Tan Chee Kean - epsmg.jkr.gov.myepsmg.jkr.gov.my/images/0/09/Pembaikan_Jambatan-BWa.pdf · Kekerapan kerja pembaikan akan meningkat kemudian hari. Keselesaan dan keselamatan pengguna

4/6/2017

1

Prepared and presented by : Tan Chee Kean 1

Tan Chee KeanPenolong Jurutera

Bahagian Pemulihan Jambatan


Ia merupakan satu kondisi semasa dimana komponen jambatan telah mula atau telah berada dalam keadaan kekurangan atau tidak lagi sempurna bila dibandingkan dengan keadaan asal.

Situasi dimana keutuhan jambatan telahmula atau telah merosot ketahap yang bolehmenjejaskan fungsi jambatan mengikutkehendak rekabentuk atau daya penahanbeban tanggungan.

4/6/2017

2


Punca-punca Kerosakan Komponen Jambatan

1. Secara Tindakan Mekanikal.2. Secara Tindakbalas Kimia.3. Secara Tindakbalas Fisikal.

Punca-punca Kejadian Kerosakan



1. Secara Tindakan Mekanikal.a) Impakb) Tanggungan Beban Berlebihanc) Penggerakand) Pemendapane) Gegaranf) Letupan

2. Secara Tindakbalas Kimia.a) Alkali-aggregate reaction.b) Serangan Sulphate.c) Serangan Chloride.d) Delayed Ettringite Formation (DEF).e) Biological activity.

Punca-punca kejadian kerosakan

AAR

DEF

4/6/2017

3



1. Secara Tindakan Mekanikal.2. Secara Tindakbalas Kimia.3. Secara Tindakbalas Fisikal.

a)Tindakbalas haba konkrit.b)Tindakbalas kecutan konkrit.c)Hakisan.d)Kekerokan.e)Kehausan.

Punca-punca Kejadian Kerosakan


Material Defects Cracks Delamination Spalling Corrosion Surface Defect Material

Deterioration Abrasion Water Leak Paint

Deterioration

Structural Defects Cracks Tilting Settlement Deformation Fracture Abnormal Bulging Abnormal Deflection

Hydrological Defects Scouring Erosion Silting Tilting Settlement

4/6/2017

4


Bahayakah ImpakKecacatan?

Akan mengurangkan keupayaan dan keutuhanstruktur jambatan untuk terus berfungsi mengikutkehendak jangka hayat yang telah direkabentukkan.

Ketahanlaksakan struktur akan terjejas.

Kos penggantian jambatan akan meningkat.

Kekerapan kerja pembaikan akan meningkatkemudian hari.

Keselesaan dan keselamatan pengguna jalanrayaakan tergugat.

Kelancaran trafik akan terganggu.


Teknik dan Operasi Penyenggaraan

Jambatan

4/6/2017

5


Teknik dan Operasi Penyenggaraan Jambatan

1. Ketahui jenis bahan komponen.

2. Fahami jenis sistem jambatan.

3. Kenalpasti jenis kecacatan, tahapkerosakan dan punca kejadiannya.

4. Laksanakan ujian jika perlu.

5. Pintar tentangan kegunaan bahanpemabaikan yang bersesuai danekonomi.

Kefahaman asas sebelum melaksanakan operasipenyenggaraan dan kerja pembaikan:-



1. Penyenggaraan biasa.

2. Pembaikan biasa.

3. Rehabilitation.

4. Strengthening.

Jenis-jenis skop kerja

4/6/2017

6


1. Penyenggaraan biasaa) Penyenggaraan biasa jambatan oleh

konsesi mengikut kontrak. (R05)

b) Operasi penyenggaraan , pemulihandan penggantian komponenbersekala kecil.



A. Penyenggaraan biasa jambatan oleh konsesimengikut kontrak. (R05)i. Kerja Pembersihan di atas deck jambatan.ii. Pembersihan weep holes.iii. Pembersihan laluan air pembetung.iv. Pembuangan semua tumbuhan.

B. Operasi penyenggaraan , pemulihan danpenggantian komponen bersekala kecil:-i. Steel Parapet.ii. Corrugated guardrail di jalantuju jambatan.iii. Drainage pipe.iv. Bridge obstruction marker.v. Bridge structure number.vi. Reflector marker.vii. Greasing of mechanical bearing.viii. Cleaning of expansion joint.


1. Penyenggaraan biasa

4/6/2017

7


2. Pembaikan biasa.a) Surface repair.

b) Surface treatment.

c) Non-structural repair.



A. Surface repairi. Kerja pembaikan kecil untuk

kecacatan ringgan seperti:-a. Surface defect and

honeycombing.b. Minor spalling and delamination.c. Non structural surface cracks or

shrinkage cracks.d. Minor surface material

deterioration.


2. Pembaikan biasa

4/6/2017

8


B. Surface treatmenti. Protective coating for steel members.

a. Mengecat kesemua permukaan komponenstruktur keluli yang terdedah untuk mengatasikekaratan.

b. Membaikpulih dan kemaskini semula kualiti cat pada kesemua komponen struktur keluli.

ii. Protective coating/concrete lining for structural concrete members.a. Mengecat kesemua komponen struktur konkrit

untuk mengatasi impak dari kesan serangan chloride dan carbopnation.

b. Memperkukuhkan permukaan konkrit denganapplikasi concrete lining atau epoxy skim coat.


2. Pembaikan biasa


C. Non- structural repairi. Membaiki atau memasang semula steel

parapet yang telah runtuh.ii. Menggantikan corrugated guardrail yang

telah runtuh.iii. Membaiki atau menggantikan expansion

joint.iv. Pembaikan kecil setempat bukan jenis

kerosakan struktur untuk kesemuakomponen konkrit jambatan.

v. Pembaikan terhadap sistem penahantebing dan cerun jambatan sediada yang rosak.


2. Pembaikan biasa

4/6/2017

9


A. Merupakan satu proses untuk mengekalkan danmemastikan tahap keupayaan dan keutuhanstruktur jambatan untuk terus berfungsimengikut kehendak jangka hayat yang telahdirekabentukkan.

B. Ia terbahagi kepada 3 ketegori:-i. Structural rehabilitation.ii. Functional rehabilitation.iii. Hydraulic rehabilitation.

