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TS 02178 - 0.00 - Timber Truss Repairs - Construction

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TfNSW QA SPECIFICATION M757

TIMBER TRUSS REPAIRS –


CONSTRUCTION
NOTICE
This document is a Transport for NSW QA Specification. It has been developed for use with
roadworks and bridgeworks contracts let by Transport for NSW or by local councils in NSW. It is not
suitable for any other purpose and must not be used for any other purpose or in any other context.
Copyright in this document belongs to Transport for NSW.

REVISION REGISTER

Ed/Rev
Clause Number Description of Revision Authorised By Date
Number

Ed 1/Rev 0 New specification GM, IC 17.12.08


Ed 1/Rev 1 2.3.1 “OHS&R” changed to “WHS”. DCS 27.10.17
Reference to “G22M” replaced by “G22”.
2.3.3, 4.1.12 Reference to “G34M” replaced by “G36”.
3.3.2.4 Reference to “B200” replaced by “B201
and the Design Drawings”.
3.3.2.5 References to “B241” and “B200”
replaced by “B201 and the Design
Drawings”.
3.3.2.7 Table 1 - column with heading
“Specification” deleted.
3.3.2.10 References to “B240” and “B241”
replaced by “B201”.
3.3.3.4 Reference to “B241” replaced by “B201”.
4.1.10 Reference to “G22M” replaced by “G22”.
Annex M Retitled.
M.1 – Referenced Documents updated.
M.2 – “Abbreviations” changed to
“Acronyms”.
M.3 – definition for Structural Engineer
updated.
Ed 1/Rev 2 Global References to “Roads and Maritime DCS 22.06.20
Services” or “RMS” changed to
“Transport for NSW” or “TfNSW”
respectively.

Edition 1 / Revision 2 TRANSPORT FOR NSW


June 2020
TfNSW QA SPECIFICATION M757
TIMBER TRUSS REPAIRS –
CONSTRUCTION

GUIDE NOTES
(Not Part of Contract Document)

The following notes are intended to provide guidance to TfNSW personnel on the application of the
Specification. They do not form part of the Specification, Contract or Agreement.

USING TFNSW M757


TfNSW M757 has been specifically developed for use under TfNSW internal Alliance arrangements
or Road Maintenance Council Contracts for repairs of timber truss bridges that are the responsibility
of TfNSW, using TfNSW ‘contract’ personnel. It should not be used for any other type of contract,
without a full review of its suitability for that application. It does not cover works on the substructure
or deck systems of timber truss spans, nor on timber beam spans.

TfNSW M757 is a QA specification and thus requires the implementation of a quality system by the
service provider which meets the quality system requirements specified in TfNSW Q4M.

EDITION 1
This is a new Specification. Further improvement and upgrading based on field experience is
expected. Comments on technical issues should be directed to the Supervising Bridge Engineer,
Rehabilitation Methods, TfNSW Bridge Engineering. Other comments or suggestions should be
forwarded to the Manager, Contracts Quality, Infrastructure Contracts Branch, Major Infrastructure.

SPECIFICATIONS FOR TIMBER TRUSS REPAIRS


The following group of four specifications applies to repairs on timber truss superstructure.

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June 2020 (a)
Number Title Description

TfNSW M757 Timber Truss Repairs– Repairs of timber truss spans based on Construction Drawings
Construction prepared in accordance with M756 and using a Temporary Support
System (TSS) designed and erected in accordance with M752.
It specifies materials procurement, fabrication and erection activities.
TfNSW M756 Timber Truss Repairs–Measure- Pre-construction activities that include measuring the existing
Up and Drawings configuration of the bridge, assessing the existing bridge condition and
developing a set of Construction Drawings for the proposed truss
repairs.
It assumes "like for like" replacement and therefore design is not
included.
TfNSW M752 Timber Truss Repairs– Structural engineering activities necessary during repair work,
Temporary Support & Structural including design and erection of the TSS to facilitate the timber truss
Engineering Requirements repairs, and development of procedures for critical activities by a
Structural Engineer.
TfNSW M743 Protective Treatment of Timber Surface preparation, painting and flashing for timber bridges.
Bridges

This group of Specifications is intended for "like for like" repairs based on the original design. Where
structural modification or strengthening is proposed, these model Specifications must be customised
by an experienced Bridge Engineer to cater for project specific requirements.

TIMBER TRUSS TYPES


The following five truss types, as shown in Figure GN.1, are covered by this group of Specifications:
 Old Public Works Department (Old PWD) truss – (1860-1886) - The older form of
"McDonald" truss, comprising single top chords (reinforced in central section), clustered timber
bottom chords, single end principals with knee braces, single vertical wrought iron tension rods
(threaded through chords), cross-braced diagonal struts, and wedges at base of diagonal struts.
 McDonald truss – (1886-1894) - Comprising single top chords, clustered timber bottom chords,
double end principals with knee braces, double vertical wrought iron tension rods (not threaded
through the chords), cross-braced diagonal struts, and wedges at base of diagonal struts.
 Allan truss – (1893-1929) - "Howe" type truss comprising open double timber top and bottom
chords, double end principals, open double diagonal struts attached to chords using shoes (not
wedges), vertical wrought iron tension rods, and cross girders at panel points only. Allan trusses
consist of two types: Type A (shorter span, shorter truss, no overhead bracing) and Type B
(longer span, taller truss, larger panel dimensions, with overhead bracing, underslung cross
girders, up to three vertical wrought iron tension rods).
 De Burgh truss – (1899-1905) - "Pratt" type composite truss, comprising open double timber
top chord, open double plate steel bottom chord, open double timber vertical struts, double
diagonal wrought iron tension rods attached to top chord using anchor blocks and attached to
bottom chord using pins (not shoes), and either timber or steel cross girders.
 Dare truss – (1903-1936) - Composite "Howe" type truss similar to Type A Allan truss,
comprising open double timber top chord, open double channel steel bottom chord, open double
diagonal struts, and double vertical wrought iron tension rods.

These truss types can be divided into the following two groups:
 Old PWD and McDonald trusses – older, heavier, cross-braced construction, and complex to
adjust.

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(b) June 2020
 Allan, De Burgh and Dare trusses – lighter, mainly non-cross-braced construction, and easy to
adjust.
The different structural design of these two groups necessitates different requirements for some
activities (e.g. construction sequence, cambering) and is reflected in many parts of the Specification.

OUTLINE OF M757
M757 is intended for the "like for like" replacement of timber and steel components on a timber truss
span, based on the Original Design. While the Specification is intended for typical major truss repairs,
it can also be used for minor works and remedial cambering (i.e. without other truss repairs), with
selective use of relevant parts of the Specification.
Scope of Timber Truss Repairs under M757 and Strategic Context
Timber truss repairs invariably entail replacement of primary, structurally non-redundant components
and are usually undertaken under trafficked conditions. To allow the removal of such structural
components during repairs, the installation of a temporary support system (TSS) is necessary. The
provision of a TSS is essential risk management. It provides safe conditions for traffic over the bridge
and maximises flexibility to deal with unforeseen additional deterioration and delays (e.g. in timber
procurement or from other causes). The detailed requirements for the TSS are specified in M752.

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June 2020 (c)
Figure GN.1 Types of Timber Truss Bridges
[Source: TfNSW Timber Bridge Manual Section 3]

Because of the large investment in the TSS and other establishment works, the most economical long
term strategy (which is assumed in M757) is for planned cyclic rehabilitations at intervals of
approximately 15-20 years (depending on local climate and traffic conditions), with only minor truss
repair works undertaken in between. It is also usually cost-effective if other works, that can only be
done when the truss is being dismantled and the TSS is providing truss support, are carried out in
conjunction with the major truss repairs.

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(d) June 2020
Examples of such works are:
 Replacement of additional deterioration found in concealed areas, which may not be critical now
but would be expected to require replacement before the next planned rehabilitation.
 Mandatory component replacements (e.g. replace all broken shoes, dismantling as necessary).
The final decision on the scope of work always remains with the Principal, usually the Regional
Bridge Maintenance Planner [RBMP]. The RBMP should consult experienced bridge structural
personnel and experienced practitioners, as appropriate. The scope of works should be determined
having regard to the relative deterioration of the bridge with respect to other bridges and overall
program priorities. Consideration must be given to all other bridge deficiencies, the remaining service
life and the long term strategy for the bridge, with public safety the paramount concern. Criteria for
individual component replacements include BIS condition rating, quality of timber, estimated service
life, loading on the component and distribution of deterioration in the truss.
Completing Annexure A
The Contract Manager is responsible for preparing Annexure A. However, the RBMP should prepare
Annexure A.1 for the Contract Manager, based on his expert knowledge of the most recent bridge
inspection and condition information and his determination of the scope of works required.
Structural Issues and Risk
The repair of timber trusses is an inherently high risk activity. Timber trusses are old, with relatively
long and tall spans (usually over water), and operating at well above their original design loading. The
timber is of variable age, quality and condition (depending on past repairs). Access and support points
are limited. Furthermore, the bridge normally must remain open to traffic during the repairs.

It is important that appropriately qualified structural engineering expertise be employed, both by the
Contractor and the Principal, for all critical structural issues and checks. The Hold Points in M757
highlight the main structural risks anticipated in timber truss repairs.
Use of M757
M757 aims to specify the end-product without prescribing the methods used by the Contractor.
However, owing to the relatively high level of risk associated with this type of work, the Specification
has a significant content of a prescriptive nature to address the key risks. There are also procedures
included in the Annexures to guide the Contractor in developing the PQP.

The Contract Manager, on the advice of the RBMP, must specify the components to be replaced. The
Contract Manager and RBMP should check the existing details to ascertain whether they incorporate
best practice requirements (e.g. splice locations). These decisions must not be left to the Contractor.

Where more than a few components within a truss need be replaced, consideration should be given by
the RBMP to strengthening and replacement of the whole truss. Strengthening and replacement of a
whole truss, or any rehabilitation work that includes significant enhancement, requires a site-specific
structural design. This should be supported by a project-specific technical specification, prepared by
the designer (e.g. project-specific version of M757). Project-specific changes to M757 which affect
structural issues must not be made without the approval of TfNSW Bridge Engineering.

M757 is prepared on the assumption that both of the following apply:


 Measure-up, inspection and Construction Drawings have already been completed
(TfNSW M756).
 TfNSW M752 and TfNSW M743 form part of the Contract Documents.
Preferably, the work under M756 should be conducted about 2 years before the commencement of the
truss repairs under M757. This lead-time will allow the determination of the final scope of works,

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June 2020 (e)
relevant project approvals, the design of the TSS and lead time to procure materials (including
12 months air drying of truss timber).

The Principal must consider and address the following:


 Heritage and Environmental requirements for timber bridges.
 Emissions control and containment requirements.
 All current TfNSW Bridge Policies and Design Notes.
For emergency work on timber truss spans, some requirements in M757 may need to be simplified,
based on structural engineering advice. Technical advice is available from the Supervising Bridge
Engineer, Rehabilitation Methods, at the Rehabilitation Design Section, TfNSW Bridge Engineering.

CLAUSE 1 GENERAL
Terminology
Figure GN.2 shows the terms for the main structural truss components of typical timber trusses. Some
truss types have unique components (e.g. De Burgh trusses), with some differences in terminology.

The standard terminology and definitions to be used for timber truss repairs are summarised in
Annexure M (located at the back of the Specification), with the terminology used in cambering
separately grouped in Annexure M.5. This terminology has been developed after consultation with the
Regions and may need to be further refined but is to be used in the interim. This standard terminology
is to provide consistency across TfNSW (e.g. for specifications, manuals, guidelines and training; or
when a bridge gang works in a different region). Where alternative terms are known to be in common
use in some regions, they are listed against the standard term. However, the standard term must be
used in Contract Documentation, Specifications and DRAWINGS. This will avoid any ambiguity,
which could have possible structural and safety implications.

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(f) June 2020
Figure GN.2 Typical Timber Truss Terminology
[Source: TfNSW Timber Bridge Manual Section 3]

DRAWINGS
In the Specification, the term ‘the DRAWINGS’ refers to the group of Drawings provided by the
Principal to show the truss repairs and may include: the Original Drawings, Drawings of approved
design modifications, Construction Drawings and Shop Drawings (produced under M756), or
Structural Drawings. The Contract Manager must ensure that the work is clearly detailed on the latest
set of Drawings provided to the Contractor. The Contractor should not be expected to refer to
different sets of drawings to decide what needs to be done.

It should be noted that the Original Drawings for most timber truss bridges are available on microfiche
from TfNSW Micrographics. Where Original Drawings are not available, a drawing of another truss
span that best matches the required truss configuration may be provided.

CLAUSE 2 PLANNING
Project Quality Plan Requirements
The PROJECT QUALITY PLAN (PQP) is critical to this QA Specification. The PQP should be prepared
before the Work commences, and be based on TfNSW Guidelines, TfNSW Manuals or other
appropriate information. The PQP must then be used by the Contractor at all times during the work.
Amendments are to be kept up to date by the Contractor and periodically resubmitted to the Principal.

The Principal must carry out regular surveillance of the contract using experienced officers.

The Contract Manager must review the PQP and raise any issues regarding the proposed methods with
the Contractor. The Principal has the opportunity to review the PQP and to request further
clarification. The Contract Manager should NOT dictate the method to be used, otherwise the
responsibility for the outcomes may no longer rest with the Contractor. Some procedures are included
in the Annexures to guide the preparation of the Contractor’s PQP.
TfNSW Timber Bridge Manual (TBM)
The best practice procedures for timber truss repairs are in the TfNSW Timber Bridge Manual (TBM)
and these should be followed when developing or reviewing the PQP. However, the TBM is in need
of updating and there may be inconsistencies between the TBM and this or other TfNSW
specifications. In such cases, the TfNSW specifications take precedence.

The TBM has replaced all former RTA/DMR publications concerning timber bridge maintenance,
including "Manual No.6 - Bridge Maintenance" (DMR, 1962 re-issued 1983) and the "Timber Truss
Bridge Maintenance Handbook" (DMR, 1987). Those former publications remain useful as
background and historical references, except that the methods of temporary support detailed in those
references must not be used.
CONSTRUCTION PROGRAM
The Contractor must supply a CONSTRUCTION PROGRAM prior to commencing work. This needs to be
reviewed by the Principal to make sure that the repairs are efficiently and effectively planned. Changes
will be required as work proceeds and the Contractor is required to keep the CONSTRUCTION
PROGRAM up to date.
PROJECT BRIEF
The PROJECT BRIEF for the truss repairs is provided by the Principal in Annexure A.3. The PROJECT
BRIEF should be based on the best available information (e.g. work under M756) and should generally
follow the format of Project Brief - Large/significant project (ILC-AM-TP2-404-S02).

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June 2020 (g)
Information provided by the Principal
The Contract Manager must collate all the relevant information for the contract (refer Annexure A),
supply it to the Contractor and ensure that no irrelevant or out of date documents are supplied.

CLAUSE 3 RESOURCES
Personnel
Timber truss repairs are complex and high-risk activities and therefore require intensive supervision
by the Contractor and intensive surveillance by the Principal.

Experienced and qualified personnel are required to supervise and carry out the work (refer
Clause 3.1). In addition to qualifications, M757 specifies the minimum number of skilled personnel
on site. These are to be included in the PQP and should be reviewed by the Principal.

The Bridge Works Supervisor should have first class experience in timber truss repairs and bridge
maintenance. The Principal's surveillance representative should have similar experience to the
Contractor’s Bridge Works Supervisor.
Materials – General
Timber components, metal components, steelwork, fasteners and other materials are specified.

The requirements for storage of materials are specified for both (a) prior to use on site, and (b) during
fabrication, until erected and fitted into the truss.
Timber Procurement and Management of New and Existing Timber
The Construction Drawings and Materials List prepared under M756 will provide the proposed scope
of works and the design dimensions of the replacement timber components. This will enable the
required sizes and lengths of components in the timber order to be determined.

The Specification for supply of new truss timber components is TfNSW 2380. However,
TfNSW 2380 is a timber supply specification only. M757 specifies the requirements for new timber
components after delivery. M757 requires that truss timber be managed as a critical and “high value”
material. This will assist long term supply of timber for heritage timber truss bridges in perpetuity.

The additional requirements in M757 include:


 The cross sections and lengths of timber components to be ordered and supplied under
TfNSW 2380 (e.g. ordered section to be 5% oversize compared to design size, to allow for
shrinkage).
 Supplied lengths to be 200 mm longer than actual required lengths, to allow for cutting off split
or damaged ends (including deterioration in storage) and to provide true ends.
 General management of timber components as “high value” product to comply with 'Australian
Hardwood Drying Best Practice Manual'.
 Prime coating of the surfaces of new timber to control the rate of air drying.
 Storage and air drying of new timber for at least 12 months from the date of delivery, before
cutting and use in fabrication. Truss timber not to be kiln-dried.
 Discouraging storage of timber at the bridge site until just before it is needed in fabrication.
 Recording and maintaining each timber component in inventory until it is fabricated.
Truss timber of the required size, strength and quality is scarce and expensive. The availability of
timber from Australian forests is much more critical than that experienced when the bridges were

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(h) June 2020
originally built. Therefore, new and existing truss timber components need to be treated as critical and
“high value” materials in accordance with the Australian Hardwood Drying Best Practice Manual.

The objective of the “high value” material management strategy is to ensure that:

(a) The Supplier will use production methods that minimise the degree of degrade due to air
drying and other damage to the truss timber prior to delivery (refer to TfNSW 2380
Clause 1.5);

(b) The Contractor will improve the management of timber after delivery (e.g. protection of
timber immediately after delivery, suitable storage to meet the 12 months air drying
requirement and minimising storage at the bridge site) to ensure that deterioration and wastage
is minimised (refer to M757 Clause 3.2.6).

Truss timber is not held in stock by the timber industry. It is usually cut to order and supplied green.
The 12 month air drying requirement for main truss components after delivery is designed to reduce
the effects of in-service shrinkage of timber (e.g. in truss shoe connections, tension splices, multi-flitch
bottom chords of Old PWD and McDonald trusses or in composite members). The Contractor must
produce verification that the air-drying requirement has been met.

Recycling of sound existing truss components is encouraged and M757 provides requirements for the
use of recycled timber, where feasible. Existing timber components that are to be recycled should be
stored separately and managed for the potential risk of contained termites and incipient decay.
TfNSW Timber Supply Strategy
The requirements of TfNSW 2380 (for supply) and M757 (for ordering, use and storage after delivery)
are consistent with the TfNSW Bridge Timber Supply Strategy. This Strategy has been developed to
ensure an effective long term supply of truss timber for TfNSW’s heritage timber truss bridges. M757
has been prepared on the assumption that TfNSW will stockpile the critical large section components
suitable for the main truss elements in accordance with the TfNSW Bridge Timber Supply Strategy.
This would allow TfNSW to build up adequate stock of timber that has been air-dried for 12 months in
regional storage sheds, in the sizes and lengths appropriate to typical timber truss repairs, even if no
immediate works are planned.

The Strategy provides for the erection of regional truss timber storage sheds, which offer the necessary
air-drying conditions of shelter, ventilation and security, at strategic locations around the State. These
sheds should be used for long term storage of truss timber and should be nominated as the delivery site
for new truss timber components, rather than the bridge site. Truss timber should not be stockpiled on
site until just before it is needed.

In the absence of suitable TfNSW stock, lead times for procurement of new truss timber must allow
for the current scarcity of supply and must also provide for 12 months air drying of the truss
components after delivery. The TfNSW Contract Manager should allow for this expected lead time in
determining the Contract Period. Where possible, timber should be ordered at least 18 months in
advance of the works. To minimise the risk of project delays, the preconstruction activities under
M756 should be carried out at least 2 years in advance of the proposed truss repairs.

Existing truss timber components that are to be recycled must be stockpiled separately and managed
for potential risk of contained termites and incipient decay.

Composite Components
In recognition of the general scarcity of large section truss timber, if whole section timber of the
required size and length proves to be unavailable within 6 months after placing the timber order, M757
allows for the use of composite components of equivalent overall cross section. The composite
components must be appropriately designed and would be subject to heritage approval. The
Contractor must firstly make a genuine effort to obtain whole section timber.

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June 2020 (i)
Metal Components
The material and fabrication requirements for metal components are extensive and complex, and vary
depending on the type of component.

Structural grade steel, stainless steel or ductile cast iron must be used regardless of the original type of
metal that is to be replaced (i.e. wrought iron, grey cast iron or “early” steel).

New steelwork must be shown on the DRAWINGS and itemised in the MATERIALS LIST provided to the
Contractor.

CLAUSE 4 EXECUTION
General
Table GN.1 sets out the scope of work under each sub-clause of Clause 4 and significant aspects.

Table GN.1 Summary of Clause 4 Specification Requirements

Sub-Clause in Clause 4 Comments

General Outlines main general requirements and makes reference to the relevant parts of this
Specification.
TfNSW M752 and TfNSW M743 to be used in conjunction with this Specification.
WORK-AS-EXECUTED DRAWINGS to be annotated as work progresses.
Survey and Measurement Establishes or re-establishes the permanent BRIDGE SURVEY CONTROL and MEASUREMENT
SYSTEM. Includes methods of camber measurement.
Management of Materials at The Principal needs to define a work area that is suitable.
the Bridge Site
Temporary Support System Where a Temporary Support System (TSS) is required, its design and erection to be as
and Provision of INITIAL specified in TfNSW M752. INITIAL CAMBER to be provided at construction stage, prior to
CAMBER commencing truss repairs.
Truss Repair – General Generally applies to all aspects of the truss repair work including fabrication, dismantling,
Requirements repair of existing components, and erection and fitting of components on the bridge.
Fabrication Off-bridge fabrication mandatory unless the Principal permits otherwise. Requires
fabrication in large sections, which may be partly dismantled to facilitate transport and
erection on the bridge.
Dismantling Progressive dismantling required (not considered demolition).
Repair of Existing Only for components that are considered suitable for repair. Relevant fabrication
Components requirements also applicable.
Erection and Fitting of Additional fabrication requirements to ensure good fit and to minimise distortion and effects
Components on the Bridge of live loads when working on the bridge.
Truss Adjustment and This is a prerequisite before final cambering. It must be undertaken after completion of any
Tightening truss repair work. INITIAL CAMBER must be provided during this work.
Cambering Cambering procedures dependent on the type of timber truss. Associated procedures to
guide the Contractor are provided in Annexure G. Remedial cambering is included for
completeness. Refer to Guide Notes below for further information.
Stage Completion of Each Specifies the criteria for completion of each individual truss and for allowing dismantling or
Truss relocation of the TSS to another truss.
WARRANTY PERIOD Joint PRESCRIBED INSPECTIONS and PRESCRIBED MAINTENANCE detailed.
Project Completion and To be read in conjunction with general conditions of contract.
Handover

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Truss Repair Sequence
M757 has two major themes regarding the work sequence within the truss:
 Fabrication, erection and truss adjustment/tightening: From centre of truss outwards, towards
ends; or
 Load transfer and camber adjustment: From ends of truss inwards, towards centre of truss.
Annexure E provides an integrated sequence of truss fabrication/repair, that includes cambering.

Fabrication and Erection


The method of fabrication and erection depends on the truss type, the scope of truss repairs, the extent
and distribution of component replacements within the truss, site-specific conditions and economics.
In general, even for relatively minor truss repairs (e.g. less than 25% of primary structural components
to be replaced), individual component assemblies comprising single or double flitch members should
be pre-fabricated off the bridge, prior to their incorporation into the truss on the bridge.

Where the truss requires a major rebuild (e.g. more than 40% of primary structural components to be
replaced), entire truss sections or even the whole truss may be pre-fabricated off the bridge. In this
case, the pre-fabricated sections are either lifted and incorporated intact into the truss or dismantled
into sub-assemblies which are then re-assembled and incorporated into the truss on the bridge.

M757 encourages progressive dismantling and replacement of truss components, rather than complete
span removal, so that dismantling operations can be treated as bridge maintenance work and not
demolition work (which has more onerous NSW Workcover OHS requirements).
Alternative Allan truss tension splice layout
For 27.43 m span Allan trusses (9 panels), the alternative bottom chord tension splice layout shown in
Figure 1 may be used in lieu of the layout in the Original Drawings (refer Clause 4.6.7.4). The
alternative layout applies to “like for like” repairs where the entire bottom chord is replaced or
repaired. Existing flitches may be re-used, after trimming their ends to remove defective timber and
shorten the flitch. This symmetrical, non-staggered layout has one additional splice (at midspan). The
maximum flitch length is 8.4 m (reduced from 11.1 m original). This facilitates timber procurement.
Cambering
M757 requires restoration of a positive camber (i.e. APPROVED CAMBER) in the truss after all timber
truss repairs. Cambering of trusses is an essential design and performance requirement, since camber
provides the main benchmark for monitoring the performance of trusses. A positive (i.e. hogging)
camber is important for bridge aesthetics and for the public perception of the structural adequacy of
the bridge. Development of negative (i.e. sagging) camber in a truss is an indicator of deterioration or
other problems in the truss. However, a truss with negative camber can still function structurally and
carry load, provided that the deterioration or other problems do not affect its structural integrity.

M757 specifies extensive new requirements for cambering of trusses, including the previously
unrecognised stages of lifting and lowering trusses by using the TSS or by tension rod loosening. The
cambering requirements have been the subject of much discussion, structural modelling and trials to
identify all significant risks and to clarify best practice.

The later truss designs (Allan, De Burgh and Dare trusses) permit camber adjustment using the tension
rods, as a design feature. However, the cross-braced design of the earlier trusses (Old PWD and
McDonald trusses) makes them complex to camber, by both tension rod and wedge adjustment.

Cambering changes the shape, load distribution and stresses in the truss. Uniform tightness in the
truss is disturbed whenever the truss shape is changed (e.g. due to camber adjustment, truss lifting or

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lowering). Therefore, during cambering work, changes in uniform tightness of the truss must be
monitored and the truss must be adjusted accordingly.

Unless the cambering procedure is highly controlled (i.e. cyclic, incremental and balanced), there is a
major risk of overloading components and damaging the truss or TSS. M757 specifies strict controls
on the cambering process, particularly where tension rod tightening is used (Allan, De Burgh and Dare
trusses). This systematic and controlled approach is similar to that necessary for transfer of dead load
to and from the TSS (refer TfNSW M752) and for truss adjustment and tightening (refer Clause 4.10).

Because cambering is a complex and critical process, involving two main stages at the start and end of
the truss repairs, a flowchart is provided in Figure 2 for cambering work procedure.

M757 adopts the concepts of:


 INITIAL CAMBER – the camber provided during all fabrication, repair, truss adjustment and
tightening work. This is zero camber for all trusses.
 APPROVED CAMBER – the camber provided after repairs are completed.
The truss must be lifted or lowered to the INITIAL CAMBER before fabrication and repair work on the
bridge commences (refer Clause 4.4). The truss must then be loosened off (i.e. at shoe connections,
with the truss at the INITIAL CAMBER), followed by truss adjustment and tightening after the repairs
(refer Clause 4.10). This process provides consistent benchmark conditions for the truss repairs and
final cambering and ensures that the uncertain past load history of the tension rods is removed (to
avoid overstressing tension rods). The only exception is remedial cambering without a TSS.
The APPROVED CAMBER is related to the DESIGN CAMBER. The DESIGN CAMBER at midspan must be
provided by the Principal in Annexure A.1 and be based on (in cascading order):
 The DESIGN CAMBER shown on the DRAWINGS (usually the Original Drawings).
 20 mm for Old PWD and McDonald trusses (it is not shown on Original Drawings).
 As shown in the Camber Tables in Annexure G.4 for Allan, De Burgh and Dare trusses. [Please
note that some of the Camber Tables are still to be finalised, hence entries are left blank.
Consult the Supervising Bridge Engineer (Rehabilitation Methods) if any such incomplete
Camber Tables are applicable to the work under the Contract.]
The DESIGN CAMBER at each panel point is then calculated by the Contractor.
The APPROVED CAMBER will be confirmed by the Principal, based on the Final Camber profile
proposed by the Contractor (refer Clause 4.11.2). For Allan, De Burgh and Dare trusses, the
APPROVED CAMBER should be the smoothed, symmetrical profile shown in the Camber Tables in
Annexure G.4 (which are based on a best fit with the DESIGN CAMBER), before allowing for localised
camber irregularities. These Camber Tables also specify the required CAMBER CORRECTION, the
number of cycles (minimum 4 cycles) and the applied tension rod shortenings to achieve the
APPROVED CAMBER. Splitting camber adjustments over 4 cycles reduces the load, effort and
temporary bending stresses per cycle, so as to reduce risks such as overstress or damage to the truss.

All camber adjustment must be carried out under load, either (a) the dead load of the truss span is
progressively transferred to the truss, or (b) the truss carries its own self-weight, or (c) the truss carries
the full truss span dead load. This preloading controls bending stresses and avoids load reversals.

M757 specifies two alternative methods of final cambering of Allan, De Burgh or Dare trusses, either:
 Under truss self weight, followed by a final transfer of the full dead load of the truss span (only
for truss repairs). The cross girders must be detached from the bottom chord; or
 Starting from a fully supported condition, with concurrent and progressive transfer of dead load
to the truss. The cross girders remain attached to the bottom chord. This method involves a
greater effort to turn the tension rod nuts in the last few cycles, as full dead load transfer occurs.

TRANSPORT FOR NSW Edition 1 / Revision 2


(l) June 2020
The change in camber after each cycle of cambering should not exceed 20 mm (at midspan).
However, for remedial cambering where the truss is carrying the full dead load of the truss span, the
change in camber after each cycle should not exceed 10 mm (at midspan).

Irregularities in the existing camber complicate both the INITIAL CAMBER “best attempt” baseline and
the camber measurements. For example, permanent deformation in steel bottom chord may only
become evident when the bottom chord is unloaded. Localised camber irregularities should be
corrected while the truss is loosened off and fully supported at zero camber, not during cambering.
Permanent deformation of the bottom chord must be repaired or, if not repaired, left in the truss and
allowed for in the camber measurements.

M757 also specifies remedial cambering of existing trusses to restore the APPROVED CAMBER, where
no component replacements or other truss repairs are planned. Remedial cambering is a common
maintenance activity which must be controlled and consistent with the cambering requirements of
M757. Remedial cambering does not require component replacements. Unless the truss geometry and
fit are correct, a conforming camber cannot be achieved, and a reasonable-match camber will be
difficult to achieve (at risk of possible overstress or damage to the truss). The truss must be brought to
the INITIAL CAMBER and adjusted and tightened prior to commencing remedial cambering.

WARRANTY PERIOD

The Contractor’s warranty on the repairs of each truss is for a period of 12 months from its DATE OF
STAGE COMPLETION. The total WARRANTY PERIOD is therefore from the completion of the first truss
to 12 months after completion of the last truss (refer Annexure A.1).

On each individual truss, after 12 months from its DATE OF STAGE COMPLETION (i.e. after the
Contractor’s warranty on that truss expires), the Principal will be responsible for the additional costs
of any additional PRESCRIBED INSPECTIONS and PRESCRIBED MAINTENANCE carried out on that
completed truss and any additional (newly identified) corrective work. It is not reasonable to expect
the Contractor to price for an extended warranty of uncertain duration for each truss. Therefore,
separate itemised Prices will need to be submitted by the Contractor for such additional works and the
Principal’s approval must be obtained prior to proceeding (refer to Clause 4.13.5).

The Contract Manager should ensure that the work is practically planned and divided into manageable
packages, so that the truss repairs under a single work order are not so extensive as to require an
excessively long WARRANTY PERIOD. For example, a rehabilitation of three timber truss spans can be
divided into two work orders: firstly for the 3 upstream trusses, secondly for the 3 downstream trusses.

CLAUSE 5 CONFORMITY
Survey and Measurement Tolerances
The tolerances in Table 4 (survey co-ordinates) and Table 5 (truss internal length measurements) are
the same as those in Tables 3 and 4 in TfNSW M756. The tolerance for truss internal length
measurements is tight at ± 1 mm, but is considered necessary to ensure a precisely fitting truss
fabrication that involves a mixture of new and old components. These lengths should be obtained by
direct length measurement, rather than at-distance survey, to obtain the necessary accuracy. Tables 4
and 5 specify features where a lower tolerance is acceptable. It is recognised that accurate bridge
survey measurements are expensive to collect. Survey procedures to achieve the specified accuracy
must be established. Accuracy can be ensured by repetition of measurements, by measuring at close
range and regular sighting to the BRIDGE SURVEY CONTROL.
NOMINATED REPAIR STANDARD for Truss Repairs
Annexure H in M757 is the same as Annexure E in TfNSW M756, except for an additional column.
The column is added so that the TfNSW Contract Manager can make project-specific variations to the

Edition 1 / Revision 2 TRANSPORT FOR NSW


June 2020 (m)
REPAIR STANDARD. Any replaced or deleted requirements in the middle column must be struck
through.

