CHINA-MALDIVES FRIENDSHIP BRIDGE

DETAILED DESIGN

VOLUME 3 OF 11 APPROACH BRIDGE

SECTION 1:PART1- APPROACH BRIDGE SUBSTRUCTURE

CHINA RAILWAY MAJOR BRIDGE RECONNAISSANCE & DESIGN INSTITUTE CO., LTD.
CCCC SECOND HARBOUR ENGINEERING COMPANY LTD.
JULY 2016, WUHAN
 CHINA-MALDIVES FRIENDSHIP BRIDGE

DETAILED DESIGN

VOLUME 3 OF 11 APPROACH BRIDGE

SECTION 1:PART1- APPROACH BRIDGE SUBSTRUCTURE

SUBSTRUCTURE DESIGNER:

DESIGN MANAGER:

DESIGN DIRECTOR:

DEPUTY CHIEF ENGINEER:

DEPUTY GENERAL MANAGER:

CHINA RAILWAY MAJOR BRIDGE RECONNAISSANCE & DESIGN INSTITUTE CO., LTD.
CCCC SECOND HARBOUR ENGINEERING COMPANY LTD.
JULY 2016, WUHAN
 DRAWING INDEX

VOLUME NO. CONTENT DWG. NO.

VOLUME 1 GENERAL DESIGN 15306-04-1101～

MAIN BRIDGE SUBSTRUCTURE (1) 15306-04-2101～

SECTION 1
MAIN BRIDGE SUBSTRUCTURE (2) 15306-04-2201～
VOLUME 2 MAIN BRIDGE
MAIN BRIDGE SUPERSTRUCTURE(1)
SECTION 2 15306-04-2301～
MAIN BRIDGE SUPERSTRUCTURE(2)

APPROACH BRIDGE SUBSTRUCTURE(1) 15306-04-3101～

SECTION 1
VOLUME 3 APPROACH BRIDGE APPROACH BRIDGE SUBSTRUCTURE(2) 15306-04-3201～

SECTION 2 APPROACH BRIDGE SUPERSTRUCTURE 15306-04-3301～

SECTION 1 SUBGRADE, PAVEMENT 15306-04-4101～

VOLUME 4 LINKING ROAD AND TRAFFIC ENGINEERING SECTION 2 ROUTE CROSSING 15306-04-4301～

SECTION 3 TRAFFIC ENGINEERING 15306-04-4501～

VOLUME 5 EMBANKMENT AND BREAKWATER 15306-04-5101～

VOLUME 6 BRIDGE AUXILIARY WORK AND ARCHITECTURAL DESIGN 15306-04-6101～

VOLUME 7 DURABILITY DESIGN

VOLUME 8 CONSTRUCTION SCHEME AND ORGANIZATION PLAN

VOLUME 9 BRIDGE OPERATION MANUAL

VOLUME10 PROJECT COST ESTIMATION

VOLUME 11 ANNEX: BASIC INFORMATION AND RELATED DOCUMENTS

 PART 1 : DIRECTORY FOR SUBSTRUCTURE OF APPROACH BRIDGE
DRAWING DRAWING
NO. DRAWING TITLE NOS NO. DRAWING TITLE NOS
NUMBER NUMBER
R.C DETAILS FOR BREAST WALL OF
1 INTRODUCTION 5 19 2 15306-04-3118
ABUTMENT 27#
QUANTITY FOR SUBSTRUCTURE OF R.C DETAILS FOR WING WALL OF
2 1 15306-04-3101 20 1 15306-04-3119
APPROACH BRIDGE(TABLE 1) ABUTMENT 27#
R.C DETAILS FOR LATERAL BLOCKS OF
3 LAYOUT OF APPROACH BRIDGE 3 15306-04-3102 21 1 15306-04-3120
ABUTMENT
PIER AND FOUNDATION ARRANGEMENT FOR R.C DETAILS FOR BORED PILE OF
4 2 15306-04-3103 22 1 15306-04-3121
PIER 7 TO 17 ABUTMENT