C. Pemeriksaan terperinci dan rekabentuk khasperlu dijalankan sebelum kerja-kerja pembaikandilaksanakan oleh specialist contractor.


3. Rehabilitation.


D. Skop-skop kerja pembaikan seperti:-i. Formwork repair to all structural

components.ii. Guniting with additional rebar.iii. Steel plate bonding.iv. Concrete lining with additional rebar.v. Total rehabilitation and replacement of

Expansion Joint.vi. Concrete jacketing of concrete piles and pier

columns.vii. Epoxy injection to all structural cracks.viii. Replacement of walked or bulged bearing

pad.


3. Rehabilitation.

4/6/2017

10


A. Merupakan satu proses peningkatan keupayaan struktur jambatanuntuk terus berfungsi dan mengekalkan keutuhannya untukmenampung tanggungan beban:-i. Kesatu tahap yang lebih tinggi berbanding dengan kehendak

rekabentuk asal.ii. Kembali kepada keadaan dan kekuatan sediakala mengikut

rekabentuk asal.B. Pemeriksaan terperinci dan rekabentuk khas perlu dijalankan

sebelum kerja-kerja strengthening dilaksanakan oleh specialist contractor.

C. Contoh skop-skop kerja strengthening:-i. Strengthening with CFRP.ii. Steel plate bonding.iii. Additional of splicing plates.iv. External post-tensioning.v. Pile jacketing with additional concrete lining and steel casing

as permanent formwork.vi. Underpining with additional piles.

Teknik dan Operasi Penyenggaraan Jambatan4. Strengthening.


Mengekalkan keupayaan dan keutuhan strukturjambatan untuk terus berfungsi mengikut kehendakjangka hayat yang telah direkabentukkan.

Memastikan kefungsian jambatan diperpanjangkandengan mengekalkan ketahanlaksakan struktur.

Kurangkan kos penggantian jambatan.

Kurangkan kos pembaikan kemudian hari.

Menjamin keselesaan dan keselamatan penggunajalanraya.

4/6/2017

11



Aturcara Pembaikan

Analisa tahapkecacatan

Pemilihan bahandan jenis

pembaikan

Sediakan kaedahpembaikan:− Lukisan− Spesifikasi− Kos anggaran

Latikan kontraktorpakar

Kenal pasti jeniskecacatan

Pemeriksaan MandatoriTahunan Jambatan

(PMTJ)

• Routine Condition Inspection Report• Kajian bahan dan Ujian dengan peralatan.

• Material specification• Buku - Bridge Appraisal

Rehabilitation and Maintenance• Keberkesanan Pembaikan

• Document Tender• Method Statement

Terima LaporanStatus Pembaikan

KemaskiniData BMS

• Tender• Pemilihan• Dokumen kontrak

4/6/2017

12


• Mengenalpasti kekuatan asal.• Melaksanakan pengukuran

perbandingan kualiti.• Meninjau dan menganalisa integriti

setiap komponen.• Mengenalpasti punca kemerosotan

kualiti dan kejadian kecacatan.

Tujuan Melaksanakan Pemeriksaan dan Siasatan Jambatan


Pemilihan Bahan Pembaikan

a. Keserasian dan kebersesuaian.b. Kondisi persekitaran.c. Keberkesanan kos.d. Jangkaan jangka hayat

penggunaan.e. Kewujudan bahan di pasaran.f. Mampu dan senang diguna.

4/6/2017

13


Proses Pembaikan Komponen Konkrit


Tatacara Untuk Proses Pembaikan Komponen Konkrit

Defective Zone

SurfacePreparation

Concrete/Steel

Repair Work

Crack

Delamination

Pre-packed Shrinkage

compensated Repair

Materials

Bonding of NewTo Old Substrate

Re-bar Cleaning to S.A. 2.5 and apply Zinc Priming

Re-bar

Existing Concrete

Surface preparation and application of bonding agent

Contaminated Concrete With Chlorides Or Carbonation

Spalled Heavily CorrodedRe-bar

Removal OfContaminatedConcrete

Prepared Edge Conditioning

4/6/2017

14


Langkah 2Gegajikan sempadan kecacatansehingga 15mm dalam dan mulakanpecahan dan pembuangan serpihankonkrit dengan kaedah yang telahdiluluskan.Gantikan besi tetulang yang menghadapi kekaratan yang seriusdan yang telah kehakisan saizdengan saiz tetulang baru dandibekalkan lapping yang mencukupi.

Langkah 1Ketuk dengan tukul untukmengenalpasti sempanandelamination.Tandakan sempadan kecacatandengan cat.Rancang dan memasangkan sistempenyokong dan penyandangmengikut rekabentuk sebelumlaksanakan pecahan konkrit.

Aturcara Penyediaan Permukaan Pembaikan

Langkah 3Sempadan potongan itu mestidalam bentuk yang mudah dibuat.Tujuan pemotongan itu adalahuntuk mengelakkan terjadinyakesan serpihan feather edges.Luas pemotongan itu jika bolehmesti dalam bentuk empat segiuntuk memudahkan kerjapembaikan.

Langkah 4Bersihkan kesemua permukaan besitetulang itu ketahap S.A. 2.5.Tiup dengan pump udara terhadappermukaan yang terdedah untukmembersihkannya dari sebarangansisa bahan serpihan.Pastikan pencapaian tahapcantuman antara permukaan lama dengan bahan pembaikan itu adalahberkualiti.


Surface Preparation - when Corroded Rebar Is Encountered

Blown clean all exposed surface and apply one layer of bonding agent

Surface after loose concrete is removed

Exposing the heavily corroded rebar

●Perimeter of spalled area is saw cut to <15mm deep prior to hacking process

●Concrete is removed to expose rebar

Concrete is removed a minimum of 20mm under corroded rebar

90

• Corroded rebar are cleaned to S.A. 2.5 and apply with one layer of zinc rich primer.

• Heavily corroded rebar with section loss are replaced with new rebar of sufficient lap length.

Continues…..

Spalled area

4/6/2017

15


Boundary Setting For Surface Repairs

Recommended layout

Boundary layout of loose and delaminated concrete

Recommended layout

Boundary layout of loose and delaminated concrete

Sectional view of loose and delaminated concrete

Note : -Layout should be made as simple as possible.