TRANSPORT FOR NSW Edition 1 / Revision 2


(n) June 2020
QA S PECIFICATION M757

TIMBER TRUSS
REPAIRS -
CONSTRUCTION

Copyright—Transport for NSW, 2008


RNIM-QA- M757

V
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Edition 1 / Revision 2 TRANSPORT FOR NSW


June 2020
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Edition 1 / Revision 2 TRANSPORT FOR NSW


June 2020
Timber Truss Repairs – Construction M757
CONTENTS
FOREWORD.............................................................................................................................................................. IV

TfNSW Copyright and Use of this Document ............................................................................................ iv


Revisions to Edition 1 ................................................................................................................................. iv
Project Specific Changes ............................................................................................................................. iv

1 GENERAL ......................................................................................................................................................... 1

2 PLANNING........................................................................................................................................................ 2

2.1 Project Quality Plan .......................................................................................................................... 2


2.2 Construction Program ....................................................................................................................... 3
2.3 Other Plans ........................................................................................................................................ 4
2.4 Documents ........................................................................................................................................ 5

3 RESOURCES ..................................................................................................................................................... 6

3.1 Personnel ........................................................................................................................................... 6


3.2 Timber components .......................................................................................................................... 7
3.2.1 General .................................................................................................................................. 7
3.2.2 Supplied size and length ........................................................................................................ 8
3.2.3 New Timber ........................................................................................................................... 8
3.2.4 Recycled Timber.................................................................................................................... 9
3.2.5 Composite Components ......................................................................................................... 9
3.2.6 Management of timber off-site ............................................................................................ 10
3.3 Metal Components, Steelwork and Fasteners ................................................................................. 12
3.3.1 General ................................................................................................................................ 12
3.3.2 New Steelwork and fasteners ............................................................................................... 12
3.3.3 Re-use of existing metal components .................................................................................. 16
3.4 Other materials ................................................................................................................................ 16

4 EXECUTION .................................................................................................................................................... 17

4.1 General ............................................................................................................................................ 17


4.2 Survey and Measurement ................................................................................................................ 19
4.2.1 General ................................................................................................................................ 19
4.2.2 Survey Control and Measurement System ........................................................................... 21
4.2.3 Measurement of Camber...................................................................................................... 21
4.3 Management of Materials at the Bridge Site ................................................................................... 22
4.4 Temporary Support System and Provision of Initial Camber ......................................................... 23
4.4.1 Provision of Temporary Support System (TSS) and Transfer of Dead Load ...................... 23
4.4.2 Proposed Camber Adjustments for the INITIAL CAMBER..................................................... 23
4.4.3 Provision of the INITIAL CAMBER ........................................................................................ 24
4.5 Truss Repair–General Requirements .............................................................................................. 25
4.5.1 General ................................................................................................................................ 25
4.5.2 Mandatory Replacement of Components............................................................................. 28
4.5.3 Greasing and protection of metal components ..................................................................... 28
4.6 Fabrication ...................................................................................................................................... 29
4.6.1 General ................................................................................................................................ 29
4.6.2 Fabrication Off-Bridge ........................................................................................................ 30
4.6.3 Fabrication On-Bridge ......................................................................................................... 30

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M757 Timber Truss Repairs - Construction

4.6.4 Fabrication of Timber Components and Assemblies ........................................................... 31


4.6.5 Fabrication of Connections .................................................................................................. 32
4.6.6 Bolted Connections – General Requirements ...................................................................... 33
4.6.7 Splices in Timber Top and Bottom Chords .......................................................................... 34
4.6.8 Shoe Connections................................................................................................................. 35
4.7 Dismantling ..................................................................................................................................... 35
4.8 Repair of Existing Components ...................................................................................................... 36
4.8.1 Existing Timber Components .............................................................................................. 36
4.8.2 Existing Metal Components ................................................................................................. 37
4.9 Erection and Fitting of Components on the Bridge ......................................................................... 37
4.10 Truss Adjustment and Tightening ................................................................................................... 38
4.10.1 General ................................................................................................................................. 38
4.10.2 Adjustment and tightening of each truss .............................................................................. 39
4.10.3 Adjustment and tightening of wind bracing ......................................................................... 40
4.11 Cambering ....................................................................................................................................... 41
4.11.1 General ................................................................................................................................. 41
4.11.2 Proposed Camber Adjustments for the Final Camber .......................................................... 44
4.11.3 General Requirements for Cambering ................................................................................. 45
4.11.4 Cambering Irregularities ...................................................................................................... 48
4.11.5 Lifting or Lowering of Truss (Using the TSS) ..................................................................... 49
4.11.6 Lowering of Allan, De Burgh and Dare Trusses (By Tension Rod Loosening) .................. 51
4.11.7 Cambering of Allan, De Burgh and Dare trusses (By Tension Rod Tightening) ................. 51
4.11.8 Cambering of Old PWD and McDonald Trusses (By Tension Rod & Wedge Adjustment) 53
4.12 Stage Completion of Each Truss ..................................................................................................... 55
4.13 Warranty Period .............................................................................................................................. 55
4.14 Project Completion and Handover .................................................................................................. 57

5 CONFORMITY ................................................................................................................................................. 57

5.1 Survey and Measurement Tolerances .............................................................................................. 57


5.2 Work-as-Executed Drawings .......................................................................................................... 58
5.3 Nominated Repair Standard for Truss Repairs ................................................................................ 59
5.4 Camber Conformity ........................................................................................................................ 59

ANNEXURE A ––DETAILS OF WORK ................................................................................................................... 60

A.1 Work Summary ............................................................................................................................... 60


A.2 Information Supplied by the Principal ............................................................................................ 60
A.3 Project Brief for Truss Repairs ........................................................................................................ 61

ANNEXURE B –MEASUREMENT AND PAYMENT .................................................................................................. 62

B.1 General ............................................................................................................................................ 62


B.2 Schedule of Pay Items ..................................................................................................................... 63

ANNEXURE C – SCHEDULE OF HOLD AND WITNESS POINTS AND IDENTIFIED RECORDS .................................... 65

C.1 Schedule of Hold and Witness Points ............................................................................................. 65


C.2 Schedule of Identified Records ....................................................................................................... 67

ANNEXURE D ––PLANNING DOCUMENTS ........................................................................................................... 69

D.1 Construction Processes .................................................................................................................... 69

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Timber Truss Repairs – Construction M757
ANNEXURE E –– SEQUENCE OF TRUSS FABRICATION/REPAIR ........................................................................... 72

E.1 General ............................................................................................................................................ 72


E.2 Repair Sequence for Allan, De Burgh and Dare Trusses ................................................................ 72
E.3 Repair Sequence for Old PWD and McDonald Trusses ................................................................. 73

ANNEXURE F ––TRUSS ADJUSTMENT/TIGHTENING PROCEDURE ....................................................................... 75

F.1 General ............................................................................................................................................ 75


F.2 Preparing truss for Adjustment (includes Truss Repairs) ............................................................... 75
F.3 Setting Rack of Truss ...................................................................................................................... 76
F.4 Corrective Adjustment of Truss Panels ........................................................................................... 77
F.5 Checklist for Conformity of Truss Geometry and Connections ...................................................... 78

ANNEXURE G ––CAMBERING PROCEDURES, TABLES AND FORMS ..................................................................... 79

G.1 General ............................................................................................................................................ 79


G.2 Final Cambering of Allan, De Burgh and Dare Trusses ................................................................. 80
G.3 Final Cambering of Old PWD and McDonald Trusses ................................................................... 82
G.4 Camber Tables ................................................................................................................................ 84
G.5 Proforma for Camber Adjustment - 7 Panel Truss (One Cross-Braced Panel) ............................. 89
G.6 Proforma for Camber Adjustment - 8 Panel Truss (Two Cross-Braced Panels) ........................... 90
G.7 Proforma for Camber Adjustment - 9 Panel Truss (One Cross-Braced Panel) ............................ 91

ANNEXURE H ––NOMINATED REPAIR STANDARDS ............................................................................................ 92

H.1 Truss Span Geometry ...................................................................................................................... 92


H.2 Assembled Component Details ....................................................................................................... 94
H.3 Component Requirements ............................................................................................................... 96

ANNEXURE I TO L––(NOT USED) ....................................................................................................................... 99

ANNEXURE M ––REFERENCED DOCUMENTS, ACRONYMS AND DEFINITIONS .................................................. 100

M.1 Referenced Documents ................................................................................................................. 100


M.2 Acronyms ...................................................................................................................................... 101
M.3 Defined Terms (non Cambering) .................................................................................................. 101
M.4 Definitions (Non Cambering) ....................................................................................................... 103
M.5 Terminology Used in Cambering .................................................................................................. 109

LAST PAGE OF TFNSW M757 IS: ......................................................................................................................... 110

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M757 Timber Truss Repairs - Construction

FOREWORD

TFNSW COPYRIGHT AND USE OF THIS DOCUMENT


Copyright in this document belongs to the Transport for NSW.

When this document forms part of a Contract or Agreement

This document should be read with all the documents forming the Contract or Agreement.

When this document does not form part of a Contract or Agreement

This copy is not a controlled document. Observe the Notice that appears on the first page of the copy
controlled by TfNSW. A full copy of the latest version of the document is available on the TfNSW
Internet website: www.rms.nsw.gov.au/doingbusinesswithus/specifications.

REVISIONS TO EDITION 1
This document has been revised from Specification TfNSW M757 Edition 1 Revision 1.

All revisions to TfNSW M757 Ed 1/Rev 0 (other than minor editorial and project specific changes) are
indicated by a vertical line in the margin as shown here.

PROJECT SPECIFIC CHANGES


Any project specific changes have been indicated in the following manner:-

(a) Text which is additional to the base document and which is included in the Specification is
shown in bold italics e.g. Additional Text.

(b) Text which has been deleted from the base document and which is not included in the
Specification is shown struck out e.g. Deleted Text.

CLAUSE REFERENCE FORMAT


References to this Specification (Examples) References to other Specifications (Examples)

 Clause 3.2 (typical clause reference)  TfNSW 3021 Clause 3.2 (corresponding reference)

 Annexure B (typical Annexure reference)  M745 Annexure B (ditto)

 Annexure B.3 (the third section within Annexure B)  M745 Annexure B.3 (ditto)

 Table 1 (the first Table within Specification)  M745 Table 1 (ditto)

 Figure 4 (the fourth Figure within Specification)  M745 Figure 4 (ditto)

 Table E.1 (the first Table within Annexure E)  M745 Figure E.1 (ditto)

 TfNSW M745 / TfNSW G10 (entire specification)

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Timber Truss Repairs - Construction M757


TIMBER TRUSS REPAIRS -
CONSTRUCTION
1 GENERAL
1.1 The Work to be executed under this Specification involves the repair Scope
of the superstructure of timber truss bridges and includes the
following activities:
.1 Supply and manage materials.
.2 Erect the Temporary Support System (TSS) and transfer dead
load according to TfNSW M752.
.3 Fabricate components.
.4 Repair components.
.5 Erect and fit fabricated or repaired components into the
existing structure.
.6 Apply protective treatments to components including flashing
according to TfNSW M743.
.7 Adjust and tighten the truss and then achieve the required
camber.
.8 Maintain the repaired truss during the WARRANTY PERIOD.
This Specification does NOT include certain repairs on timber truss
spans (i.e. substructure below the jacking blocks, deck above
stringers, kerbs and handrailings), or preparation of Construction
Drawings or structural designs for the proposed truss repairs.

1.2 Details of the Work are described in ANNEXURE A. Details of Work

1.3 At all times during the Work until completion of the truss repairs to Your
the last truss, You must keep the whole bridge and TSS safe for the responsibility for
APPROVED LOADING REGIME according to TfNSW M752. safety of bridge

Your responsibilities during the WARRANTY PERIOD are set out in


Clause 4.13.

1.4 Payment for the activities associated with completing the Work Measurement and
detailed under this Specification will be made using the pay items payment
listed in ANNEXURE B.

1.5 Provide the Identified Records (refer to TfNSW Q4M Annexure E.2) Records
summarised in Annexure C.2.

1.6 The standards, specifications and test methods referred to in this Reference
Specification are referenced using an abbreviated form (e.g. documents
AS 1478). The titles are given in ANNEXURE M.

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M757 Timber Truss Repairs – Construction

1.7 Some words and phrases have special meanings in this Specification. Defined terms
In some cases, the defined meaning is different from the meaning that
the word or phrase might have in ordinary usage. In order to
understand the Specification, You need to take these special
meanings into account.

Defined terms have the special meanings set out in ANNEXURE M.

All defined terms are indicated by using small capitals (e.g. DEFINED
TERM) unless they are one of the following basic terms, which appear
too often for small capitals to be used.
 Principal  Work
 You / Your  Bridge Site
 Specification  Contractor
1.8 Some technical words and abbreviations used in this Specification are Definitions and
also defined in ANNEXURE M. abbreviations

1.9 The term 'the DRAWINGS' in this Specification means the group of DRAWINGS
Drawings provided by the Principal to represent the truss repairs and
may include: Construction Drawings, Original Drawings, Structural
Drawings (e.g. for approved design modifications) or Shop
Drawings. The DRAWINGS are specified in ANNEXURE A.

1.10 Unless otherwise specified, the issue of an Australian Standard or Applicable issue
TfNSW Test Method to be used is the issue current one week before
closing date of tenders. The TfNSW Specification to be used is the
issue contained in the contract documentation.

1.11 You are responsible for all activities, actions, works and supply of Interpretation
materials required under this Specification, unless specifically stated
otherwise. Accordingly, this Specification does not generally use
wording such as "You shall …" or "You must …" because this is the
underlying requirement. However, such wording is used where
actions in a clause involve both You and the Principal and the roles
need to be unambiguous.

2 PLANNING

2.1 PROJECT QUALITY PLAN


Process Held: Commencement of work. HOLD POINT
Submission: At least 10 BUSINESS DAYS prior to commencing work,
submit the following documents:
.1 PROJECT QUALITY PLAN (PQP) conforming to this clause.
.2 CONSTRUCTION PROGRAM (refer to Clause 2.2).

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Timber Truss Repairs - Construction M757


2.1.1 The requirements of the PROJECT QUALITY PLAN are defined in
TfNSW Q4M. In addition, the PROJECT QUALITY PLAN must:
.1 Address the HOLD and WITNESS POINTS required by this HOLD and
Specification and summarised in Annexure C.1. The Principal WITNESS POINTS
will consider the submitted documents prior to the release of
any HOLD POINT.
.2 Address each of the construction process requirements in this Construction
Specification. A list to assist preparation is summarised in Processes
Annexure D.1.
.3 Include a requirement for the routine submission of conformity Conformity data
data and supporting documentation, which will verify the
conformity of all work and materials.
2.1.2 In addition, some procedures to be included in the PROJECT QUALITY Certified
PLAN require certification by a Structural Engineer according to procedures
TfNSW M752. Examples include the following:
.1 Use and installation of composite components.
.2 Lifting, cranage and jacking operations, where entire trusses or
truss spans are being lifted or moved (this includes the truss
installation or removal procedure).
.3 Use of the Temporary Support System (TSS) taking into
account the particular construction requirements or loadings
(e.g. cranage, or scaffold supported from span).
.4 Temporary bracing or stiffening.
.5 Dismantling of timber truss components, including local
support arrangements for the partially-dismantled truss.
.6 Camber adjustment.
2.1.3 Update Your PROJECT QUALITY PLAN whenever amendments are Updating PQP
necessary due to changed project requirements or circumstances and
resubmit the amended section(s) of the PQP to the Principal.

2.2 CONSTRUCTION PROGRAM


2.2.1 Provide a CONSTRUCTION PROGRAM to address all the requirements Provision of a
and constraints imposed by the Specification, the physical conditions CONSTRUCTION
at the site and Your proposed work methods. PROGRAM
Make adequate allowance for additional deterioration that is likely to
be found during the work.

2.2.2 The CONSTRUCTION PROGRAM must show the sequence / timing of: Details
.1 Procurement of materials including air-drying of timber.
.2 Work on the different trusses.
.3 The proposed activities on each truss, itemised by primary
structural components.

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M757 Timber Truss Repairs – Construction

2.2.3 The CONSTRUCTION PROGRAM must be in the format of an event Format


oriented, critical path network, drawn to a weekly time scale (e.g.
Gantt Chart) and must:
.1 Provide sufficient details to allow the Principal to identify the
sequence and timing of, and the inter-relationships between,
the planned events and activities for the Work.
.2 Show the critical path.
.3 Cross-reference the DRAWINGS and MATERIALS LIST.
.4 Show all proposed replacements of primary structural
components, using the appropriate component codes.
.5 Show any resources, financial, engineering or other logic on
which the CONSTRUCTION PROGRAM specifically relies.
2.2.4 Within two weeks of a change to the scope or timing of the work, Updated
submit to the Principal an updated CONSTRUCTION PROGRAM. CONSTRUCTION
PROGRAM
The updated CONSTRUCTION PROGRAM must include:
.1 The original and revised sequence and timing shown on the
time based chart.
.2 The "as-built" truss repairs shown on annotated WORK-AS-
EXECUTED DRAWINGS (refer Clause 5.2).
.3 Reasons for any deviation from the previously submitted
CONSTRUCTION PROGRAM.

2.3 OTHER PLANS


2.3.1 Provide Your Project WHS Management Plan according to Managing
TfNSW G22. potentially
hazardous
Lead coatings, arsenic and other potentially hazardous materials may materials
be present at or in the bridge or in recycled timber. The Principal will
advise You of any toxic or hazardous chemicals known to be present
in or adjacent to the bridge (as nominated in Annexure A.2).

Incorporate appropriate standards (e.g. from Worksafe Australia or


Workcover) and relevant requirements in TfNSW B223 in Your
Project WHS Management Plan.

2.3.2 Provide a TRAFFIC MANAGEMENT PLAN (which includes a TRAFFIC TRAFFIC


CONTROL PLAN) that is co-ordinated with the bridgeworks according MANAGEMENT
to TfNSW G10. Where a TSS is provided, this will be the same TMP PLAN
provided under TfNSW M752.

2.3.3 Where You are provided with the REVIEW OF ENVIRONMENTAL CEMP
FACTORS (REF), STATEMENT OF HERITAGE IMPACT (SOHI) or
CONSERVATION MANAGEMENT PLAN (CMP) for the bridge,
incorporate details into the CONTRACTOR’S ENVIRONMENTAL
MANAGEMENT PLAN (CEMP) according to TfNSW G36.

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Timber Truss Repairs - Construction M757


2.3.4 As part of the CEMP, the WASTE MANAGEMENT PLAN must include: WASTE
MANAGEMENT
.1 Assessing the contamination risk and suitability of timber PLAN
components removed from the bridge for recycling, either at
the same bridge or other bridges or at an approved timber
recycler, according to Clause 3.2.4.
.2 Delivering timber assessed as suitable for recycling to the
Principal or to an approved timber recycler.
.3 Salvaging all cast iron shoes that have been replaced and
delivering them to the Principal for heritage preservation.
.4 Intercepting and collecting any debris or residues that would
otherwise fall into the river during dismantling.
.5 Controlling the discharge of emissions during surface
preparation according to TfNSW M743.
.6 Controlling, storing and disposing of all other surplus material,
waste and residues in accordance with relevant environmental
requirements.
Timber suitable for recycling and components salvaged for heritage
preservation remain the property of the Principal.

2.4 DOCUMENTS
2.4.1 The PROJECT BRIEF provided in Annexure A.3 specifies the scope of PROJECT BRIEF
the proposed timber truss repair work to the bridge.

2.4.2 The Principal will supply the information identified in Annexure A.2 Information
to provide background and reference for the Work.

2.4.3 Do not assume the information supplied by the Principal is a correct Verify
representation of the existing bridge. information

You must assess the adequacy and accuracy of the information and
the Design Drawings supplied by the Principal, especially the
correctness of the locations of all existing components and features,
for feasibility of the proposed method of construction, prevention of
possible misfits or clashes with existing details, and availability of
the sizes of ancillary items to be procured. However, this does not
extend to structural design checks of the supplied DRAWINGS.

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M757 Timber Truss Repairs – Construction

3 RESOURCES

3.1 PERSONNEL
3.1.1 Manage the Work using a Project Engineer with the following Project Engineer
qualifications and experience:
.1 Is eligible for membership of the Institution of Engineers,
Australia.
.2 Has understanding and knowledge of structural design of
timber truss bridges and Temporary Support Systems (TSS).
.3 Has not less than 1 year of experience in the planning,
construction and site inspection of timber truss repairs.
3.1.2 Supervise the Work at the Bridge Site using a person with the Bridge Works
following experience: Supervisor
.1 Has not less than 5 years experience as Works Supervisor (i.e.
USS Grade 7 or equivalent), and
.2 Has not less than 10 years experience in the repair of timber
truss bridges, including the type of truss in the Work.
3.1.3 Surveyors must have qualifications according to TfNSW G71. You Surveyors
may propose Surveyors who do not meet this requirement but have
suitable experience.

3.1.4 Provide the following minimum number, skills and experience for Personnel at the
personnel at the Bridge Site: Bridge Site
.1 One team leader (with the delegated authority at the Bridge
Site) who has not less than 5 years experience in the repair of
timber truss bridges.
.2 One trade-qualified bridge and wharf carpenter or civil
construction carpenter with not less than 5 years experience in
the repair of timber truss bridges. This may be the team leader
referred to above.
.3 Another person with not less than 5 years experience in the
repair of timber truss bridges.
.4 One person holding a current NSW Workcover Basic Rigging
Certificate, present at all times during work on the truss span.
This may be any person referred to above.
.5 One person holding a current NSW Workcover Advanced
Scaffolding Certificate, present at all times during erection and
dismantling of scaffolding (including suspended scaffolds).
This may be any person referred to above.
3.1.5 Where required, inspect components using personnel accredited in Inspectors
the TfNSW Bridge Inspection Procedure who have not less than
5 years experience in the inspection of timber truss bridges.

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3.1.6 Alternative qualifications for personnel or changes to personnel must Alternatives or
be submitted to the Principal for approval. changes

3.1.7 Document Your personnel's names, qualifications experience and role PROJECT
in the PROJECT QUALITY PLAN. QUALITY PLAN

3.2 TIMBER COMPONENTS


3.2.1 General

3.2.1.1 Clause 3.2 sets out the requirements for timber components before Scope of clause
trim cutting, finishing or fabrication.

3.2.1.2 Unless otherwise specified, all timber must be supplied to meet the Timber supply
requirements of 'Truss Span Superstructure Components' according to requirements
TfNSW 2380.

3.2.1.3 Order and supply timber of the dimensions specified in Clause 3.2.2. Supplied
dimensions

3.2.1.4 Supply timber components for the Work from either: Source
 New timber according to Clause 3.2.3, or
 Recycled timber according to Clause 3.2.4, or
 Composite components according to Clause 3.2.5.
3.2.1.5 Associated timber components (e.g. spacer blocks, permanent steel Associated timber
packers and wedges, timber shear keys in Old PWD and McDonald components
truss bottom chords) must meet the same requirements as the primary
components that are in contact with the associated component. In
addition, they must be fully seasoned and free of defects.

Timber for refuge platforms must meet the requirements of 'Deck and
Railing Components' according to TfNSW 2380.

Temporary timber packers and wedges (e.g. supporting TSS) must be


seasoned and meet the requirements of 'decking components'
according to TfNSW 2380.

3.2.1.6 Timber components must not be joined by splices except where Splices
shown on the DRAWINGS (refer to Clause 4.6.5).

3.2.1.7 To minimise misalignments, the timber for new paired flitches should Matched
be cut from opposite sides of the same original log, bundled together components
and marked according to TfNSW 2380, wherever possible. If the
paired flitches cannot be supplied from the same original log, they
must be of the same species and of equivalent quality and
straightness.

3.2.1.8 A new flitch that is to be paired with or overlaps an existing flitch Matching existing
must be of equivalent quality and straightness. flitch

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3.2.1.9 Do not use preservative treated timber in timber truss repairs without Preservative
the approval of the Principal. treated timber

3.2.1.10 Store and air dry timber off-site according to Clause 3.2.6 until it is Storage and air
transferred to the Bridge Site. drying off-site

3.2.1.11 Manage timber following delivery to the Bridge Site and prior to Managing timber
being used in the Works according to Clause 4.3. at the Bridge Site

3.2.1.12 Certify that timber complies with the Specification and provide Certification of
relevant inspection certificates. timber

3.2.2 Supplied size and length

3.2.2.1 The dimensions of all timber components shown on the DRAWINGS Design dimensions
are the design length and cross-section (i.e. width and thickness) and
are itemised in the MATERIALS LIST.

3.2.2.2 The length of timber ordered and supplied must be 200 mm longer Length of timber
than the design length to allow for cutting to the required size and for
the removal of end seals and of any end damage.

3.2.2.3 To allow for shrinkage in new timber, the cross sectional dimensions Cross sectional
(width and depth) ordered and supplied must be 5% (i.e. 1 mm per dimensions of new
20 mm) greater than the design cross-sectional dimensions. timber

These dimensions are to apply on the date of delivery from the


supplier to the delivery location, unless it can be verified that the
dimensions were met on the date of the timber inspection according
to TfNSW 2380 (the date of inspection for each piece must be
verified).

The cutting tolerance -0/+6 mm in TfNSW 2380 Clause 4.1 applies


over and above the 5% allowance for shrinkage.

3.2.2.4 For recycled timber, supply timber with the design cross sectional Cross sectional
dimensions, provided that the timber is exempted from 12 months air dimensions of
drying according to Clause 3.2.6. A cutting tolerance -0/+6 mm recycled timber
applies to these dimensions.

3.2.3 New Timber

3.2.3.1 Deliver new timber to a secure storage shed that meets the Delivery location
requirements of Clause 3.2.6. Do not deliver new timber directly to
the Bridge Site unless approved by the Principal.

3.2.3.2 Within 2 BUSINESS DAYS of delivery from the supplier, check all Conformity
new timber for conformity with the Specification and record the
details in inventory (showing the timber as reserved for the Work).
Itemise each timber component and maintain them as items in
inventory until the component is fabricated into the Work.

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3.2.3.3 After delivery, manage new timber according to the requirements of Management after
Clause 3.2.6. delivery

3.2.4 Recycled Timber

3.2.4.1 Recycled timber must be sound, assessed to have a BIS condition Assessing
rating of 1 or 2 and have an estimated service life of at least 15 years, suitability
based on methods such as:
.1 Visual inspection.
.2 Sounding.
.3 Non-destructive testing.
.4 Timber pathology of one sample from each end of the
component to detect fungal decay.
Do not test bore recycled timber unless approved by the Principal.

3.2.4.2 Recycled timber must only be used with the approval of the Principal Approval and
and You must clearly mark on recycled timber the following: marking
.1 Name of the original bridge.
.2 Original bridge element.
.3 A code that identifies the suitability of the timber for re-use.
3.2.4.3 Where the timber has an existing paint coating that is potentially Coated timber
hazardous or is in unsuitable condition, prepare the surface according
to TfNSW M743 prior to use.

3.2.4.4 Recycled timber for re-use in the Work must be recorded in inventory Management
(shown as reserved for the Work), and managed according to the prior to use
requirements of Clause 3.2.6.

3.2.5 Composite Components

3.2.5.1 You may propose the use of a composite component designed on the Permitted use of
basis of joined timber sections if: composite
component
.1 Conforming whole section timber of the required size and
length cannot be supplied within 6 months of placing the order.
.2 The overall design cross sectional area exceeds 40,000 mm2.
3.2.5.2 For Allan truss bottom chords, do not replace single flitches with Allan truss bottom
composite components. In this case, replace the entire bottom chord chords
with composite components that incorporate a continuous steel
section. Verify the load carrying capacity of the truss span.

3.2.5.3 Each composite component must have overall dimensions and Replicating
appearance similar to the original component. original

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3.2.5.4 Timber for composite components must comply with Clause 3.2 for Timber and metal
the original component. In addition, it must be free of heart. materials

Metal components, steelwork and steel fasteners for composite


components must comply with Clause 3.3.

3.2.5.5 The composite component must meet heritage requirements and be Heritage
compatible with the CMP or SOHI, where available.

3.2.5.6 Design composite components according to TfNSW M752 to meet Design


the following requirements: requirements
.1 Of equal or greater strength than the original component and
structurally compatible with the original component.
.2 Compatible with other components in terms of fit, shrinkage,
connectivity and long-term performance.
.3 Durable (e.g. orientation of heart side of timber, drainage).
.4 Not more than 20% heavier than the original component,
except in the case of an Allan truss bottom chord.
.5 Joints to be formed of stainless steel shear connectors,
lubricated with approved mineral-based grease.
.6 Protective treatment according to TfNSW M743 (e.g. bolt
holes and contact surfaces sealed against moisture ingress).
.7 Not complicated to install or replace.
.8 Must facilitate future maintenance and tightening.
3.2.5.7 Verify the load carrying capacity of the truss span where the dead Increased dead
load of the truss span is increased by more than 5%. load

Process Held: Use of composite components. HOLD POINT

Submission: Submit documentation including:


.1 Design of the composite component.
.2 Justification for the composite component, which includes
demonstrating the efforts made to supply the timber and a
whole-of-life cost comparison with the original.
.3 Proof that the component meets heritage requirements.

3.2.6 Management of timber off-site

3.2.6.1 Manage timber at all times (i.e. prime coat, handle, transport, stack, Management of
store and dry) to minimise contamination, damage, deterioration, timber
exposure to termites and wastage of the timber.

Manage the timber as “high value” product according to the


'Australian Hardwood Drying Best Practice Manual'.

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3.2.6.2 Store and air dry timber in a secure storage shed that: Storage and air
drying of timber
.1 Provides shelter against rain and direct sunlight (or heat).
.2 Is well ventilated.
.3 Has sufficient size and capacity for the timber.
.4 Has a level, compacted and well drained floor.
3.2.6.3 Stack new timber in the storage shed within 4 weeks of delivery. Stacking timber in
shed within
Use temporary covers to protect the timber against rain until the 4 weeks
primer coat has been applied and timber stacked in the storage shed.
Temporary covers must be waterproof and secured against the wind.
Where dark-coloured plastic sheeting is used, provide an air gap of at
least 50 mm under the plastic sheeting.

3.2.6.4 To control the rate of air drying, prime coat all uncoated surfaces of Prime coating
new timber according to TfNSW M743, using the primer coat for
Coating System TC1 (preferred) or TC2. Do not prime or disturb the
end seals.

Apply the primer coat:


 Within 1 week of delivery (or 4 weeks if temporarily stored in a
storage shed), or
 For wet timber, within 1 week of the timber surfaces drying out.
After the primer coat has cured, retie the timber into bundles, with
additional strapping as required to control bowing.

3.2.6.5 Ensure that timber identification marks are not removed or defaced Identification
until just before the timber is used in the Work. marks

3.2.6.6 Stack all timber in the storage shed after prime coating of new timber Stacking
and comply with the following:
.1 Implement the minimum requirements of TfNSW 2380
Clause 8.
.2 Suitably restrain timber components alongside timber of
similar dimensions, where feasible.
.3 Adapt the best practices for long term stacking according to
“Australian Hardwood Drying Best Practice Manual”.
.4 Store recycled timber separately from new timber.
.5 Take measures to address risk of termite attack (e.g. infested
timber, growth).
3.2.6.7 All new timber must be air dried for at least 12 months from the date Air drying of new
of delivery in the storage shed, except for cross girders or stringers. timber in shed

Kiln drying is not permitted.

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3.2.6.8 New timber for cross girders or stringers is exempt from the Exemptions from
12 months air drying requirement. 12 months air
drying
Recycled timber is deemed to have achieved 12 months of air drying requirement
and does not require a primer coat. If its age cannot be ascertained,
apply the primer coat and air dry as for new timber.

3.2.6.9 Transfer timber from the storage shed to the Bridge Site just before it Transfer of timber
is intended to be used at the Bridge Site. to Bridge Site

3.3 METAL COMPONENTS, STEELWORK AND FASTENERS


3.3.1 General

3.3.1.1 Clause 3.3 sets out the requirements for metal components, steelwork Scope of clause
and fasteners for the Work either by:
 Fabrication of new steelwork and fasteners according to
Clause 3.3.2; or
 Re-use of existing metal components from the existing timber
truss according to Clause 3.3.3
3.3.2 New Steelwork and fasteners

3.3.2.1 Supply new steelwork and fasteners conforming to the materials Materials
requirements in Table 1, unless otherwise specified in the requirements
DRAWINGS.

3.3.2.2 New steelwork is shown on the DRAWINGS and is itemised in the MATERIALS LIST
MATERIALS LIST.

3.3.2.3 New steelwork components must closely replicate the shape, Replicating
dimensions and finish of the original metal components to be original
replaced, as shown on the Original Drawings, unless:
.1 A different drawing, design or dimension is provided by the
Principal.
.2 Otherwise specified on the DRAWINGS.
.3 Otherwise specified in Annexure H.3.
3.3.2.4 Fabricate major new steelwork (refer Table 1 Item A) in accordance Fabrication of
with TfNSW B201 and the Design Drawings. major steelwork

3.3.2.5 Fabricate all other new minor steelwork items in accordance with Fabrication of
TfNSW B201 and the Design Drawings. minor steelwork

3.3.2.6 Where necessary, straighten steel and correct distortion according to Correcting
Clause 4.8.2: distortion
.1 Prior to its fabrication
.2 For distortion caused during fabrication (e.g. welding)
.3 For distortion due to hot dip galvanising (after fabrication).

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3.3.2.7 Carry out shop assembly to check the fabrication procedures, the fit Shop assembly
of components, and the suitability of templates used in fabrication.

Process Held: Fabrication of new steel components. HOLD POINT

Submission: Submit documentation including:


.1 Evidence that steel materials used for the new components
conform to the Specification.
.2 Shop Drawings for fabricated components.
.3 Steel fabrication procedures.

Table 1 —Requirements for New Steelwork and Fasteners

Component Requirement

A. Plate sections and Major Steelwork


 Major steelwork  Hot rolled structural steel plate Grade 300 to AS/NZS 3678.
(e.g. plates for
 Steelwork welded together using full penetration welds, category SP welds to AS/NZS 1554.1.
bottom chord
strengthening, - Stress relieving heat treatment after welding.
steel bottom
 In lieu of rivets, new plates joined together by:
chords)
 Extensive - High strength steel bolts property class 8.8 to AS/NZS 1252/ AS 1110.1
sections of - High strength steel nuts property class 8 to AS/NZS 1252/ AS 1112.1 or AS 1112.2
original
steelwork, - Bolting category 8.8/TF to AS 5100.6
previously
riveted

 Bearing plate for  Hot rolled structural steel plate Grade 300 to AS/NZS 3678
cross girder
 Welded together using full penetration welds, category SP welds
(De Burgh)
- Stress relieving heat treatment after welding.
 Cover plate for
cross girder  Controlled heat bending at bends.
(Dare)
 Splice plates  Hot rolled structural steel plate Grade 300 to AS/NZS 3678.
 Other flat plates  For tension splices, shear keys welded to plate using full penetration welds; category SP
welds.
B. Shoes and Anchor Forgings at Panel Points
 Shoes Preferred Method
 Anchor block  Cast from ductile cast iron Grade 400-18 LT to AS 1831:
shoes
- Free from pouring faults, sponginess, cracks, blowholes and other defects that may affect its
(De Burgh)
strength and serviceability.
Alternative Method
 Fabricated hot rolled structural steel plate Grade 300 to AS/NZS 3678.
 Welded together using full penetration welds, category SP welds to AS/NZS 1554.1.
- Stress relieving heat treatment after welding.