5 COORDINATE FOR PILE OF PIER 7 TO 17 1 15306-04-3104 23 R.C DETAILS FOR APPROACH SLAB 1 15306-04-3122

LAYOUT OF TENDONS FOR CAP BEAM OF PIER

6 2 15306-04-3105 24 GENERAL ARRANGEMENT OF PEDESTAL 1 15306-04-3123
7 TO 17
R.C DETAILS OF APPROACH BRIDGE
7 R.C DETAIL FOR CAP BEAM OF PIER 7 TO 17 2 15306-04-3106 25 1 15306-04-3124
PEDESTAL
R.C DETAIL FOR LATERAL BLOCK OF CAP
8 1 15306-04-3107 26 BEARING LAYOUT OF APPROACH BRIDGE 1 15306-04-3125
BEAM OF PIER 7 TO 17
POSITIONING REBAR FOR CAP BEAM
9 1 15306-04-3108 27
TENDONS OF PIER 7 TO 17
REBAR UNDER ANCHOR FOR CAP BEAM
10 1 15306-04-3109 28
TENDONS OF PIER 7 TO 17
R.C DETAIL FOR PIER COLUMNS OF PIER 7 TO
11 6 15306-04-3110 29
17

12 PILE CAP R.C DETAIL FOR PIER 7 TO 10 3 15306-04-3111 30

13 PILE CAP R.C DETAIL FOR PIER 11 TO 17 3 15306-04-3112 31

14 R.C DETAILS FOR BORED PILE OF PIER 7 TO 17 2 15306-04-3113 32

15 ABUTMENT 0# GENERAL ARRANGEMENT 2 15306-04-3114 33

16 ABUTMENT 27# GENERAL ARRANGEMENT 2 15306-04-3115 34

R.C DETAILS FOR BREAST WALL OF

17 2 15306-04-3116 35
ABUTMENT 0#
R.C DETAILS FOR WING WALL OF ABUTMENT
18 1 15306-04-3117 36
0#
 Introduction

1 Design Content C35 tremie concrete for bored piles, C45 concrete for pile cap, and C50 concrete for pier shaft and cap

beam. The cement, sand, stone, water and other materials used for concrete preparation, concrete
Volume III-1 construction drawings (Volume III: approach bridge) of the Maldives-aid project,
mixture ratio, mixing, transportation and concrete pouring shall be in strict subject to Technical
CHINA-MALDIVES FRIENDSHIP BRIDGE, indicate the approach bridge substructure (I), including
Specification for Highway Bridge Culverts and Quality Control Standard of High Performance
the substructure of 7-17# pier, 0# and 27# abutment. The drawings mainly include: bridge general
Concrete for Sea Port Engineering.
layout, pier and foundation general arrangement, cap beam tendon layout, pile foundation RC details,

pile cap RC details, abutment RC details and bearing pedestal arrangement etc.
All the materials and mixtures for concrete preparation shall be tested. The test method shall

comply with relevant provisions of the state and industry departments currently in effect. The concrete
2 Main Design Reference
mixing water shall comply with the provisions specified in Clause 6.5 of JTG/T F50-2011 Technical
（1）Bidding Document for “Engineering, Procurement and Construction (EPC)” Contract of
Specification for Highway Bridge Culverts.
China-Maldives Friendship Bridge Published by Commerce Ministry(October, 2015） ；
（2）Reinforcement
（2）Regulations on administration of foreign aid project（Trail）（Decree No.3 in 2015 by
HPB300、HRB400 rebar have been employed in the structure design, HPB300 rebar shall comply
Commerce Ministry）；
with the requirements in Steel application for reinforcement concrete:hot-rolling plain round bar（GB
（3）Engineering Feasibility Study Report For China-Maldives Friendship Bridge(June, 2015）；
1499.1-2008 ） HRB400 reinforcement bar shall comply with the requirements stipulated in
（4）Conceptual Design For China-Maldives Friendship Bridge (July, 2015）；
(GB1499.2-2007) Steel for the reinforcement of concrete-ribbed bars. As per the durability overall
（5）Technical Assignment Book For China-Maldives Friendship Bridge（July, 2015）
plan of the bridge, it is recommended to use epoxy-coated steel complying with (GBT 25826-2010)
3 The main design standard and refernence code Epoxy-coated steel for the reinforcement of concrete in cap beam（pier 7 to 9） on the splash zone.

The main design standard and code refer to Design Outline of China-Maldives Friendship Bridge.