Recommended Section


Peralatan Untuk Surface Preparation

4/6/2017

16


Concrete Removal Methods : Partial Depth

1. Pneumatic Chipping Hammer- The 15# to 30# class chipping hammers are the most common removal tools for surface repair.- Hammer larger than 30# can damage encountered reinforcing steel.

2) Hydro Removal- High pressure water (20,000 to 40,000 psi) projected on affected concrete surfaces effectively removes concrete

3) Pneumatic Scabbler- Utilize reciprocating bushing tools hitting the concrete surface.- Effective tools for removal up to 6.5mm of surfaces for preparation of overlay.

4) Rotary Milling Machine- Most utilize carbide-mounted tips on a rotary drum.- Milling is generally used for removing concrete surfaces in preparation for an overlay.


Concrete Removal Methods : Full Depth

1. Hand Held Pneumatic Breaker- 30# to 90# class are effective tools for concrete removal.- Care must be taken not to damage reinforcing steel.

2) Pneumatic/Hydraulic Mounted Breakers- Effective high volume removal tools.- Caution should be exercised to avoid bruising of the concrete surface.

3) Splitters- Tools used to fracture concrete into easily removal debris.- Available in 3 types : hydraulic wedges, fluid pressure and expansive cements.

4) Hydro Demolition- Utilizes high pressure water (20,000 to 40,000 psi) projected on to the concrete surfaces.- Can be effective on thin slabs.

4/6/2017

17


Reinforcing Steel Cleaning

Types Of Heavy Rust And Scale Cleaning Methods

1) Needle ScalesPneumatic tools utilizing a group of small diameter steel rods powered by an internal piston.

2) High Pressure Water CleaningUsing high pressure water 3,000 to 10,000 psi.Fine sands were added for better and faster results

3) Abrasive Blast CleaningAbrasive mixed with pressurised air and projected through a nozzle

4) Power Wire BrushingVery slow and ineffective operation


Reinforcing Steel Cleaning

Needle Scaler

High Pressure Water Gun

Steel needle rods

4/6/2017

18


Steel Surface Preparation by Abrasive Blast Cleaning

Flexible Abrasive Hose

Concrete Substrate

Abrasive Nozzle

Reinforcing steel

Abrasive Paths

Blind spot


The standard grades of cleanliness for abrasive blast cleaning in accordance with BS EN ISO 8501-1 are:

Sa 1 – Light blast cleaning Sa 2 – Thorough blast cleaning Sa 2.5 – Very thorough blast cleaning Sa 3 – Blast cleaning to visually clean steel

Reinforcement and Steel StructureSurface Preparation Requirement

Sample of blast cleaned steel surface to Sa 2.5 standard

Surface Preparation Quality Chart

4/6/2017

19


Reinforcing Steel Protection


Reinforcing Steel Protection

Alkaline Protection Cathodic Protection Electrical Insulation

Alkaline slurry coating enhances the alkaline

environment around the bar

Natural protection by alkaline environment

created by cement matrix

Zinc applied to bar surface sacrifices itself to protect

the steel

Surface installed anode connected to bar with

impressed current changes the flow of electrical

current to protect the steel

Zinc applied to concrete surface sacrifices itself to protect the steel

Epoxy encapsulation

electrically insulates reinforcing bar

4/6/2017

20


Patch Repair Technique


Patch Repair By Dry Packing Method

Slab

Beam

Restraining formwork

Dry pack material placed in layers

Dry pack material should be dry but cohesive enough to be formed into a ball

After

Before

4/6/2017

21


Formwork Repair Technique


Fromwork Repair for Beam and Column

Cross Section

Vertical Section

Horizontal Section

Slab

BeamColumn

Column

Longitudinal Section

Slab

Beam

a) Saw cut a pre-marked perimeter boundary at spalled area of the concrete surface to a depth of 10mm-15mm as per mapping detail shown in the drawing.

b) Remove and clean all loose, spalled and defective concrete to a depth of 20mm behind rebar.

c) Clean all rebar to S.A. 2.5.d) Provide additional and replace new rebar of the same type and

Ø with the provision of sufficient lap length by spot weld to the existing rebar.

e) Priming of rebar with Zinc rich primer to 50 micron dry film thickness.

f) Apply one layer of bonding agent to prepared concrete surfaceg) Formwork repair with prepackaged free flowing, shrinkage

compensated cementitious micro concrete grout by means of pumping.

4/6/2017

22


Fromwork Repair for Beam and Column

a) Saw cut a pre-marked perimeter boundary at spalled area of the concrete surface to a depth of 10mm-15mm as per mapping detail shown in the drawing.

b) Remove and clean all loose, spalled and defective concrete to a depth of 20mm behind rebar.

c) Clean all rebar to S.A. 2.5.d) Provide additional and replace new rebar of the same type and

Ø with the provision of sufficient lap length by spot weld to the existing rebar.

e) Priming of rebar with Zinc rich primer to 50 micron dry film thickness.

f) Apply one layer of bonding agent to prepared concrete surfaceg) Formwork repair with prepackaged free flowing, shrinkage

compensated cementitious micro concrete grout by means of pumping.


Slab Or Wall Partial Depth

Sectional view(before repair)

SlabSlab Or Wall Full Depth

Sectional view(surface preparation)

SlabSlab Or Wall Full Depth

Sectional view(after repair)

Fromwork Repair for R.C. Slab and R.C. Wall

Repair Material

4/6/2017

23


Consolidation of the repair material is accomplished with one of the following techniques :

1.The repair material is formulated to be extremely flowable and self-consolidating enough to fill the entire voids.(Self Compacting Concrete)

or 2.Pre-beg free flow shrinkage

compensated cementitiousgrout with predetermine dosage of water/cement ration.

or 2.Predesign mix grout with the

use of vibrating rod or external vibration of formwork.

Formwork Repair Technique

Concrete Vibrator

Repair Material

Wall or Column

Water Tight Formwork


Pumping Repair Technique

Repair material, while flowing within the formed cavity, will remove air from the profile

Shutter valve

Repair material

Pressure Gauge

Pressure pump

Repair material flowing from pump to formed cavity through flexible host

Entry valve

Outlet / overflow valve

Notes :1. All pumping equipment must have

adequate controls to regulate flow rates.2. Arrangement of ports for pump line

attachments is usually horizontal with spacing of 900mm to 1200mm in grid form.

