launching UFT proposed by CHUNGDO have been considered and
applied the following system.

1-1. Casting ; Separate casting into two part

- Casting the edge girder at the front part (Seg N+1) and casting the top slab /
cross beam at the rear part (Seg N) to connect the edge girder casted in the
previous cycle at the same time together.

1-2. Longitudinal Truss (LT)

- LT consist of twin rectangular shape girder shall be in modules not only to

expedite handling and transportation to site but also taking into consideration
the LT arrangement during both first and second pairs of segment construction.
- It basically supports the edge girder in front and cross beam and top slab in rear
and temporary steel works during construction and the latter during launching
operation. During segment construction, LT are supported by “C” frame and
permanent stays while during launching, LT are supported by two “C” frame.
- For easy vertical adjustment of the front part of longitudinal truss enable to
connect the stay cable.
- The hydraulic jack and spreader beam which is hanged from the deck casted
previously is provisioned.
- Refer to appendix for sketches
Bach Dang Cable Stayed Bridge project

1-3. Transverse Truss (TT)

- TT is a support structure for FS that form the two concrete transverse beams. It is
supported at both ends by LT. Walkways to access the FS shall be provided.
- Refer to Appendix for sketches.

1-4. “C” Frame ( Front and Rear )

- “C” Frames are one of the support structures for LT during launching operation
and segment construction. During segment construction, the “C” frame is
supported by some hanger bars anchored to the deck previously constructed.
During launching operation, the hanger bars are removed and the “C” frame is
equipped with slide bearing is supported by Rail Beam on deck. A horizontal
hydraulic jack anchored to Rail Beam is introduced to launch the “C” frame.
- A vertical hydraulic jack located in between the “C” frame and reaction beam
which is suspended with hanger bars is also introduced for level adjustment.
- For the lifting and lowering of the UFT, the telescoping hydraulic lifting system is
applied.

1-5. Rail Beam (RB)

- RB is the support structure for HF. It is supported directly on completed concrete

deck. During launching operation, “C” frame will be lowered first to slightly above
RB to allow launching the RB forward by activating the horizontal hydraulic jack
anchored to “C” frame.
- After RB was completely launched, “C” frame is lowered directly to RB and the
UFT is launched forward.
- Refer to Appendix for sketches.

1-6. Formwork System (FS)

- The segment will be cast in two pour and FS will form the edge girder in front
and top slab, Cross beam in rear. To minimize weight of steel works, tie rods were
introduced when casting concrete transverse beams only. For concrete edge
girder, turnbuckles were introduced as a support and as a stripping tool.

2. ANTICIPATED STEEL TONAGE PER UFT : AROUND 280 TON.

Bach Dang Cable Stayed Bridge project

3. WORKSCOPE

a. Design

- Structural steel work

- Formwork

- Lifting, Lowering device including two hanger frames

- Launching device

- Load transfer system design

- Mech-hydraulic component design specification

b. Static calculation

c. B.O.M

d. Major equipment supply

- Hydraulic equipment ; See the attachment

e. Operation manual

- Typical UFT operation

- Launching sequence

- Lifting / Lowering of UFT using two hanger frames

- Load transfer procedure

- Main span key segment construction plan

- Side span key segment construction plan

f. Supervision for function and load test

g. Excluded part

- Design and supervision for heavy lifting of UFT

- Heavy lifting work of the UFT ; 1st Lifting / Lowering

- Cable Work

h. Delivery : 3 Month after receipt of ILC and down payment

i. The price ;

- Design : USD
Bach Dang Cable Stayed Bridge project

- Hydraulic Equipment for one pair (2sets) :

The price is variable from USD

Depending upon the system to be applied.

The final price will be decided after tech meeting with contractor.

- Supervision ( 1 man x 3month ) : USD

The site accommodation, catering, transportation are borne by contractor

j. Payment condition

1) Down payment : 30% of contract amount shall be paid by T/T within 10days after
contract.

2) Progress payment ; 60% of contract amount shall be paid by ILC against

Following shipping document within 2,5month after contract.

- Shipping document (invoice, B/L, Packing list)

- Design package (Drawings and static calculation)

3) Final payment : 10% of contract amount shall be paid by ILC against following
document

- Test certificate of the function / Load test

- Operation manual

- Warranty bond for mech hydraulic part supplied by CHUNGDO.

