BAC ADVANCED COMPOSITE TECHNOLOGIES Bridge Installation Guide Revision 1: 11 March 2016 Prepared By: Lachlan Nicol 11/03/16 Page 1 of 10
Contents 1. Introduction... 3 1.1 BAC Bridges... 3 1.2 Purpose of this guide... 4 2. Bridge Components... 5 3. Handling & Installation... 6 3.1 Safety Recommendation... 6 3.2 Delivery... 6 3.3 Lifting... 7 3.4 Bridge Installation... 8 3.4.1 Preferred Installation Procedure... 8 3.4.2 Optional/Additional Installation Procedures... 10 Page 2 of 10
1. Introduction 1.1 BAC Bridges BAC s fibre composite modular bridge systems utilise state of the art fibre composite technology and procedures to create a single, integral structure. BAC has designed and certified both pedestrian and cyclist bridges as well as fully functional road bridges. Being a lightweight, integral structure; installation costs and site works are significantly reduced, allowing the bridge system to be installed in less than one day onto pre-established abutments or headstocks. The bridge and handrail system is manufactured in BAC s Toowoomba factory and trucked as a single unit to the desired location ready for installation. All bridges are designed in accordance with the Australian Standard for bridge design: AS 5100 and in conjunction with other relevant standards including but not limited to: AS 1170, AS 2156, AS 1657, and AS 1428. All bridges are design certified by a structural Registered Professional Engineer of Queensland (RPEQ) as well as having construction certification for the manufacture of the bridge superstructure. A standard BAC bridge has a design life in excess of 100 years with no structural maintenance required over its lifespan. Bridge units can be designed to meet site-specific parameters and tolerances and can also incorporate specific customer requirements such as colour, handrailing, and sizing. All BAC bridges are provided with appropriate slip resistance coating to the top of the decks depending on the specific use. BAC prides themselves on delivering customised solutions to help maximize installation, performance, and budgetary outcomes for their customers. Figure 1 - Hardgrave Rd. Bridge Page 3 of 10
1.2 Purpose of this guide This guide outlines the construction procedures and requirements for the installation of BAC s modular, fibre composite bridge system. This document should be reviewed by supervisory personnel prior to commencing any bridge installation. This guide is of general nature only and should be read in conjunction with any project-specific documents including contract, project specifications, and project drawings. This guide is not a substitute for the official project management plans and documentation. Site specific requirements may take precedence over any aspects outlined within this guide. All photos and drawings in this guide are purely for explanation purposes and are not site specific. Where the contents of this guide differs from project specification and drawings, supervisory personnel should consult with BAC s project engineer for clarification. In the event of any conflict between the information in this guide and local legislative requirements, the legislative requirements will take precedence. It is the responsibility of the site supervisor and all associated contractors and consulting engineers to determine the site s suitability for construction, including access for plant and other issues. No statement in this guide is to be interpreted as a guarantee or warranty. Figure 2 - Noble St. Pedestrian Bridge Page 4 of 10
2. Bridge Components BAC s fibre composite bridges are manufactured as a single integrated part by our state of the art resin infusion process. Although BAC s composite bridges are supplied as a single part, there are several components which should be identified for identified for purpose of explanation. The various bridge components are shown in Figure 3 and are as listed below: Composite Bridge Components - - Girders - Deck - Concrete Abutments/Headstocks - Approach Works - Handrailing - Hold Down Brackets and Bolts Approach Works Bridge Deck Handrailing Concrete Abutments Bridge Girders Figure 3 - Bridge Component Layout Hold Down Brackets & Bolts Page 5 of 10
3. Handling & Installation 3.1 Safety Recommendation Safety requirements and regulations must be observed during the transportation, handling, storage, and installation of BAC s modular bridges. It is the responsibility of the contractor installing the bridges to produce a Safe Work Method Statement that complies with relevant law, codes of practice, standards, and safety regulations. All lifting equipment must be certified to lift the specific mass and approved for lifting heavy componentry. The mass of BAC s bridges varies depending on their geometry; delivered weights will be clearly marked on all relevant project drawings and given to site supervisor. Figure 4 - John W. Mott Pedestrian Bridge 3.2 Delivery The rate of delivery should be decided by the main contractor or installation contractor in consultation with BAC; this will be dependent on factors including: - On-site access - Crane size & reach - Transport availability - Site traffic control - Nominated project timing BAC recommends the development of a shipping plan to document the sequence, date, and delivery time of each bridge should the project require several deliveries. This will provide better management of transport access, carriage, and on-site materials. Figure 5 - Bridge Delivery Page 6 of 10