3. For vertical faces placement or pumping should begin at the lowest elevation.

4. Large areas of repair should be sectionalized utilizing bulkheads.

Slab/wall

4/6/2017

24


Grouted Preplaced Aggregate

Restraining formwork

Wall or Column

Flowable grout is mixed and placed into pump

Entry valve

Outlet valve

Gap-graded aggregates

Flowable grout

Sequence of repair :1. Gap-graded aggregates

must be washed, free of fines and bond-inhibiting materials.

2. Washed aggregates are placed into formed cavity.

3. Forms are fitted with pipe nipples and valves for placement of grout.

4. Flowable grout is mixed and pumped into formed cavity, filling space between aggregatesPressure pump


Slab Or Wall Full Depth

Full Depth Repair

Slab Or Wall

Extensive deterioration may require complete section replacement

Temporary Support System

Concrete Vibrator

Repair Material

4/6/2017

25


High performance shrinkage compensated repair concrete

Plywood shutter

High performance shrinkage compensated repair concrete

Loading funnel for bucket pouring

Steel bucketEdge of parent concrete prepared by water blasting

Timber formwork

Flexible hose fixed to support timbers

Existing parent concrete

Flexible hose clipped to entry port in soffit shutter

Existing re-bars wire brush to SA-2.5 and prime with Zinc rich primer

Clipper used to hold the flexible hose


Formwork Repair – Spalled Beam Soffit

Before

After

4/6/2017

26


Formwork Repair – Spalled Pier

Before

After


Structural Repair Technique

4/6/2017

27


Membaiki Kerosakan Pada Beam Yang menghadapi kesan impact damage denganpeningkatan kekuatan melalui balutan CFRP.

d) Formwork repair doneb) Splicing of torn strands c) Preparing formwork repaira) Impact damage

e) Application of CFRP fabric f) Application protective coating g) Completed repair


Membaiki Kerosakan Pada Pier di Jambatan Sg. Tebrau, Jalan Lebuhraya Pasir Gudang, Daerah Johor Bahru, Johor.

1500

500

Existing circular r.c. column.

6mm thk. steel casing as a permanent formwork with 150mm thk. Grade 50 pre-packaged, free flowing micro-concrete infill. Normal water

level

10mm thk. steel plate bonding with 5mm thk epoxy infill and 3 rolls of 16mm Ø X 150mm anchor bolts @ 200mm c/c.

Existing river bed level

Typical Sectional View

Pier Column Repair1. All dimensions are in mm unless otherwise

stated.2. Any change of dimensions, shape and concept of

repair shall not be allowed unless otherwise get the approval from the CSFJ.

3. The contractor is only allowed to hack and repair one pier column per location at one time after proper propping and support had been designed and supported as directed by the s.o.

4. Hack and remove all unsound concrete and clean all the corroded rebar to SA 2.5 at defective area of the pier column.

5. Install all necessary anchor bars and new rebar as per detail drawing.

6. Clean all the existing concrete surface with high pressure water jet prior to the installation of water tight formwork.

7. Fix the 6mm thk water tight steel permanent formwork with proper propping system and bracing to keep it in-place.

8. 2 layer of zinc primer coats and 2 layer of epoxy coating shall be applied to all the steel members.

9. Only pre-packed micro concrete of grade 50 shall be used.

10.All propping shall not be remove until the concrete had achieved the desired strength and with approval of the s.o.

Existing r.c. pier cross-head

Z

Z

YY

4/6/2017

28



Steel Plate Bonding1. All dimensions are in mm unless otherwise

stated.2. Contractor must do a detail measurement of the

pier crosshead prior to the repair process.3. Any change of shape and concept of repair shall

not be allowed unless otherwise approved by the CSFJ.

4. The contractor must repair all cracks and any other spalling detected prior to steel plate bonding process as directed by the s.o.

5. Carry out cover meter survey to mark points and locations for the installation of the 16mmØ anchor bolts.

6. All the anchor bolt locations shall then be map and transfer it into a detail drawings prior to the drilling of holes on the cut steel plate.

7. Launch and lifting of the steel plate, securing and position it with 16mmØ anchor bolts with 5mm-10mm gaps formed within the interface of concrete surface.

8. Pump in epoxy grouts to fill the 5mm-10mm water tight void and allow it to set.

9. Surface preparation of the entire steel plate to surface quality of S.A. 2.5.

10.Apply 2 layer of zinc primer coats and 2 layer of epoxy top coating to all the steel surface.

1500

500



level





Z

Z

YY


3 Dimension View of Column Repair

6mm thk. steel casing as a permanent formwork with 150mm thk. Grade 50 pre-packaged, free flowing micro-concrete infill.

2000

T25 vertical main bars to be placed @ 175 c/c

T16 @ 175 c/c links

T16 hook with 150 embedded length @ 300 c/c for holding the vertical main bars

Before

During

After


4/6/2017

29


Beam-Column Moment Capacity Strengthening

A

Beam/Slab

Column

Section A-A

Steel plate assembly compositely fastened to existing concrete members

A

Steel plate assembly compositely fastened to existing concrete members

High tensile fastening bolts

High tensile fastening bolts

Site Elevation

Sectional View

Beam

Column Concrete shear walls added to existing column and beams

Footing


External Post-Tensioned Reinforcement

Sectional View

Flexural cracks are pressure epoxy grouted prior to stressing

End bearing assembly

Bridge Pier Bent

I-beam

Side Elevation

End anchorage

Beam

ColumnExternally mounted post-tensioned strand on each side of beam

Reaction frame

External post-tensioned threaded bar Bridge deck

4/6/2017

30


Strengthen by Pultruded CFRP Plates

Sectional View

All shear and flexural cracks are pressure epoxy treated prior to application of CFRP

Bridge deck

Bridge Pier Bent

Pultruded CFRP plates

I-beam

a) Surface preparation of affected substrate to remove oil, grease, dust, cement laitance and any coated materials.

b) Apply one coat of primer epoxy resin to prepared concrete surface.c) Apply one coat of epoxy resin to prepared concrete surfaced) Cut the pultruded CFRP plates to required length and place onto applied

epoxy resin with a roller according to the fiber direction to spread even fabric so as to ensure a proper adhesion.

e) Apply one coat of epoxy resin onto the fixed CFRP surface after it had archived sufficient strength as per recommendation by the supplier.