* Encl : 1) General assembly drawing

2) Hydraulic equipment to be provided by CHUNGDO

3) Working procedure
Bach Dang Cable Stayed Bridge project

Hydraulic Equipment list per UFT for Bach Dang Bridge project to be provided by ChungDo
Capacity
No Item Description Specification Stroke Purpase Quantity
Pull Push
Solid ram, Double acting, Clevis type Lifting & Lowering of the
1 "C" Frame Telescopic Jack 100 ton 85 ton 570 m/m 8 ea/UFT
both side UFT through "C" Frame

Solid ram, Single acting UFT front Longitudinal Truss,

2 Vertical Adjustment 250 ton 350 m/m 4 ea/UFT
with Ring nut Level controling

Launching of the rail beam

3 Launching jack Solid ram, Double acting 60 ton 30 ton 1050 m/m 2 ea/UFT
Launching of the UFT

"C" Frame Telescopic Solid ram, Double acting,

4 15 ton 10 ton 540 m/m "C" Frame Telescopic jack pinning 8 ea/UFT
Pinning Jack Clevis type

- "C"Frame Telescopic jack

5 Hydraulic power pack ( A )
- Working Pressure 600 bar
- Vertical adjustment jack
- Delivery : 4 x 4 l/min 2 sets/UFT
- Launching jack
- Radial piston pump
- Center hole jack for P.T bar stressing

- 6-Stress bar stressing &

Center hole jack - Hollow ram force equalizing ( front )
6 100 ton 50 ton 50 m/m 12 ea
( Bar jack ) - Double Acting - 6-Stress bar stressing &
force equalizing ( Rear )

*P/S : - The working pressure for above jacks is 350 bar

- The working pressure for power pack is 600 bar for using above jacks
as well as for post tensioning too.
- For hydraulic circuit for power pack (A) and (B), refer to attachment
 For work procedure,
see working procedure attached herewith

UNDERSLUNG FORM TRAVELLER

BACH DANG BRIDGE GENERAL ASSEMBLY
 UNDERSLUNG FORM TRAVELLER
BACH DANG BRIDGE GENERAL ASSEMBLY (CASTING PHASE)
 UNDERSLUNG FORM TRAVELLER
BACH DANG BRIDGE GENERAL ASSEMBLY (LAUNCHING PHASE)
 UNDERSLUNG FORM TRAVELLER
BACH DANG BRIDGE CROSS SECTION (SEG N+1)
Hanger frame Telescopie tube

Rail beam
Stress bar for fixing of UFT to the edge girder
Pre-casted stay cable blister
Edge girder to be casted

UNDERSLUNG FORM TRAVELLER

Bach Dang cable stay bridge CASTING OF EDGE GIRDER
Hanger frame Telescopie tube

Rail beam

Pre-casted stay cable blister

Edge girder to be casted

UNDERSLUNG FORM TRAVELLER

Bach Dang cable stay bridge LAUNCHING POSITION FOR EDGE GIRDER
 UNDERSLUNG FORM TRAVELLER
BACH DANG BRIDGE CROSS SECTION (SEG N)
Hanger frame Telescopie tube

CROSS GIRDER CASTING TOP SLAB CASTING

Rail beam

Pre-casted stay cable blister

Edge girder

2.0% 2.0%

UNDERSLUNG FORM TRAVELLER

Bach Dang cable stay bridge
 UNDERSLUNG FORM TRAVELLER
BACH DANG BRIDGE HANGER FRAME CROSS SECTION
 N+1 SEG. N SEG. N-1 SEG.

STEP 1
- UFT setting and pre-casting blister installation.
STEP 2
- Pre-cast blister tie down by stress bar.
- Horizontal strut installation and fix each other. - Post tension for cross beam (N seg.)
- Camber control by stressing of cables (N, N+1 seg.) - Load transfer at (N+1 seg.) from UFT to deck.
- Casting of top slab and cross beam (N seg.) - Cable stressing at N seg. and N+1 seg. if necessary.
- Casting of edge girder (N+1 seg.)
- Curing
※ P/S ; UFT is supported by stay cable in front
and by stress bar anchored previous N seg. in rear.

UNDERSLUNG FORM TRAVELLER

BACH DANG BRIDGE WORKING PROCEDURE
 N+1 SEG. N SEG. N-1 SEG.

STEP 3
- Lowering

UNDERSLUNG FORM TRAVELLER

BACH DANG BRIDGE WORKING PROCEDURE
 N+2 SEG. N+1 SEG. N SEG. N-1 SEG.

STEP 4
- Launching to next segment (N+2 seg.)

UNDERSLUNG FORM TRAVELLER

BACH DANG BRIDGE WORKING PROCEDURE
 N+2 SEG. N+1 SEG. N SEG. N-1 SEG.

STEP 5
- UFT setting and pre-casting blister installation.
STEP 6
- Pre-cast blister tie down by stress bar.
- Horizontal strut installation and fix each other. - Post tension for cross beam (N+1 seg.)
- Camber control by stressing of cables (N+2, N+1 seg.) - Load transfer at N+2 seg. from UFT to deck.
- Casting top slab and cross beam (N+1 seg.) - Cable stressing at N+1 seg. and N+2 seg. if necessary.
- Casting edge girder (N+2 seg.)
※ P/S ; UFT is supported by stay cable in front
and by stress bar anchored previous N seg. in rear.

UNDERSLUNG FORM TRAVELLER

BACH DANG BRIDGE WORKING PROCEDURE
 N+2 SEG. N+1 SEG. N SEG. N-1 SEG.

STEP 7
- Lowering and launching to next segment. (N+3 seg.)

UNDERSLUNG FORM TRAVELLER

BACH DANG BRIDGE WORKING PROCEDURE