3.3 Lifting This set of lifting instructions is to be taken purely as a guide with final lifting plans to be developed by the onsite installers based on but not limited to the following variables: - Weather at time of install - Ground conditions onsite - Available crew onsite - Crane type and size used for bridge lift - Relevant health and safety procedures for onsite work Prior to delivery to site, BAC will supply the onsite installation contractors with all critical lifting data including: length, width, height, weight, and centre of gravity. The manufactured deck will be transported in a Figure 6 - Bridge Delivery & Crane Setup horizontal position as per Figure 6. Predominantly, BAC will have handrails fitted to the bridge therefore careful attention needs to be made to ensure handrails are not damaged during the lifting process. Where possible, all modular bridge components should be lifted from the delivery truck and installed directly to the prepared substructure. However, if temporary site storage is necessary, the bridges can be stored on firm, levelled ground onto hardwood timber bearers. If the ground is suitable, a maximum of three decks may be stacked with hardwood timber bearers in between (one side of handrail may need to be removed for stacking). Figure 7 - Stacked Bridges During Packing & Shipping Page 7 of 10
3.4 Bridge Installation The preferred bridge installation procedure is as follows: 1. Lift bridge off truck using suitable crane. 2. Place bridge superstructure on prepared abutments/headstocks and mark hold down bolt locations. 3. Lift bridge back off abutments/headstocks. 4. Drill holes in abutments at all hold down locations (including through bearing pads). 5. Place bridge back on abutments/headstocks and fill drilled holes with Ramset - Chemset 801 or approved equivalent. 6. Insert threaded rod and secure bridge 7. Pour ballast walls and approach works up to installed bridge. BAC s preferred installation procedure provides the most accurate positioning of the bridge for final securing and reduce onsite installation time. Variations of procedure may be undertaken and are detailed in section 3.4.2 Optional/Additional Installation Procedures. 3.4.1 Preferred Installation Procedure Installation Setup Upon delivery of the BAC bridge, it is assumed that abutment/headstock work has been cured and finished appropriately according to project specifications. For ease of installation, it is suggested that the ballast wall of the abutment is not poured until the bridge has been fully positioned and secured. Bridge Mark Out Once lifted off the delivery truck, the bridge superstructure needs to be aligned and placed on the prepared abutments/headstocks for marking. Figure 8 - Prepared Abutments & Bearing Pads BAC will provide all relevant drawings detailing the position of the bridge onto the abutments/headstocks and hold down bracket locations. The beam extents and hold down bolt locations should be marked. Rubber bearing pad locations must be also be marked at this stage. Drill Holes Once the bridge superstructure has been removed off the abutments/headstocks and safely stored, holes can be drilled at all hold down bracket locations using a carbide or core drill bit. BAC requires a minimum depth of 200mm to be drilled through concrete abutments/headstocks to ensure full restraint is achieved. 26-27mm hole diameters are necessary for effective bonding of Chemset 801. Holes must also be drilled in 6mm rubber bearing pads at all appropriate locations. All holes must be flushed, cleaned, dry, and free of any remaining dust or debris generated by drilling of holes into concrete. Page 8 of 10
Bridge Placement & Securing The bridge superstructure can now be reinstated onto the abutments/headstocks on top of the 6mm rubber bearing pads. Fill predrilled holed approximately 2/3 to 3/4 full with Chemset 801. Insert M24 threaded rod into all holes through hold down brackets and bearing pads and lightly secure appropriate nuts & washers. Ensure the final position of threaded rod is perpendicular to the abutments/headstocks. Allow to cure for a minimum of 60 minutes (depending on weather conditions & temperature) before fully tightening. Figure 9 - Bridge Placement For further Chemset 801 installation details and safety data please refer to appropriate technical and safety data sheets provided on the Ramset website: http://www.ramset.com.au/product/detail/5/chemset-801 Finishing Once all brackets have been secured tightly and the bridge is positioned in final location according to relevant drawings, the ballast wall and approach works can be poured up to the bridge superstructure. 10mm expansion adhesive is to be placed at ends of bridge superstructure before pouring of ballast wall. Figure 10 - Josling St. Completed Bridge Page 9 of 10
3.4.2 Optional/Additional Installation Procedures - Handrailing will typically be supplied pre-fitted to BAC s bridges however under certain circumstances, such as stacking for delivery, handrails may be supplied separate. BAC will have already pre-fitted and then removed the handrails before transport to reduce onsite installation time. Onsite installation subcontractors will need to reinstate the handrail into specified, pre-drilled bolt locations and securely tighten. Figure 11 - Handrail & Hold Down Bracket Diagram - Where multiple spans are to be installed, BAC will supply relevant information regarding expansion joint installation. - Ballast walls may be pre-poured before delivery of bridge to reduce installation time, careful attention needs to be taken to ensure ballast walls are poured accurately to ensure the BAC bridge will fit within the nominated tolerance. - Ferrules may be pre cast into abutments/headstocks to allow for hold down brackets, this will remove the need for drilling onsite and can save time during installation. Before casting ferrules into concrete abutment/headstock, seek accurate measurements from BAC of all hold down bracket locations to ensure onsite alignment. - Should the contractor propose an alternative bridge installation procedure, prior approval by BAC is required before commencement. Page 10 of 10