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Component Requirement

 Bottom chord  Steel grade and type, chemical composition, heat treatment and required mechanical
forged pins properties as specified by the Principal.
(De Burgh)
 Machined to shape.
C. Tension Rod Assemblies
 Tension rods  Hot rolled structural steel round bar Grade 300 to AS/NZS 3679.1.
 Welding not permitted.
 Rolled screw threads according to AS 1275 * at each end:
- The thread diameter and pitch to be closest metric thread equivalent to the original
Whitworth thread.
- The thread lengths the same as the original design.
- Cut threads not permitted. * NOTE: Adopt the cut thread screw forms in AS 1275 as
necessary to suit rolled thread form.
 De Burgh tension rods: Bottom pin end forged and machined to provide female connection for
the pin.
 Tension rod nuts  Large non-standard size ISO metric hexagon nuts and locknuts Product Grade C to AS 1112.3
and locknuts (general characteristics)
 Notwithstanding the requirements of AS 1112.3:
- Hot rolled structural steel to be Grade 300 to AS/NZS 3679.1.
- Overall height and size to replicate Original Drawings.
 Screw thread to be rolled form according to AS 1275 * (see Note).
 Tension rod  Large non-standard plain washers Product Grade C to AS 1237.1.
washers
 Overall height and size to replicate Original Drawings.
 Washer plates  Hot rolled steel to minimum yield strength of 250 MPa to AS 1442.
 Cut, forged or machined to shape from a single piece (welding not permitted).
 Rounded edges (sharp unfilleted angles or corners not permitted).
D. Braces
 Sway braces  Hot rolled structural steel plate Grade 300 to AS/NZS 3678.
 Alternatively, fabricated from cut-down hot rolled structural steel universal beam sections
Grade 300 to AS/NZS 3679.1.
 Welded together from plates or sections using full penetration welds; category SP welds.
 Controlled heat bending at bends.
 Wind bracing  Hot rolled structural steel round bar Grade 300 to AS/NZS 3679.1.
(under deck)
 Attachment ends and turnbuckles by forging.
 Bottom chord attachment end forged to provide connection for attachment.
 No welding permitted.
 Cut threads on braces and turnbuckles to AS 1275, using closest metric thread equivalent to
existing Whitworth thread.

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Component Requirement

E. Fasteners and Packers


 Hot dip  ISO metric hexagon bolts and screws Product Grade C Property Class 4.6 to AS 1111 (except
galvanised Grade 8.8 at tension splices)
fasteners (i.e.
 ISO metric hexagon nuts Product Grade C Property Class 5 to AS 1112
bolts, nuts,
screws and  Plain washers Product Grade C to AS 1237.1
washers)
 Stainless steel  Fasteners to meet ISO 3506 (referenced from AS 4673)
fasteners
 Made from wrought alloy stainless steel Grade 316 to AS 2837
 Stainless steel  Wrought alloy stainless steel Grade 316 to AS 2837
shear
connectors and
accessories
 Permanent steel  Hot rolled structural steel plate Grade 300 to AS/NZS 3678
wedges and
packers
 Shims  Stainless steel coil sheet minimum thickness 1 mm
 Rolled from wrought alloy stainless steel Grade 304 to AS 2837

3.3.2.8 The cross-section dimensions and profile of new steelwork and Conversion to
fasteners (i.e. diameter, thread length, nut and washer sizes) must be metric
the nearest metric equivalent of the original component shown on the
Original Drawings (rounded up). However, where a new component
must fit into an existing metal component, propose to the Principal
the cross-section dimensions and profile to achieve fit.

3.3.2.9 The overall length of new fasteners must be at least the same as the Length of new
original and the thread length must be adequate for tightening. fasteners

3.3.2.10 The following new steel components (as supplied) must be painted Protective
according to TfNSW M743 and must not be hot dip galvanised: treatment
requirements (new
.1 Major steelwork to replace extensive riveted sections of steelwork)
original steelwork.
.2 Tension rods and washer plates.
.3 Tension rod nuts, locknuts, washers and pins.
Protective treatment of other fasteners must conform to
TfNSW B201.

Hot dip galvanise all other new steelwork in accordance with


TfNSW B201.

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3.3.3 Re-use of existing metal components

3.3.3.1 Do not re-use original metal components salvaged from repairs of Re-use of salvaged
other trusses or other bridges, even if they appear to be suitable and metal components
in good condition. not permitted

3.3.3.2 Where an existing metal component is not to be replaced as part of Re-use of existing
the Work, re-use the component at the same location within the truss, metal components
provided that the component:
.1 Is in a sound condition (i.e. undamaged, free of defects).
.2 Meets the section loss limits in Annexures H.2 and H.3.
.3 Is in accordance with the Original Drawings or Drawings of
approved design modifications.
Appropriately restore such components according to TfNSW M743.

3.3.3.3 Where the component has limited damage or defects (e.g. bent Components with
plates), but You consider it repairable, notify the Principal. limited damage or
defects
For extensive riveted sections of steelwork (e.g. steel bottom chords),
notify all damage or defects to the Principal.

Process Held: Repair of an existing metal component. HOLD POINT

Submission: Submit proposal for repair of the existing component


that includes:
.1 Details of the damage or defect to be repaired.
.2 Condition and the section loss of the component.
.3 Repair procedure according to Clause 4.8.2.

3.3.3.4 The following existing metal components must not be hot dip Protective
galvanised: treatment
requirements
.1 Tension rods and their accessories and washer plates, which (re-used
must be painted in accordance with TfNSW M743. steelwork)
.2 Existing extensive riveted sections of steelwork (e.g. steel
bottom chords), which must be painted in-situ in accordance
with TfNSW M743.
.3 Other metal components that are not being dismantled.
All other dismantled metal components must be hot dip galvanised
according to TfNSW B201 after repair and before reinstallation.

3.4 OTHER MATERIALS


3.4.1 Supply other materials according to the materials requirements in Supply details
Table 2, unless otherwise specified on the DRAWINGS.

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3.4.2 Supply and use materials according to the manufacturer's Materials
requirements unless otherwise specified. The material must not
exceed the manufacturer's recommended shelf life or pot life where
applicable.

Table 2 —Requirements for Other Materials

Component Requirement Specification

 Thin lead sheeting  Soft lead sheet to AS 1804 AS 1804


for enhanced
 5 kg/m2 mass sheet
bearing
 Mineral grease  A type that inhibits corrosion and is free of moisture or impurities n.a.
(e.g. Denso paste, nickel-chromium paste, petroleum jelly,
molybdenum).

4 EXECUTION

4.1 GENERAL
4.1.1 The Work must be based on the following: Basis for the
Work
.1 The PROJECT BRIEF specified in Annexure A.3.
.2 The DRAWINGS specified in Annexure A.1.
.3 The APPROVED LOADING REGIME as provided in
TfNSW M752.
.4 The NOMINATED REPAIR STANDARD in Clause 5.3.
4.1.2 Carpentry, finish and general workmanship must be consistent with Standard of
established bridge and wharf carpentry trade and industry best workmanship and
practice. guide reference

All work must be guided by the TfNSW Timber Bridge Manual


(TBM). Where there is an inconsistency, this Specification takes
precedence.

4.1.3 Carry out the work according to Your CONSTRUCTION PROGRAM in Follow PROGRAM
Clause 2.2.

4.1.4 The requirements for a Temporary Support System (TSS), including Temporary
design, construction, transfer of dead load from TSS to the truss and Support
vice versa, maintenance, dismantling, and provision of the INITIAL requirements
CAMBER, are set out in Clause 4.4.

4.1.5 The general requirements for truss repairs are set out in Clause 4.5. General
This includes requirements regarding additional deterioration found requirements for
during dismantling work. truss repairs

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4.1.6 Unless otherwise approved, after completion of the truss repairs Tightening and
(irrespective of the extent of repairs) or for remedial cambering: cambering entire
truss after repairs
.1 Adjust and tighten the entire truss according to Clause 4.10;
.2 Camber the truss to provide the APPROVED CAMBER according
to Clause 4.11.
Provision of the INITIAL CAMBER is set out in Clause 4.4.

4.1.7 Immediately stop work and consult Your Structural Engineer if any Stopping work
procedure produces abnormal or potentially unsafe results (e.g. an due to safety
unreasonable amount of tightening or force is required to transfer concerns
load, close gaps in the truss or achieve camber). Where necessary,
restore full TSS support to the truss.

Your certified structural procedures in the PROJECT QUALITY PLAN


must provide suitable points for stopping work in such situations.

4.1.8 Structural assessments, inspections and advice must be in accordance Structural


with TfNSW M752, and include: assessments,
inspections and
.1 Structural engineering during construction. advice
 Structural procedures which are incorporated into the
PROJECT QUALITY PLAN (refer Clause 2.1).
 Structural assessments, inspections and advice.
 Certification.
 Any structural design tasks associated with construction.
.2 Inspecting the bridge and maintaining its structural integrity.
.3 Other requirements nominated in this Specification.
4.1.9 Apply protective treatments (e.g. coatings, preservatives and Protective
flashing) to components according to TfNSW M743, co-ordinated treatments
with the truss repair sequence.

4.1.10 Provide safe access and working conditions for the proper execution Safe access and
of the Work according to TfNSW G22. working
conditions

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4.1.11 Stop traffic from using the bridge in order to carry out the Work Stoppage of traffic
safely during but not limited to the following circumstances: on bridge
.1 Taking survey measurements on the bridge (refer Clause 4.2).
.2 Where specified in TfNSW M752, carrying out activities such
as:
 Lifting and cranage operations.
 Transfer of dead load to and from the TSS.
 Relocating Bailey assemblies along or across the bridge
deck.
.3 Actual tightening or loosening of tension rods or TSS hanger
supports for camber adjustment or truss lifting or lowering
(refer Clause 4.11).
.4 As specified on the DRAWINGS.
4.1.12 Surplus or waste material for recycling or disposal must be managed Surplus or waste
according to the CEMP in accordance with TfNSW G36 and material
Clause 2.3.

4.1.13 Progressively annotate any changes to the DRAWINGS on a separate WORK-AS-


set of WORK-AS-EXECUTED DRAWINGS according to Clause 5.2. EXECUTED
DRAWINGS

4.1.14 After completion of truss repairs and final cambering: WARRANTY


PERIOD and
.1 Inspect and maintain the work during the WARRANTY PERIOD Project
according to Clause 4.13. Completion
.2 Inspect and hand over the work at completion according to
Clause 4.14.
4.1.15 The sequence of sub-clauses in Clause 4 should not be taken to imply Use of clauses for
the time sequence of execution of the work. Combine requirements truss repairs
from different clauses as required to suit the work.

4.2 SURVEY AND MEASUREMENT


4.2.1 General

4.2.1.1 Prior to the commencement of Work, establish a setting out control to Setting out control
achieve conforming spatial layout, take measurements and minimise
cumulative errors.

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4.2.1.2 The permanent BRIDGE SURVEY CONTROL and MEASUREMENT BRIDGE SURVEY
SYSTEM will be provided by the Principal where indicated in CONTROL and
Annexure A.2 and must be re-established for use on the Work. MEASUREMENT
SYSTEM
Where an existing BRIDGE SURVEY CONTROL and MEASUREMENT
SYSTEM is not provided, establish a permanent BRIDGE SURVEY
CONTROL and MEASUREMENT SYSTEM by accurate bridge survey
according to Clause 4.2.2.

4.2.1.3 Apply the permanent BRIDGE SURVEY CONTROL to enable spatial Use of BRIDGE
referencing of the bridge components and features. SURVEY CONTROL

4.2.1.4 Apply the MEASUREMENT SYSTEM to control configuration and Use of


dimensions of the bridge components and features. MEASUREMENT
SYSTEM
The Truss Baseline (joining the ends of the bottom chord) is the
primary control for fabrication and erection of the truss.

Use the centre of the truss (i.e. at centres of top and bottom chords) as
the primary reference to set out, fabricate, set rack and adjust each
end of the truss (measuring from centre outwards, at equal spacings).

Ensure that the MEASUREMENT SYSTEM is consistent for work on the


bridge and off-bridge.

4.2.1.5 Carry out bridge surveys and measurements according to Survey


TfNSW G71. requirements and
tolerances
Replace the tolerances specified in TfNSW G71 Clause 5.5 with the
tolerances specified in Clause 5.1.

4.2.1.6 Unless otherwise specified, survey and measure features of the bridge Conditions for
only when the bridge: survey and
measurement
.1 Is not deflecting or moving (e.g. no traffic, no vibration, no
sidesway due to wind or flood loading).
.2 Has no superimposed dead load, except for access scaffolding.
.3 Is in a relatively dry condition.
4.2.1.7 Ensure that all survey and measurements allow for the effects of an Allowing for TSS
installed TSS or dismantled components (i.e. altered shape of truss). or dismantled
components

Process Witnessed: Re-establishing or setting out the BRIDGE WITNESS POINT


SURVEY CONTROL.

Submission Details: At least 3 BUSINESS DAYS notice of intention to


set out the BRIDGE SURVEY CONTROL.

4.2.1.8 Document the BRIDGE SURVEY CONTROL and MEASUREMENT Documentation of


SYSTEM, measurement procedures and procedures to verify system and
conformity of measurements in the PROJECT QUALITY PLAN. procedures

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4.2.2 Survey Control and Measurement System

4.2.2.1 Where a permanent BRIDGE SURVEY CONTROL is not available, BRIDGE SURVEY
establish a permanent BRIDGE SURVEY CONTROL by accurate bridge CONTROL
survey. Locate permanent Survey Marks to provide line of sight to
all main features on the bridge and away from areas that may be
disturbed during future work.

4.2.2.2 Calculate the coordinates of required survey control marks and take Using ground
survey measurements using ground distances. distances

4.2.2.3 Establish a MEASUREMENT SYSTEM that achieves conforming MEASUREMENT


measurements and minimises cumulative errors (e.g. measurements SYSTEM
within the truss must be consistent with the measured overall truss
dimensions). The MEASUREMENT SYSTEM must be suitable for
measurements taken by non-survey personnel and for setting out
future work. The MEASUREMENT SYSTEM must be referenced to the
BRIDGE SURVEY CONTROL and define the Truss Baseline, the
Common Reference Point and the Bridge Centreline.

4.2.2.4 Where there are variations in size within a component, take several Size variations
measurements to obtain the average dimensions.

4.2.2.5 Calculate the spatial position and centreline of multiple flitch Multiple flitch
components (e.g. truss chords, end principals or struts), making due components
allowance for variability in the size, spacing and level of flitches.

Use the derived spatial position and centreline when determining the
relevant dimensions.

4.2.3 Measurement of Camber

4.2.3.1 Measure (using survey equipment) and record the camber levels at Measuring
each panel point of the truss bottom chord on each of the following camber
occasions:
.1 The existing camber, prior to erection of the TSS or remedial
cambering without TSS.
.2 During provision of INITIAL CAMBER (refer Clause 4.4.3).
.3 As required during fabrication, adjustment or cambering of the
truss (refer Clauses 4.5, 4.6, 4.10 and 4.11).
.4 During final cambering, to assess conformity (refer Clause 5.4)
.5 As part of the PRESCRIBED INSPECTIONS during the
WARRANTY PERIOD (refer Clause 4.13).
Where a TSS has been erected, note whether the truss is fully, partly
or not supported by the TSS, and the type of TSS.

Note any localised irregularities in the existing camber. Check if


these coincide with observed lack of fit or loose tension rods.

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4.2.3.2 Measure camber referenced to the top surface of the outer flitch in the Reference for
bottom chord. Camber is measured at the panel points and at the measuring camber
midspan of the truss.

The Camber Baseline is a straight line between the camber


measurement points at each end of the truss (i.e. end panel points).

4.2.3.3 Calculate the existing camber at each panel point, which is the Calculating
difference between the existing level and the corresponding level on existing camber
the Camber Baseline.

4.3 MANAGEMENT OF MATERIALS AT THE BRIDGE SITE


4.3.1 Store materials at the Bridge Site in a secure works compound that: Secure works
compound
.1 Meets the same requirements as the fabrication site (refer
Clause 4.6.1); and
.2 Is of sufficient size for material storage and for easy access.

Process Held: Delivery of timber to Bridge Site. HOLD POINT

Submission: Submit the following documentation:


.1 Certification that timber conforms to the Specification.
.2 Verification that new timber has been air dried for at least
12 months.

4.3.2 After delivery to the Bridge Site, stack timber in the compound Storage of timber
according to TfNSW 2380 Clause 8. Do not store unfabricated truss at site
timber exposed to the weather conditions at site.

4.3.3 Store and handle metal components and fasteners as follows: Metal components
and fasteners
.1 Store items in dry conditions under cover and at least 150 mm
above the ground, to minimise corrosion or contamination risk.
.2 Handle and stack items so as to prevent distortion or damage to
the steelwork and its protective coating.
.3 Stack newly galvanized components with the items sufficiently
separated to allow air circulation around each item, so as to
prevent formation of "white rust".
4.3.4 Store paints, sealants, flashing and other protective treatment Storing protective
materials according to TfNSW M743. treatment supplies

4.3.5 Store other materials according to the manufacturer’s Storing other


recommendations, under conditions that do not lead to deterioration. materials

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4.4 TEMPORARY SUPPORT SYSTEM AND PROVISION OF INITIAL CAMBER
4.4.1 Provision of Temporary Support System (TSS) and Transfer of Dead Load

4.4.1.1 Always provide an appropriate TSS to safely and efficiently support TSS for safe and
the truss span: efficient support
.1 During all truss repairs that involve component dismantling or
replacement (including jacking blocks and butt blocks).
.2 During all fabrication, erection, in-situ repairs and truss
adjustment and tightening work on the bridge structure.
.3 For altering the existing truss camber, including truss lifting or
lowering, to provide the INITIAL CAMBER for truss repairs.
.4 For all other cambering, as provided in Clause 4.11.1.
The support conditions and geometry for timber truss repairs are set
out in Clause 4.5.1.

However, a TSS is not required for the replacement of some types of


cross girders or stringers (refer to Table 1 of TfNSW M752).

4.4.1.2 Where a TSS is required, provide the TSS and transfer the full dead Provision of TSS
load from the truss to the TSS while the truss is supported at the and transfer of
existing camber according to TfNSW M752. dead load to TSS

TfNSW M752 includes HOLD POINTS for the TSS that You must use Use of HOLD
in conjunction with the truss repairs. POINTS in
TfNSW M752

4.4.1.3 Relocate, dismantle or remove the TSS according to TfNSW M752 Relocation or
upon the completion of the truss repairs (refer 4.12). removal of TSS

4.4.2 Proposed Camber Adjustments for the INITIAL CAMBER

4.4.2.1 Calculate the following deflections of the repaired truss according to Calculating truss
TfNSW M752: deflections
.1 Deflection due to truss self weight only.
.2 Additional deflection due to the transfer of the full truss span
dead load from the TSS to the truss.
.3 Further deflection arising from other planned changes to the
truss span dead load after dead load transfer (e.g. repairs to
cross girders, deck or footway).
.4 The TOTAL DEAD LOAD DEFLECTION under maximum dead
load (i.e. the sum of the preceding 3 deflections).
.5 The live load deflection of the fully repaired truss, based on the
permanent traffic loading for the bridge.
4.4.2.2 The INITIAL CAMBER must be zero camber at each panel point. INITIAL CAMBER

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4.4.2.3 Calculate the following (as Your proposal for the cambering work): Calculating
proposed
.1 The required CAMBER CORRECTION at each panel point, to CAMBER
provide the INITIAL CAMBER (refer Table 3). CORRECTION and
.2 Where tension rod adjustments are proposed to provide the tension rod
INITIAL CAMBER, the tension rod shortenings or loosening adjustments
adjustments to be applied (based on the relevant Camber Table
in Annexure G.4). For the purpose of this calculation,
substitute the “Approved Camber” in the relevant Camber
Table with Your proposed CAMBER CORRECTION.

4.4.3 Provision of the INITIAL CAMBER

Process Held: Cambering of the truss, including truss lifting or HOLD POINT
lowering, to alter the existing camber of the truss so as to provide the
INITIAL CAMBER, prior to truss repairs or remedial cambering.

Submission: At least 5 BUSINESS DAYS prior to providing the


INITIAL CAMBER in each truss, submit the following information:
.1 Your proposed CAMBER CORRECTION at each panel point, to
provide the INITIAL CAMBER (refer Clause 4.4.2.3).
.2 Where tension rod adjustments are proposed, Your proposed
tension rod shortenings or loosening adjustments, applied to
provide the INITIAL CAMBER.
.3 The intended date/time for the cambering work.
.4 Cambering procedures to provide the INITIAL CAMBER (refer
Clauses 2.1, 4.1.7 and 4.11.1).
4.4.3.1 Provide the INITIAL CAMBER in the bottom chord of an existing truss Providing the
(prior to truss repairs or remedial cambering) by lifting or lowering INITIAL CAMBER
the truss camber, by one or both of the following methods:
.1 Using the TSS according to Clause 4.11.5 (for truss repairs of
all truss types and for all remedial cambering); or
.2 By tension rod tightening according to Clause 4.11.7 or tension
rod loosening according to Clause 4.11.6, after detaching the
bottom chord from the TSS-supported cross girders (for truss
repairs of Allan, De Burgh and Dare trusses only).
During this work, apply the general cambering requirements that are
relevant for providing the INITIAL CAMBER (refer Clause 4.11.1).
Note that lifting or lowering the truss will result in changes to height
of truss and non-conforming truss geometry.

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4.4.3.2 After completion of truss lifting or lowering: Ensuring full dead
load transfer and
.1 Check for full transfer of dead load to the TSS at the INITIAL fine adjustment of
CAMBER. INITIAL CAMBER
.2 Complete the full dead load transfer by further tension rod
loosening according to Clause 4.11.5, where necessary.
.3 Make further adjustments to ensure that the INITIAL CAMBER
conforms to Annexure H.1, by using the TSS hanger supports
according to Clause 4.11.5, as required.
.4 Correct localised camber irregularities to achieve a precise best
fit for the INITIAL CAMBER (refer Clause 4.11.4).

4.5 TRUSS REPAIR–GENERAL REQUIREMENTS


4.5.1 General

4.5.1.1 Clause 4.5 generally applies to all aspects of the truss repair work Application of
including fabrication, dismantling, repair of existing components, and clause
erection and fitting of components on the bridge.

Do not start repairs to any part of the truss until the relevant HOLD Using HOLD
POINTS in TfNSW M752 are released. POINTS in
TfNSW M752

Process Held: Commencement of truss repairs on each truss after HOLD POINT
transfer of dead load to TSS and provision of INITIAL CAMBER.

Submission Details: Submit the Bridge Works Supervisor’s


certification (based on a personal inspection) verifying that the full
transfer of dead load from the truss to the TSS has occurred
according to TfNSW M752 and the INITIAL CAMBER has been
achieved.

Release of Hold Point: The Principal will consider the submission


and may require corrective action on deficiencies prior to authorising
the release of the HOLD POINT.

4.5.1.2 Support the truss at the INITIAL CAMBER (refer Clause 4.4.1) Support
throughout all fabrication, erection and truss repair work, except as conditions for
necessary to remove or install components, as follows: truss repairs
.1 For work on the bridge, using the TSS (direct or indirect
support) according to Clause 4.4.
.2 For fabrication or repair work off-bridge, using fabrication
blocks according to Clause 4.6.2.
The truss geometry and component lengths (e.g. in DRAWINGS) must
allow for these conditions (i.e. truss unloaded and fully supported).

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4.5.1.3 Ensure stability of the truss (e.g. lateral stability) at all stages of dead Stability of truss
load transfer, dismantling, fabrication, erection and truss repair work
on the bridge structure. Temporary measures may be required.

Provide adequate temporary support to components and assemblies to


prevent overturning or collapse of any section of the truss.

4.5.1.4 Fabricate or repair trusses in accordance with the integrated truss Integrated truss
fabrication/repair sequence set out in ANNEXURE E, as follows: fabrication/repair
sequence
.1 Annexure E.2 for Allan, De Burgh and Dare trusses.
.2 Annexure E.3 for Old PWD and McDonald trusses.
4.5.1.5 The detailed requirements for truss geometry, fabricated components Detailed repair
and individual components are set out in ANNEXURE H. requirements

4.5.1.6 Inspect each component against the requirements in ANNEXURE H Reporting


as Work progresses and components are exposed, for the following deficiencies
deficiencies (generally known as ‘additional deterioration’):
.1 Deterioration in condition or defects that were not apparent
prior to the dismantling of the component, in particular on
surfaces that were previously concealed (i.e. where the
estimated service life is less than 15 years).
.2 Any deficiencies that were not previously noted.
Progressively inspect each repaired component for:
.1 Any dimensional mismatch that remains after the repair is
completed (e.g. gaps, mismatch in length or cross-section
between new and existing paired components, deviations from
dimensions shown on the DRAWINGS).
.2 Any apparent performance mismatch between new and
existing paired components that occurs after repair is
completed (e.g. unequal tightness or bearing, misalignment or
distortion due to unequal load sharing, significant difference in
material properties).
Immediately advise the Principal of such deficiencies.

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Process Held: Further work on components directly affected by a HOLD POINT
deficiency, including covering up the deficiency.

Submission Details: Within 1 BUSINESS DAY of identifying any


deficiency, submit a report with details and photographs of the
deficiency which must include:
.1 Any deviations from the DRAWINGS, Original Drawings or
Drawings of approved design modifications.
.2 Existing condition of the components and change in condition
when compared with the previous BIS Level 2 inspection.
.3 Test results, where testing is directed by the Principal.
Release of Hold Point: The Principal will consider the submission
and may require additional testing or corrective action on deficiencies
prior to authorising the release of the HOLD POINT.

4.5.1.7 Make due allowance for the differential shrinkage between new Allowance for
components and existing components. shrinkage

4.5.1.8 Salvage original metal components that are being replaced according Salvage of original
to the CEMP (refer Clause 2.3). metal components

4.5.1.9 Do not apply excessive force that may cause damage or distortion to No excessive force
components (e.g. hammering, tightening or jacking to achieve fit of
components).

4.5.1.10 Provide adequate support to components and assemblies during all Preventing
stages of truss repair, to prevent bending, distortion or damage. distortion or
Temporary support must be provided wherever necessary. damage

4.5.1.11 Locate any required temporary cross girders, props, lifting and Temporary load
jacking points on the chord within 800 mm of the nearest panel point bearing
and not bearing on any part of a chord splice.

4.5.1.12 Existing components that are out-of-position (e.g. bowed, warped) Aligning of
must be carefully pulled into the correct position over their full length components
(as shown on the DRAWINGS), without imposing excessive loads on
or destabilising other sections of the truss or bridge structure.

Where feasible, carry out aligning work during fabrication off-bridge.

4.5.1.13 Dismantle and inspect metal components when the attached timber Dismantling and
components are also dismantled as part of the Work. Restore and re- inspection of metal
use the metal components according to Clause 3.3.3. components

4.5.1.14 Loosen off sway braces during any repairs or cambering work (refer Loosening off
Clause 4.11.3.4) that changes the height of the truss, and then sway braces
re-attach them. Provide temporary lateral support to the trusses.

Loosen off and re-attach sway braces, one panel point at a time,
during replacement of each cross girder.

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4.5.2 Mandatory Replacement of Components

4.5.2.1 Replace all spacer blocks attached to primary structural timber Spacer blocks
components that are nominated for replacement.

4.5.2.2 Notwithstanding the requirements shown on the Original Drawings: Additional sway
braces and long
.1 Provide additional sway braces at intermediate panel points, cross girders
where absent; and
.2 Provide long cross girders to suit the new sway braces at (1).
4.5.2.3 Replace all fasteners that are loosened, disconnected or removed Fasteners
during the Work with new fasteners according to Clause 3.3.2, unless
otherwise specified.

4.5.2.4 Where a tension rod must be replaced, replace any parallel tension Tension rods
rods located at the same panel point where the cross sectional area of
the replacement tension rod is more than 5% larger in cross sectional
area than the parallel tension rod.

4.5.2.5 Replace any shoes, tension rods, washer plates, pins or splice plates Defective
that are confirmed as defective by the Principal. components

4.5.2.6 Where a wind brace must be replaced, replace the complete assembly Wind braces
between the points of attachment to the truss.

4.5.3 Greasing and protection of metal components

4.5.3.1 Clean and lubricate the threads of TSS hanger supports, tension rods, Cleaning and
wind braces, turnbuckles, and pins of De Burgh trusses with mineral lubrication of
grease as necessary prior to any adjustments (e.g. for cambering). threads

4.5.3.2 Clean and provide a permanent coat of mineral grease to the surfaces Greasing of metal
of metal components that will be inaccessible after erection as components
follows:
.1 Shafts of bolts prior to their insertion into bolt holes.
.2 All surfaces of bolts, nuts, screws and washers and splice
plates that will be in contact with timber.
.3 The section of each tension rod to be enclosed by the top and
bottom chord washer plates
.4 The section of each tension rod in the gap between the bottom
chord flitches (e.g. above the level of the bottom washer plate).
.5 Contact surfaces between washer plates, washers and nuts.
4.5.3.3 Paint all exposed ends of tension rods and other threaded metal Painting of
components in accordance with TfNSW M743, including a final exposed ends of
touch up paint of the exposed threaded sections, after final bolt threaded
tightening and cambering of the truss. Carry out the appropriate components after
surface preparation prior to painting. final tightening

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4.6 FABRICATION
4.6.1 General

4.6.1.1 Fabricate new or repaired components according to the DRAWINGS Scope


either as:
 Whole assemblies that can be lifted into place,
 Assemblies that are to be subsequently dismantled for re-
assembly on the bridge, or
 Individual components for on bridge fabrication.
4.6.1.2 Fabricate components under stable and controlled conditions to Stable and
ensure: controlled
conditions
.1 Consistent quality.
.2 A repeatable set-up for staged work.
.3 Accurate and consistent measurements for setting out and
conformity.
4.6.1.3 The fabrication site should be: Fabrication site
.1 A level, firm and well drained surface that is able to support
the equipment and components.
.2 Secure.
.3 Sited above the 20 year ARI flood level, if possible.
.4 Of sufficient size to provide good access for activities.
4.6.1.4 Pre-fabricate assemblies comprising single or double flitch members Extent of
(e.g. strut assemblies, chords) off-bridge according to Clause 4.6.2. fabrication off-
bridge
Fabricate components and assemblies off the bridge according to
Clause 4.6.2 unless otherwise shown in Your CONSTRUCTION
PROGRAM and approved by the Principal.

Where permitted, fabricate components on the bridge according to


Clause 4.6.3.

4.6.1.5 Fabricate timber components according to Clause 4.6.4. Fabricating


timber

4.6.1.6 Fabricate and erect connections according to Clause 4.6.5. Connections

Comply with the additional requirements for bolted, spliced and shoe
connections according to Clauses 4.6.6, 4.6.7 and 4.6.8.

4.6.1.7 Fabricate the truss symmetrically from the midspan of the truss, Symmetrical
except for location of chord splices that may not be symmetrical. fabrication

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4.6.2 Fabrication Off-Bridge

4.6.2.1 Establish a local measurement system consistent with the BRIDGE Local
SURVEY CONTROL and MEASUREMENT SYSTEM in Clause 4.2. measurement

4.6.2.2 Pre-fabricate assemblies into the largest practical assembly that Size of pre-
ensures the best fit and alignment of components when erected on the fabricated
bridge. Avoid incremental fabrication and erection of components. assemblies

Fabrication off-bridge may include re-incorporating existing sections


of the truss that remain (e.g. to make up a complete chord or truss), if
approved by the Principal.

4.6.2.3 Provide support for assemblies during fabrication (e.g. using Support
fabrication blocks) that must be: conditions for
fabrication of
.1 Located at least at each panel point. assemblies
.2 Adjustable for provision of accurate levels.
.3 Sufficiently strong, durable and stable .
4.6.2.4 Store prefabricated, painted truss assemblies at least 150 mm above Storage of
ground and provide adequate support to prevent excessive distortion prefabricated
of the prefabricated assembly, by either of the following methods: assemblies
 Placed horizontally and supported level at the panel points and
at additional intermediate locations as required, or
 Stood vertically and supported at all bottom chord panel points.
4.6.2.5 Once an assembly has been fabricated and fully tightened to ensure Limited
its conformity: dismantling after
final assembly
.1 Minimise the extent of break-down into sub-assemblies to
facilitate transport and erection on the bridge.
.2 Only one cycle of dismantling is permitted, to minimise
damage to splices.
4.6.3 Fabrication On-Bridge

4.6.3.1 Fabricate timber truss components or re-assemble prefabricated Fabrication work


components or assemblies on the bridge according to: on bridge
.1 The same requirements as Clause 4.6.2, except that allowance
must be made for the more difficult conditions of temporary
support by TSS and working at height on the bridge.
.2 The additional requirements for erection and fitting of
components on the bridge specified in Clause 4.9.