The construction specificationcan refer to Construction Technique Standard. Plain round bar HPB300 is expressed as "" in the document and ribbed bar HRB400 is

4 Coordinate and elevation system expressed as "".

Ribbed bars (HRB400) with a diameter not less than 25mm are subject to mechanical splicing;
The plane coordinate system and the elevation system are both adopt local systems of Maldives.
the performance of mechanical coupler shall meet the requirements stipulated in Technical Code for
5 Main Material
rebar mechanical splicing (JGJ107-2010). The coupler is of Grade I. Reinforced couplers shall be
（1）Concrete
arranged at positions with smaller stress of the component in interlace. The connector distribution rate
High performance concrete for maritime work complying with the Code for Design of Highway
at the same cross section shall be no greater than 50%; in addition, special attention shall be paid to
Reinforced Concrete and Prestressed Concrete Bridge and Culvert (JTG D62-2004) is to be adopted,

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ensure protection layer thickness of each type of reinforcement bar. Welded joint can be adopted on Rectangular solid pier with rounded (R=30cm) is adopted, plane dimension is 4.0m (transverse

ribbed bar (HRB400) with a diameter less than 25mm. The weld length of double-side welding is 5d direction of bridge) × 2.0m (longitudinal direction of bridge), using C50 marine durability concrete.

and that of single-side welding is 10d. Both male side (abutment 0#) and the airport island side (abutment 27#) adopt reinforced concrete

（3）Tendon, anchorage and duct column abutment and bored pile foundation.

Low relaxation prestressed steel strand with a nominal diameter of 15.2mm, fpk=1860MPa and The abutment foundation adopts single row pile, 4 bored piles with each pile diameter 1.5m, the

Ep=1.95*105MPa is to be used. The technical standard shall comply with the requirements stipulated spacing of pile center is 5.5m; abutment dimensions are 21.0×5.0m, bidirectional 2.5% cross slope

in Steel Strand for Prestressed Concrete (GB/T5224-2003). are arranged on the top surface of the abutment. the elevation at center line of abutment 0# is 3.65m

Prestressed anchorage, clamping piece and connector shall comply with relevant regulations of while at abutment 27# is 3.652m; abutment longitudinal length 5.0m, breast wall width 20.0m , thick

Prestressed anchorage, clamping piece and connector (GB/T 14370-2007) and Applied technology 2.0m. The central line of breast wall of abutment 27# is rotated 0.216 degrees to southeast.

specification of prestressed anchorage, clamping piece and connector (JGJ 85-2010). Transition slab is arranged for both abutments to connect the subgrade, with one end set on the

Embedded duct of prestressed steel strand shall be plastic corrugated pipe complying with the breast wall of the abutment, and the other end set on the subgrade. The slab thickness is 0.35 m, total

requirements stipulated in Plastic bellows for prestressed concrete bridge (JT/T 529-2004). Duct width 19.96m, longitudinal length 6m, devided into 4 blocks in transverse direction, each blocks width

adopts vacuum aided grouting technique. The detailed information of specific technical requirements is 4.975m, with 2cm intermediate breaking joint.

as shown in relevant technical standards. Piers 7# ~ 10 # at Male side adopts rectangular pile cap with round chamfer (R=125cm), pile cap

(4) The approach bridge adopt antiseptic rectangular slab-type rubber bearing dimensions 7.0m (transverse direction of bridge) × 6.25m (longitudinal direction of bridge), thick

GJZ400*300*74mm. The elevation of approach bridge base is low. Some bases are located at the 2.5m. 4 bored piles with each pile diameter 1.5m, determinant arrangement, the spacing of pile center

splash zone. The thickness of rubber protection layer shall be appropriately increased. is 4.5m in transverse direction and 3.75m in longitudinal direction of bridge.

6 Development of Substructures Piers 11# ~ 17# at Male side adopts rectangular pile cap with round chamfer (R=125cm), pile cap

dimension 10.0m (transverse direction of bridge) × 6.25m (longitudinal direction of bridge), thick
The pier adopts large cantilever of prestressed concrete T-type cap beam, the full prestressed
3.0m. 6 bored piles with each pile diameter 1.5m, determinant arrangement, the spacing of pile center
concrete inverted T-type cap beam is 2.5m width in the longitudinal direction and 18.7m (excluding
is 3.75m in both transverse and longitudinal direction of bridge.
block) in the transverse direction of bridge, with bidirectional 2.5% cross slope on the top surface.
The pile cap adopts C45 marine durability concrete while the pile foundation adopts C35 marine
Lateral block is arranged in the middle of cap beam. The height at the cantilever end of cap beam is
durability tremie concrete.
1.8m, the under edge of the cap beam is arranged by slope 1:6.11 to tangent to pier with round fillet

R=300cm. The cap beam adopts C50 marine durability concrete. 7 Construction Attentions
4 strands of Φs15.2-15 and 6 strands of Φs15.2-17 prestressed strand are used for the cap beam The bridge construction technology, material requirements and quality should not only be in

with two batches of tensioning. Tension the first batch of prestressed strand when concrete age up to 7 accordance with the relevant provisions of the“Technical Specifications for Construction of Highway

days, and concrete strength reached 90% of the design strength, tension the second batch of prestressed Bridges and Culverts” JTG/T F50-2011, but also pay special attention to the following matters:

strand after erection of I beam.