Pier Cross-head


Steel Plate Bonding

Sectional View

Steel plate secure with threaded anchor bolts and bonded with epoxy adhesive

New composite member

See Detail ‘A’

Detail ‘A’

Concrete flexural member

Apply epoxy sealant and allow to set prior to pumping of epoxy adhesive

32mm Ø threaded anchor rod provides additional shear capacity and erection support

15mm thks. steel plate bonding with zinc primer and epoxy paint as top coat

Epoxy adhesive pressure grouted into plate concrete interface

steel plate bonding

4/6/2017

31


Reconstruction of Underdesigned or Nonfunctioning Corbel

Before Reconstruction

Existing corbel

Inadequate reinforcement

Frozen bearing

After Reconstruction

Fill reconstruct corbel with dual shrinkage compensated grout

Additional steel reinforcement doweled into existing concrete

Jack and lifting of beam

New rubber bearing


Pembaikan TerhadapCorbel Approach Slab

Yang Rosak AkibatPemasangan Dowel Bar

Yang Salah

4/6/2017

32


Stage-1

• Mark, saw cut to required length and depth.

• Hack to required depth and remove all the unsound concrete.

• Use high pressure water jet to clean the prepared surface.

• All hacking should be executed alternately at the maximum repair length of not exceeding 1.5m at any one go.

Reconstruction of Wrongly Constructed Corbel


Stage-2

• Scan to locate the existing rebar with concrete scanner prior to the marking of proposed location of the new dowel bars at the soffit of the approach slab.

• Drill at the pre-marked location to required size and depth as per detail design.

• Blow clean all the holes with air-jet.

• Cut and prepare the new dowel bars to required size and length as per design.

• Pump in approved epoxy sealant, insert and fix the new dowel bars, allow it to set as per recommendation by the supplier.


4/6/2017

33


Stage-3

• Scan to locate the existing rebar with concrete scanner prior to the marking of proposed location of the new dowel bars at the soffit of the approach slab.

• Drill at the pre-marked location to required size and depth as per detail design.

• Blow clean all the holes with air-jet.

• Cut and prepare the new anchor bars to required size and length as per design.

• Pump in approved epoxy sealant, insert and fix the new dowel bars, allow it to set as per recommendation by the supplier.



Stage-4

• Cut and prepare the new rebar to required size and length as per design.

• Fix and tire all the additional new rebar as per approved detail drawing.


4/6/2017

34


Stage-5

• Prepare and assembly of water tight formworks with pre-fixed injector pipe at the lower most location and overflow outlet pipe as per directive and approval by the S.O.

• Pump in shrinkage compensated micro concrete as per approval by the S.O.

• All formwork must be properly support to prevent any happening of segregation.

Outlet pipe

Injector pipe



Stage-6

• Remove all the formwork when the micro concrete achieved the required strength.

• Repeat the same process until the repair work reached the full length of the defective corbel.


4/6/2017

35


Pengukuhan Pier Dengan Kaedah

Tambahan Lateral Cross Tie-beam


MEMBAIKI Jambatan No. FT001-454-50, Kerling, Daerah Hulu Selangor, Selangor.

Lateral bracing dengan pemasangan rasuk konkrit tambahantelah dibina bagi membaiki jambatan yang menghadapi

pemendapan dan keretakan rasuk.

Keadaan jambatan sebelum kerjapembaikan.

Cadangan kerja pembaikan

4/6/2017

36


Kaedah PembaikanDengan Menggunakan

Carbon Fiber Reinforced Plastic


Sequence on installation of Carbon Fibre Reinforced Plastic (CFRP)

Concrete Substrate

Primer

Epoxy Putty Filler

1st Resin Coat

Carbon Fibre2nd Resin Coating Epoxy based

Protective Coating

a) Surface preparation of affected substrate to remove oil, grease, dust, cement laitance and any coated materials.

b) Apply one coat of primer epoxy resin to prepared concrete surface.

c) Apply one coat of epoxy putty filler prior to the application of 1st layer of epoxy resin for installation of CFRP.

d) Cut and place CFRP onto applied epoxy resin with a roller according to the fiber direction to spread even the fabric so as to ensure a proper adhesion.

e) Apply 2nd coat of epoxy resin onto the fixed CFRP surface after it had archived sufficient strength as per recommendation by the supplier.

f) Top one layer of epoxy based protective coating to protected the applied CFRP from damages.

4/6/2017

37


Pembaikan Jambatan Merdeka di Seberang Perai Selatan,

Pulau Pinang.


Pemasangan CFRP di Jambatan Merdeka (FT001/782/10), Daerah S.P. Selatan.

CFRP Pultruded plates Part A & B Epoxy adhesive

Application of epoxy primer

Securing of CFRP plates using roller

Finished fixing condition of CFRP plates

Cutting of CFRP plates Removing of protective wrap

Mixing of Part A & B Epoxy adhesive

Control application to required thickness of Part A & Part B Epoxy adhesive in progress

Fixing and gluing CFRP Pultruded plates

Repeat process of securing of CFRP plates using roller

4/6/2017

38



CFRP Fabric Epoxy Primer Epoxy Primer Surface preparation

Application of Epoxy Primer

Cutting of CFRP Fabric to required size

Epoxy Resin part A & part B components

Mixing of part A & part B components

Application of Epoxy resin for CFRP

Application of CFRP pultruded plates

Application of CFRP fabric wraps

Finished application of CFRP fabric wraps



CFRP Fabric Epoxy Primer Epoxy Primer Surface preparation

Application of Epoxy Primer

Cutting of CFRP Fabric to required size

Epoxy Resin part A & part B components

Mixing of part A & part B components

Application of Epoxy resin for CFRP

Application of CFRP pultruded plates

Application of CFRP fabric wraps

Finished application of CFRP fabric wraps

4/6/2017

39


Crack Repair Technique


• Keretakan akan terjadi apabila tekanantegangan terhadap komponen konkrit itu telahmelebihi kemampuan untuk menampung.