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4.6.4 Fabrication of Timber Components and Assemblies

4.6.4.1 Where possible, position timber of lesser quality (e.g. with minor Position of lesser
defects, checks or section loss) as follows: quality timber
.1 Within the truss at positions of least structural risk (e.g. away
from splices, where load is less).
.2 With the deficiency oriented to minimise exposure to rain and
direct sunlight (e.g. facing downwards).
4.6.4.2 Where a flitch forming part of a double flitch end principal or strut Comparable
has to be replaced, both flitches must be replaced with timber that has shrinkage in
comparable shrinkage performance (i.e. both flitches of new timber, double flitch
or both flitches of recycled timber).

4.6.4.3 Orient sawn timber components according to the general orientation Orientation of
of "heart side inwards then downwards" (i.e. with the heart side sawn timber
facing inwards and generally facing downwards) as follows: components
.1 For multiple flitch components, "inwards" is in relation to the
centreline of the multiple component.
.2 For matched components (refer to Clause 3.2.1), the flitches
must be consistent with the original log and not transposed
(use the original log cut orientation markings as a reference).
.3 For single flitch longitudinal or sloped components, "inwards"
is in relation to the Bridge Centreline.
.4 For single flitch transverse components, "inwards" is in
relation to the truss midspan.
Orient sawn sound boxed heart components with the bow upwards
(i.e. so that water sheds off).

4.6.4.4 At the time of truss fabrication, the cross section of flitches must Sizing of
meet the following requirements: components to
meet cross
.1 Square to within the tolerances specified in AS 2082. sectional
.2 For new or recycled timber flitches, within -5/+10 mm of the requirements
design cross section dimensions shown on the DRAWINGS.
.3 For existing timber flitches, within ±5% of the design cross
section dimensions.
Where required, dress oversize or out of square flitches over their full
length to meet these requirements.

4.6.4.5 Cut the timber component to the length specified on the DRAWINGS Cutting at ends
with the ends precisely cut square or to the specified angle of cut.

Do not alter the angle of cut based on measurements of the existing


truss unless approved by the Principal.

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4.6.4.6 For a timber component assembly, make the precise cut after the Precise cut for
component assembly is sprung and bolts tightened to snug tight fit. length
Allow for this cut when sizing components.

4.6.4.7 For each timber flitch, record the species and stress grade on the Traceability of
progress WORK-AS-EXECUTED DRAWINGS prior to cutting. timber

4.6.4.8 Provide connections according to Clause 4.6.5. Connections

4.6.4.9 Accurately cut all end contact surfaces between flitches and metal Providing tightly
fittings (e.g. splices, shoes) to provide a uniformly tight fit without fitted joints
packing or shimming. A trial fit of components and a fine trim cut
may be required.

4.6.4.10 Ensure that each adjacent flitch of an assembled component will Even load sharing
continue to take equal load after future shrinkage and bedding in. between adjacent
flitches

4.6.4.11 Round off exposed edges of main timber truss components to a radius Finishing
of 5 to 10 mm or arriss them neatly to an equivalent dimension.

Finish the faces and edges of existing components smoothly to meet


the requirements of TfNSW M743.

4.6.4.12 Apply protective treatments to the contact interfaces between timber Protective
components according to TfNSW M743 prior to final assembly of the treatment of
timber components. timber interfaces

4.6.5 Fabrication of Connections

4.6.5.1 Install all connections that join components at the locations and Connections
according to the configurations shown in the DRAWINGS (e.g. bolted according to the
connections, spliced connections and shoe connections). DRAWINGS

Advise the Principal where:


.1 Existing connections do not conform to the details shown in
the Original Drawings or are deficient.
.2 DRAWINGS do not show connections shown on the Original
Drawings.
4.6.5.2 Cut timber components at interfaces between timber and metal Precise cut of
fittings (e.g. keyways for shoes or chord splices) using very precise timber/metal
carpentry to ensure: interfaces
.1 A uniformly tight fit on all loaded faces of shear keys, shoe
recess edges, and bolt holes.
.2 A uniformly tight fit on all main bearing surfaces such as shoe
faces and splice plate faces.
.3 Bearing of components conforms to Annexure H.2.
Ensure correct alignment of metal fittings before cutting commences.

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4.6.5.3 Precisely align notches, recesses and keyways in adjacent and Aligning metal
opposite flitches that secure metal components (e.g. shoes, tension components on
splices). This applies whether the metal components straddle the opposite flitches
flitches or are in pairs divided over the opposite flitches.

4.6.5.4 Do not use filler materials (e.g. thin lead sheeting) in shear keyways. Filler materials

Such filler materials may only be used to achieve enhanced contact in


other connections once the REPAIR STANDARD in Annexure H.2 has
been achieved. Do not rely upon filler materials to achieve the
standard.

4.6.5.5 Do not use wedges, packers or shims to adjust for misfits in the Wedges and
lengths of timber struts, except where shown on the Original packers
Drawings (e.g. Old PWD and McDonald trusses).

Permanent steel wedges and packers that are critical for the structural
integrity and camber of the truss (e.g. Old PWD and McDonald
trusses) must be retained in position to prevent slippage by using
mechanical guides that meet heritage requirements.

During truss repairs or cambering, wedges and packers must be


regularly checked, adjusted and tightened to re-engage and tighten
the adjoining strut. If necessary, insert thicker wedges or packers.

Apply protective treatment to wedges and packers according to


TfNSW M743 to minimise corrosion (e.g. metal components in
contact).

4.6.5.6 Apply protective treatments to timber/metal contact interfaces Protective


according to TfNSW M743 and prior to placement of any filler treatment of
materials or final assembly of the metal components. timber/metal
interfaces

4.6.6 Bolted Connections – General Requirements

4.6.6.1 Use new steel fasteners supplied according to Clause 3.3.2. New fasteners

4.6.6.2 Position bolt holes in timber components according to the locations Position of bolt
shown on the Original Drawings, except that the distance between the holes
edges of the bolt hole and the timber must be not less than 40 mm.

4.6.6.3 Bolt holes through assemblies or components must be: Requirements for
bolt holes
.1 No more than 2 mm larger than the bolt diameter.
.2 Square to the faces of the component, with a tolerance of ± 1%
deviation in position (based on the hole length, measured
between opposite faces of the assembly or component).
.3 Parallel where multiple bolts secure the same feature.
.4 Of uniform diameter throughout.

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4.6.6.4 Arrange fasteners (i.e. washers, nuts, locknuts) according to the Installation of
DRAWINGS. fasteners

4.6.6.5 Achieve a uniformly snug tight fit for bolts according to Bolting Tightening of bolts
Category 4.6/S of AS 4100 (i.e. as achievable with an ordinary hand
spanner without excessive crushing of timber under the washer) by:
.1 Initially tightening bolts to a finger tight fit.
.2 Incrementally tightening the bolts with hand tools.
.3 For a group of bolts, checking and making final tightening
adjustments to ensure equal tightness of the bolts.
4.6.7 Splices in Timber Top and Bottom Chords

4.6.7.1 No splices are permitted in timber components other than in top or Splice locations
bottom chords at the locations shown in the Original Drawings (refer
Clause 4.6.5), unless otherwise approved by the Principal or the
alternative Allan truss tension splice layout in Clause 4.6.7.4 is used.

4.6.7.2 Re-use an existing splice plate where permitted in Clause 3.3.3. Splice plate
Otherwise replace it with a new splice plate (refer Clause 3.3.2).

4.6.7.3 In addition to the requirements in Clause 4.6.6, bolt holes in tension Additional
splices must: requirements for
bolt holes in
.1 Line up to within ± 1 mm in position on opposite faces of the tension splices
same flitch (including holes in the splice plates).
.2 Be accurately line-bored between the holes in the splice plates
on opposite faces of the flitch, using the plates as a template.
This overrides the squareness requirement in Clause 4.6.6.
.3 Not be reamed to facilitate bolt installation, except for small
diameter pilot holes or with the approval of the Principal.
4.6.7.4 For 27.43 m span Allan trusses (9 panels), in lieu of the bottom chord Alternative
tension splice layout shown on the Original Drawings, You may use tension splice
the alternative splice layout specified below, provided that: layout
(27.43 m span
.1 The entire bottom chord is replaced/repaired, not strengthened. Allan trusses)
.2 New timber flitches are used. Alternatively, the existing
flitches may be re-used, after trimming the ends of each piece
to remove all defective timber at existing splices and to shorten
the length. Each shortened flitch must be of sound timber.
The alternative splice locations are at the centres of the 3rd, 5th and 7th
panels (refer Figure 1), providing an additional splice at midspan and
a reduced maximum flitch length of 8.382 m.

 Splice
Locations

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Figure 1 – Alternative Tension Splice Layout (27.43 m span Allan truss)

4.6.7.5 For splice plates, cut the shear keyway slots in timber chords to Clearance at non-
provide 1 mm clearance between the timber and the metal shear key loaded faces of
at the non-loaded face of each shear key, to facilitate later removal of shear keys
the splice plate without damage to the timber. Splice plates must be
clamped into straight alignment before cutting commences.

4.6.7.6 Inspect all existing splices in timber chords that are not to be totally Inspection of
replaced according to Clause 4.5.1, at locations such as: existing splices
.1 Where neither of the joined flitches is to be replaced; or
.2 Where the flitch on one side is to be replaced, but the flitch on
the other side is to be retained.
4.6.7.7 Where You identify a deficiency in an existing splice, advise the Repair of existing
Principal and submit the following to the Principal: splice deficiencies
.1 Details of the deficiency according to Clause 4.5.1.
.2 Your proposal for repair of the splice (if feasible) or (only if
repair is not considered feasible) additional work to address the
deficiency.
Additional work may include replacing additional timber flitches or
the entire chord, converting an Allan truss bottom chord to the
alternative splice layout in Clause 4.6.7.4, or chord strengthening.

The Principal will determine the repair or additional work required.

4.6.8 Shoe Connections

4.6.8.1 At each panel point, install all shoe connections and tension rods Relative
according to the precise configuration shown on the DRAWINGS (i.e. configuration of
relative position and alignment of shoes, chord, struts and tension shoes and tension
rods), to prevent eccentric forces at panel points. Ensure that the rods at panel
design lines of force between these components intersect as shown on points
the Original Drawings.

4.6.8.2 Do not notch shoes into the timber chords. The timber chords must No notching of
be dressed to constant dimensions. shoe faces

4.6.8.3 For shoes, cut the shear keyway slots in timber chords with 1 mm Extra depth of
extra depth, to prevent transfer of vertical load through the shear key. shear keyway slots

4.7 DISMANTLING
4.7.1 Progressively dismantle components of each truss. Do not dismantle Dismantling of
more of the structure than identified in the PROJECT QUALITY PLAN. components

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4.7.2 Dismantled components and fittings to be retained in the structure (at Management of
the same location) must be: dismantled
components
.1 Marked and coded to facilitate re-assembly of the truss.
.2 Inventoried, handled and stored according to Clause 4.3.

4.8 REPAIR OF EXISTING COMPONENTS


4.8.1 Existing Timber Components

4.8.1.1 Clause 4.8.1 applies to the repair of existing timber components that Scope of
are sound and not nominated for replacement. component repairs

Such repair work involves rectifying minor defects or modifying the


components prior to fabrication, either on or off the bridge.

4.8.1.2 Ensure that the repair meets: Requirements


.1 The requirements for fabrication in Clause 4.6.
.2 The requirements for components in Annexure H.3.
4.8.1.3 Components must be appropriately restored according to Protective
TfNSW M743. treatment

Coat all uncoated surfaces of repaired timber components according


to TfNSW M743 using Coating System TC1 (preferred) or TC2.

4.8.1.4 Repair activities include but are not limited to the following: Repair activities
.1 Cleaning, removing obstructions and improving drainage in
difficult-to-access areas, upon dismantling of components.
.2 Adjusting the position or orientation of components (e.g. to
rectify truss geometry or eliminate gaps/looseness).
.3 Facing or sizing oversize components to correct dimensions.
.4 Trimming ends of components (e.g. to correct length).
.5 Reaming or plugging existing bolt holes.
.6 Improving bearing of components (e.g. providing square ends).
.7 Rectifying keyways and contact surfaces (e.g. splice plates).
.8 Rehabilitating existing splices.
.9 Improving poor detailing (e.g. stress raisers, misaligned bolts).
.10 Replacing existing attachments with an alternative design that
improves structural or durability performance (e.g. eliminating
drilled holes in bottom chords at cross girder connections).

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4.8.2 Existing Metal Components

Process Held: Repair of existing metal components. HOLD POINT

Submission: Submit Your proposal for repair of the existing


component, including:
.1 Details of the damage or condition of the defect (e.g. section
loss) to be repaired.
.2 Assumed material properties of the metal component.
.3 Repair procedures (e.g. tension rod repair, camber correction).

4.8.2.1 Repair existing metal components according to the following Requirements


requirements:
.1 Straightening and correction of distortion or camber must be
carried out by mechanical or thermal means.
.2 The process used must be appropriate for the material
properties, and must not damage the components or impair
their intended use.
.3 Where flame or heating methods are to be used:
 The temperature of the steel must not exceed 600°C. This
temperature must be measured and recorded.
 Artificial cooling must not be used until the temperature of
the steel has dropped below 300°C.
 The use of solid water jets to cool heated parts is not
permitted. Water fog nozzles may be used.
4.8.2.2 Welding or heat-based treatment must be appropriate for the metal Welding or heat-
properties (i.e. material, mechanical). based treatment

Do not weld or heat treat existing cast or wrought iron components


unless approved by the Principal.

Do not repair defective cast iron shoes, tension rods, washer plates or
anchor blocks and pins of De Burgh trusses. Replace such defective
components according to Clause 4.5.2.

4.8.2.3 Do not carry out heat-based treatment of existing tension rods closer Repair of tension
than 300 mm to the threaded section. rods

4.9 ERECTION AND FITTING OF COMPONENTS ON THE BRIDGE

Process Held: Erection of assemblies or components on the bridge. HOLD POINT

Submission Details: At least 5 BUSINESS DAYS prior to commencing


erection, submit a report verifying that each fabricated assembly or
component conforms with the Specification.

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M757 Timber Truss Repairs – Construction

4.9.1 Erect and fit truss components and assemblies on the bridge: Requirements
.1 Under consistent, controlled and repeatable conditions, as
specified in the DRAWINGS (e.g. erection under traffic); and
.2 With the truss fully supported according to Clause 4.5.1; and
.3 According to Your CONSTRUCTION PROGRAM (Clause 2.2).
4.9.2 Support and fit components or assemblies using a procedure and Capability for fine
equipment capable of providing fine adjustment to achieve an exact adjustment
fit to the position and alignment shown on the DRAWINGS.

4.9.3 Avoid erection and fitting of components during wet weather. Wet weather

4.9.4 Provide stable and effective support, and prevent excessive stresses, Lifting and
distortion or damage during all stages of lifting and transporting cranage of
components and assemblies. Use a sufficient number of lifting points, components and
appropriately located. Apply smooth, controlled and balanced lifting. assemblies

Use structurally-certified procedures (refer to Clause 2.1.2) for lifting


and cranage and for temporary bracing or stiffening.

4.9.5 Cross check key truss dimensions (e.g. overall length, height, pier Cross checking
position) prior to fully connecting up the repaired truss, as follows: existing truss
components
 Periodically, during prolonged erection; and
 After events that could significantly affect the truss geometry
(e.g. impact damage, flood, intensive use by heavy vehicles).

4.10 TRUSS ADJUSTMENT AND TIGHTENING


4.10.1 General

4.10.1.1 Clause 4.10 sets out the requirements for removing residual looseness Application
in a truss and achieving a structurally self-supporting truss, ready for
direct transfer of dead load to the truss and final cambering, either in:
.1 A repaired truss; or
.2 An existing truss, prior to remedial cambering (except for
remedial cambering without a TSS – refer Clause 4.11.3).

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4.10.1.2 Adjustment and tightening of each truss involves: Scope
.1 Assessing the truss geometry, after tightening all connections
to develop “just tight” force in all members and close all gaps.
.2 Adjustment and tightening within the truss, after loosening off
the truss (refer Clause 4.10.2), including:
 Carrying out work required to adjust the truss geometry.
 Final tightening of components throughout the truss.
 Adjustment of sway braces to ensure truss lateral stability.
.3 Adjustment and tightening of wind bracing to straighten the
upstream and downstream trusses (refer to Clause 4.10.3).
4.10.1.3 Support the truss at the INITIAL CAMBER (refer Clause 4.4.1) for all Support
truss adjustment / tightening work (except for wind bracing), either: conditions for
truss adjustment
.1 Using the TSS (direct or indirect support), e.g. where
components are loosened off for corrective work or repairs; or
.2 Where the truss carries its own self-weight only, with cross
girders detached from the bottom chord (provided that all other
corrective work or repairs on components has been completed).
4.10.1.4 Procedures to guide the truss adjustment and tightening work are Guide procedures
provided in ANNEXURE F.

4.10.1.5 Assess the geometric conformity of the truss (e.g. symmetry, gaps, Assessment of
even bearing, tightness), using the checklist in Annexure F.5. geometric
conformity
Identify any remaining misfits or geometric irregularities requiring
correction or adjustment.

4.10.1.6 Determine the adjustment work necessary to improve the truss Determination of
geometry. For remedial cambering, base this on striking the best required
practicable balance between ANNEXURE H and the existing truss. adjustment work

Do not use packers or shims except as provided in Clause 4.6.5.

4.10.1.7 Truss adjustments must not cause out of position loads or eccentric No out of position
forces (e.g. at panel points). At each panel point, preserve the design loads or eccentric
configuration of the chord / shoe(s) / tension rod(s) / strut(s), ensuring forces
that their lines of force intersect as shown on the Original Drawings.

4.10.2 Adjustment and tightening of each truss

4.10.2.1 Loosen off the truss for all adjustments to truss overall geometry, but Loosening off
only “just loose” to the extent necessary to allow the required truss for
adjustments without interference (e.g. at cross braces of Old PWD adjustments
and McDonald trusses). Refer Clause 4.11.8.7 and Annexure F.2.

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M757 Timber Truss Repairs – Construction

4.10.2.2 Prior to racking the truss, carry out the required adjustment work on Adjustments of
components of both the end panels and the central cross-braced end panels and
panel(s), and then check the conformity of these adjustments by test central cross-
tightening these panels. braced panel(s)

4.10.2.3 Set the symmetrical rack and overall geometry of the truss by Setting rack of
adjusting the end tension rods at the panel points at opposite ends of truss (in elevation)
the top chord (refer Annexure F.3). Tighten one end and loosen off
the opposite end, by equal increments, as necessary to ensure that the
centre of the top chord is plumb above the centre of the bottom chord.

4.10.2.4 Immediately after racking the truss, tighten the central cross-braced Tightening of
panel(s) to snug tight fit and lock in the symmetrical truss geometry central cross-
(refer Annexure F.3). These cross-braced panel(s) are the reference braced panel(s)
panels and provide stability to the truss during the adjustment work.

Do not further adjust or tighten the central cross-braced panel(s), so


as to avoid possible overstress due to their cross-braced design.

4.10.2.5 After locking in the truss geometry, carry out the required adjustment Adjustment and
work to the remaining non cross-braced panels, tightening each tightening of other
adjusted panel to snug tight fit (refer Annexure F.4). non cross-braced
panels
Start with the opposite pair of panels on each side of the cross-braced
panel(s) and work symmetrically towards each end of the truss.

NOTE: This order of work (i.e. from centre outwards) is the


reverse of all other truss adjustment and camber procedures.

4.10.2.6 At the completion of the required adjustment work, check for any Final adjustments
remaining misfits, differences in tightness of tension rods and other to ensure uniform
geometric irregularities in the truss. Carry out final adjustments and tightness of
corrective work. Ensure that all tension rods are uniformly snug tight. tension rods

4.10.2.7 Restore truss lateral stability by adjusting the sway braces (position, Adjustment of
tightness) to suit the adjusted truss geometry and be uniformly tight. sway braces

4.10.3 Adjustment and tightening of wind bracing

4.10.3.1 Where cross-braced wind bracing is present, align and straighten the Adjustment of
bottom chords to conforming straightness and squareness in plan (i.e. truss bays to be
entire truss span, each bay), by adjusting the wind braces in each bay. square and
straight
Start with the opposite pair of bays at each end of the span and work
symmetrically towards midspan. To adjust each bay, tighten one
cross-brace and loosen the other, in equal increments. After correct
alignment is achieved, ensure that all cross braces are snug tight.

4.10.3.2 Ensure that the protruding thread length at each end of each wind Protruding thread
brace remains approximately equal in accordance with Annexure H.3. lengths equalised

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4.11 CAMBERING
4.11.1 General

4.11.1.1 Clause 4.11 sets out the requirements for all cambering work on Scope of
timber trusses, including the following: cambering work
.1 Camber adjustments required prior to truss repairs:
 To lower the truss, to transfer dead load to TSS or provide
the INITIAL CAMBER.
 To lift the truss and provide the INITIAL CAMBER.
.2 Providing the APPROVED CAMBER in the truss as an integrated
part of the truss repairs.
.3 Camber adjustment at any time during truss repairs.
.4 Remedial cambering of an existing truss, where no component
replacements or other truss repairs are planned.
.5 Carrying out remedial work to achieve a final conforming
camber in the repaired truss, using additional cycles of
lowering, corrective adjustment, tightening and cambering.
4.11.1.2 Your procedures for dead load transfer and cambering must be Certified
certified according to TfNSW M752 (refer Clause 2.1). procedures, guide
procedures, and
Procedures to guide cambering work are provided in ANNEXURE G. proformas

Guide proformas for use in cyclic camber adjustment work are


provided in Annexures G.5 to G.7.

4.11.1.3 A flowchart to guide cambering work is provided in Figure 2. Flowchart

4.11.1.4 The terminology (i.e. Defined Terms and Definitions) used in Terminology
cambering work is separately grouped in Annexure M.5.

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4.11.1.5 All camber adjustment must be carried out under load, under one of Support
the following truss support conditions: conditions for
camber
.1 The truss is supported according to Clause 4.11.7 or 4.11.8 (for adjustment
truss lowering); or
.2 The truss is initially fully supported, either on a TSS or on
fabrication blocks, so as to achieve progressive transfer of dead
load to the truss during the adjustment (for final cambering); or
.3 The truss carries its own self-weight only (for final cambering
of Allan, De Burgh and Dare trusses – after truss repairs only);
or
.4 The truss carries the full truss span dead load (no TSS), for
remedial cambering of Allan, De Burgh and Dare trusses if:
 The CAMBER CORRECTION is less than 20 mm and the
existing camber is even and symmetrical; and
 Previous remedial cambering without TSS was limited.
4.11.1.6 Always provide a high degree of control for all cambering work by Cyclic and
using cyclic and incremental cambering procedures, which must be: incremental
cambering
.1 Well-controlled (e.g. sensitive equipment used, reversible) procedures
.2 Cyclic – using several cycles and a strict work order within
each cycle to smooth out the camber adjustments.
.3 Incremental – a slow rate of adjustment to control truss
interactions and avoid overloads.
.4 Balanced (i.e. working symmetrically within the truss, except
for final adjustment of camber).
4.11.1.7 Comply with the following constraints for each cambering procedure: Number of cycles
and camber
.1 A minimum of three symmetrical cycles to achieve as close to increments
the required CAMBER CORRECTION as possible.
.2 Where required, one final symmetrical adjustment cycle (part
or full) to achieve the best fit for the APPROVED CAMBER.
.3 For each cycle, change in measured camber (at midspan) not to
exceed 20 mm (TSS support) or 10 mm (remedial cambering).
4.11.1.8 For each cycle of cambering, unless otherwise specified: Order of work
within each cycle
.1 Commence each cycle with the opposite pair of panel points at
each end of the truss and progressively work inwards towards
the centre of the truss.
.2 Work on each opposite pair of panels at one time (i.e. complete
work on that pair before moving to the next inner pair).

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CAMBERIN G W O RK PRO CEDU RE

Inputs Activities O utcomes M757


Reference

Original Drawings Calculate truss deflections 4.4.2.1

Drawings showing
Design Camber Calculate Design Camber 4.11.2.1

Annexure A.1
Measure existing camber 4.2.3.1

Calculate camber adjustments Required camber corrections


4.4.2.3
(Initial Camber) (Initial Camber)

M752 Procedures Provide TSS 4.4.1

Approved PQP Lift or lower truss


Camber procedures 4.4.3 and 4.11.5
to Initial Camber

Carry out fabrication and 4.5.1


truss repairs *

Approved Camber 4.11.2.2 and


Propose Final Camber profile
(confirmed by Principal) 4.11.3.1

Calculate camber adjustments Required camber corrections


4.11.2.3
(Approved Camber)
Applied tension rod shortenings
(Allan, DeBurgh and Dare trusses)

Adjust and tighten truss * 4.10

Approved PQP Camber the truss 4.11.3 and


Camber procedures (as calculated) 4.11.7 or 4.11.8

Camber No
Irregularities?
4.11.4 Measure new camber & compare 4.11.3.13
with Approved Camber and 4.2.3
4.11.4.3 Carry out rectification work Yes
Calculate additional camber 4.11.7.8
corrections

4.11.4.3 Lower truss to Initial Camber Make additional camber 4.11.7.9 - 10


adjustments or 4.11.8.5

No W hen first conforms


Final Camber Run in under traffic
4.11.3.15
conforms? (24 hrs)
5.3
Yes, after running in

Remove TSS 4.12 N otes:


* while supported at the Initial Camber

Figure 2 –Flowchart for Cambering Work (includes providing the INITIAL CAMBER)

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M757 Timber Truss Repairs – Construction

4.11.2 Proposed Camber Adjustments for the Final Camber

4.11.2.1 Calculate the DESIGN CAMBER at each panel point, based on: DESIGN CAMBER
.1 The DESIGN CAMBER at midspan specified in Annexure A.1.
This must be based on the camber shown on the DRAWINGS or,
for Old PWD and McDonald trusses, 20 mm at midspan.
.2 A camber profile conforming to Annexure H.1 that suits the
DESIGN CAMBER at midspan and is consistent with the DESIGN
CAMBER of a comparable truss (i.e. same type and span).
4.11.2.2 Review the DESIGN CAMBER and propose Your Final Camber for Proposed Final
each repaired truss (or for remedial cambering, a “best fit” which Camber
may differ from the DESIGN CAMBER), after considering and
reconciling the following:
.1 The measured camber of the existing truss. Note the support
conditions for the existing camber.
.2 Localised irregularities in existing camber. Note any
permanent deformations in the existing bottom chord.
.3 Differences in camber of the upstream and downstream trusses.
.4 The need for a smoothed, symmetrical profile in direct
proportion to the APPROVED CAMBER shown in the Camber
Tables in Annexure G.3, allowing for localised irregularities.
4.11.2.3 Based on Your proposed Final Camber, calculate the following (as Proposed CAMBER
Your proposal for the cambering work): CORRECTION and
tension rod
.1 The required CAMBER CORRECTION at each panel point, to adjustments
provide the proposed Final Camber (refer Table 3).
.2 Where tension rod adjustments are proposed, the tension rod
adjustments to be applied, to provide the proposed Final
Camber (based on relevant Camber Table in Annexure G.3).
In the above calculations, substitute the “Approved Camber” in the
above Tables with Your proposed Final Camber.

4.11.2.4 Your proposed camber adjustments must allow for the following: Restrictions on
adjustments of
.1 During truss lifting or lowering using TSS, all cross girders cross-braced
within cross-braced panel(s) must be adjusted uniformly. panels
.2 Tension rod adjustments must not be applied within any cross-
braced panel(s), except for initially tightening of the panel.
4.11.2.5 Allow for differences from the symmetrical APPROVED CAMBER Allowing for
profile due to continuity effects in the vicinity of intermediate piers, differences in
where the bottom chords of adjoining truss spans are joined across camber profile at
the pier (e.g. fully continuous or spliced using cover blocks). joined bottom
chords over piers
Do not change the symmetrical applied camber adjustments to
compensate for these effects. These allowances for continuity effects
are “accepted non-conformances” for assessing camber conformity.

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Table 3 - Determination of required CAMBER CORRECTION

Type of Truss Support Condition for Formula for required CAMBER CORRECTION
Cambering

Initally fully supported Required CAMBER CORRECTION occurs in two stages:


on a TSS; or
 From existing camber to the INITIAL CAMBER.
Carrying self weight of
 From the INITIAL CAMBER to the APPROVED CAMBER.
truss only
The CAMBER CORRECTION for the second stage is the sum of the following:
Old PWD and
McDonald (INITIAL CAMBER is  The difference between the APPROVED CAMBER and the INITIAL CAMBER.
trusses measured under this
support condition,  The calculated TOTAL DEAD LOAD DEFLECTION of the truss.
Allan, De Burgh APPROVED CAMBER is  An additional correction for slack in truss connections upon initial
and Dare measured under full loading and bedding in of connections under service loads (estimated
trusses dead load) at 30 % of calculated TOTAL DEAD LOAD DEFLECTION).
Not supported by a TSS Required CAMBER CORRECTION occurs in one stage:
(remedial cambering)
 From existing camber to the APPROVED CAMBER.
This is the difference between existing camber and APPROVED CAMBER.
Note: The required CAMBER CORRECTIONS at each panel point must be smoothed to be in direct proportion to the
CAMBER CORRECTION shown in the Camber Tables in Annexure G.3, after allowing for localised camber
irregularities. The APPROVED CAMBER will be a smoothed profile.

4.11.3 General Requirements for Cambering

Process Held: All cambering of the truss, including truss lifting or HOLD POINT
lowering, except for provision of the INITIAL CAMBER.

Submission: At least 5 BUSINESS DAYS prior to commencing the


cambering work, submit the following information:
.1 Your proposed Final Camber at each panel point, together with
the supporting calculations and details (refer Clause 4.11.2.2).
.2 Your proposed CAMBER CORRECTION at each panel point
(refer Clause 4.11.2.3)
.3 Where tension rod adjustments are proposed, Your proposed
tension rod shortenings to be applied, to provide Your
proposed Final Camber.
.4 Cambering procedures (refer Clauses 2.1, 4.1.7 and 4.11.1).
.5 Following truss repairs, a report that verifies that the truss
repairs conform and that any geometric misfits or irregularities
identified during truss adjustment have been rectified.
.6 For remedial cambering, Your proposal for corrective work to
the truss to ensure effective cambering, where required (refer
to Clause 4.11.7.12).

4.11.3.1 Following release of the HOLD POINT, Your proposed Final Camber APPROVED
(as reviewed) becomes the APPROVED CAMBER. The required CAMBER
CAMBER CORRECTION must be based on the APPROVED CAMBER.

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Process Witnessed: Each stage of cambering work, on each truss. WITNESS POINT

Submission Details: At least 3 BUSINESS DAYS notice of intention to


carry out each stage of cambering work.

4.11.3.2 Maintain stability of the truss according to Clause 4.5.1 (e.g. so as to Maintaining
prevent racking or lean of the truss when the truss is loosened off). stability

4.11.3.3 Prior to cambering, loosen off the tension rod locknuts at each Loosening tension
tension rod to be adjusted. Re-tighten them after cambering. rod locknuts

4.11.3.4 c At panel points where cambering changes the truss height (e.g. truss Loosening and
lifting using TSS or tension rod adjustment [except for De Burgh adjusting sway
trusses]): braces
.1 Prior to cambering, loosen off each relevant sway brace from
the top chord (except at cross braced panels). Do not loosen
off more than one-half of the sway braces at any time.
.2 Check and adjust the plumb of the truss top chord.
.3 After cambering, adjust each sway brace to suit the adjusted
position of the truss top chord and re-attach the sway brace.
4.11.3.5 Use manual methods to ensure a slow rate of tension rod or TSS Method and
hanger support adjustment. The adjustment equipment must permit: equipment for
applying tension
.1 Precise control of the number of turns of the tension rod or rod adjustments
TSS hanger support nuts.
.2 Constant and accurate assessment of the torque resistance to
tightening each tension rod or TSS hanger support.
4.11.3.6 For multiple tension rods or TSS hanger supports at the panel point, Interactive
achieve the cyclic adjustment by interactive adjustment within the adjustment of
group, incrementally and systematically, to equalise the loadings. multiple
This will make adjustment easier and minimise differential loadings. components

4.11.3.7 For cambering using tension rod adjustment, You may use the TSS to Use of TSS to
temporarily ease load on the tension rods, to assist initial loosening of assist loosening of
the tension rod nuts. Otherwise, do not use the TSS when cambering. tension rod nuts

4.11.3.8 Do not carry out actual cambering adjustments when live loads are No adjustments
present on the truss span (refer Clause 4.1). under live loads

4.11.3.9 Just prior to each cycle of cambering, check all shoes, tension rods, Checking main
tension rod accessories and washer plates. Ensure that they conform load transfer
with Annexure H.3, are correctly aligned and are evenly bearing on components prior
the chord flitches. to cambering

Pay particular attention to the washer plates of Old PWD trusses at


the top of the end principals.