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7.1 Construction of Bored Pile foundation (7) As the pile foundation is located in the coral reef geology, post grouting for pile base is needed

because of uncertainty of the soil mechanical properties. The grouting tube for pile base should be
（1）Bored pile is adopted for all the approach bridge foundation, The detailed requirements
reserved during pile foundation construction.
didn’t specify in the drawings, the contractor shall decide the diameter, thickness of wall, and bury
（8）The pile base grouting is controlled by grouting volume and pressure, mainly by grouting
depth, etc. by itself according to actual site conditions and relevant Standards & Codes.
volume. The calcultion of grouting volume refers to related requirements for gravelly soil in appendix
（2）During drilling, contractor shall compare the actual soil conditions with the adjacent
N "key technology for post grouting" of "Code for Design of Ground Base and Foundation of
borehole log. If there is obvious difference between the two, influencing the bearing capacity of the
Highway Bridges and Culverts"（JTGD63-2007）. The maximun control pressure of grouting shall be
pile, shall inform the designer immediately for adjusting the pile length.
6 ～ 8Mpa. The slurry strength grade shall be one grade higher than the pile concrete design strength
（3）The borehole drilling shall be followed the specifications of “Technical Specifications for
at least. The slurry fluidity shall be less than 18s. Technical parameter of pile base grouting could be
Construction of Highway Bridges and Culverts” （JTG_TF50-2011）. The deviation of the pile after
appropriately adjusted according to the test result of trial pile.
completion shall be less than 1/200, the position deviation of bored pile top center shall not larger than
(9) The mud should be properly handled during construction of bored piles to avoid pollution.
10cm, and the borehole diameter shall not less than the design pile diameter. The borehole should be

timely cleaned after drilling completion, and the thickness of sediment shall not exceede 10cm before 7.2 Construction of Pile cap
casting the tremie concrete. With secondary pile hole cleaning before the pouring of concrete, to avoid (1) Cofferdam design should consider the water force, wave force, wind and a variety of

sediment thickness affect the bearing capacity of pile. installation force, to meet the strength, stiffness requirements and ensure safety during construction.

（4）Reinforcement cage can be machined in segments, and extended in length during installation, (2) The construction of bottoming concrete, binding reinforcement and pouring concrete for the

for the fabrication of rebar, shall follow the specifications of “Technical Specifications for pile cap should be done as soon as possible, to reduce the risk of construction in the water.

Construction of Highway Bridges and Culverts” （JTG_TF50-2011）. (3) To ensure the thickness of concrete cover, the spacer rebar should be arranged at the outer

(5) The reinforcement cage should be fixed, and the deviation of the center of the reinforcement reinforcement of the bottom and the side surface, the thickness of concrete cover should be strictly in

cage and the borehole should not be more than 5cm. And due measures shall be adopted to prevent the accordance with the drawings, with no binding steel wire going inside, the concrete cover thickness

reinforcement cage float-up during casting concrete. The construction process shall meet the relevant error should be less than 5 mm.

requirements specified in the Standards & Codes. （4）The pile cap is mass concrete. Effective temperature control meatures shall be taken to

（6）Steel tubes for sonic-testing are installed for each pile, the construction methodology shall decrease the influence of hydration heat and outside temperature to the concrete pouring, avoid the

meet the relevant requirements specified in relevant standards. To prevent slurry leakage, plugging crack of concrete and ensure the appearance quality of concrete.The curing time shall be no less than

pipe incident, acoustic pipe connection must be reliable, sheathed threaded joints should be adopted, 14 days after puring.

the pressure performance (external pressure) of sonic test tube wall and joints should not less than 5.0 （5）The concrete shall be covered with curing agent and plastic film in time after the pouring is