• Faktor kejadian keretakan adalah sepertiberikut:– shrinkage – thermal– alkali aggregate reaction– corrosion of reinforcement – applied load– differential settlement

• Jenis keretakan itu akan dibahagikanmengikut lokasi, corak, saiz dan masakejadian.

Types Of Crack

Structural Crack

4/6/2017

40


Crack Repair By Epoxy Injection

Mechanical Packers – for high and low pressure injection where hole drilling is possible. Used for

repair the structural cracks.

Surface Packer – for low pressure injection where hole drilling is not possible and is

used to repair surface cracks.Mechanical Pressure Pump

a) Surface preparation with approved tools to all the marked crack lines as per mapping detail shown in the drawing.

b) Fixed injector nipples with epoxy sealant to all marked crack lines at desired spacing as per specification.

c) Sealed all the marked crack lines with epoxy sealant.

d) Mix and inject epoxy resin as per specification with proper approved pumping system.

e) Remove all sealant and injector nipples. Grind and smoothen the affected repaired surface.


Crack Injection Process

1. Use steel wire brush to clean the crack lines.

2. Fixing of injector nipple. 3. Sealing of the crack lines with epoxy mortar.

4. Pump until the epoxy flows out from the second packer, fix the valve quickly. Stop injection and continue pumping at the second packer. Repeat this procedure from packer to packer.

Ujian Ultrasound Pulse Velocity akan dilaksanakanselepas kesemua keretakan itu dibaiki dengantujuan menyemak kualiti pembaikan demi menjadikeutuhan komponen tersebut. Kadar pengukuranbacaannya adalah seperti di atas.

Ultrasound Pulse Velocity

4/6/2017

41


Contoh KaedahPembaikan Terhadap

Pier Yang MenghadapiMaterial Deterioration


Jambatan No FT0002/210/10 Di Atas Sg. Kepong, Daerah Temerloh, Pahang.

SECTION VIEW

• Clean all exposed surface with high pressure water jet to remove all laitance, dirt and any contaminants.

• Drill, fix and secure 16mm Ø X 175mm long anchor bolts with epoxy (to be placed alternately @ 300mm c/c).

• Cast 75mm thk r.c. wall complete with one layer of BRC-8 with pre-beg free flow shrinkage compensated cementitious grouts.

3000

Concrete lining repair for material deterioration.

New 75mm thkconcrete lining

Concrete surface deteriorated

4/6/2017

42


Formwork Repair to Material Deteriorated Pile Columns

Before

After

Surface condition before repair


Slope Protection Technique

4/6/2017

43


MEMBAIKI JAMBATAN NO FT003/522/20, DI ATAS SG. RINTING,SEBERANG MARANG, TERENGGANU.

PLAN VIEW

3m 3m

16

.0m

Existing boundary of gabion layers to be removed, trimmed and set back as indicated for the laying of new gabions

Existing embankment2 stacks of 1m x 1m x 2m Wire Mesh Rock Filled Gabions (5 Tilted)

150mm x 150mm x 5000mm H.W. Timber Piles At 2000mm c/c

10

.0m

300mm thk. Rubble pitching complete with 75mm Ø P.V.C. weep pipes @ 1000 c/c

DOWN STREAM


TYPICAL SECTIONAL VIEW AT ABUTMENT

3m

1m

Existing gabions and rubble pitching layer to be removed, trimmed and set back as indicated for the laying of new gabions


2 stacks of 1m x 1m x 2m Wire Mesh Rock Filled Gabions (5 Tilted)

300mm thk. Rubble pitching complete with 75mm Ø P.V.C. weep pipes @ 1000 c/c

50mm-75mm size rubble stones as base to new rubble pitching

100mm to 250mm rubble stone base

N.W.L

MEMBAIKI JAMBATAN NO FT003/522/20, DI ATAS SG. RINTING,SEBERANG MARANG, TERENGGANU.

4/6/2017

44


MEMBAIKI JAMBATAN NO FT014/007/80, DI ATAS SG. PERASING,DAERAH KEMAMAN, TERENGGANU.

250mm thk. r.c wall complete with 150mm x 150mm r.c piles @ 1500mm c/c as anchoring post and 2 layer of BRC B12

Scoured portion to be back filled and compacted to its original slope before laying of 300mm thk. Rubble pitching

Existing un-scoured embankment

2.0m

10

.21

6m

6.0m6

.0m

PLAN VIEW AT ABUTMENT-A



Made good approach to thickness as specified after re-launching of existing r.c. approach slab

App 2.5m

3.5

m

SECTIONAL VIEW AT ABUTMENT-A

1.0m

1m

250mm thk. r.c wall complete with 2 layer of BRC B12

Scoured portion to be back filled and compacted with suitable fill materials

300mm x 600mm r.c footing with 2 layers of BRC B12

150mm x 150mm r.c piles at 1500mm c/c as anchoring post

50mm Ø WEEPHOLES AT 3.0m C/C Alternately

4/6/2017

45



TYPICAL DETAIL OF R.C RETAINING WALL

0.6m

0.3

m

Scoured portion to be back filled and compacted with suitable fill materials

300mm x 600mm r.c footing with 2 layers of BRC B12

3m x 3 length 150mm x 150mm r.c piles at 1500mm c/c as anchoring post

250mm thk. r.c wall complete with 2 layer of BRC B12

BRC B12

4.2

m

1m

1m 0.25m

Existing Pile Cap

Existing Steel H-Pile

Prepared By : Tan Chee KeanChecked By : Ir. Leow Choon Heng

Existing Ground Profile

50mm thk. lean concrete



Made good settlement at approach to required profile according to the specified thickness

350

SECTIONAL VIEW OF PROPOSED REPAIR

2.0m

Suitable fill materials lay to required profile to underside of the 125mm thk. r.c. slab

Existing Partially Settled Flat Slab

3 rolls of 50mm Ø Upvc weep holes @1000mm c/c alternately with 75mm protruding length

125mm thk. Grade 30 concrete slab with 2 layers of BRC 12 complete with Y16 anchor bars @ 1m c/c

250 X 350 r.c. ground beam with 4 nos of Y16 main bars and R10 @ 100mm c/c/

MEMBAIKI JAMBATAN No. FT028/019/95 (DEPAN ZOO NEGARA)DI JALAN LINGKARAN TENGAH 2 (MRR2), DAERAH GOMBAK, SELANGOR.