4.11.3.10 Ensure that the protruding thread length at each end of each tension Protruding thread
rod remains approximately equal in accordance with Annexure H.3. lengths equalised

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4.11.3.11 Where a TSS is used, maintain the TSS during cambering as follows: Monitoring and
restoring even
.1 Monitor the evenness of TSS load distribution (even tightness load distribution
of hanger supports and even, symmetrical sag camber in TSS). in TSS
.2 Progressively adjust TSS hanger supports for interactions in
load distribution between TSS and truss, observed as follows:
 Abnormal tightness in the other TSS hanger supports.
 Excessive torque required for tightening.
 Abnormal tightness of truss tension rods.
.3 After each cycle, adjust TSS hanger supports to restore
uniform tightness between:
 Multiple TSS hanger supports at the same panel point; and
 Each opposite pair of panel points.
4.11.3.12 After each cycle of cambering, correct losses in uniform tightness Restoring uniform
within the truss resulting from the changed truss shape until the truss truss tightness
is “equalised” at the changed camber, by carrying out the following:
.1 Adjust tension rods to restore uniform tightness between:
 Multiple tension rods at the same panel point; and
 Each opposite pair of panel points.
.2 Progressively tighten loose components and remove sources of
observed intermittent or partial looseness in the truss.
4.11.3.13 Monitor and record the following after each cycle of cambering: Monitoring and
recording each
.1 The applied tension rod or TSS hanger support adjustments cycle of cambering
(refer Clauses 4.11.7.7 or 4.11.5.13).
.2 Changes to the measured camber.
.3 Changes in the truss geometry (e.g. height of truss at each
panel point, bearing of component ends in shoes).
.4 Changes in tightness (i.e. torque resistance) of all tension rods
and truss components not actively being tightened. Repeatedly
check for any looseness or tightness interactions.
.5 Changes in tightness (i.e. torque resistance) of the TSS hanger
supports, where a TSS is providing support (full or partial).
4.11.3.14 After cambering each truss, the truss must conform to Clause 5.4. Conformity

4.11.3.15 Repeat the camber measurements after the cambered truss has carried Re-checking
normal traffic (this must include some heavy vehicles) for at least camber
24 hours but no more than 1 week. after use by traffic

Where the camber has changed by more than 5 mm at any panel


point, advise the Principal. Carry out further remedial cambering
where directed by the Principal.

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4.11.4 Cambering Irregularities

4.11.4.1 Immediately stop cambering and diagnose problems according to Stopping


Clause 4.11.4.2 if any of the following problems occur: cambering due to
problems
.1 Camber irregularities (refer Clause 4.11.4.5).
.2 Cambering produces abnormal or potentially unsafe results
(refer Clause 4.1.7).
.3 The cambering process is clearly defective (e.g. insufficient
camber, loss of camber, asymmetrical camber, new camber
irregularities develop during cambering).
.4 After applying the calculated tension rod shortenings, the
deviation from the APPROVED CAMBER exceeds 10 mm at any
panel point.
.5 Signs of problems in the truss response under load (e.g. signs
of looseness, distortions in truss geometry).
If necessary, immediately lower the truss back down to the (zero)
INITIAL CAMBER and transfer dead load back to the TSS.

4.11.4.2 Where cambering has been stopped due to any problem listed in Proposing
Clause 4.11.4.1: rectification work
and lowering truss
.1 Consult Your Structural Engineer to diagnose possible causes. to INITIAL
.2 Take measurements of existing camber and truss geometry (i.e. CAMBER
at position where cambering stopped).
.3 Develop Your proposal for rectification work to address the
problems (e.g. additional repairs, truss adjustments).

Process Held: Further camber adjustment of the truss, where any of HOLD POINT
the problems listed in Clause 4.11.4.1 occur during cambering.

Submission: At least 3 BUSINESS DAYS prior to commencing further


cambering or rectification work, submit the following information:
.1 Measurements of existing camber and truss geometry (refer
Clause 4.11.4.2).
.2 Calculations for the remaining and/or additional CAMBER
CORRECTION, based on the existing camber (where applicable).
.3 Report on the problems and Your diagnosis.
.4 Your proposal for rectification work (refer Clause 4.11.4.2).

4.11.4.3 Following release of the above HOLD POINT, proceed as follows: Rectification work
and further
.1 Lower the truss back down to the (zero) INITIAL CAMBER and cambering from
transfer dead load back to the TSS; INITIAL CAMBER
.2 Carry out any rectification work approved by the Principal
according to Clause 4.10 (supported at the INITIAL CAMBER);
.3 Then recommence cambering from the INITIAL CAMBER.

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4.11.4.4 Problems that the Principal considers not feasible to correct are Rectification not
“accepted non-conformances” for assessing camber conformity. feasible

4.11.4.5 Check for localised camber irregularities from a smooth, symmetrical Localised camber
camber profile. The truss must be fully supported and loosened off at irregularities
the INITIAL CAMBER, with even load distribution in the TSS (refer
Clause 4.11.3.11) to assist in the determination of such irregularities.

Assess irregularities for possible links with other truss deficiencies


(e.g. lack of fit, loose components). Determine if irregularities are
due to permanent deformation (e.g. in a steel bottom chord).

Diagnose the problems and propose the necessary rectification work


(refer Clause 4.11.4.2) and observe the HOLD POINT in Clause 4.11.4.
Do not use tension rod tightening to correct irregularities.

4.11.4.6 Permanent deformation of the bottom chord must be repaired, and Permanent
must not be corrected using camber adjustment. Allow for residual deformation of
permanent deformation when taking camber measurements. These bottom chord
are “accepted non-conformances” for assessing camber conformity.

4.11.5 Lifting or Lowering of Truss (Using the TSS)

4.11.5.1 Clause 4.11.7 applies for the lifting or lowering of a fully supported, Use of TSS hanger
loosened-off truss by incremental adjustment of the TSS hanger support
supports, in order to change the camber of the truss bottom chord to adjustments to lift
the required symmetrical camber (e.g. INITIAL CAMBER). or lower truss

4.11.5.2 Keep the truss fully supported by the TSS and in loosened-off Support and truss
condition throughout the truss lifting or lowering work. Ensure full conditions
dead load transfer to the TSS before lifting or lowering commences.

4.11.5.3 Achieve the required symmetrical camber in two stages as follows: Two stages
(symmetrical, then
.1 First stage: Several cycles of symmetrical TSS hanger support non-symmetrical)
adjustments, to achieve the best practical fit for the camber;
.2 Second stage: One or more cycles of local adjustment (non-
symmetrical), as necessary, to achieve the precise camber.
4.11.5.4 In the first stage (symmetrical cycles), the applied TSS hanger Applied TSS
support tightening or loosening adjustments at each panel point (per adjustments per
cycle) must be equal to (or a constant part of) the applied CAMBER symmetrical cycle
CORRECTION (per cycle) shown in the relevant Camber Table in (first stage)
Annexure G.4. This applied CAMBER CORRECTION (per cycle) must
not be exceeded.

4.11.5.5 In each symmetrical cycle, progressively adjust the TSS hanger Order of
supports, starting with the end hangers, according to Clause 4.11.1.8. adjustment
(first stage)

4.11.5.6 Repeat symmetrical cycles until the bottom chord has reached a best Completion of
practical fit for the required camber (averaged for irregularities). first stage

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4.11.5.7 In the second stage (local non-symmetrical adjustment), the total Applied TSS
applied TSS hanger support tightening or loosening adjustment at adjustments for
each panel point must be equal to the residual CAMBER CORRECTION local adjustment
to achieve the required bottom chord camber. (second stage)

4.11.5.8 Local adjustment is an iterative process, requiring several cycles, due Iterative local
to TSS and truss interactions. In each cycle, the difference in applied adjustment
TSS hanger support adjustments between adjacent panel points must
not exceed two turns of the hanger rod nut.

4.11.5.9 In each cycle of local adjustment, commence with the panel points Order of
that require the largest residual CAMBER CORRECTION and work adjustment
progressively through the adjacent panel points requiring adjustment. (second stage)

4.11.5.10 Reassess the residual CAMBER CORRECTIONS and required TSS Completion of
hanger support adjustments at the end of each cycle. second stage

Repeat local adjustment cycles until the bottom chord conforms


precisely to the required camber according to Annexure H.1.

4.11.5.11 At the end of each cycle, adjust the TSS hanger supports to provide Uniform tightness
uniform tightness according to Clause 4.11.3.11. of TSS hangers

4.11.5.12 If the observed TSS interactions are excessive (e.g. uneven load TSS interactions
distribution in TSS, excessive torque required to adjust TSS), reduce
the applied TSS adjustment per cycle (i.e. more cycles).

4.11.5.13 Monitor and record the applied TSS hanger support adjustments (per Monitoring and
cycle and cumulative), using a precise method (e.g. direct thread recording TSS
measurement, number of turns of each hanger rod nut). Note that the adjustments
TSS hanger rod diameter and thread pitch may vary along the TSS.

4.11.5.14 During lifting or lowering of Old PWD and McDonald trusses, Old PWD and
progressively loosen off the truss to allow the truss geometry to be McDonald trusses
changed without interference, according to Clause 4.11.8.7.

4.11.5.15 During truss lifting, progressively tighten truss tension rods to take Removal of slack
up any slacks due to the changed truss geometry, pending truss in tension rods
adjustments to restore conforming truss height and geometry. (truss lifting)

4.11.5.16 During truss lowering, progressively loosen off the truss tension rods Maintaining slack
to maintain continuous slack in each tension rod, so as to allow the in tension rods
truss geometry to be changed without interference (i.e. to avoid any (truss lowering)
tension rod seizing, that would cause excessive local stresses in truss
and uneven load TSS distribution).

For Allan, De Burgh and Dare trusses, calculate the required slacks
using the relevant Camber Table in Annexure G.4, based on the
applied tension rod adjustments corresponding to an equivalent best
fit symmetrical CAMBER CORRECTION. Provide additional slack to
allow for the dynamic effects of heavy vehicles on the truss span.

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4.11.6 Lowering of Allan, De Burgh and Dare Trusses (By Tension Rod Loosening)

4.11.6.1 Clause 4.11.8 applies for the lowering of Allan, De Burgh and Dare Use of tension rod
trusses by incrementally and symmetrically loosening of the tension loosening to lower
rods, to change the camber and geometry of the truss (e.g. to bring a truss or ensure
hogging truss to INITIAL CAMBER prior to truss repairs). full dead load
transfer to TSS
Clause 4.11.8 also applies where such a truss is only partially
supported by a TSS, to ensure the full transfer of dead load to the
TSS by further loosening off the truss.

4.11.6.2 Carry out truss lowering using tension rod loosening under either of Support and load
the following truss support conditions: transfer
conditions
.1 The truss carries the full dead load of the truss span throughout
(no TSS); or
.2 The truss initially carries the full or part dead load of the truss
span and the dead load is progressively transferred to a TSS.
In this case, tension rod loosening achieves a simultaneous and
controlled transfer of the full dead load from the truss to the
TSS. Full dead load transfer will be achieved by the end of the
last cycle.
4.11.6.3 For truss lowering by tension rod loosening, the same requirements Process related to
as Clause 4.11.7 apply, except that: tension rod
tightening
.1 The truss support conditions must conform to Clause 4.11.6.2.
.2 The CAMBER CORRECTION is negative.
.3 The applied tension rod shortenings shown in the Camber
Tables in Annexure G.4 must be converted to applied tension
rod loosening adjustments, to achieve the equivalent amount of
truss lowering (i.e. negative CAMBER CORRECTION).
4.11.6.4 When progressive transfer of dead load to a TSS is required and full Loosening tension
transfer of dead load from the truss to the TSS is not fully achieved rods during truss
after application of the calculated tension rod loosenings, carry out lowering
additional cycles of loosening until transfer of dead load is complete.

4.11.7 Cambering of Allan, De Burgh and Dare trusses (By Tension Rod Tightening)

4.11.7.1 Clause 4.11.5 applies for the final cambering (including remedial Use of tension rod
cambering) of an Allan, De Burgh or Dare truss, during which the tightening to
truss is lifted by incremental and symmetrical tension rod tightening, camber truss
to change the camber and geometry of the truss from the (zero)
INITIAL CAMBER to the APPROVED CAMBER.

However, for remedial cambering without a TSS, commence final


cambering from the existing camber (refer Clause 4.11.7.16).

4.11.7.2 A guide procedure for final cambering of an Allan, De Burgh or Dare Guide procedure
truss is provided in Annexure G.2.

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4.11.7.3 Carry out final cambering by tension rod tightening under either of Support and load
the following truss support conditions: transfer
conditions
.1 For truss repairs or remedial cambering: The truss is initially
supported by the TSS, with the cross girders attached to the
bottom chord. In this case, tension rod tightening achieves a
progressive, simultaneous and controlled transfer of dead load
from the TSS to the truss. Full dead load transfer will be
achieved by the end of the last cycle.
.2 For truss repairs only: The truss carries its own self weight
only during all tension rod adjustments. In this case, the TSS
must support the cross girders (which are temporarily detached
from bottom chord) at just above the APPROVED CAMBER.
Full dead load must be transferred to the truss after completion
of the last cycle, by adjusting TSS hanger supports. Dead load
transfer must be completed on the same working day.
4.11.7.4 The applied CAMBER CORRECTION and tension rod shortenings (refer Applied camber
Clause 4.11.2.3) must be directly proportional to the symmetrical adjustments and
CAMBER CORRECTION shown in the relevant Camber Table in number of cycles
Annexure G.4, after allowing for localised camber irregularities. based on Camber
Tables
The calculated tension rod shortening to be applied at each panel
point (per cycle) must be based on the number of cycles in the
relevant Camber Table and must not be exceeded.

4.11.7.5 In each cycle of cambering, progressively tighten the truss tension Order of
rods, starting from the end tension rods (refer Clause 4.11.1.8). tightening in cycle

4.11.7.6 At the end of each cycle, adjust the tension rods to remove slacks and Uniform tightness
provide uniform tension rod tightness according to Clause 4.11.3.12. of tension rods

4.11.7.7 Monitor and record the applied tension rod shortenings (per cycle and Monitoring and
cumulative), using a precise method (e.g. direct thread measurement, recording tension
number of turns of each tension rod nut). Note that the tension rod rod shortenings
diameter and thread pitch may vary between panel points.

4.11.7.8 If the APPROVED CAMBER is not fully achieved after application of Calculation of
the calculated tension rod shortenings, calculate the required additional
additional CAMBER CORRECTION. [When cambering under truss self CAMBER
weight, do this before final dead load transfer to the truss and allow CORRECTION
for the additional dead load deflection in truss (refer Table 3)].

4.11.7.9 If the required additional CAMBER CORRECTION does not exceed Additional
10 mm at any panel point (excluding camber irregularities), carry out CAMBER
one additional cycle of symmetrical camber adjustment (part or full) CORRECTION
according to this clause. Otherwise, cambering is deemed to have
been defective and the HOLD POINT in Clause 4.11.4 applies.

4.11.7.10 Local and fine adjustments of camber by tension rod tightening must Fine adjustment of
be limited to 2 mm CAMBER CORRECTION (total) at any panel point camber
with no adverse effects (e.g. on camber at other panel points).

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4.11.7.11 When the truss is initially fully supported on a TSS and full transfer Dead load transfer
of dead load from the TSS to the truss has still not occurred after the incomplete after
applied tension rod shortenings: applied tension
rod shortenings
.1 Loosen off the TSS hanger supports according to (progressive
Clause 4.11.5, until full dead load transfer is confirmed; then transfer)
.2 Measure the camber and carry out any required additional
CAMBER CORRECTION according to Clause 4.11.7.8.
4.11.7.12 Where remedial cambering of an existing is required, restore a “best Remedial
fit” APPROVED CAMBER in the truss conforming to Annexure H.1, by cambering
symmetrical tension rod tightening.

4.11.7.13 Before commencing remedial cambering, assess the existing truss Corrective work
geometric conformity and the possible causes of camber loss in the to ensure effective
truss (e.g. mismatched strut lengths) according to Clause 4.10.1. remedial
cambering
Where You consider that corrective work to the truss (e.g. packing
mismatched struts, truss adjustments) is necessary to ensure that
remedial cambering will be effective and lasting, determine the
necessary adjustment work according to Clause 4.10.1.

4.11.7.14 Do not attempt to correct existing camber irregularities (e.g. due to Irregularities left
permanent deformation of bottom chord) during remedial cambering. uncorrected
These are “accepted non-conformances” for assessing camber during remedial
conformity. Allow for such irregularities in determining Your cambering
proposed Final Camber (refer Clause 4.11.2).

4.11.7.15 Where truss support using a TSS is necessary for remedial cambering Remedial
(including cases where corrective work is required): cambering with
TSS
.1 Provide the TSS according to Clause 4.4.1.
.2 Change the existing camber to the (zero) INITIAL CAMBER
according to Clause 4.4.3.
.3 Carry out any truss corrective work and truss tightening at the
INITIAL CAMBER according to Clause 4.10.
.4 Provide the APPROVED CAMBER by symmetrical tension rod
tightening from the INITIAL CAMBER according to this clause.
4.11.7.16 Where remedial cambering without a TSS is permitted (refer Remedial
Clause 4.11.1.5), provide the APPROVED CAMBER by symmetrical cambering
tension rod tightening, starting from the existing camber. The without TSS
required CAMBER CORRECTION is based on the existing camber.

4.11.8 Cambering of Old PWD and McDonald Trusses (By Tension Rod & Wedge
Adjustment)

4.11.8.1 Clause 4.11.8 applies for the final cambering of an Old PWD or Use of direct
McDonald truss, during which the truss is lifted by direct, empirical, empirical tension
symmetrical tension rod tightening and wedge adjustment, to change rod tightening and
the camber and geometry of the truss from the (zero) INITIAL wedge adjustment
CAMBER to the APPROVED CAMBER. to camber truss

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4.11.8.2 These truss types are complex to adjust, due to their cross-braced Guide procedure
(structurally redundant) design. A guide procedure for final
cambering of an Old PWD or McDonald truss is provided in
Annexure G.3.

4.11.8.3 The requirements for remedial cambering are the same as for the Remedial
cambering of a repaired truss, except for the permitted level of truss cambering
geometric non-conformity, both prior to and after cambering.

4.11.8.4 The truss must be initially supported (e.g. by the TSS or on Support and load
fabrication blocks) for cambering of Old PWD and McDonald transfer
trusses. In this case, the cambering process achieves a simultaneous conditions
and controlled transfer of dead load from the TSS to the truss. Full
dead load transfer will be achieved by the end of the last cycle.

4.11.8.5 Provide the APPROVED CAMBER in the adjusted and tightened truss Cambering
as follows: sequence
.1 Ensure that the truss is fully supported at the INITIAL CAMBER.
.2 Confirm the geometric conformity of the truss (e.g. truss
height, parallel top and bottom chords) at the (zero) INITIAL
CAMBER. Make fine adjustments according to Clause 4.10.
.3 Camber the truss to achieve the APPROVED CAMBER according
to the sequence set out in Annexure G.3, based on:
 A single cycle of direct and empirical adjustment; then
 Fine adjustments, as required.
4.11.8.6 Final cambering must also provide an internal camber (upwards) in: Providing internal
camber in top
.1 The top chord, not exceeding 12 mm between ends. chord and end
.2 Each end principal, not exceeding 6 mm between ends. principals

4.11.8.7 Progressively loosen off tension rods and wedges to the extent Avoiding
necessary to allow the truss camber and geometry to be changed interference to
without interference (i.e. no cross brace to resist truss adjustments). changed camber
Do not over-loosen the tension rods and wedges (e.g. to the extent and geometry (Old
that there is loss of precamber in the sprung top chord). Jacks may be PWD and
used to hold existing precamber in the top chord and allow McDonald trusses)
adjustment of diagonal struts and wedges.

4.11.8.8 If the APPROVED CAMBER cannot be achieved, or can be achieved Iterative process
only with difficulty, or the truss geometry does not conform, to achieve
cambering is deemed to have been defective and the HOLD POINT in APPROVED
Clause 4.11.4 applies. Lower the truss to the (zero) INITIAL CAMBER CAMBER
and transfer dead load back to the TSS according to Clause 4.11.4.2.

4.11.8.9 After cambering, retighten all bolts and shear keys in butt blocks, Final tightening
chords and primary cross girders.

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4.12 STAGE COMPLETION OF EACH TRUSS
4.12.1 Carry out a joint STAGE INSPECTION of each repaired truss after the STAGE
final tightening and cambering of the repaired truss and prior to the INSPECTION of
removal of the TSS from the truss. each truss

This must be a joint inspection with the Principal.

Process Held: Relocation, dismantling or removal of TSS from each HOLD POINT
repaired truss. (Also refer to HOLD POINTS in TfNSW M752).
STAGE
Submission Details: At least 3 BUSINESS DAYS prior to the intended INSPECTION for
date of the joint STAGE INSPECTION on each truss: each truss
.1 Notify the Principal of the intended date and time of the joint
STAGE INSPECTION; and
.2 Submit certification that the specified repairs (including final
cambering) of the truss that is supported by the TSS have been
completed and conform to the Specification.
Release of Hold Point: The Principal will conduct a joint STAGE
INSPECTION and may require corrective action on deficiencies prior to
authorising the release of the HOLD POINT.

4.12.2 The DATE OF STAGE COMPLETION of each individual truss is the date DATE OF STAGE
on which the TSS is dismantled or relocated to another truss, after COMPLETION of
completion of all repairs and conformity checks to that truss. each truss

4.12.3 Submit to the Principal two copies of the WORK-AS-EXECUTED WORK-AS-


DRAWINGS within 20 BUSINESS DAYS of the DATE OF STAGE EXECUTED
COMPLETION of each individual truss. DRAWINGS

4.13 WARRANTY PERIOD


4.13.1 The WARRANTY PERIOD is set out in Annexure A.1 and applies to: Application
.1 The truss components or features repaired as part of the Work.
.2 The overall truss geometry and camber of those truss spans
tightened and cambered as part of the Work.
4.13.2 You are responsible during the WARRANTY PERIOD for: Your
responsibility and
.1 The integrity of all truss repairs completed as part of the Work. Your warranty
.2 PRESCRIBED INSPECTIONS and MAINTENANCE and their safety.
.3 Corrective work to remedy non-conformity.
Your warranty for Your repairs of each truss is for a period of
12 months from its DATE OF STAGE COMPLETION. On each truss, the
Principal will be responsible for payment of (2) and (3) after this
warranty period expires (refer to Clause 4.13.5 below).

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4.13.3 The DATE OF COMPLETION of the entire truss repairs, for the purpose DATE OF
of determining the expiry of the WARRANTY PERIOD, is the DATE OF COMPLETION of
STAGE COMPLETION of the last truss repaired as part of the Work. all truss repairs

4.13.4 Carry out PRESCRIBED INSPECTIONS and PRESCRIBED MAINTENANCE Timing of


during the WARRANTY PERIOD at the following intervals: PRESCRIBED
INSPECTIONS and
.1 Prior to the DATE OF COMPLETION: PRESCRIBED
 On each completed truss, at 6 months and at 12 months MAINTENANCE
after its DATE OF STAGE COMPLETION, then (subject to the
Principal’s agreement) at 6 monthly intervals.
.2 After the DATE OF COMPLETION, on all trusses:
 At 6 months after the DATE OF COMPLETION.
 At 2 to 4 weeks before the end of the WARRANTY PERIOD
(this is the joint HANDOVER INSPECTION).
4.13.5 PRESCRIBED INSPECTIONS and MAINTENANCE, including additional Work beyond
corrective work to remedy newly identified non-conformity, that are Your warranty on
carried out on each completed truss after 12 months from its DATE OF each truss
STAGE COMPLETION will be at additional cost to the Principal.
Progressively submit Your separate itemised Prices for the additional
inspections and the additional corrective work and obtain the
Principal’s approval prior to proceeding.

Process Witnessed: Each PRESCRIBED INSPECTION. WITNESS POINT

Submission Details: At least 3 BUSINESS DAYS notice of intention to


carry out each PRESCRIBED INSPECTION.

4.13.6 Each PRESCRIBED INSPECTION must include the following: PRESCRIBED


INSPECTION
.1 Camber measurement according to Clause 4.2.3.
.2 Visual inspection and assessment to identify:
 Signs of structurally significant changes (e.g. misfits,
misalignment, dimensional changes, loss of camber).
 Adverse live load response of the truss span (e.g. abnormal
deformations/movements under live load).
 Signs of loosening or other effects of shrinkage to bolts
and nuts and composite sections.
 Fit and tightness of components, bracing and connections.
 Condition of permanent steel packers and wedges.
.3 Take sufficiently accurate measurements to ascertain or verify
concerns identified during the visual inspection.
4.13.7 Provide the Principal with a written report of each PRESCRIBED Inspection report
INSPECTION. List non-conformity as required by TfNSW Q4M and
highlight any additional issues.

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4.13.8 Carry out PRESCRIBED MAINTENANCE as follows: PRESCRIBED
MAINTENANCE
.1 Adjust and tighten all bolts and nuts, as necessary.
.2 Adjust connections to ensure the fit, tightness and even bearing
of all components (e.g. struts, tension rods, braces).
.3 For Old PWD and McDonald Trusses, adjust permanent steel
packers and wedges and drive them tight. If necessary, insert
additional packers or wedges.
.4 During the 12 months PRESCRIBED MAINTENANCE only (if
required), carry out a single cycle of remedial cambering (not
exceeding 20 mm from the existing camber, without a TSS),
using the relevant Camber Table.

4.14 PROJECT COMPLETION AND HANDOVER


Process Held: HANDOVER INSPECTION. HOLD POINT

Submission Details: At least 3 Business Days notice of intention to


carry out the joint HANDOVER INSPECTION.

4.14.1 At the end of the WARRANTY PERIOD, carry out a joint HANDOVER HANDOVER
INSPECTION of all the repaired trusses with the Principal. At this INSPECTION
inspection, the Principal will document any nonconformity in a
'Nonconforming Product Notification'. Any nonconformity must be
repaired to comply with the Specification according to TfNSW Q4M.

Carry out any required repair work at Your cost, except for that
specified in Clause 4.13.5.

4.14.2 Project Completion occurs when all of the following have been Project
completed to the Principal’s satisfaction: Completion
.1 PRESCRIBED INSPECTIONS and PRESCRIBED MAINTENANCE
during the WARRANTY PERIOD.
.2 Rectification of all non-conformities identified at all STAGE
INSPECTIONS and up to the end of the WARRANTY PERIOD.
.3 The joint HANDOVER INSPECTION.
.4 Submission of the Final WORK-AS-EXECUTED DRAWINGS.
.5 The site has been vacated and restored, and all waste removed.

5 CONFORMITY

5.1 SURVEY AND MEASUREMENT TOLERANCES


5.1.1 The tolerances for survey measurements and truss internal length Survey and length
measurements are specified in Table 4 and Table 5 respectively. tolerances

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5.1.2 The tolerance for component length, cross sectional dimensions, Other dimensional
assembly and connection dimensions and detail locations along truss tolerances
components is ± 1 mm unless otherwise specified.

Table 4 —Tolerances for Survey Co-ordinates

Tolerance

Feature Plan dimension Reduced Level


(mm) (mm)

.1 Panel Points:
 Each panel point of the top and bottom chord
 1  1
 Position of shoes on top and bottom chords
.2 Other Truss Span features:
 Sway braces  2  1
 Cross girders  2  2
 Top of piers or top of abutment supporting truss span  2  2
 Stringers  5  2
 Deck system components  5  2
 Other components not specified above  5  2
.3 Other bridge approach spans:
 All components  10  5
.4 Camber:
 Camber of bottom chord n/a  1

Table 5 —Tolerances for Truss Internal Length Measurements

Feature Length Tolerance (mm)

 Overall length of top and bottom chord  1


 Length between adjacent panel points  1
 Panel height at each bottom chord panel point  1
 Length of end principals and diagonal struts (between shoes)  1

5.2 WORK-AS-EXECUTED DRAWINGS


5.2.1 The WORK-AS-EXECUTED DRAWINGS must show any changes to the Purpose
configuration and dimensions of the truss spans and their components
and features as compared with the DRAWINGS.

5.2.2 Present the WORK-AS-EXECUTED DRAWINGS as neat and accurate Presentation


sketches, guided by the requirements in Sections 7 and 18 of the standard
TfNSW Structural Drafting Manual, except for dimensional
tolerances.

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5.2.3 In the WORK-AS-EXECUTED DRAWINGS, the dimensional tolerance is Drawing
to the nearest millimetre (e.g. for overall truss dimensions, dimensions
component lengths, cross sectional dimensions, assembly and
connection details and spacings along truss structural components).

5.2.4 The WORK-AS-EXECUTED DRAWINGS must be verified by a qualified Verification of


person who has not been directly involved in preparing the Drawings. WORK-AS-
EXECUTED
DRAWINGS

5.3 NOMINATED REPAIR STANDARD FOR TRUSS REPAIRS


5.3.1 The NOMINATED REPAIR STANDARDS for the truss repairs are NOMINATED
specified in ANNEXURE H, with details grouped as follows: REPAIR
STANDARDS
.1 Annexure H.1 Truss Span Geometry - including Overall Truss
Span Geometry, Horizontal Alignment of Chords, Plumb Of
Trusses, Sway Braces and Wind Braces and Camber.
.2 Annexure H.2 Assembled Component Details - including
timber and metal components and timber/metal interfaces.
.3 Annexure H.3 Component Requirements – other requirements
for each type of timber and metal truss component.
5.3.2 In Annexures H.1 to H.3, the columns in the tables with heading Variations to
“Variation to REPAIR STANDARD” specify amended or additional REPAIR
requirements for the Work (if any). STANDARD

5.3.3 The Principal may revise the NOMINATED REPAIR STANDARDS Variations by
during the course of Work (e.g. due to additional deterioration). Principal

5.3.4 You may propose further variations to the NOMINATED REPAIR Further proposed
STANDARDS prior to commencing repairs on the truss. Any proposed variations
variation is subject to approval by the Principal.

5.4 CAMBER CONFORMITY


5.4.1 The INITIAL CAMBER and Final Camber of the truss must conform to Camber profile
the tolerances specified in Annexure H.1.

5.4.2 Following cambering, comply with the following requirements: Truss geometry
and tightness
.1 Truss geometry conforms to Annexure H.1.
.2 Truss connections are tight and conform to the end bearing
requirements of Annexure H.2.
.3 Tension rods conform to Annexure H.3.

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ANNEXURE A––DETAILS OF WORK


A.1 WORK SUMMARY
Contract Reference:
Bridge Name and
Location

TfNSW Bridge No
Extent of Work Nominated Truss Spans:
(refer to DRAWINGS)
Nominated Approach Spans:
DRAWINGS forming basis Drawing No.: ________________________________ Drawing Type: ________________
of Work (Clause 4.1)
Drawing No.: ________________________________ Drawing Type: ________________
Drawing No.: ________________________________ Drawing Type: ________________
Approved Loading
Regime (refer
TfNSW M752)
Setting Out Information Refer to Site Drawing No.: ________________________________
DESIGN CAMBER of Truss __________ at midspan (mm)
(Clause 4.11.1)
WARRANTY PERIOD Commences: At the DATE OF STAGE COMPLETION of truss repairs of the first truss.
(Clause 4.12)
Ends: At 12 months after the DATE OF COMPLETION of all truss repairs of all trusses
(i.e. the DATE OF STAGE COMPLETION of the last truss repaired as part of the Work).

Notes: (*) Strike out options that do not apply

A.2 INFORMATION SUPPLIED BY THE PRINCIPAL


Paper copy

Reference Date on
Electronic

Supplied by
Document
Principal
(dd-mm-yyyy)
Documentation

1. Project Brief that outlines the proposed repair Work YES


2. Most recent BIS bridge condition inspection reports for YES
the bridge
3. Original Drawings of the bridge. YES / NO
4. Metric Maintenance Drawings of the bridge. YES / NO
5. Measure-up Drawings. YES / NO
6. Construction Drawings. YES / NO
7. WORK-AS-EXECUTED DRAWINGS. YES / NO
8. Drawings of approved design modifications on the truss YES / NO
spans.
9. TSS Drawings YES / NO
10. Procedures for TSS YES / NO

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Timber Truss Repairs - Construction M757

Paper copy
Reference Date on

Electronic
Supplied by
Document
Principal
(dd-mm-yyyy)
Documentation

11. Structural assessments and reports relating to the truss YES / NO


spans superstructure, substructure and foundations.
12. Component Schedule YES / NO
13. MATERIALS LIST YES / NO
14. REVIEW OF ENVIRONMENTAL FACTORS (REF) YES
15. STATEMENT OF HERITAGE IMPACT (SOHI) YES
16. CONSERVATION MANAGEMENT PLAN (CMP) YES / NO
17. Heritage assessments relating to the proposed repairs. YES / NO
18. Records of application or presence of toxic or YES / NO
hazardous chemicals on, or in vicinity of the bridge.
19. Structural capacity check of truss. YES / NO
20. Proof load test of bridge. YES / NO
21. Inspection Report (part of TfNSW M756 work) and YES / NO
marked up Drawing
22. BRIDGE SURVEY CONTROL YES / NO
23. MEASUREMENT SYSTEM
24. Other documentation: ______________________

A.3 PROJECT BRIEF FOR TRUSS REPAIRS


The PROJECT BRIEF is attached.

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ANNEXURE B–MEASUREMENT AND PAYMENT


B.1 GENERAL
B.1.1 Pay items are identified in Annexure B.2. Pay Items to be
used

B.1.2 The price(s) of pay items with a quantity of work in the schedule Prices
must be costed and make due allowance for the cost of the activity.

Any item of work with a quantity of work that is not priced is


deemed to be included in other priced pay items.

B.1.3 Any overheads must be distributed between pay items. Overheads

B.1.4 Pay items with a quantity of work specified must not be tendered as No Lump Sum
a lump sum price.

B.1.5 Maintenance Activity Pay Item 904 applies to work relating to site Site establishment
establishment, when this is a significant cost. In this case, the cost
must not be absorbed across the other Pay Items.
B.1.6 Maintenance Activity Pay Item 909 applies to work relating to Provision for traffic
provision for traffic / traffic control in accordance with
TfNSW G10, when this is a significant cost.

B.1.7 Pay items for work relating to the TSS are specified in TSS pay items
TfNSW M752 Annexure B.2.

B.1.8 Pay items for work relating to protective treatment of timber truss Protective
spans are specified in TfNSW M743 Annexure B.2. treatment pay items

B.1.9 You will bear the costs of work that does not conform to the No payment
Specification.

You will bear the costs of the following work or materials:


.1 Additional material provided to allow for cutting of timber
components to size, including additional length that is offcut.
Payment will be made only for the design size.
.2 Removing and replacing nonconforming components with
conforming components.
.3 Repeat cycles of camber adjustment, where calculated
camber adjustment has not been achieved.
.4 Rework required to achieve conformity (including repeat
cycles of dead load transfer to and from the TSS to carry out
corrective adjustment or camber adjustment).
.5 Warranty repairs.

