Construction Methodology for Suramadu Main Bridge

1. Introduction of the Main Bridge Description Twin-pylon double-plane composite steal beam cable-stayed bridge (192m + 434m m) The height of the main pylon is m

Layout of Main Bridge

2. Construction Method 2.1 Construction of Platform 2.2 Construction of bored pile 2.3 Construction of pile cap 2.4 Construction of pylon 2.5 Construction of superstructure 2.6 Miscellaneous

2.1 Construction of Platform Description Platform comprised of concrete batching platform, drilling platform and auxiliary platform. Steel casing & pile will be driven by piling barge.

2.2 Construction of bored pile Machine High power, hydraulic bidirectional cycles drilling machine will be adopted for drilling. 3 drilling machines per platform. Construction sequence drilling work formation of piles installation of rebar concreting under water

Conventional drawing of bored pile construction

2.3 Construction of pile cap Description Pile cap will be constructed by steel caisson method Underwater concrete sealing layer will be poured by tremie pipe. Mass concrete of the pile cap will be poured in 3 layers with internal water pipes cooling system. Flow chart

Step 1. After completion of bored pile, remove the connection components of deck of platform and steel casing of the drilling paltform.

Step 2 Assemble the steel caisson

Step 3 Pour concrete sealing layer

Step 4 Install rebar & cast concrete in 3 layers

2.4 Construction of pylon Description The lower pylon will be constructed with turnover formwork. Middle and upper pylon will be cast in segments with self-climbing formwork system. transom will be cast with the support of false work. Flow chart

Step 1 Tower crane installaiton

Step 2 Tower base and lower pylon construction & elevator installation

Step 3 Lower transom construction

Step 4 Middle pylon construction

Step 5 Middle transom construction

Step 6 Upper pylon construction

Step 7 Upper transom construction

2.5 Construction of superstructure Description 0#,1# and tail-cable segment will be lifted by 500t barge crane and erected on temporary falsework. Other segments will be assembled by cantilever crane on bridge floor. Flow chart

Step1 1 、 Install 0# and 1# segment temporary falsework on the pile cap. 2 、 Install 0# 、 1# segment of steel girder by crane barge, temporary fix in between pylon and girder 3 、 tension cable of B1,Z1.

Step 2 Install cantilever crane on bridge floor.

Step 3 1 、 Install main girder by cantilever crane on bridge floor and tension corresponding cables. 2 、 Install deck slabs of first two segments and cast joints.

Step 4 1 、 Install main girders by cantilever crane on bridge floor, tension corresponding cables. 2 、 At the same time, construct temporary piers and temporary falsework for tail-cable segment before installation 12# segment.

Step 5 1 、 Install girders segment above the temporary pier by crane barges. 2 、 Install tail-cable segment by crane barge and apply counterweight.

Step 6 Continue installation symmetrically till closure of side span

Step 7 1 、 Install middle span steel girders closure segment, the entire bridge is closed, 2 、 Remove temporary connection in between pylon and column.

2.6 Miscellaneous Installation of motorcycle lane and pipe line. Installation of lighting posts, guardrails. Installation of expansion joints. Construction of asphalt pavement.