100

22

00

Existing rock filled gabion blocks

Existing G.L.

DETAIL ‘X’

See detail ‘X’

250

4/6/2017

46


Slope Protection At Abutment-B For Bridge No. FT004/175/60 at Sg. Sat,Jalan Timur Barat, Jajahan Machang, Kelantan

SECTIONAL VIEW

Dilukis Oilh : Tan Chee Kean

6m x 2m x 0.3m Rock Filled Mattress

100mm to 250mm Rubble Stone Base


6m x 2m x 0.17m Rock Filled Mattress


1m x 1m x 2m Wire Mesh Rock Filled Gabions (5 Tilted)

7.5m

6.5

m

Non-woven GeotextileMactex245 or equivalent

1m x 1m x 2m Wire Mesh Rock Filled Gabions (5 Tilted)



PLAN VIEW SHOWING THE ACTUAL CONDITION OF RIVER CHANNEL AND PROPOSED LOCATION OF R.C. WALL

ABUT-A ABUT-B

MEMBAIKI JAMBATAN FT014/142/70 (DURIAN KASSIM),JALAN JABOR-JERANGAU-K.BERANG, DAERAH HULU TERENGGANU, TERENGGANU.

10m

7.0m

Existing River Channel

14

m

SG. MELAKA

10

m

10

m

10

m

10

m

8.0m

9.5m

PROPOSED 300mm THK R.C. Wall

4/6/2017

47

Prepared and presented by : Tan Chee Kean 93TYPICAL SECTIONAL VIEW OF R.C RETAINING WALL AT ABUTMENT-A

0.6m

0.3

m

300mm THK. R.C WALL

Fill with Sand or Coarse Aggregates To Voids Behind R.C. Wall

300mm X 600mm R.C Footing With 2 Layers Of Y12 @ 150 C/C

2 ROWS OF 75mm DIA. Bakau Piles @ 400 C/C Alternately

2 Layers Of Y12 @ 150 C/C

3.5

m

0.5

m

0.75m 0.3m

Existing Pile Cap To Base Of R.C. Fin

Existing R.C. Pile

Existing Ground Profile 50mm THK. Lean

Concrete

0.4m

2.5

m

R.C. Fin To Abutment




Prepared and presented by : Tan Chee Kean 94TYPICAL SECTIONAL VIEW OF R.C RETAINING WALL AT ABUTMENT-B

0.6m

300mm X 600mm R.C FOOTING WITH 2 LAYERS OF Y12 @ 150 C/C

2 ROWS OF 75mm Ø BAKAU PILES @ 400 C/C ALTERNATELY

0.5

m

2.0m0.3m

EXISTING PILE CAP TO BASE OF R.C. FIN

EXISTING R.C. PILE

EXISTING GROUND PROFILE

50mmTHK. LEAN CONCRETE

0.4m

R.C. FIN TO ABUTMENT

PROPOSED CUT AREA

300mm THK. R.C WALL

2 LAYERS OF Y12 @ 150 C/C



0.3

m3

.5m

2.5

m

Fill with Sand or Coarse Aggregates To Voids Behind R.C. Wall

4/6/2017

48


9.9

m

7.5m

4.0

m

PLAN VIEW AT ABUTMENT-A

18

.0m

Scoured portion to be back filled and compacted to required profile and top with 6m x 2m x 0.17m rock filled mattress

Reconstruct 3 stacks of 1m x 1m x 2m Wire Mesh Rock Filled Gabions (5Tilted)


SIMPANG TROLAK / IPOH

FELDA TROLAK TIMUR

MEMBAIKI JAMBATAN NO FT1153/007/70, JALAN FELDA TROLAK TIMUR, DAERAH BATANG PADANG, PERAK.

Existing Wire Mesh Rock Filled Gabions

Existing embankment

Scoured portion to be back filled and compacted to required profile and top with 6m x 2m x 0.17m rock filled mattress

100mm to 250mm rubble stone base

New r.c. bridge access with 2 layers of BRC10 cast to required profile


SECTIONAL VIEW AT ABUTMENT-A

scoured portion to be back filled and compacted with suitable fill materials

6m x 2m x 0.3m rock filled mattress

100mm to 250mm rubble stone basenon-woven geotextile

mactex245 or equivalent

6m x 2m x 0.17m rock filled mattress

150mm x 150mm x 3000mm h.w. timber piles at 2000mm c/c

3 stacks of 1m x 1m x 2m Wire Mesh Rock Filled Gabions (5 Tilted)

MEMBAIKI JAMBATAN NO FT1153/007/70, JALAN FELDA TROLAK TIMUR,DAERAH BATANG PADANG, PERAK.

SIMPANG TROLAK/IPOH

1.0m 1.2m

2.4m

3.2m 1.5m

0.5m

18.90m inverted tee beam

FELDA TROLAK TIMUR

4.0m

W.L.

4/6/2017

49


MEMBAIKI JAMBATAN FT1208-000-90, DI ATAS SG. BUAYA (KG. KOSKAN),DAERAH HULU SELANGOR, SELANGOR

Tebing jambatan yang menghadapi kesan kekerukan telah dibaiki dengan kaedah“stone filled gabion block” dan taburan batu.

Keadaan jambatan sebelum kerjapembaikan.

Cadangan kerja pembaikan


0.6m

0.3

m

300mm thk. r.c wall complete with 2 layer of Y12 @ 150 c/c

Fill coarse aggregates to voids behind r.c. wall

300mm x 600mm r.c footing with 2 layers of Y12 @ 150 c/c

2 rows of 75mm dia. bakau piles @ 400 c/c alternately

2 layers of Y12

0.5

m

0.5m 0.3mExisting Pile Cap

Existing steel H-pile

Existing Ground Profile

50mm thk. lean concrete

0.4m

1.5

m

50mm dia. UPVC weep pipes @ 1000mm c/c complete with non-woven filter cloth

MEMBAIKI JAMBATAN NO FT2491/005/10, Daerah Rompin, Pahang.(Retaining Wall Technique)

0.3

m

300mm thk. rubble pitching

Existing ground profile to be trimmed and removed away from site

Varie

s

4/6/2017

50


Rock Filled Gabion Block and Gabion Mattress Installation


Contoh KaedahPembaikan Base CMP

Yang MenhadapiKekaratan Teruk

4/6/2017

51


Membaiki base CMP Culvert No. FT012/054/90, Di Daerah Rompin, Pahang.