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B.2 SCHEDULE OF PAY ITEMS
Maintenance Units of
Item Name and Description
Activity Code Measurement

 757 Replace Timber Truss Elements Each

Like-for-like replacement of individual components in a timber truss, including:


 Establishing the BRIDGE SURVEY CONTROL and MEASUREMENT SYSTEM..
 Ensuring full transfer of dead load to and from the TSS
 Providing the INITIAL CAMBER in existing truss prior to truss repairs
 Dismantling of and removing existing components.
 Supply, receiving treatment, storage and air drying of materials and fasteners.
 Fabrication and erection of components.
 Dismantling of and re-erecting additional components, dismantled only to enable
Work.
 Corrective adjustment and tightening of repaired truss
 Camber adjustment of truss from INITIAL CAMBER to APPROVED CAMBER
 STAGE INSPECTION of the repaired and cambered truss.
 PRESCRIBED INSPECTIONS and PRESCRIBED MAINTENANCE during the WARRANTY
PERIOD according to Clause 4.13.
NOTE: Payment does not include carrying out PRESCRIBED INSPECTIONS and PRESCRIBED
MAINTENANCE on each completed truss after 12 months from its DATE OF STAGE
COMPLETION. This is beyond the Contractor’s warranty of the repairs on that truss, and will
be at additional cost to the Principal. Submit Your separate itemised Price(s) for these
additional inspections and related additional work (refer Clause 4.13). Payment for this
additional work will require a supplementary work order from the Principal.
Installation, use and dismantling of Temporary Support System is covered by Pay Item 753
(refer TfNSW M752)

757.01 Replace Timber End Principals / End Posts / Chords (TPCH) Each
757.02 Replace Steel Bottom Chords (TSBC) Each
757.03 Replace Timber Struts (TSTT) Each
757.04 Replace Tension Rods (Steel, Wrought Iron) (TTIE) Each
757.05 Replace Sway Brace, Wind Braces or Undertrussing (TSBR) Each
757.06 Replace Metal Shoe (TSHO) Each
757.07 Replace Butt / Jacking Block (TBJB) Each
757.08 Replace Truss Cross Girder (TTCG) Each
757.09 Replace Stringer (TSTR) Each

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Maintenance Units of
Item Name and Description
Activity Code Measurement

 758 Replace Entire Timber Truss Metre of Span


Length
Replacement of entire timber truss, by prefabrication of entire truss, including (in addition
to tasks listed under Pay Item 757):
 Adaptation of TSS to suit removal and insertion of entire trusses.
 Off-bridge prefabrication of new truss, and breakdown into transportable sections.
 Lifting and erecting the prefabricated truss sections(s) on bridge.
 Connecting truss into existing span (e.g. cross girders)
Note: This work requires a site-specific design, a customised version of this Specification
and may require special pay items.

 759 Strengthen Timber Truss Elements Each

Strengthening of individual components in a timber truss, corresponding to the elements


listed under pay item 757, (for like-for-like repairs) includes the following tasks:
 Dismantling of and removing the existing component(s)
 Supply of materials and fasteners.
 Fabrication and erection of strengthened component.
 Dismantling of (only to enable Work) and re-erecting additional components.
Note: This work requires a site-specific design, a customised version of this Specification
and may require special pay items similar to the sub-items listed under pay item 757.
It includes replacing existing components with composite components (refer Clause 3.2.5).

 760 Timber Truss Elements, Repair or Other Specific Maintenance - Each


Tightening and Flashing
Repair or other specific maintenance of individual components in a timber truss,
corresponding to the elements listed under pay item 757 (for like-for-like repairs). Includes
the following tasks:
 In-situ repair of existing component or dismantling and temporary removal of existing
component for repair
 Supply of materials and fasteners.
 Tightening of truss components
 Flashing of truss components

 761 Timber Truss – Remedial Cambering of Existing Truss (Provisional Item) Item

Provision of the APPROVED CAMBER in an existing truss, where no other timber truss repairs
are planned. Includes the following tasks:
 Camber adjustment from existing camber to INITIAL CAMBER, then APPROVED CAMBER.
 Loosening off and corrective truss adjustment and tightening at INITIAL CAMBER.
Installation, use and dismantling of Temporary Support System is covered by Pay Item 753
(refer TfNSW M752).

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ANNEXURE C– SCHEDULE OF HOLD AND WITNESS POINTS AND
IDENTIFIED RECORDS
C.1 SCHEDULE OF HOLD AND WITNESS POINTS
Reference Type Process Held or Witnessed Submission Details

TfNSW Q4M HOLD POINT Commencement of Work At least 10 BUSINESS DAYS prior to commencing work:
and
 PROJECT QUALITY PLAN.
Clause 2.1
 CONSTRUCTION PROGRAM
Clause 3.2.5 HOLD POINT Use of composite  Design of the composite component.
components
 Justification for the composite component,
demonstrating the efforts made to supply timber
and whole-of-life cost comparison with the original.
 Proof that the composite component meets
heritage requirements.
Clause 3.3.2 HOLD POINT Fabrication of new steel  Evidence that steel materials used for the new
components components conform to the Specification.
 Shop Drawings for fabricated components.
 Steel fabrication procedures.
Clause 3.3.3 HOLD POINT Repair of an existing metal Proposal for repair of existing component that includes:
component
 Details of the damage or defect to be repaired.
 Condition and the section loss of the component.
 Repair procedure according to Clause 4.8.2.
Clause 4.2.1 WITNESS Re-establishing or setting out At least 3 BUSINESS DAYS notice of intention to set out
POINT the BRIDGE SURVEY CONTROL. the BRIDGE SURVEY CONTROL.
Clause 4.3 HOLD POINT Delivery of timber to Bridge  Certification that timber conforms to the
Site Specification.
 Verification that new timber has been air dried for
at least 12 months.
Clause 4.4.1 HOLD Provision of TSS and dead  Various requirements for TSS to be used in
POINTS load transfer to TSS conjunction with the truss repairs
(TfNSW
M752)
Clause 4.4.3 HOLD POINT Cambering of the truss, At least 5 BUSINESS DAYS prior to providing the INITIAL
including truss lifting or CAMBER in each truss:
lowering, to alter the existing
 Your proposed CAMBER CORRECTION at each panel
camber of the truss so as to
point, to provide the INITIAL CAMBER
provide the INITIAL CAMBER,
prior to truss repairs or  Where tension rod adjustments are proposed, Your
remedial cambering. proposed tension rod shortenings or loosening
adjustments, applied to provide the INITIAL CAMBER.
 The intended date/time for the cambering work
 Cambering procedures (to provide INITIAL CAMBER).

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Reference Type Process Held or Witnessed Submission Details

Clause 4.5.1 HOLD Commencement of truss  Various requirements for TSS


POINTS repairs on any part of the
(TfNSW truss.
M752)
Clause 4.5.1 HOLD POINT Commencement of truss  The Bridge Works Supervisor’s certification (based
repairs on each truss after on a personal inspection) verifying that the full
transfer of dead load to TSS transfer of dead load from the truss to the TSS has
and provision of INITIAL occurred according to TfNSW M752 and the INITIAL
CAMBER. CAMBER has been achieved.

Clause 4.5.1 HOLD POINT Further work on components Within 1 BUSINESS DAY of identifying any deficiency, a
directly affected by a report with details/photographs of deficiency which must
deficiency, including covering include:
up the deficiency.
 Any deviations from the DRAWINGS, Original
Drawings or Drawings of approved design
modifications.
 Existing condition of components and change in
condition when compared with the previous BIS
Level 2 inspection.
 Test results, where testing is directed by the
Principal.
Clause 4.8.2 HOLD POINT Repair of existing metal Your repair proposal for the existing metal component,
components including:
 Details of the damage or condition of the defect
(e.g. section loss) to be repaired.
 Assumed material properties of the metal
component.
 Repair procedure (e.g. tension rod repair, camber
correction).
Clause 4.9 HOLD POINT Erection of assemblies or At least 5 BUSINESS DAYS prior to commencing erection:
components on the bridge.
 A report verifying that each fabricated assembly or
component conforms with the Specification.

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Reference Type Process Held or Witnessed Submission Details

Clause 4.11.3 HOLD POINT All cambering of the truss, At least 5 BUSINESS DAYS prior to commencing the
including truss lifting or cambering work:
lowering, except for provision
 Your proposed Final Camber at each panel point,
of the INITIAL CAMBER.
together with supporting calculations and details
 Your proposed CAMBER CORRECTION at each panel
point.
 Where tension rod adjustments are proposed, Your
proposed tension rod shortenings to be applied, to
provide Your proposed Final Camber.
 Procedures for cambering.
 Following truss repairs, a report that verifies that
the truss repairs conform and that any geometric
misfits or irregularities identified during truss
adjustment have been rectified.
 For remedial cambering, Your proposal for
corrective work to the truss to ensure effective
cambering, where required.
Clause 4.11.3 WITNESS Each stage of cambering At least 3 BUSINESS DAYS notice of intention to carry out
POINT work, on each truss. each stage of cambering work.
Clause 4.11.4 HOLD POINT Further cambering of the At least 3 BUSINESS DAYS prior to commencing further
truss, where any of the cambering or rectification work:
problems listed in Clause
 Measurements of existing camber / truss geometry.
4.11.4.1 occur during
cambering.  Calculations for the remaining and/or additional
CAMBER CORRECTION based on the existing camber
(where applicable).
 Report on the problems and Your diagnosis.
 Your proposal for the necessary rectification work,
where required.
Clause 4.12 HOLD POINT Relocation, dismantling or At least 3 BUSINESS DAYS prior to the intended date of
removal of TSS from each the joint STAGE INSPECTION on each truss:
(also refer
repaired truss
to HOLD  Notification of the intended date and time of the
POINTS in [STAGE INSPECTION for each joint STAGE INSPECTION.
TFNSW M7 truss].
 Certification that the specified repairs (including
52)
final cambering) of the truss that is supported by
the TSS have been completed and conform to the
Specification.
Clause 4.13 WITNESS Each PRESCRIBED INSPECTION At least 3 BUSINESS DAYS notice of intention to carry out
POINT each PRESCRIBED INSPECTION.
Clause 4.14 HOLD POINT HANDOVER INSPECTION. At least 3 BUSINESS DAYS notice of intention to carry out
the joint HANDOVER INSPECTION.

C.2 SCHEDULE OF IDENTIFIED RECORDS


Reference Description of Identified Record

Clause 2.1 PROJECT QUALITY PLAN.

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Reference Description of Identified Record

Clause 2.2 CONSTRUCTION PROGRAM.


Clause 2.3 OHS&R Management Plan.
Clause 2.3 TRAFFIC MANAGEMENT PLAN (TCP).
Clause 2.3 CONTRACTOR'S ENVIRONMENTAL MANAGEMENT PLAN (CEMP) including the WASTE MANAGEMENT PLAN.
Clause 3.2.1 Record of marking on new timber and relevant inspection certificates.
Clause 3.2.4 Assessment of recycled timber.
Clause 3.2.5 Design of composite component
Clause 3.3.3 Assessment of existing metal components.
Clause 3.3 Deficiencies in components that are exposed during the Work.
Clause 4.1 Progressive WORK-AS-EXECUTED DRAWINGS.
Clause 4.2 Survey field books and calculations.
Clause 4.11 Calculations for cambering.
Clause 4.12 Final WORK-AS-EXECUTED DRAWINGS for each truss.
Clause 4.13 Inspection reports and maintenance records during the WARRANTY PERIOD
Clause 5 Conformity and nonconformity reports.

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ANNEXURE D––PLANNING DOCUMENTS
D.1 CONSTRUCTION PROCESSES
The information to be supplied must include, but not be limited to, the following:

Clause Process Details

Clause 2.1 Certified procedures Procedures that require certification by a Structural Engineer according to
(refer to TfNSW M752) TfNSW M752, including:
 Use and installation of composite components.
 Lifting, cranage and jacking operations.
 Use of Temporary Support System.
 Temporary bracing or stiffening.
 Dismantling timber truss components, including local support
arrangements for the partially-dismantled truss.
 Camber adjustment.
Clause 3.1 Personnel  Names, qualifications experience and role.
Clause 3.2.3 Receipt of new timber  Checking for conformity with the Specification and recording details.
Clause 3.2.4 Details of recycled timber  Method to assess the suitability of recycled timber for re-use.
 Method of marking and recording details of recycled timber.
Clause 3.2.6 Management of timber  Storage in a secure storage shed.
off-site
 Stacking and air drying of timber.
 Preparation, prime coating and retying bundles.
 Separation of new timber from recycled timber.
 Method to address the risk of termite attack.
Clause 3.3.2 Supply of new steel
 Shop assembly to check conformity.
components
Clause 3.3.3 Re-use of existing metal  Method to assess the suitability of salvaged timber for recycling.
components
 Repair methods.
Clause 3.4 Materials information  Preventing shelf or pot life from being exceeded.
Clause 4.1 Carpentry, finish and  Consistent with established bridge and wharf carpentry trade and industry
general workmanship best practice.
Clause 4.2.2 Establishment of BRIDGE
SURVEY CONTROL and  Setting out control.
MEASUREMENT SYSTEM
Clause 4.2.3 Measurement of Camber  Determination of levels.
Clause 4.3 Management of Materials
 Methods of storage of materials at the Bridge Site.
at the Bridge Site
Clause 4.4.2 Provision of INITIAL
 Calculation of truss deflections, proposed CAMBER CORRECTION and
CAMBER for repairs, using
tension rod adjustments
TSS

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Clause Process Details

Clause 4.5.1 Truss repairs – General  Complying with integrated truss repair sequence (refer ANNEXURE E).
Requirements
 Method and order of assembly including temporary fixing
 Method of progressive inspection (including each repaired component)
and reporting deficiencies.
 Method to maintain the INITIAL CAMBER during repairs.
Clause 4.5.2 Mandatory replacement of
 Confirming extent of repairs and mandatory replacements
components
Clause 4.5.3 Greasing and protection  Cleaning/greasing threads prior to adjustments (e.g. cambering)
of metal components
 Greasing hidden surfaces prior to insertion
 Painting of exposed threads.
Clause 4.6 Fabrication  Ensuring that measurements on DRAWINGS are checked against the
existing bridge prior to cutting.
 Correcting any discrepancies on the DRAWINGS and using the correct
measurements for cutting and shaping components.
 Accurately cutting and sizing components to the specified dimensions.
 Fabricating components off and on the bridge.
 Fabricating components into the largest practical assembly.
 Replacing bolted, spliced and shoes connections according to DRAWINGS.
 Accurately cutting, drilling, finishing and fitting components and
connection details (e.g. shear keys, notches, bolt holes at splices, shoes)
to achieve the specified tight fit and uniform bearing at connections.
 Bolting procedures, including methods of aligning holes, marking bolts,
and tightening to ensure reliable uniform “snug tight”, and records.
 Installation of fasteners.
Clause 4.7 Dismantling  Extent of dismantling integrated into the CONSTRUCTION PROGRAM.
 Marking and coding of dismantled components.
 Installing and removing local temporary supports within the truss during
dismantling and prior to reinstatement of replacement components.
 Managing waste components according to Your CEMP (refer
Clause 2.3).
Clause 4.8.1 Repair of existing timber Methods of repair, including:
components
 Cleaning and improving drainage in difficult-to-access areas.
 Adjusting components to improve truss geometry or eliminate looseness.
 Facing, sizing and trimming oversize or over-length components.
 Reaming or plugging existing bolt holes.
 Improving bearing of components (e.g. providing square ends).
 Improving keyways and contact surfaces (e.g. splice plates)
 Rehabilitating existing splices
 Improving poor details (e.g. stress raisers, misaligned bolts or fittings).
 Improving existing attachment details (e.g. at cross girder connections).

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Clause Process Details

Clause 4.8.2 Repairs to existing metal


 Welding, mechanical or heat-based treatments.
components
Clause 4.9 Erection and fitting of Certified procedures (refer to TfNSW M752):
components on the bridge
 Lifting and carnage including:
- Type and capacity (at operating radius) of lifting equipment.
- Assessment of supporting ground conditions, and minimum
clearances to aerial electrical cables.
- Safe working capacity of slings.
 Temporary bracing or stiffening.
 Method of alignment of components.
Clause 4.10 Truss Adjustment and  Adjusting overall truss geometry (e.g. position and length of components)
Tightening
 Adjustment and tightening of wind braces.
 Adjustment and tightening of tension rods prior to final cambering.
Clause 4.11 Cambering  Methods of cambering to provide the APPROVED CAMBER, using cyclic and
incremental procedures that provide a high degree of control
 Progressively monitoring, measuring and recording camber.
 Managing camber irregularities.
Clause 4.13 PRESCRIBED INSPECTIONS  Measuring the existing camber according to Clause 4.2.3.
and PRESCRIBED
 Visual assessment to identify:
MAINTENANCE during the
WARRANTY PERIOD - Signs of structurally significant changes (e.g. misalignment,
dimensional changes, loss of camber).
- Adverse live load response of truss span (e.g. abnormal deflections).
- Signs of loosening due to shrinkage or other effects of shrinkage to
bolts and nuts and composite sections
- Fit and tightness of components, bracing and connections.
- Condition of permanent packers and wedges.
 Taking sufficiently accurate measurements to ascertain or verify concerns
identified during the visual inspection.
 Methods of PRESCRIBED MAINTENANCE..
Clause 4.14 Project Completion and
 Submission process and checklist
Handover
Clause 5 Assessment of conformity  Inspection and measurement

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ANNEXURE E–– SEQUENCE OF TRUSS FABRICATION/REPAIR


E.1 GENERAL
E.1.1 Annexure E provides the general integrated sequence of the Scope
fabrication or repair of a single truss:
.1 Annexure E.2 - for Allan, De Burgh and Dare trusses.
.2 Annexure E.3 - for Old PWD and McDonald trusses.
Each sequence integrates the fabrication, temporary support and
cambering requirements. Pre-fabrication of components is assumed.
The sequences are written for fabrication of an entire truss.
However, each sequence is also applicable to truss repairs.

E.1.2 For partial or limited truss repairs, component replacement or repair Partial or limited
must be carried out at the appropriate stage of the sequence. truss repairs

E.2 REPAIR SEQUENCE FOR ALLAN, DE BURGH AND DARE TRUSSES


E.2.1 Fabricate the bottom chord, set at the (zero) INITIAL CAMBER, Fabricate bottom
supported on the TSS (directly or indirectly, on bridge) or fabrication chord at zero
blocks (off bridge). This includes preparing shoe keyways and camber and attach
tension splices. Set existing steel bottom chords at the (zero) INITIAL shoes
CAMBER. Locate and attach bottom chord shoes to the bottom chord.

E.2.2 Fabricate the top chord off bridge, supported on fabrication blocks set Fabricate top
at zero camber. Locate and attach top chord shoes to the top chord. chord

E.2.3 Stand end principals and diagonal struts (or vertical struts for Stand end
De Burgh trusses) on the bottom chord and attach them to bottom principals and
chord shoes. Hold end principals and struts in design position with struts on bottom
temporary props from the bottom chord. chord

E.2.4 Ensure even end bearing of end principals and struts against the Even end bearing,
bottom chord shoes. Ensure correct geometry and good fit of any good fit and
cross braced diagonal struts in the central truss panel(s). correct geometry

E.2.5 Erect the (straight) top chord, supported on top ends of end principals Install top chord
and struts. Ensure good bearing of principals and struts against shoes.

E.2.6 Erect cross girders at each panel point and attach them to the bottom Erect cross girders
chord.

E.2.7 Assemble and install all tension rods and tension rod accessories Install tension
(including washer plates), initially finger tight fit. rods

E.2.8 Adjust and tighten the end tension rods (i.e. at opposite end panel Set rack of truss
points of top chord) against the top chord and end principals. by tightening the
end tension rods
Set the rack of the truss, equalise the end panels and correct the truss
geometry by adjusting these end tension rods (refer Annexure F.3).

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E.2.9 Confirm correct geometry and good fit of cross braced diagonal struts Correct geometry,
(or cross braced diagonal tension rods in De Burgh trusses) in the good fit , even
central truss panel(s) (i.e. at the adjusted rack). bearing and
uniform tightness
Ensure that end principals are locked in equally tight, with even end
bearing. Ensure uniform snug tight fit of the end tension rods.

E.2.10 Tighten all remaining tension rods, working panel by panel and Tighten remaining
symmetrically from each end of the truss toward centre of truss. panels

E.2.11 When every truss panel has been tightened, ensure that all struts are Preparing truss
bedded in equally tight and with even end bearing, uniformly snug for taking load
tight tension rods and effective truss frame action (i.e. in tightened
condition). The truss is then self-supporting at the zero camber,
ready for cambering and transfer of dead load to the truss.

E.2.12 Camber the truss in-situ on the bridge to achieve the APPROVED Cambering of
CAMBER, using tension rod tightening (refer Clause 4.11.7 and truss and transfer
Annexure G.2). Either camber the repaired truss under its own self of dead load to
weight and then transfer full truss span dead load to the truss, or truss
camber the truss initially fully supported by the TSS and concurrently
transfer dead load from TSS to the truss.

E.2.13 If necessary, transfer dead load back to the TSS, lower the truss to Corrective work
zero camber, carry out corrective work and recamber the truss. and recambering

E.2.14 Erect sway braces and attach to the top chord and cross girders. Erect remaining
Install decking, kerbs, refuge platforms and railing. components

E.3 REPAIR SEQUENCE FOR OLD PWD AND MCDONALD TRUSSES


E.3.1 Fabricate and assemble the bottom chord, set at the (zero) INITIAL Fabricate bottom
CAMBER, supported on the TSS (on bridge) or fabrication blocks (off chord at zero
bridge). This includes notches, mortises and holes for diagonal camber
struts, knee struts, cross girders, and butt blocks.

E.3.2 Locate and install the butt blocks and primary cross girders (at each Install butt blocks
panel point) attached to the bottom chord. Drill holes in the cross and primary cross
girders to suit the position of the tension rods. girders

E.3.3 Stand end principals on bottom chord, attach to chord and butt block. Stand end
Stand cross-braced diagonal struts and knee struts on the bottom principals,
chord, inserted in bottom chord mortises, with the diagonal struts diagonal struts
packed off cross girders using steel wedges. Set wedges initially and knee struts on
“just tight” to allow capacity for tightening and loosening adjustment. bottom chord

Hold end principals and diagonal struts in design position with


temporary props from the bottom chord.

E.3.4 Ensure even bearing of end principals and struts against the bottom Even bearing,
chord and cross girders (through wedges). Ensure correct geometry good fit and
and good fit of all cross braced diagonal struts in their truss panels. correct geometry

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E.3.5 Fabricate the top chord off bridge, supported on fabrication blocks set Fabricate top
at zero camber. Attach top chord shoes and connections to top chord. chord

E.3.6 Erect the (straight) top chord, supported on top ends of end principals Install top chord
and struts. Ensure good bearing of principals and struts against shoes.

E.3.7 Assemble and install all tension rods and tension rod accessories Install tension
(including washer plates), threading each tension rod through the rods
cross girder and top chord, initially finger tight fit.

E.3.8 Adjust and tighten the end tension rods (i.e. at opposite end panel Set rack of truss
points of top chord) against the top chord and end principals. by tightening the
end tension rods
Set the rack of the truss, equalise the end panels and correct the truss
geometry by adjusting these end tension rods (refer Annexure F.3).

E.3.9 Confirm correct geometry and good fit of cross braced diagonal Correct geometry,
struts, knee struts and their truss panels (i.e. at the adjusted rack). good fit, even
bearing and
Ensure that end principals are locked in equally tight, with even end uniform tightness
bearing. Ensure uniform snug tight fit of the end tension rods.

E.3.10 Tighten all truss panels, working panel by panel and symmetrically Progressive
from each end of the truss toward centre of truss. tightening of
remaining tension
Tighten each panel, symmetrically and iteratively, by simultaneously rods and diagonal
tightening the tension rods and adjusting the wedges of both cross struts
braced diagonal struts, to tighten these cross braces equally. Jacks
may be required to assist adjustment of cross braces.

E.3.11 When every truss panel has been tightened, ensure that all diagonal Preparing truss
and knee struts are bedded in equally tight and with even end bearing, for taking load
uniformly snug tight tension rods and effective truss frame action (i.e.
in tightened condition). The truss is then self-supporting at the zero
camber, ready for cambering and transfer of dead load to the truss.

E.3.12 Camber the truss to achieve the APPROVED CAMBER, by tightening Cambering
the tension rods and simultaneously adjusting the wedges (refer concurrent with
Clause 4.11.8 and Annexure G.3). Jacks may be required to assist transfer of dead
adjustment of cross braces. These cambering adjustments load to truss
concurrently transfer dead load from TSS to the truss (truss initially
under truss self weight or full dead load of span).

E.3.13 If necessary, transfer dead load back to the TSS, lower the truss to Corrective work
zero camber, carry out corrective work and recamber the truss. and recambering

E.3.14 Install remaining truss span components as follows: Erect remaining


components
.1 Erect sway braces and attach to the top chord and cross girders.
.2 Locate and erect secondary cross girders (between panel
points) and attach to bottom chord.
.3 Install decking, kerbs, refuge platforms and railing.

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ANNEXURE F––TRUSS ADJUSTMENT/TIGHTENING PROCEDURE
F.1 GENERAL
F.1.1 Annexure F provides a guide procedure for the systematic adjustment Scope of
and tightening of a single truss (but not camber adjustment), to procedure
provide correct truss geometry and remove any residual looseness so
that the truss is structurally self-supporting and ready to carry loads.

Annexure F may be used for:


 Ensuring correct truss geometry and tight fit of connections
during the truss repairs, including initial fabrication.
 Final adjustment and tightening of the truss prior to transfer of
dead load to the truss and final cambering (including remedial
cambering). This is done after completion of any truss repairs.
Annexure F is consistent with the truss fabrication/repair sequence
provided in ANNEXURE E. This procedure is written for an Allan,
De Burgh or Dare truss. However it may be applied to an Old PWD
or McDonald truss, with suitable modifications.

F.1.2 Annexure F must be read and used in conjunction with Clause 4.10. Compliance with
Comply with all relevant requirements of Clause 4.10. Clause 4.10

F.1.3 Truss adjustment and tightening is an iterative process. More than Iterative process
one cycle of corrective adjustment may be necessary. Local
adjustment of single panels is permitted after the first cycle.

F.2 PREPARING TRUSS FOR ADJUSTMENT (INCLUDES TRUSS REPAIRS)


F.2.1 Set the truss at the (zero) INITIAL CAMBER, under either of the Support
following support conditions: conditions for
adjustment
.1 The truss is supported by the TSS (directly or indirectly, with (includes truss
cross girders attached to the bottom chord); or repairs)
.2 The truss carries its own self weight (with cross girders
detached from the bottom chord), provided that all corrective
work or repairs on components has been completed.
F.2.2 Before loosening off the truss (i.e. connections tight), check the Assessing
conformity of the truss geometry and connections (e.g. symmetry, conformity of
gaps, even bearing, tightness), using the checklist in Annexure F.5. truss geometry
Identify any remaining misfits or geometric irregularities requiring and connections
correction or adjustment.

F.2.3 Propose the panel dimensions for the final truss geometry (e.g. panel Proposed truss
height, shoe positions, length of chords). For remedial cambering, geometry
this must be based on striking the best practicable balance of
conformity between ANNEXURE H and the existing truss.

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F.2.4 Determine the corrective and adjustment work necessary to achieve Determining
the improved truss geometry. corrective work

F.2.5 Obtain the Principal’s approval for the proposed final truss geometry Principal’s
and corrective work on truss components before continuing. approval

F.2.6 Insert and adjust props as required to internally stabilise the truss and Propping for
allow for loosening of components during repairs or adjustments. internal stability

F.2.7 Loosen off the following components for the adjustment/repair work: Loosening off
tension rods, sway
.1 All tension rods, “just-loose” so as to release all force in the braces and wedges
tension rod and attached strut(s) but without the washer plate
swinging loose. Grease threads to assist loosening / tightening.
.2 All sway braces, at the top chord connection.
.3 Wedges at the base of diagonal struts in Old PWD and
McDonald trusses, as necessary to ensure that cross braces do
not resist truss geometry adjustments (refer Clause 4.11.8.7).
Before loosening off, ensure that the truss geometry is stable.
Additional loosening may be necessary to remove components.

F.2.8 Carry out any truss repairs and the required corrective work to truss Truss repairs and
components (e.g. altered lengths, replacements) in accordance with corrective work to
the approved final truss geometry and the Specification requirements. components

F.3 SETTING RACK OF TRUSS


F.3.1 Annexure F.3 applies for setting the rack of the truss, so that the truss Racking of truss
chords are parallel and symmetrical about the truss centreline. This to control overall
provides the main control on overall truss geometry (i.e. in outline). truss geometry

F.3.2 Adjust the length of each tension rod to the approved panel height at Correct panel
each panel point. For remedial cambering, the existing panel heights heights
are likely to be too short, due to past cambering adjustments.

F.3.3 After any repairs and corrective work to components and panel height Tension rods
adjustments, ensure that each tension rod is “just-loose” so that the “just-loose”
truss can be easily adjusted as a mechanism. Adjust the tension rod
nut to provide more slack, if required, during the adjustments.

F.3.4 Ensure that the end principals at opposite ends of the truss have equal Correct length of
length (± 10 mm), consistent with the approved final truss geometry. end principals

F.3.5 Straighten the rack of the truss (in elevation) by adjusting the end Setting rack
tension rods at opposite ends of the top chord. Apply equal but square by
opposite increments to these two tension rods from the approved adjusting end
panel height (i.e. tighten one, loosen off the opposite one by the same tension rods
amount), as necessary, to set the rack of the truss square, with the
centre of the top chord plumb above the centre of the bottom chord.

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F.3.6 Ensure that the central cross-braced panel(s) are square and plumb Conformity of
and correctly adjusted according to Step F.4.3. These panels provide cross-braced
internal stability to the truss and will serve as the reference panel(s). panels(s)

F.3.7 If the cross-braced panel(s) conform, tighten all tension rods within Tightening central
these panel(s) to be uniformly snug tight, so as to lock in the adjusted cross-braced
rack and truss geometry. Do not adjust these tension rods further, in panels(s) to lock in
order to avoid overstress of these structurally redundant panels. geometry

F.3.8 After locking off the cross-braced panel(s), adjust the end tension Tightening end
rods at opposite ends of the top chord to be uniformly “just firm”. tension rods

F.4 CORRECTIVE ADJUSTMENT OF TRUSS PANELS


F.4.1 Annexure F.4 applies for systematic minor corrective adjustments to Systematic
all remaining truss panels after the central cross-braced panel(s) have adjustment of
been set, as required, to achieve conforming panel geometry and panels
uniform tightness and end bearing of components.

F.4.2 Start with the opposite pair of panels each side of the central cross- Sequence of
braced panel(s) and progressively work outwards towards each end of adjustment
the truss (i.e. work on opposite pairs of panels at the same time).

F.4.3 Carry out corrective adjustment of each truss panel as follows: Adjustment
procedure within
.1 Within each panel, temporarily loosen off the tension rods and each panel
adjust the props, as required, to make the required adjustments.
.2 Adjust the tension rod nuts to suit correct panel height.
.3 Adjust the panel until it is square (i.e. truss verticals plumb).
.4 Ensure that the ends of all timber struts are trimmed square.
.5 Check the length of each strut (squared ends) for conformity.
.6 Trim the ends of any strut flitch that is too long to achieve the
correct length.
.7 Do not pack or shim struts that are too short, except for
remedial cambering. If any strut flitch is short by more than
10 mm, replace it with one of correct length.
.8 The difference in length of the opposite cross braced diagonal
struts (in a cross braced panel) must not exceed 10 mm.
.9 Close all gaps and check that all connections are engaged tight.
.10 Adjust shoes, washer plates and connections as necessary to
achieve correct position, true alignment and even bearing (e.g.
between shoes and ends of struts).
.11 Retighten each panel after its corrective adjustment, by
tightening the tension rods within the panel in equal increments
so as to achieve uniform snug tightness.
.12 Remove the props and monitor any changes to the panel shape,
before moving subsequently to the opposite pair of panels.

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F.4.4 Monitor the effect of the corrective adjustments on overall truss Monitoring truss
geometry, before and after tightening each panel. geometry

F.4.5 After adjustment and retightening of every truss panel, the truss Truss ready for
structural action will have been restored, ready for final cambering. cambering

F.4.6 Where it is impractical to adjust an existing component and a new Non-scheduled


component is required (i.e. non-scheduled replacement), do not component
replace that component unless directed by the Principal. replacement

F.4.7 Advise the Principal of any problems with truss geometry or misfits Problems that
that remain after completion of the corrective adjustments. Your remain after
proposed Final Camber (refer Clause 4.11.2) must make due adjustments
allowance for any outstanding truss geometry problems.