MPa, the joints can bear 4.5 MPa external pressure under the condition of 3KN axial tensile. The finished.The concrete shall be covered tightly. And the integrality and moisturizing effect of plastic

contractor should take measures to protect the sonic test tube in the installation of reinforcement cage film need to be checeked frequently.

and pouring concrete, each steel pipe is required to be grouted after the sonic-testing. （6）The setting of pre-embedded reinforcement in the pier shaft shall be noticed during the

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construction of pile cap. checking the security of structure. The construction could not proceed until the approval of the

7.3 The construction of shaft column and cap beam designer.

（1）As the pier shaft and cap beam have great influence on the appearance of bridge, the 8 Others
construction formwork shall be smooth and have good water permeability to ensure that the concrete （1）The contractors shall have a careful study and overall consideration on the design documents.

of pier shaft and cap beam is smooth outside with compacted inside. The coordinates, elevation, reinforcement details and related dimensions of structure shall be checked

（2）The interface between fresh and hardened concrete shall be roughened and cleaned at carefully. Once the problem is found, it should be reported to the design company.The construction

construction joint to ensure effective combination between concrete. could not start until the problem is solved.

（3）The concrete of pier shaft shall be poured within two weeks aftter the completion of pile （2）The contractors shall make detailed construction organization plans and feasible construction

caps. Effective measures shall be taken to decrease the hydration heat of concrete. In order to avoid schemes, and carry out strictly after approval to ensure the quality of bridge and security in

crack on the pier shaft, the curing shall be strengthened. construction.

（4）After the pouring of cap beam, effective measures shall be taken to block both sides of （3）The contractors shall take notice of the relationship between members and related design

prestressed pipe to prevent chloride deposition. The interval between strand penetration and documents to ensure the accuracy of pre-embedded parts and avoid missing.

prestressed tension shall not exceed 12 hours. When the concrete strength of cap beam reaches 90% （4）The contractors shall communicated with the relevant part of Maldives in time to ensure the

of design strength and concrete age is not less than 7 days, the first batch of tendons are tensioned. aviation safety during the construction with large construction machinery within the liminted height for

After the erection of I girder, the other tendons are tensioned. The tension of prestressed tendons aviation.

follows the principle: intermediate first and later on both sides with symmetrical tension. The tension （5）The contractors shall take feasible construction methods to refuse pollution and protect local

of prestressed tendons is controlled by tension force and elongation, mainly by tension force. The natural ecological environment.

control stress under anchor is 1339Mpa. The error between actual stretching elongation and theoretical （6）The hydrological condition at project location is complex.The influence of ocean current and

calculation shall be controlled within 5%. wave shall be taken into consideration adequately during construction of foundation and superstructure.

（5）After the tendons are tensioned, the pipe shall be grouted densely in time and the An emergency plan is necessary for construction security.

interval time shall not exceed 12 hours. The grade of cement paste shall be not less than M50. And （7）The contractors shall monitor the ocean current, wave condition, construction platform,

then the sealing anchor concrete is poured. The grade of concrete is C50. Cement paste and sealing stress and deformation of bridge and build early warning mechanism to ensure the construction

anchor concrete materials shall meet the relevant regulation in article 5.3 and 4.2.12 of “Corrosion security in the whole period.

Prevention Technical Specifications for Concrete Structures of Marine Harbour Engineering” （8）When the substructure is under construction, the contractors shall make calculations for

(JTJ275-2000). temporary structures. The calculations focus on the influence to major structure caused by external

（6）The lifting of precast beam should follow the principle: from the centre line to both sides and load such as cofferdams, jacket platform and ship’s temporary stop. The auxiliary measures shall be

symmetrical construction. The bridge deck should also follow the principle as pier shaft. taken to ensure the security of major structures in construction.

（7）The contractor should provide the construction load and its position to designer for （9）The contractors shall take feasible wind protection measures to ensure the security during

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construction.

（10）If there are abrupt slope and steep shore, the disturbance of rock around shall be decreased

in construction. If the nature rock aroud or the rock disturbed in construction are found to be unstable,

it shall be reported to the management department in time. The construction could not be continued

until some measures are taken.

（11）The contractors shall take necessary measures to ensure the security of construction and

workers during construction of whole bridge.

（12）Other specific construction requirements refer to other volumns. And the requirements not

included shall meet “Technical Specification for Construction of Highway Bridge and Culverts”

(JTG/T F50-2011) and “Quality Inspection and Evaluation Standards for Highway Engineering” (JTG

F80/1-2001).

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