Existing CMP culvert

High water level

50mm Ø x 150mm predrilled hole

150mm thk. grade 25 concrete

2 layers of BRC 12 cut and curved to shape

Anchoring at 200mm c/c

Scoured cavity to be filled with pre-beg free flow cementitious grouts


0.5

m


Contoh KaedahPembaikan Pier Column

Untuk TingkatkanTanggungan Beban

4/6/2017

52


Formwork Repair to R.C. Pile at Jambatan Hang Tuah (FT005/226/90),Daerah Melaka Tengah, Melaka.

6mm Thk. Steel Casing Formwork With Inner Ø Of 600mm

Prepared Pile Surface40mm

G.L

BRC B10

AV

ER

AG

E H

EIG

HT

3.0

0m

Dual Shrinkage Compensated Free Flowing Pre-packaged Micro-concrete

25mm Ø X 200mm Anchoring Bars Complete With Zinc Rich Primer

N.W.L.

100mm



1500

500



level




Notes:-1.All dimensions are in mm unless otherwise stated.2.Any change of dimensions, shape and concept of

repair shall not be allowed unless otherwise get the approval from the CSFJ.

3.The contractor is only allowed to hack and repair one pier column per location at one time after proper propping and support had been designed and supported as directed by the s.o.

4.Hack and remove all unsound concrete and clean all the corroded rebar to SA 2.5 at defective area of the pier column.

5.Install all necessary anchor bars and new rebar as per detail drawing.

6.Clean all the existing concrete surface with high pressure water jet prior to the installation of water tight formwork.

7.Fix the 6mm thk water tight steel permanent formwork with proper propping system and bracing to keep it in-place.

8.2 layer of zinc primer coats and 2 layer of epoxy coating shall be applied to all the steel members.

9.Only pre-packed micro concrete of grade 50 shall be used.

10.All propping shall not be remove until the concrete had achieved the desired strength and with approval of the s.o.


Z

Z

YY

4/6/2017

53


Notes:-1. All dimensions are in mm unless otherwise stated.2. Any change of dimensions and shape shall not be allowed unless otherwise get the approval from the s.o.3. The contractor is only allowed to hack and repair one pile column per pier location at one time or as directed by the s.o.4. Clean all the existing concrete surface with high pressure water jet prior to the installation of water tight formwork.5. All formwork shall be properly braced, propped, leveled and water tight.6. Provide a minimum concrete cover of 30mm.7. Only pre-packed micro concrete of grade 50 shall be used.8. All propping shall not be remove until the concrete had achieved the desired strength and with approval of the s.o.

T25 vertical main bars to be placed @ 175 c/c

L.L.W.L.

300

2500

100 mm thk grade 50 pre-packed micro concrete

T16 @ 175 c/c

T16 hook with 150 embedded length @ 300 c/c for holding the vertical main bars

100

Keadah Pembaikan Secara Pile Jacketing


Kaedah MenggantikanBearing Pad Yang

Teranjak Dari Kedudukan Asal

4/6/2017

54


A

B

D

C

E

F

Menggantikan Bearing Pad di FT005-549-10, Daerah Sabak Bernam, Selangor.


D

C

E

F

B

Dari SabakBernam

Expansion joint telah condong

A

Ke Teluk Intan

Dari SabakBernam

Ke Teluk Intan

Dari SabakBernam

Keseluruhan Expansion joint telahtwisted dan parapet terangkat.

Sebahagian Expansion joint telahmendap dan tilted sebelah.

Pandangan dari tebing sungai yang menunjukkan keadaan parapet . Parapet turut mendap sekali

dengan geladak.

Dari SabakBernam

Parapet turut mendap danteranjak secara ufuk (sway).


4/6/2017

55



Condition of the pier and bearing shelve.

Most of the bearing pads had walked form its

original position.

Uneven settlement of the bridge deck caused by the

impact of walk bearing pads.

Fixing and assembling of the gantry working platform

system.

Fixing and assembling of the hydraulic jack system in

progress.

Shimming of the thin steel plates on top of the jack to achieve the

required finished level.



Fixing and installation of injector hose in progress prior to the jacking process.

Shimming of the thin steel plates along the jacking process to act as

temporary support.

Fixing of the temporary steel girder system for horizontal pushing of the moved deck.

Shimming and fixing of horizontal jack for the pushing

of the moved deck.

4/6/2017

56



Part A (resin) + Part B (hardener) prepacking

epoxy resin

Part C prepacking fine aggregates

Mix Part A + Part B evenly for >2 mins, then add in the Part C.

Continue mixing until homogenous mortar obtained.

Pour to form required thickness and shape it to about the size of

elastomeric bearing pad.

Shape the epoxy mortar to form down stand of beam to

overcome problem of walking bearing pad caused by uneven

seating of beam.

A completed new beam down stand with no gap within the interface between topside of bearing pad and beam soffit

detected.


Kaedah MenggantikanExpansion Joint Rosak

Mengikut Jenis

4/6/2017

57


Rekabentuk mengikut luas expansion gap.

Lukisan perincian mengikut keadaan tapak.

Method Statement yang cukup jelas.

Material specification mengikut komponen.

Keperluan ujian bahan mengikut komponen.

Quality Control (QC) dan Maintenance manual.

Jangka Hayat Waranti dan jenis tanggungan yang harus dilaksanakan dalam tempuh jeminan.

Keperluan dan syarat-syarat dalampemasangan Expansion Joint


Asphaltic Plug Joint Replacement Sequence

4/6/2017

58


Elastomeric Joint Replacement Sequence

Mark, cut and breaking out Application of bonding agent prior to leveling process

Bed leveling with epoxy mortar

Drilling of anchor bolt holes Installation and securing of anchor bolts in process

Application of epoxy nosing and sealing of joints


Documents

Tan Chee Kean - epsmg.jkr.gov.myepsmg.jkr.gov.my/images/0/09/Pembaikan_Jambatan-BWa.pdf · Kekerapan kerja pembaikan akan meningkat kemudian hari. Keselesaan dan keselamatan pengguna