F.5 CHECKLIST FOR CONFORMITY OF TRUSS GEOMETRY AND CONNECTIONS


F.5.1 The following checklist identifies the key aspects of truss geometry Conformity check
that need to be checked prior to final cambering, at the (zero) INITIAL before final
CAMBER. It does not over-ride the requirements of ANNEXURE H. cambering

Activity Requirements

Correct overall length of top/bottom chords  Conforming to approved truss geometry (i.e. the DRAWINGS).
Constant panel height at each panel point  Equal at all panel points, conforming to approved truss geometry
(vertical separation of shoe faces at top and
 Before corrective adjustments, allowance to be made for applied
bottom chords)
tension rod shortenings from past cambering.
Consistent panel geometry  Location of panel points conforming to approved truss geometry
 Length of diagonals/end principals in correct proportion to panels
Cross braced panels  Square, plumb and good fit
Tension rods plumb (in line of truss and in  Rack of truss to be square (in line of truss)
US/DS direction)
 No lean of truss (in US/DS direction)
Equal length of strut flitches (includes end  End principals at opposite ends: Maximum difference 10 mm
principals)
 Diagonal struts in different panels: Maximum difference 20 mm
 Opposite cross braces (same panel): Maximum difference 10 mm
 Paired flitches: No difference permitted
No gaps/ misfits in diagonals/end principals  All gaps identified and corrected, especially in paired flitches
Uniform tightness in tension rods  No loose tension rods and equal tightness of multiple tension rods
at same panel point.
 All differences in tightness or loose rods identified and corrected
(confirm tightness by applying lateral force at middle of rod).
Shoes, washer plates and connections  In correct position and true alignment
 Good fit and even bearing on timber components
 No relative movements under live loads

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ANNEXURE G––CAMBERING PROCEDURES, TABLES AND FORMS
G.1 GENERAL
G.1.1 Annexure G provides guide procedures for final cambering of a truss Scope
(repaired or existing), after truss adjustment and initial tightening:
.1 Allan, De Burgh or Dare truss (Annexure G.2).
.2 Old PWD or McDonald truss (Annexure G.3).
G.1.2 These procedures must be read and used in conjunction with the Specification
Specification, in particular Clauses 4.4 and Clause 4.11. Observe all requirements
relevant requirements and HOLD POINTS of the Specification.

G.1.3 After completing any truss repairs, adjust the truss as necessary at the Adjusting truss at
(zero) INITIAL CAMBER (refer Clause 4.10 and ANNEXURE F). INITIAL CAMBER

G.1.4 Propose Your Final Camber for each truss (refer Clause 4.11.2). Proposed Final
Camber and
Determine the required CAMBER CORRECTION at each panel point required CAMBER
based on the Principal’s APPROVED CAMBER (refer Clause 4.11.3). CORRECTION

G.1.5 Loosen off all tension rod locknuts at tension rods to be adjusted. Loosening off
Loosen off sway braces at panel points where the truss height will be tension rods and
adjusted by cambering. Maintain truss stability during cambering. sway braces

G.1.6 Measure/record the camber (no live loads) according to Clause 4.2.3: Measuring
camber
.1 Before and after each cycle of cambering.
.2 After full transfer of dead load to the truss (Final Camber).
G.1.7 Monitor the following during cambering: Monitoring
changes during
.1 Changes in tightness of other tension rods not to be tightened cambering
(repeatedly check).
.2 Changes in tightness of TSS hanger supports (where a TSS is
present and provides full or partial support).
.3 Changes in the truss geometry (e.g. height of truss at each
panel point, bearing of component ends).
G.1.8 Camber correction is complete if the following requirements are met: End of camber
correction
.1 The camber profile conforms to Annexure H.1.
.2 All truss connections are tight and conform to Annexure H.2.
G.1.9 Where a conforming camber is not achieved: Conforming
camber not
.1 Diagnose causes of the non-conformity, then lower the truss achieved
back to the (zero) INITIAL CAMBER, transfer dead load back to
the TSS and carry out rectification work (refer Clause 4.11.4).
.2 Repeat the cambering procedure (Annexure G.2 or G.3) until
the camber conforms.

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M757 Timber Truss Repairs – Construction

G.1.10 After completion of cambering, tighten all tension rod locknuts and: Reconnecting
sway braces and
.1 Re-attach cross girders to the bottom chord, where detached. cross girders
.2 Re-attach sway braces to the top chord and adjust as necessary.
G.1.11 Repeat camber measurements after the cambered truss has carried Re-checking
traffic for at least 24 hours but no more than 1 week. If the camber camber after use
has changed, Step G.1.9 applies. by traffic

G.2 FINAL CAMBERING OF ALLAN, DE BURGH AND DARE TRUSSES


G.2.1 This procedure is for final cambering of an Allan, De Burgh or Dare Application
truss by incrementally tightening the tension rods to change the
camber to the APPROVED CAMBER.

G.2.2 Observe the general requirements for cambering in Clause G.1. General issues

G.2.3 Set the truss initially at the (zero) INITIAL CAMBER, under either of Support and load
the following support conditions: transfer
conditions
.1 The truss is fully supported by the TSS (with cross girders
attached to the bottom chord); or
.2 The truss carries its own self weight (with the cross girders
detached from bottom chord and supported by the TSS just
above the Final Camber).
Load transfer in each case will be according to Clause 4.11.7.3.

G.2.4 Use the relevant Camber Table in Annexure G.4 for the particular: Use of relevant
Camber Table
.1 Type of truss and span length;
.2 Truss configuration (number of panels / cross-braced panels).
These Camber Tables require symmetrical tension rod shortenings
that meet the constraints specified in Clause 4.11.1.

G.2.5 Determine the following from the relevant Camber Table: Determination of
cyclic camber
.1 The APPROVED CAMBER, based on DESIGN CAMBER (Item B). increments and
.2 The number of cycles (Item B). tension rod
shortenings from
.3 The applied CAMBER CORRECTION, per cycle (Item C). Camber Table
.4 The applied tension rod shortenings:
 Total, achieved in 4 or 5 cycles (Item D);
 Per cycle (Item E).
G.2.6 The main control is by tightening the tension rods (i.e. shortening the Control of actual
length between the opposite nuts). The nuts of the tension rods of lift
each opposite pair of panel points must be gradually and equally
tightened to achieve the required tension rod shortening increment.
Do not exceed the applied tension rod shortening per cycle (Item E).

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G.2.7 Measure and record the tension rod shortenings, either: Measurement of
tension rod
.1 By direct thread measurement; or shortenings
.2 Based on the number of turns of the tension rod nut. Calculate
the number of threads on the tension rod that provides the
required shortening. One thread equals one full 360 turn of the
nut. Note that the thread pitch may vary between panel points.
G.2.8 For the first cycle, lift the truss by adjusting tension rods as follows: First cycle of
camber
.1 Start with the opposite pair of panel points at each end of the increments
truss and progressively work inwards towards the centre of the
truss in opposite pairs.
.2 Tighten the top chord nut on each tension rod to achieve the
required shortening.
.3 Do not tighten or adjust the length of the tension rods located
within the central cross braced panel(s).
.4 At the end of the cycle, check that the applied CAMBER
CORRECTION (per cycle) has been achieved (Item C).

G.2.9 Similarly, repeat for each subsequent cycle, working from the panel Subsequent cycles
points at the ends of the truss inwards towards the centre, until the
required number of cycles has been carried out.

G.2.10 Where camber adjustment is carried out under the truss self-weight Final dead load
(with cross girders detached from the bottom chord), transfer the full transfer (self
dead load of the truss span from the TSS to the truss after completion weight cambering)
of the last cycle, by loosening off the TSS hanger supports.

G.2.11 Assess successful completion of dead load transfer as follows: Assessing transfer
of dead load
.1 Check that all the TSS hanger supports are loose. Identify any
hanger supports that are still tight and taking load.
.2 Where cross girders are detached from the bottom chord,
confirm by visual inspection that every cross girder engages
with the bottom chord (i.e. all gaps close up).
.3 Monitor the reduced sag camber in the TSS and the
downwards deflection of the timber truss (i.e. reduced hog
camber) as the dead load is transferred.
G.2.12 If dead load transfer is not completed on achieving the APPROVED Dead load transfer
CAMBER, transfer extra dead load to the truss as follows: not complete
.1 Loosen off each TSS hanger support to apply an equivalent
CAMBER CORRECTION (i.e. lowering) as in a single cycle of
tension rod loosening (Item C of the relevant Camber Table).
.2 Start with the opposite pair of TSS hanger supports at each end
of the truss and progressively work inwards towards the centre
of the truss in opposite pairs of TSS hanger supports.
.3 Check the resulting deflection and camber of the timber truss.

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M757 Timber Truss Repairs – Construction

G.3 FINAL CAMBERING OF OLD PWD AND MCDONALD TRUSSES


G.3.1 This procedure is for final cambering of an Old PWD or McDonald Application
truss, by incrementally tightening the tension rods and adjusting the
strut wedges to change the camber to the APPROVED CAMBER. This
procedure is adopted from the old Manual No.6 Bridge Maintenance.

G.3.2 Use Figure G.3 (22.86 m McDonald truss shown, Old PWD truss Reference
similar) as the reference diagram for this procedure and the panel diagram
point numbering. Adopt the procedure as appropriate for other spans.

G.3.3 Observe the general requirements for cambering in Clause G.1. General issues

U2 U3 U31 U21

U11
U1

L0 L1 L2 L3 L31 L21 L11


L01

Figure G.3 Typical Old PWD / McDonald Truss Panel Geometry

G.3.4 Set the truss initially at the (zero) INITIAL CAMBER, with the truss Support and load
fully supported by the TSS or on fabrication blocks, and with the transfer
cross girders attached to the bottom chord. Cambering will conditions
simultaneously transfer dead load to the truss (refer Clause 4.11.8.4).

G.3.5 The main control is by tightening the tension rods and adjusting the Control of actual
wedges, incrementally, to achieve measured displacements of the lift
bottom chord above zero camber to locally meet the required camber.

This is achieved in a single main cycle of direct, empirical


adjustment, followed by iterative fine adjustments, as required.

G.3.6 Start the main cycle with the opposite pair of bottom chord panel Starting main
points corresponding to each end of the top chord (L2 and L21) and cycle at ends of
lift the bottom chord (transferring dead load to the truss) as follows: top chord

.1 At L2, loosen off wedges at the base of struts L2U1 and L2U3.
.2 Tighten tension rod L2U2 until the bottom chord CAMBER
CORRECTION at L2 is slightly more than that required.
.3 Similarly, and simultaneously, repeat for panel point L21.
.4 After achieving the required camber at both L2 and L21, tighten
(i.e. drive in) the wedges at the base of struts L2U3 and L21U31
(i.e. struts leaning toward the centre of the truss) until any sag
in the top chord at points U3 and U31 is removed. Leave the
outwards-leaning struts L2U1 and L21U11 loose at this stage.

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G.3.7 Similarly, repeat the above process for the second opposite pair of Main adjustments
bottom chord panel points (L3 and L31), to obtain the required bottom at inner top chord
chord CAMBER CORRECTION at the panel points and the required panel points
internal top chord camber (at its centre).

The inwards-leaning struts at L3 and L31 will be tight after these


adjustments. Leave the outwards-leaning struts loose at this stage.

G.3.8 For longer spans, repeat the process for additional inner cross-braced Additional
truss panels. Progressively work inwards towards the centre of the adjustments for
truss, adjusting each opposite pair of bottom chord panel points. longer spans

G.3.9 After adjustments: Assessing dead


load transfer and
.1 Assess full transfer of dead load according to Step G.2.11; checking camber
.2 If full dead load transfer is achieved, measure the camber of
the bottom chord and top chord at every panel point for
conformity with the required camber.
G.3.10 Carry out fine adjustments of the tension rods and wedges, following Fine adjustment of
the same sequence as above, as necessary until the camber conforms. camber (central)

G.3.11 After achieving conforming bottom chord camber and top chord Tightening of
camber at every panel point, tighten (i.e. drive in) the wedges at the outwards-leaning
base of the (loose) outwards-leaning struts in the following sequence: struts

.1 L3U2 and L31U21; then


.2 On longer spans, at each inner opposite pair of bottom chord
panel points, working inwards towards the centre of the truss;
then
.3 L2U1 and L21U11, driven tight as necessary to provide the
required internal camber in each end principal (at its centre).
G.3.12 Measure the camber at bottom chord panel points L1 and L11 for Fine adjustment of
conformity with the required camber. Obtain the required camber camber at ends
locally at L1 and L11, by tightening tension rods L1U1 and L11U11.

G.3.13 Carry out the final camber conformity check. If satisfactory, in Final conformity
addition to complying with Step G3.10 retighten all bolts and shear check and
keys in butt blocks, chords and primary cross girders. tightening

G.3.14 Cambering must provide internal cambers in the top chord and end Internal camber of
principals as specified in Clause 4.11.8.6. top chord and end
principals

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M757 Timber Truss Repairs – Construction

G.4 CAMBER TABLES

G.4.1 Cambering of 70 ft (=21.33 m) span Allan Type A truss (7 panels)

End of 1st panel 2nd panel 3rd panel Midspan


Bottom point point point (mid-
Item Description Chord from end from end from end panel)

Panel Point No. L0 L1 L2 L3

70 ft (=21.33 m) span Allan Type A truss with 7 panels (including end panels and one central cross-braced panel)
A DESIGN CAMBER (i) Nil 19 mm 31 mm 37 mm 38 mm
B APPROVED CAMBER (ii)
Nil 24 mm 37 mm 36 mm 35 mm
(achieved in 4 cycles)
C Applied CAMBER CORRECTION (iii)
Nil 6 mm 9 mm 9 mm 9 mm
(per cycle, based on 4 cycles)
D Applied Tension Rod Shortening (iii)
28 mm 16 mm Nil
(total, achieved in 4 cycles)
E Applied Tension Rod Shortening (iii)
7 mm 4 mm Nil
(per cycle)
Notes: (i) The DESIGN CAMBER is a uniform circular hog camber with 38 mm camber at midspan.
(ii) The APPROVED CAMBER is the best practical fit to the DESIGN CAMBER, using tension rod adjustment (but
avoiding adjustment of cross-braced panels). This is the total CAMBER CORRECTION from zero camber.
(iii) For truss lowering, use same cyclic camber loosening adjustments.

G.4.2 Cambering of 90 ft (=27.43 m) span Allan Type A truss (9 panels)

End of 1st panel 2nd panel 3rd panel 4th panel Midspan
Bottom point point point point (mid-
Item Description Chord from end from end from end from end panel)

Panel Point No. L0 L1 L2 L3 L4

90 ft (=27.43 m) span Allan Type A truss with 9 panels (including end panels and one central cross-braced panel)
A DESIGN CAMBER (i) Nil 20 mm 35 mm 45 mm 49 mm 50 mm
B APPROVED CAMBER (ii)
Nil 28 mm 44 mm 49 mm 48 mm 47 mm
(achieved in 4 cycles)
C Applied CAMBER CORRECTION (iii)
Nil 7 mm 11 mm 12 mm 12 mm 12 mm
(per cycle, based on 4 cycles)
E Applied Tension Rod Shortening (iii)
32 mm 20 mm 8 mm Nil
(total, achieved in 4 cycles)
D Applied Tension Rod Shortening (iii)
8 mm 5 mm 2 mm Nil
(per cycle)
Notes: (i) The DESIGN CAMBER is a uniform circular hog camber with 50 mm camber at midspan.
(ii) The APPROVED CAMBER is the best practical fit to the DESIGN CAMBER, using tension rod adjustment (but
avoiding adjustment of cross-braced panels). This is the total CAMBER CORRECTION from zero camber.
(iii) For truss lowering, use same cyclic camber loosening adjustments.

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Timber Truss Repairs - Construction M757


G.4.3 Cambering of 110 ft (=33.60 m) span Allan Type B truss (7 panels)

End of 1st panel 2nd panel 3rd panel Midspan


Bottom point point point (mid-
Item Description Chord from end from end from end panel)

Panel Point No. L0 L1 L2 L3

110 ft (=33.5 m) span Allan Type B truss with 7 panels (including end panels and one central cross-braced panel)
A DESIGN CAMBER (i) Nil 31 mm 52 mm 63 mm 64 mm
B APPROVED CAMBER (ii)
Nil 45 mm 60 mm 57 mm 56 mm
(achieved in 5 cycles)
C Applied CAMBER CORRECTION (iii)
Nil 9 mm 10 mm 11 mm 11 mm
(per cycle, based on 5 cycles)
D Applied Tension Rod Shortening (iii)
50 mm 20 mm Nil
(total, achieved in 5 cycles)
E Applied Tension Rod Shortening (iii)
10 mm 4 mm Nil
(per cycle)
Notes: (i) The DESIGN CAMBER is a uniform circular hog camber with 64 mm camber at midspan.
(ii) The APPROVED CAMBER is the best practical fit to the DESIGN CAMBER, using tension rod adjustment (but
avoiding adjustment of cross-braced panels). This is the total CAMBER CORRECTION from zero camber.
(iii) For truss lowering, use same cyclic camber loosening adjustments.

G.4.4 Cambering of 70 ft (=21.33 m) span Dare truss (7 panels)

End of 1st panel 2nd panel 3rd panel Midspan


Bottom point point point (mid-
Item Description Chord from end from end from end panel)

Panel Point No. L0 L1 L2 L3

70 ft (=21.33 m) span Dare truss with 7 panels (including end panels and one central cross-braced panel)
A DESIGN CAMBER (i) Nil 19 mm 31 mm 37 mm 38 mm
B APPROVED CAMBER (ii)
Nil mm mm mm mm
(achieved in 4 cycles)
C Applied CAMBER CORRECTION (iii)
Nil mm mm mm mm
(per cycle, based on 4 cycles)
D Applied Tension Rod Shortening (iii)
mm mm Nil
(total, achieved in 4 cycles)
E Applied Tension Rod Shortening (iii)
mm mm Nil
(per cycle)
Notes: (i) The DESIGN CAMBER is a uniform circular hog camber with 38 mm camber at midspan.
(ii) The APPROVED CAMBER is the best practical fit to the DESIGN CAMBER, using tension rod adjustment (but
avoiding adjustment of cross-braced panels). This is the total CAMBER CORRECTION from zero camber.
(iii) For truss lowering, use same cyclic camber loosening adjustments.

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M757 Timber Truss Repairs – Construction

G.4.5 Cambering of 91 ft (=27.74 m) span Dare truss (7 panels)

End of 1st panel 2nd panel 3rd panel Midspan


Bottom point point point (mid-
Item Description Chord from end from end from end panel)

Panel Point No. L0 L1 L2 L3

91 ft (=31.67 m) span Dare truss with 7 panels (including end panels and one central cross-braced panel)
A DESIGN CAMBER (i) Nil 25 mm 41 mm 49 mm 50 mm
B APPROVED CAMBER (ii)
Nil 28 mm 48 mm 46 mm 45 mm
(achieved in 4 cycles)
C Applied CAMBER CORRECTION (iii)
Nil 7 mm 12 mm 11 mm 11 mm
(per cycle, based on 4 cycles)
D Applied Tension Rod Shortening (iii)
32 mm 24 mm Nil
(total, achieved in 4 cycles)
E Applied Tension Rod Shortening (iii)
8 mm 6 mm Nil
(per cycle)
Notes: (i) The DESIGN CAMBER is a uniform circular hog camber with 50 mm camber at midspan.
(ii) The APPROVED CAMBER is the best practical fit to the DESIGN CAMBER, using tension rod adjustment (but
avoiding adjustment of cross-braced panels). This is the total CAMBER CORRECTION from zero camber.
(iii) For truss lowering, use same cyclic camber loosening adjustments.

G.4.6 Cambering of 104 ft (=31.70 m) span Dare truss (8 panels)

End of 1st panel 2nd panel 3rd panel 4th panel


Bottom point point point point
Item Description Chord from end from end from end (midspan)

Panel Point No. L0 L1 L2 L3

104 ft (=31.7 m) span Dare truss with 7 panels (including end panels and one central cross-braced panel)
A DESIGN CAMBER (i) Nil 22 mm 38 mm 47 mm 50 mm
B APPROVED CAMBER (ii)
Nil mm mm mm mm
(achieved in 3 cycles)
C Applied CAMBER CORRECTION (iii)
Nil mm mm mm mm
(per cycle, based on 3 cycles)
D Applied Tension Rod Shortening (iii)
mm mm Nil
(total, achieved in 3 cycles)
E Applied Tension Rod Shortening (iii)
mm mm Nil
(per cycle)
Notes: (i) The DESIGN CAMBER is a uniform circular hog camber with 50 mm camber at midspan.
(ii) The APPROVED CAMBER is the best practical fit to the DESIGN CAMBER, using tension rod adjustment (but
avoiding adjustment of cross-braced panels). This is the total CAMBER CORRECTION from zero camber.
(iii) For truss lowering, use same cyclic camber loosening adjustments.

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G.4.7 Cambering of 91 ft (=27.74 m) De Burgh truss (7 panels)

End of 1st panel 2nd panel 3rd panel Midspan


Bottom point point point (mid-
Item Description Chord from end from end from end panel)

Panel Point No. L0 L1 L2 L3

91 ft (=27.4 m) span De Burgh truss with 7 panels (including one central cross-braced panel)
A DESIGN CAMBER (i) Nil 25 mm 41 mm 49 mm 50 mm
B APPROVED CAMBER (ii)
Nil mm mm mm mm
(achieved in 3 cycles)
C Applied CAMBER CORRECTION (iii)
Nil mm mm mm mm
(per cycle, based on 3 cycles)
D Applied Tension Rod Shortening ** (iii) Adjust to
mm ** mm ** mm **
(total, achieved in 3 cycles) keep tight *
E Applied Tension Rod Shortening ** (iii)
mm ** mm ** mm ** Ditto *
(per cycle)
Notes: (i) The DESIGN CAMBER is a uniform circular hog camber with 50 mm camber at midspan.
(ii) The APPROVED CAMBER is the best practical fit to the DESIGN CAMBER, using tension rod adjustment (but
avoiding adjustment of cross-braced panels). This is the total CAMBER CORRECTION from zero camber.
(iii) For truss lowering, use same cyclic camber loosening adjustments.
** This refers to the diagonal tension rod joining the TOP CHORD at the same panel point

G.4.8 Cambering of 104 ft (=31.70 m) De Burgh truss (8 panels)

At End of 1st panel 2nd panel 3rd panel 4th panel


Bottom point from point from point from point
Item Description Chord end end end (midspan)

Panel Point No. L0 L1 L2 L3 L4

104 ft (=31.70 m) span De Burgh truss with 8 panels (including two central cross-braced panels)
A DESIGN CAMBER (i) Nil 22 mm 38 mm 47 mm 50 mm
B APPROVED CAMBER (ii)
Nil 23 mm 41 mm 49 mm 48 mm
(achieved in 4 cycles)
C Applied CAMBER CORRECTION (iii)
Nil 6 mm 10 mm 12 mm 12 mm
(per cycle, based on 4 cycles)
D Applied Tension Rod Shortening * (iii) Adjust to
20 mm * 16 mm * 8 mm *
(total, achieved in 4 cycles) keep tight *
E Applied Tension Rod Shortening * (iii)
5 mm * 4 mm * 2 mm * Ditto *
(per cycle)
Notes: (i) The DESIGN CAMBER is a uniform circular hog camber with 50 mm camber at midspan.
(ii) The APPROVED CAMBER is the best practical fit to the DESIGN CAMBER, using tension rod adjustment (but
avoiding adjustment of cross-braced panels). This is the total CAMBER CORRECTION from zero camber.
(iii) For truss lowering, use same cyclic camber loosening adjustments.
* This refers to the diagonal tension rod joining the TOP CHORD at the same panel point

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M757 Timber Truss Repairs – Construction

G.4.9 Cambering of 117 ft (=35.66 m) De Burgh truss (9 panels)

End of 1st panel 2nd panel 3rd panel 4th panel Midspan
Bottom point point point point (mid-
Item Description Chord from end from end from end from end panel)

Panel Point No. L0 L1 L2 L3 L4

117 ft (=35.7 m) span De Burgh truss with 9 panels (including one central cross-braced panel)
A DESIGN CAMBER (i) Nil 25 mm 44 mm 57 mm 63 mm 64 mm
B APPROVED CAMBER (ii)
Nil mm mm mm mm mm
(achieved in 4 cycles)
C Applied CAMBER CORRECTION (iii)
Nil mm mm mm mm mm
(per cycle, based on 4 cycles)
E Applied Tension Rod Shortening (iii) Adjust to
(total, achieved in 4 cycles) mm * mm * mm * mm * keep
tight*
D Applied Tension Rod Shortening (iii)
mm * mm * mm * mm * Ditto *
(per cycle)
Notes: (i) The DESIGN CAMBER is a uniform circular hog camber with 64 mm camber at midspan.
(ii) The APPROVED CAMBER is the best practical fit to the DESIGN CAMBER, using tension rod adjustment (but
avoiding adjustment of cross-braced panels). This is the total CAMBER CORRECTION from zero camber.
(iii) For truss lowering, use same cyclic camber loosening adjustments.
** This refers to the diagonal tension rod joining the TOP CHORD at the same panel point

88 Ed 1/Rev 2
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G.5 PROFORMA FOR CAMBER ADJUSTMENT - 7 PANEL TRUSS (ONE CROSS-BRACED PANEL)
End A of At 1st panel At 2nd panel At 3rd panel At 3rd panel At 2nd panel At 1st panel End B of
At midspan
Bottom point from point from point from point from point from point from Bottom
(mid-panel)
Item Description Chord end A end A end A end B end B end B Chord

L0 L1 L2 L3 L4 L5 L6 L7

Truss Type: ______________ Span length: ____ __m No. Panels: 7 No. of Cross-Braced Panels: One

A APPROVED CAMBER (i) 0 mm + mm + mm + mm n.a. + mm + mm + mm 0 mm


B Applied CAMBER CORRECTION (ii)
0 mm + mm + mm + mm n.a. + mm + mm + mm 0 mm
(per cycle, based on Number of Cycles)
C Applied Tension Rod Shortening [De Burgh [De Burgh
only] only]
 Total, achieved over all cycles
(Number of Cycles = _____) mm mm mm mm mm mm
 Per cycle mm mm mm mm mm mm
D Tension Rod Nut (hexagonal): [optional]
 Pitch over 5 turns mm mm mm mm mm mm
 Number of turns, per cycle turns turns turns turns turns turns
E Zero Camber (best attempt) (iii) 0 mm +/- mm +/- mm +/- mm n.a. +/- mm +/- mm +/- mm 0 mm
F Required Final Camber (iii) 0 mm + mm + mm + mm n.a. + mm + mm + mm 0 mm
G Actual Final Camber 0 mm + mm + mm + mm n.a. + mm + mm + mm 0 mm
H Difference 0 mm +/- mm +/- mm +/- mm n.a. +/- mm +/- mm +/- mm 0 mm
Notes: (i) The APPROVED CAMBER is a best fit to the DESIGN CAMBER, based on no adjustment of cross-braced panels). Obtain the APPROVED CAMBER from the relevant Camber Table in
Annexure E.4. This is the total CAMBER CORRECTION from zero camber.
(ii) Monitor the change in camber (actual CAMBER CORRECTION) against Item B, after completion of each cycle of tension rod adjustment.
(iii) Includes camber irregularities due to existing bottom chord distortion or irregularities that cannot be corrected during remedial cambering. May not be symmetrical (about midspan).

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M757 Timber Truss Repairs – Construction

G.6 PROFORMA FOR CAMBER ADJUSTMENT - 8 PANEL TRUSS (TWO CROSS-BRACED PANELS)
End A of At 1st panel At 2nd panel At 3rd panel At middle At 3rd panel At 2nd panel At 1st panel End B of
Bottom point from point from point from panel point point from point from point from Bottom
Item Description Chord end A end A end A (midspan) end B end B end B Chord

L0 L1 L2 L3 L4 L5 L6 L7 L8

Truss Type: ______________ Span length: ____ __m Total No. Panels: 8 No. of Cross-Braced Panels: Two

A APPROVED CAMBER (i) 0 mm + mm + mm + mm + mm + mm + mm + mm 0 mm


B Applied CAMBER CORRECTION (ii)
0 mm + mm + mm + mm + mm + mm + mm + mm 0 mm
(per cycle, based on Number of Cycles)
C Applied Tension Rod Shortening [De Burgh [De Burgh
only] only]
 Total, achieved over all cycles
(Number of Cycles = _____) mm mm mm mm mm mm
 Per cycle mm mm mm mm mm mm
D Tension Rod Nut (hexagonal): [optional]
 Pitch over 5 turns mm mm mm mm mm mm
 Number of turns, per cycle turns turns turns turns turns turns
E Zero Camber (best attempt) (iii) 0 mm +/- mm +/- mm +/- mm +/- mm +/- mm +/- mm +/- mm 0 mm
F Required Final Camber (iii) 0 mm + mm + mm + mm + mm + mm + mm + mm 0 mm
G Actual Final Camber 0 mm + mm + mm + mm + mm + mm + mm + mm 0 mm
H Difference 0 mm +/- mm +/- mm +/- mm +/- mm +/- mm +/- mm +/- mm 0 mm
Notes: (i) The APPROVED CAMBER is a best fit to the DESIGN CAMBER, based on no adjustment of cross-braced panels). Obtain the APPROVED CAMBER from the relevant Camber Table in
Annexure E.4. This is the total CAMBER CORRECTION from zero camber.
(ii) Monitor the change in camber (actual CAMBER CORRECTION) against Item B, after completion of each cycle of tension rod adjustment.
(iii) Includes camber irregularities due to existing bottom chord distortion or irregularities that cannot be corrected during remedial cambering. May not be symmetrical (about midspan).

90 Ed 1/Rev 2
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Timber Truss Repairs - Construction M757


G.7 PROFORMA FOR CAMBER ADJUSTMENT - 9 PANEL TRUSS (ONE CROSS-BRACED PANEL)
1st panel 2nd panel 3rd panel 4th panel 4th panel 3rd panel 2nd panel 1st panel
End A of Midspan End B of
point point point point point point point point
Bottom (mid- Bottom
Chord panel) Chord
Item Description from end A from end B

L0 L1 L2 L3 L4 L5 L6 L7 L8 L9

Truss Type: ______________ Span length: ____ __m Total No. Panels: 9 No. of Cross-Braced Panels: One

A APPROVED CAMBER (i) 0 mm + mm + mm + mm + mm n.a. + mm + mm + mm + mm 0 mm


B Applied CAMBER CORRECTION (ii)
0 mm + mm + mm + mm + mm n.a. + mm + mm + mm + mm 0 mm
(per cycle, based on Number of Cycles)
C Applied Tension Rod Shortening [De Burgh [De Burgh
only] only]
 Total, achieved over all cycles
(Number of Cycles = _____) mm mm mm mm mm mm mm mm
 Per cycle mm mm mm mm mm mm mm mm
D Tension Rod Nut (hexagonal): [optional]
 Pitch over 5 turns mm mm mm mm mm mm mm mm
 Number of turns, per cycle turns turns turns turns turns turns turns turns
E Zero Camber (best attempt) (iii) 0 mm + / - mm +/- mm + / - mm +/ - mm n.a. +/ - mm + / - mm + / - mm +/ - mm 0 mm
F Required Final Camber (iii) 0 mm + mm + mm + mm + mm n.a. + mm + mm + mm + mm 0 mm
G Actual Final Camber 0 mm + mm + mm + mm + mm n.a. + mm + mm + mm + mm 0 mm
H Difference 0 mm + / - mm + / - mm + / - mm +/ - mm n.a. +/ - mm + / - mm + / - mm +/ - mm 0 mm
Notes: (i) The APPROVED CAMBER is a best fit to the DESIGN CAMBER, based on no adjustment of cross-braced panels). Obtain the APPROVED CAMBER from the relevant Camber Table in
Annexure E.4. This is the total CAMBER CORRECTION from zero camber.
(ii) Monitor the change in camber (actual CAMBER CORRECTION) against Item B, after completion of each cycle of tension rod adjustment.
(iii) Includes camber irregularities due to existing bottom chord distortion or irregularities that cannot be corrected during remedial cambering. May not be symmetrical (about midspan).

Ed 1/Rev 2 91
(TfNSW COPYRIGHT AND USE OF THIS DOCUMENT - Refer to the Foreword after the Table of Contents)

M757 Timber Truss Repairs – Construction

ANNEXURE H––NOMINATED REPAIR STANDARDS


H.1 TRUSS SPAN GEOMETRY
Feature REPAIR STANDARD Variation to REPAIR
STANDARD
.1 Overall Truss Span Geometry
The upstream (US) and  Parallel in plan & symmetrical about the Bridge Centreline. 
downstream (DS) trusses
 Equidistant from the Bridge Centreline to within ± 10 mm.
 Same overall length of US/DS trusses to within ± 100 mm.
Piers and abutment  Square to Bridge Centreline to within ±2 degrees measured 
centrelines supporting the at the headstocks.
truss spans
 Parallel to within ± 10 mm.
Bottom chords of truss  Ends of all trusses (i.e. Truss Baselines) to be at same 
spans reduced level to within ± 5 mm.
 Top of butt blocks to be level to within ± 0.5 mm over full
width supporting end of bottom chord (excluding camber).
Height of each truss  All trusses of same span and type on bridge to have same 
height to within ± 10 mm.
 Top chord to be same height above bottom chord at all
panel points, to within ± 5 mm (before final cambering).
 Height measured as the vertical separation between bottom
face of top chord and top face of bottom chord, measured
at shoe faces (i.e. contact face of metal shoe with timber).
- For truss repairs, height to be measured after completion
of repairs, while at zero camber, prior to final cambering.
- For measure-up of existing truss in service, measured
heights need to be adjusted to allow for changes in
length of the tension rods (e.g. shortenings) to achieve
the APPROVED CAMBER.
Timber flitches of each  All flitches at all panel points to be the same depth, to within 
chord ± 1 mm (after dressing of shoe faces).
 At each panel point, shoe faces of each flitch to be at same
reduced level to within ± 0.5 mm (after dressing shoe face)
 Non-bowed flitches to have constant separation to ± 5 mm.
Panel dimensions of the  Overall length and height of each panel to conform to 
trusses on each span dimensions on the Original Drawings, to within ± 5 mm.
Cross girders at each  Parallel to each other and square to the Bridge Centreline, 
panel point and equally spaced to within ± 10 mm.
Inclination of struts  Struts inclined at constant slope in accordance with details 
shown on the Original Drawings [except De Burgh trusses].
 Struts vertical [De Burgh trusses].
Inclination of tension rods  Tension rods vertical except for De Burgh truss. 
 Tension rods on De Burgh truss inclined at constant slope

92 Ed 1/Rev 2
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Timber Truss Repairs - Construction M757


Feature REPAIR STANDARD Variation to REPAIR
STANDARD

.2 Horizontal Alignment of Chords


Centreline of each fully  Straight between ends of chord, to within ± 10 mm at any 
rebuilt chord panel point.
Centreline of each  Straight between ends of chord, i.e. not deviating from the 
partially rebuilt chord Chord Baseline by more than 10% (top chord) or 5%
(bottom chord) of the overall chord width [at midspan],
reducing pro-rata to zero towards each end of chord]
 Overall chord width to be measured between the outer
faces of the outermost flitches.
Double flitches of top  Horizontal bow of each flitch: 
chords that are sprung by
- Conform to dimensions on Original Drawings to ± 5 mm.
design.
- Equal bow of each pair of flitches to within ± 5 mm.
- Even, symmetrical curvature over full length of top chord.
.3 Plumb Of Trusses
Plumb in lateral direction  Deviation from true vertical line  10 mm at each panel 
point.
 Measured as the lateral offset between top and bottom
chords.
.4 Sway Braces and Wind Braces
Sway braces  Parallel and in lateral alignment with the same slope to 
within ± 10 mm.
 Where the top chord flitches are bowed, base of sway
braces to be in same straight line, with top chord
connections rising towards midspan to accommodate bow.
Wind bracing  Straight and level between attachment points. 
.5 Camber
All trusses  Difference in camber between the upstream and
downstream trusses to be ≤ 10 mm at any panel point.
INITIAL CAMBER Tolerances for the (zero) INITIAL CAMBER (at each panel point):
 New truss fabrication off bridge: ± 1 mm
 In-situ repairs on an existing truss: ± 2 mm
 Remedial cambering: ± 4 mm
Final Camber  Even, symmetrical and circular hog curvature over full
length of bottom chord, matching the APPROVED CAMBER.
 Tolerances for the APPROVED CAMBER (at each panel point):
- ± 2 mm (after truss repairs or new truss fabrication)
- ± 4 mm (remedial cambering - “best fit”)
Notes 1. These measurements must take into account local recesses, unevenness in the timber surfaces and timber
dimensional variations.
2. Camber measurements must allow for “accepted non-conformances” (refer Clause 4.11.4)

Ed 1/Rev 93
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M757 Timber Truss Repairs – Construction

H.2 ASSEMBLED COMPONENT DETAILS


Feature REPAIR STANDARD Variation to REPAIR
STANDARD
.1 Timber Components
Alignment of Timber Single flitch components (e.g. McDonald truss top chord): 
Components that are not
 Bow, spring and twist conforming to Appendix C of AS 2082
sprung by design (i)
Double flitch components (parallel or splayed):
 Each flitch straight to within ± 5 mm at any point.
Multiple flitch components (e.g. McDonald truss bottom chord):
- Each flitch straight to within ± 2 mm at any point.
Alignment of Timber  Bow of each flitch: 
Double Flitch
- Conform to dimensions on Original Drawings to ± 5 mm.
Components that are
sprung by design (i) - Equal bow of each pair of flitches to ±5 mm.
(e.g. diagonal struts, end - Even, symmetrical curvature over full length of flitch.
principals)
- Measured in the plane of the double components at the
centroid of the double component
 Spring and twist conforming to Appendix C of AS 2082.
Multiple flitches of the  At each panel point, top of each flitch to be at same 
same chord reduced level to within ± 3 mm.
Bearing on ends of  Ends to be cut planar 
compression components
 Minimum 80% bearing contact area (under dead load).
(ii)
Insertion of 0.5 mm feeler gauge not possible at any point.
 No sign of unevenly distributed load on contact face.
 Equal and even bearing between paired flitches of double
flitch components or between the matching joined sections
of multiple flitch or built-up composite components.
Bearing of components  Contact surface at bottom face of supported component to 
directly supported by a be planar and parallel to top face of supporting component.
transverse component (ii)
 For components intersecting at right angles, contact surface
 Cross girder on under supported component to be  40% of design width of
bottom chord supporting component.
 Stringer on cross  Minimum 80% bearing contact area (under dead load).
girder Maximum gap to be < 0.5 mm (measured by feeler gauge).
 No sign of rocking or crushing under loads.
Component directly in  Contact surface dressed planar and parallel to axis of 
contact with a parallel components.
component (ii)
 Minimum 80% contact area (bolts tightened, under load).
 Multiple flitches of Insertion of 0.5 mm feeler gauge not possible at any point.
bottom chords
 Butt blocks
Cover blocks
Jacking blocks
Spacer blocks

94 Ed 1/Rev 2
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Timber Truss Repairs - Construction M757


Feature REPAIR STANDARD Variation to REPAIR
STANDARD

.2 Metal Components
Steel Bottom chord (Dare  Straight between ends of chord to within L / 500, where L is 
& De Burgh) the length of bottom chord, excluding DESIGN CAMBER
 Cross Section - Deviation from true vertical plane:
- Twist ≤ 2 degrees of angular rotation (i.e. 3.5 mm per
100 mm of depth) at any point along the bottom chord
relative to its vertical axis
 Cross section loss < 5% of original cross section area at
any point, evenly distributed around the cross section.
.3 Timber/Metal Contact Interfaces
Shear keys:  All keyway contact surfaces at the splice, shoe or bottom 
chord panel point to make contact simultaneously and
 At tension splices
uniformly with the loaded faces.
 At shoes
 Insertion of 0.2 mm feeler gauge not possible at any point
 Between butt blocks on keyway contact surface (under dead load).
or diagonal struts
 Snug tight fit and no sign of unevenly distributed load on
and bottom chord
each keyway.
(Old PWD and
McDonald)
Contact surface between  Surface to be cut planar and parallel to face of timber flitch. 
metal plate and timber
 Minimum 80% bearing contact area when the bolts are
component: (ii)
tightened or load applied. Insertion of 0.5 mm feeler gauge
 At tension and not possible at any point. No sign of unevenly distributed
compression splices load on each contact face.
 At shoe faces  Equal and even bearing between paired flitches of double
flitch components or between the matching joined sections
of multiple flitch or built-up composite components.
Note (i) Measured between adjacent panel points, after final tightening of assembly.
(ii) These requirements must be met by means of precise carpentry of the timber. Filler materials (e.g. thin lead
sheeting) may only be used for enhanced contact after the standard has been achieved. Filler materials must
not be relied upon to achieve conformity.

Ed 1/Rev 95
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M757 Timber Truss Repairs – Construction

H.3 COMPONENT REQUIREMENTS


Feature REPAIR STANDARD Variation to REPAIR
STANDARD
.1 Timber Components
General  Cross section in accordance with Clause 4.6.4
 Nominal length according to the DRAWINGS.
 Orientation in accordance with Clause 4.6.4
Bearing block  In accordance with the details shown on Original Drawings.
Bottom Chords (Steel)  In accordance with the details shown on Original Drawings.
Butt blocks (Old PWD,  In accordance with the details shown on Original Drawings.
McDonald, Allan trusses)
Camber logs and  No drilled holes in bottom chord flitches at new connections
distribution blocks (i.e. no drilled/bolted connections - see “Cross Girders”).
(Allan Type B trusses)
 No deck crossfall.
 Secured to prevent any slippage:
- Stringers directly located above distributing blocks and
attached to camber log.
- Distributing blocks notched into soffit of camber log.
 Other details according to Original Drawings.
Chords - Top and Bottom  In accordance with the details shown on Original Drawings.
Connecting pieces  In accordance with the details shown on Original Drawings.
Cross girders  Uniform length and in accordance with the cross sectional 
details on Original Drawings.
 Except for Allan Type B trusses, short cross girders at
intermediate panel points to be converted to long sway
cross girders by installing new sway braces to the top chord
(to match existing sway braces).
 Other truss types according to Original Drawings.
 No drilled holes in Allan truss bottom chord flitches at new
connections (i.e. no drilled/bolted connections). A clamped
arrangement must be used (refer Clause 4.8.1).
Jacking Blocks  Bolts joining upper truss elements to jacking blocks to be 
tied to pier transverse supports (i.e. headstocks, capwales).
Cover Blocks
 Otherwise, details to conform to Original Drawings.
 Upper exposed end grain to be protected according to
TfNSW M743.
Permanent Packers  In accordance with the details shown on Original Drawings
(Old PWD and McDonald trusses).
Refuge Platforms  Handrails to be installed around the platform, suitable for 
public use and child proof standard.
 Concealed timber components under platform to be
protected according to TfNSW M743.

96 Ed 1/Rev 2
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Timber Truss Repairs - Construction M757


Feature REPAIR STANDARD Variation to REPAIR
STANDARD

Spacer blocks  Timber grain orientation of spacer block parallel to that of 


the primary load bearing components in contact.
 May be built-up of no more than two smaller components
aligned parallel to the primary load bearing components.
 Upper exposed end grain to be protected (sloping or
vertical primary components) according to TfNSW M743.
 Other details according to Original Drawings.
Stringers  Equally spaced laterally within the truss span. 
 Of uniform cross section (NOTE: Edge stringers are of
same sizes as internal stringers in the Original Drawings).
 Continuous over 2 bays of truss span, except at end bays
where necessary due to staggered joints (see below).
 Joints of adjacent stringers staggered by 1 bay, except at
ends of truss span.
 Butt jointed, with joints at centre of supporting cross girders.
 Aligned with approach span girder spacing, where feasible.
 Temporary supplementary stringers placed aside deficient
stringers to be separated by an air gap  50 mm.
 Other details according to Original Drawings.
Timber Shear Keys,  In accordance with the details shown on Original Drawings
Mortises and Notches (Old PWD and McDonald trusses).
.2 Metal Components
General  Cross section loss < 10% of original cross section area and 
evenly distributed around the cross section perimeter.
 Free of excessive pitting or corrosion.
 Free of defects (e.g. cracks, fatigue damage, excessive
wear deformation, damage, bent or distorted).
Bearing Plates  In accordance with the details shown on Original Drawings. 
(De Burgh Trusses)
 Deformed bearing plates may be packed with precisely
fitted steel wedges to accommodate the deformation and
ensure uniform bearing on the bearing plate.
Bolts, Nuts, Screws and  Clean cut full threads of Whitworth standard
Washers
 Shank straight
Pins (De Burgh Trusses)  Pins not bent or distorted
Shims  Stainless steel of minimum thickness 1 mm
 Secured to shoe or timber using durable mechanical
fasteners to prevent slip
Shoes  Free of excessive wear on bearing faces.
 In accordance with the details shown on Original Drawings,
unless otherwise approved by the Principal.

Ed 1/Rev 97
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M757 Timber Truss Repairs – Construction

Feature REPAIR STANDARD Variation to REPAIR


STANDARD

Splice plates  Flat and not bent.


 Only surface rust with minimal rust pitting.
 Minimal wear at the bolt holes.
 Diameter of circular holes 4 mm larger than bolt diameter.
Sway braces  In accordance with the details shown on Original Drawings, 
unless otherwise approved by the Principal.
 Free of defects
 Threads of turnbuckles sound
 Sound attachment points (i.e. at cross girder and top chord)
Tension Rods  Straight between ends of component to within L / 500,
where L is the length.
 Correct overall length and no signs of elongation.
 Cross sectional loss < 10% of original cross section
diameter, evenly distributed around section. No pitting.
 Not cracked or elongated.
 Rolled threads and not cut threads.
 Threaded length at each end adequate for all adjustments
 Protruding thread length at each end (beyond nut)
approximately equal
 Threads free of defects (e.g. excessive wear or corrosion)
 Snug tight fit.
 Multiple tension rods (at same panel point) parallel and of
equal tightness.
Tension Rod Accessories  Threads free of defects (e.g. excessive wear or corrosion)
Washer Plates  In accordance with the details shown on Original Drawings 
 Free of defects (excessively worn or notched due to wear)
 Square to tension rod.
 Even bearing on the chord
 No packers between washer plate and tension rod nut
Permanent steel packers  Packer plates between timber and non-galvanised metal
and wedges components
Wind braces  Conforming to the details shown on the Original Drawings 
 Free of defects (e.g. broken, damaged).
 Adequate clearance between cross braces.
 Cross braces of equal tightness within each bay.
 Adequate threaded length at each end
 Protruding thread length at each end (beyond turnbuckle)
approximately equal.

98 Ed 1/Rev 2
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Timber Truss Repairs - Construction M757


ANNEXURE I TO L––(NOT USED)

[BELOW THIS NOTICE LEFT INTENTIONALLY BLANK]

Ed 1/Rev 99
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M757 Timber Truss Repairs – Construction

ANNEXURE M––REFERENCED DOCUMENTS, ACRONYMS AND


DEFINITIONS
M.1 REFERENCED DOCUMENTS
M.1.1 Australian and International Standards
 AS 1110.1 ISO metric hexagon bolts and screws - Product grades A and B - Bolts
 AS 1111 ISO metric hexagon bolts and screws - Product grade C
 AS 1112.1 ISO metric hexagon nuts - Style 1 - Product grades A and B
 AS 1112.2 ISO metric hexagon nuts - Style 2 - Product grades A and B
 AS 1112.3 ISO Metric Hexagon Nuts - Part 3: Product grade C
 AS 1237.1 Plain Washers for Metric Bolts, Screws and Nuts for General Purposes - Part 1: General Plan
 AS 1275 Metric Screw Threads for Fasteners
 AS 1442 Carbon Steels and Carbon-Manganese Steels - Hot-rolled Bars and Semifinished Products
 AS 1804 Soft Lead Sheet and Strip
 AS 1831 Ductile Cast Iron
 AS 2082 Timber - Hardwood - Visually Stress-graded for Structural Purposes
 AS 2837 Wrought Alloy Steels - Stainless Steel Bars and Semi-Finished Products
 AS 4100 Steel Structures
 AS 4673 Cold-formed Stainless Steel Structures
 AS 5100.6 Bridge design - Steel and composite construction
 AS/NZS 1252 High strength steel bolts with associated nuts and washers for structural engineering
 AS/NZS 1554.1 Structural Steel Welding – Part 1: Welding of Steel Structures
 AS/ NZS 3678 Structural Steel - Hot-rolled Plates, Floorplates and Slabs
 AS/ NZS 3679.1 Structural Steel - Part 1: Hot-rolled Bars and Sections
 AS/NZS 4491 Timber - Glossary of Terms in Timber Related Standards
 ISO 3506 Mechanical Properties of Corrosion-Resistant Stainless Steel Fasteners

M.1.2 TfNSW Specifications


 TfNSW G10 Traffic Management
 TfNSW G22 Work Health and Safety (Construction Work)
 TfNSW G36 Environmental Protection
 TfNSW G71 Construction Surveys
 TfNSW Q4M Quality Management System (Maintenance)
 TfNSW 2380 Timber for Bridges
 TfNSW B201 Steelwork for Bridges
 TfNSW B223 Lead Paint Management
 TfNSW M743 Protective Treatment of Timber Bridges
 TfNSW M752 Timber Truss Repairs – Temporary Support & Engineering for Construction

100 Ed 1/Rev 2
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Timber Truss Repairs - Construction M757


 TfNSW M756 Timber Truss Repairs – Measure, Inspect & Draw

M.1.3 TfNSW References

 BIS Business Rules TfNSW Business Rules for the Bridge Information System

 TfNSW Bridge Inspection


Procedure

 TfNSW Structural Drafting Manual

 TfNSW Timber Bridge Manual


(TBM)

M.1.4 Standard Industry References

 Australian Hardwood Drying Best Hardwood Drying Best Practice Compendium


Practice Manual

M.2 ACRONYMS
 ARI Average Return Interval of Design Flood according to Engineers Australia
“Australian Rainfall and Runoff”
 BIS TfNSW Bridge Information System
 CEMP CONTRACTOR’S ENVIRONMENTAL MANAGEMENT PLAN
 CMP CONSERVATION MANAGEMENT PLAN
 DS Downstream
 REF REVIEW OF ENVIRONMENTAL FACTORS
 SOHI STATEMENT OF HERITAGE IMPACT
 TBM TfNSW Timber Bridge Manual
 TCP TRAFFIC CONTROL PLAN
 TSS Temporary Support System
 US Upstream

M.3 DEFINED TERMS (NON CAMBERING)


 APPROVED LOADING REGIME The live loading that will apply during the Work (refer TfNSW M752 Clause 4.2.1).
It includes the following aspects:
 Design live load capacity or load limit
 Traffic and pedestrian restrictions, including lateral lane positions on deck
 Other loading conditions to apply during work
 Stage construction sequence
 Scope of TSS
 Bridge Site The bridge and immediate precinct for the truss repairs specified in Annexure A.1
 BRIDGE SURVEY CONTROL The survey control network for the bridge (refer Clause 4.2 and TfNSW G71). In
the case of truss repairs, the control will be shown on the Construction Drawings.
Where Construction Drawings are not available, refer to TfNSW M756

Ed 1/Rev 101
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M757 Timber Truss Repairs – Construction

Clause 4.2.2.
 BUSINESS DAY Any day other than a Saturday, Sunday or public holiday or 27, 28, 29, 30 or 31
December.
 CONSERVATION MANAGEMENT PLAN Documented plan to manage the preservation of a bridge which has heritage value
(CMP) (refer Clause 2.2)
 CONSTRUCTION PROGRAM Refer Clause 2.2.
 CONTRACTOR’S ENVIRONMENTAL Refer TfNSW G36
MANAGEMENT PLAN (CEMP)
 DATE OF COMPLETION Refer Clause 4.12
 DATE OF STAGE COMPLETION Refer Clause 4.12
 DRAWINGS The group of drawings provided by the Principal to represent the truss repairs and
that show all the information required for the truss repairs (refer Annexure A.1).
 HANDOVER INSPECTION Joint inspection mandated at end of the WARRANTY PERIOD (refer Clause 4.12).
 HOLD POINT A point beyond which a work process must not proceed without the Principal's
express written authorisation (refer TfNSW Q4M).
 MATERIALS LIST Refer Clause 3 and TfNSW M756 Clause 4.5.
 MEASUREMENT SYSTEM. The system to take measurements of bridge components and features based on
the BRIDGE SURVEY CONTROL (refer Clause 4.2 and TfNSW M756 Clause 4.2.2).
 NOMINATED REPAIR STANDARD Refer Clause 5.3 and Annexure H
 PRESCRIBED INSPECTION Inspection mandated during the WARRANTY PERIOD (refer Clause 4.13).
 PRESCRIBED MAINTENANCE Maintenance work mandated during the WARRANTY PERIOD (refer Clause 4.13).
 Principal Means the Transport for NSW.
 PROJECT BRIEF Document provided by the Principal to identify the project scope for the proposed
timber truss repair work (refer Annexure A.3).
 PROJECT QUALITY PLAN Refer Clause 2.1.
 REPAIR STANDARD Refer Clause 5.3 and Annexure H
 REVIEW OF ENVIRONMENTAL Refer TfNSW G36
FACTORS (REF)
 Specification Means TfNSW M757.
 STAGE INSPECTION Joint inspection mandated at completion of repairs of each truss (refer
Clause 4.12).
 TRAFFIC MANAGEMENT PLAN Refer Clause 2.3.
 WARRANTY PERIOD Refer Clause 4.13
 WASTE MANAGEMENT PLAN Refer TfNSW G36
 WITNESS POINT A point in a work process where You must give prior notice to the Principal and the
option of attendance may be exercised by the Principal (refer TfNSW Q4M).
 Work The truss repair works specified under the Contract (refer Annexure A, Clause 1
and TfNSW Q4M).
 WORK-AS-EXECUTED DRAWINGS Drawings recording details of the construction following its completion.
 You Means the Contractor, including subcontractors, employees and agents of the
contractor.

102 Ed 1/Rev 2
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Timber Truss Repairs - Construction M757


M.4 DEFINITIONS (NON CAMBERING)
Term Alternative Definitions
Term
 Additional Structural damage, deterioration or defects in components not nominated for
Deterioration replacement, which exceeds the level identified in the most recent BIS condition
inspection by the Principal.
 Anchor Block The upper end attachment component for a diagonal tension rod in a De Burgh
Shoe truss, notched into the top chord at each panel point.
 Assembly Sub-assembly More than one component fabricated together into one assembled unit.
 Associated Secondary structural components joining or supporting primary structural
Component components (e.g. connections, joints, shoes, bolts, splices, saddles, permanent
packers, wedges, spacer blocks)
 Bailey Bailey TSS Proprietary modular welded steel lattice truss bridging system designed for
System strengthening by assembly of multiple panels side by side, multi-storey or
reinforced chords. Assemblies built up of panels connected by pins (refer
TfNSW M752).
 Bay Panel The plan area of the truss span between adjacent panel points of the upstream
and down stream trusses. Each bay corresponds to a panel in each truss.
 Bearing Block In Old PWD and McDonald trusses, an end bearing component for a compression
member, specifically a cast iron joint component for timber diagonal struts and end
principals.
 Bottom Chord The bottom horizontal longitudinal member of a truss (tension member).
 Bottom chord The lateral position halfway between the outer edges of the double (for Allan,
centroid De Burgh and Dare trusses) or outermost (for Old PWD and McDonald trusses)
flitches of the bottom chord, at mid-depth of the flitches and adjusted for
differences in the lateral dimensions of the bottom chord flitches.
 Brace Bracing Component providing stability to a member or assembly of members such as
timber cross bracing on piles. See ”Sway Brace” and “Wind Bracing”
Sway Brace
 Bridge A common longitudinal straight line of best fit through all truss spans of the bridge,
Centreline in plan view.
 Bridge TfNSW bridge inspection and condition rating reporting system and its database
Information
System (BIS)
 Bridge Works The Works Supervisor supervising the Work at the Bridge Site.
Supervisor
 Butt Block Butting Block Longitudinal timber component attached to top of bottom chord, that provides a
horizontal prop against the base of the end principal, thereby assisting load
transfer from the end principal to the bottom chord.
 Camber Log Camber Bearer An intermediate transverse bearing member sitting above the cross girder of a
Block Type B Allan truss, profiled to provide a two-way cross fall in the deck it supports.
 Centroid The centre of area of a solid cross section, effectively the neutral axis. For circular
and rectangular sections, it is at mid-depth of each axis.
 Check A separation of fibres along the grain but not extending through the timber. Also
known as a fissure. A type of timber defect.
 Chord Bottom Chord The primary longitudinal tension and compression members in a truss.
Top Chord

Ed 1/Rev 103
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M757 Timber Truss Repairs – Construction

Term Alternative Definitions


Term
 Chord Baseline The straight line between the ends of the top or bottom chord, at the centroid of
the chord.
 Common A point located halfway between the end panel points of the truss on the Truss
Reference Baseline.
Point
 Component Member Any member or element forming part of a structural assembly.
 Composite A member with two or more components or materials structurally joined to form
Component one member.
 Compression Strut A truss member usually subject to compression loading, such as end principals,
member top chords and diagonal or vertical struts. Usually timber in a timber truss.
 Construction Fabrication A set of drawings that show all the information required for the truss repairs.
Drawings Drawings
Accurate and comprehensive drawings, fully representing the proposed truss
Field Drawings repairs, providing the overall design plan for fabrication and erection, showing all
survey and for setting out details, and demonstrating the fitness and compatibility
of existing and new components.
The Construction Drawings usually form the basis for the WORK-AS-EXECUTED
DRAWINGS.

 Cross Girder Primary transverse bending member in a truss, joining the trusses and supporting
the deck system
 Deck System The assembly of deck components supported by the cross girders (typically
stringers, decking and sheeting).
 Deterioration Progressive decay or insect attack in timber, corrosion in steel and general wear
of components, which have resulted in loss of structural capacity.
 Diagonal Strut Any intermediate sloping timber compression member in the truss, excluding end
principals.
 Durability The natural resistance of timber to biodeterioration due to fungi, insects or
mechanical breakdown caused by weathering, checking and splitting.
 Emergency Repairs needed to temporarily stabilise a structurally critical situation, in the
repairs opinion of a structural engineer.
 End Post The timber end vertical strut of a De Burgh truss transferring the truss vertical load
to the truss supports.
 End Principal Principal The primary end sloping timber compression member (in trusses other than
De Burgh trusses) joining the top chord to the bottom chord and transferring the
truss vertical load to the truss supports.
 Estimated Residual Life The remaining life of a component (assuming normal routine maintenance) before
Service Life its condition deteriorates to the extent that it can no longer perform at its required
level of service (i.e. load capacity, functionality) unless it is repaired or replaced.
 Fastener Commercial bolts, nuts, screws and washers used to join truss components,
except for tension rod accessories.
 Flashing Attached elements providing physical waterproofing to main truss members.
 Flexural A component primarily subjected to bending between supports.
Member

104 Ed 1/Rev 2
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Timber Truss Repairs - Construction M757


Term Alternative Definitions
Term
 Flitch A piece of sawn timber of large rectangular cross section, to a specified size (refer
AS/NZS 4491).
In timber trusses, each individual component of a multiple component member
system, acting either:
 In parallel (e.g. a double flitch strut); or
 In series (e.g. midspan inner flitch of a bottom chord).
 Heart side The preferred orientation of timber flitches to minimise weather exposure and
inwards then improve durability.
downwards
 Inwards – the face nearest the heart of the original log.
 Downwards - the majority of the timber grains on the weather-exposed outer
faces oriented, so as to drain water out of any minor checks or imperfections
that exist or may later develop in the timber.
 Inner Facing the roadway and centre of deck.
 Jacking Block Truss Corbel Timber components under bottom chord at ends of trusses, supporting the trusses
in bearing and distributing load from trusses to the substructure
 Joint Location (typically along a top or bottom chord) where members intersect or come
together
 Keyway Shear Key A rectangular notch cut into a timber component to precisely fit with a mating
component (usually steel), and designed to transfer longitudinal forces between
the two components using the shear key of the mating component.
 Knee Strut In Old PWD and McDonald trusses, the sloping strut bearing against the centre of
the end principal.
 Lateral A component oriented at right angles to the roadway, oriented
upstream/downstream
 Longitudinal A component oriented parallel to the Bridge Centreline
 Measure-up Drawings that represent the geometric layout and dimensions of existing
Drawings components and features of the existing truss spans.
 Metric A comprehensive redrafting of the Original Design Drawings to current standard
Maintenance drafting standards, in metric dimensions.
Drawings
 Midspan The vertical axis at the middle of the truss (i.e. at midpoint of bottom chord),
viewed in elevation.
 Notch Recess A rectangular-shaped recess cut into a timber surface to receive the edge or end
or face of another timber or steel component (e.g. splice plate, shoe).
Check
Rebate
 Original Original Design The original bridge design drawings or original WORK-AS-EXECUTED DRAWINGS
Drawings
 Outer Facing away from the roadway and centre of deck.
 Packer A thin piece of solid timber or metal, of uniform thickness, placed between load
bearing components to fill the gap and carry load between the components.
 Panel The section of truss between corresponding top and bottom chord panel points.

Ed 1/Rev 105
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M757 Timber Truss Repairs – Construction

Term Alternative Definitions


Term
 Panel Point Node The point where the centreline of a truss chords intersects the centreline of other
primary components within the truss frame (e.g. diagonal or vertical members).
 Pin The component joining diagonal tension rod and steel bottom chord of a De Burgh
truss.
 Plan Position The two dimensional horizontal position. The 'x' co-ordinate is parallel to the
Bridge Centreline and the 'y' co-ordinate is at right angles to the Bridge Centreline.
 Plumb Measurement of the variation from the vertical of a component.
 Primary Member Main linear load bearing timber and metal components of a truss (e.g. struts,
Structural chords), joined and supported by associated components (e.g. shoes).
Component
 Principal See “End Principal”
 Principal axes The two orientations of a component, firstly displacements oriented in the
upstream / downstream direction, and secondly displacements oriented in line with
the plane of truss.
 Project The Engineer involved in managing the Works.
Engineer
 Protective Protection applied to a component to provide resistance to deterioration. Refer
Treatment TfNSW M743.
 Racking Rack Distortion of the rectangular truss geometry (in elevation) due to longitudinal
displacement of the top chord (towards one abutment) relative to the bottom
Shear Distortion
chord, caused by unequal horizontal forces in the plane of truss. This tends to:
 Distort the geometry of truss panels from rectangular to parallelogram shape.
 Alter the plumb of vertical members to a constant lean towards one
abutment.
 Recycled Salvaged Timber that has been previously been used and has been recovered for re-use.
Not limited to timber recovered from bridges.
 Reduced Level The vertical height ('z' co-ordinate) above the survey datum.
 Related A primary structural component acting in parallel with another primary component
component (e.g. multiple flitches or tension rods).
 Saddle Plate Saddle In a De Burgh truss, load distributing component at the base of vertical strut and
under cross girder that transmits load from the strut and cross girder to the steel
Stirrup
plate bottom chord.
 Seasoned A timber component which has air dried to remove some moisture.
 Service Life See “Estimated Service Life”.
 Shear Key A projecting section of a component (usually steel) precisely fitting into the keyway
of a mating timber component and designed to transfer longitudinal forces by
means of shear.
 Shoe Metal component at a panel point, designed to transfer loads between intersecting
members, using tight fitting and balanced bearing surfaces
 Shoe Face The contact surface (normally notched in) between a metal shoe and the timber
flitch supporting the shoe.
 Shop Drawings Detailed drawings of new components showing all necessary information for the
fabrication of these components.
 Snug Tight fit Term according to Bolting Category 4.6/S of AS 4100.

106 Ed 1/Rev 2
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Timber Truss Repairs - Construction M757


Term Alternative Definitions
Term
 Spacer Block A solid timber component placed between load bearing timber components of the
truss, to separate and maintain the spacing between them but is not intended to
carry load between the components.
 Splice A joint between timber components of the same cross-section, using attached and
keyed metal elements to transfer the load by shear and bending. Usually
compression splices in top chord and tension splices in bottom chord.
 Steelwork Components or sections made of metal such as sections of metal bottom chords,
metal cross girders, tension rods, tension rod accessories, washer plates, shoes,
splice plates, bearing plates, pins and anchor blocks of De Burgh trusses.
 Straightness For a timber component, the bow, spring and twist as set out in Appendix C of
AS 2082.
 Stringer Longitudinal sawn timber member supporting deck on cross girders
 Structural Existing deterioration or damage in a component (such as a split, check, fracture,
Defect section loss) that results in reduced structural capacity.
 Structural Structural drawings of truss repairs prepared and certified by a Structural
Drawings Engineer.
 Structural A Chartered Engineer eligible for registration with Engineers Australia (IEAust) as
Engineer a structural engineer on the National Engineering Register (NER).
 Strut End Principal A structural timber compression member (either vertical or sloping) in the truss,
which resists compressive forces along the grain.
Diagonal
Vertical Post
 Substructure Load-carrying components (i.e. piers, abutments and their foundations) that
support the superstructure and transmit the load to the ground.
 Superstructure Load-carrying components spanning between and supported by the substructure
(piers and abutments).
 Survey Mark A survey peg, bench mark, reference mark, signal, alignment, level mark or any
other mark used or intended to be used for the purpose of setting out, checking or
measuring the work under the Contract (refer Clause 4.2 and TfNSW G71).
 Sway Brace Lateral Brace Bracing members required to resist the transverse movement of a structural
element.
Sloped transverse steel member outside the truss, joining the top chord to the
cross girder, which stabilises the top chord against lateral sway and bucking.
 Sway Cross A cross girder to which a sway brace is attached.
Girder
 Temporary Bailey Bridge Temporary structure erected under and across existing truss span to support the
Support entire span. Carries dead and live loads during truss repairs thus allowing the
System (TSS) truss to be dismantled (refer TfNSW M752).
 Tension Truss member loaded in tension, such as vertical bars and bottom chords
Member
 Tension Rod Tie Rod A vertical or diagonal steel truss member in tension
King Bolt
Tie
Hanger Bolt

Ed 1/Rev 107
(TfNSW COPYRIGHT AND USE OF THIS DOCUMENT - Refer to the Foreword after the Table of Contents)

M757 Timber Truss Repairs – Construction

Term Alternative Definitions


Term
 Timber Truss A truss comprising timber components of high quality and large cross section, and
steel tension components. Spans from 15 m to 36 m.
 Timber Truss For the purposes of this Specification, this term includes the timber trusses on the
Span upstream and downstream sides of the span, the cross girders supported by the
trusses, associated sway and wind bracing, the stringers supporting the deck and
the butt blocks and jacking blocks supporting the ends of the trusses.
 Top Chord The top horizontal member of a truss, acting as a compression member.
 Top Chord An imaginary line (not necessarily straight) located at the top chord centroid and
Centreline defined as the lateral position halfway between the top outer edges of the double
(for Allan, De Burgh and Dare trusses) or single (for Old PWD and McDonald
trusses) flitches of the top chord, at each top chord panel point.
 Transverse A component oriented at right angles to the roadway.
 Truss A triangulated structural frame in single plane with minimum structural
redundancy, built up wholly of members in tension or compression, usually aligned
longitudinally and connected to at least one other truss for stability. All members
are critical (i.e. removal or failure of any member will cause collapse of frame).
 Truss Baseline The notional straight line between the existing end panel points of the truss bottom
chord. Specifically, the line joining the points where the bottom chord centroid
intersects the existing centreline of the pier or abutment headstock.
 TSS Abbreviation for the Temporary Support System.
 Vertical Strut A vertical timber compression member in a De Burgh truss
 Washer Plate Yoke A metal component, bearing against the multiple flitches of the top and bottom
Stirrup chords (in McDonald, Allan and Dare trusses), that transfers vertical load from the
Cradle tension rod to the top or bottom chord, through intermediate nut, locknut and
Spreader washer components. Also functions to spread the load between multiple tension
rods at the same panel point.
 Wedge In an Old PWD or McDonald truss, a solid piece of timber (obsolete) or steel
(specified), thick at one edge and tapered to a thin edge at the other, that is
inserted and driven into the gap between the cross girder and the bottom of a
diagonal strut, to keep the strut in tight fit or to adjust the shape of the truss panel.
 Wind Bracing Bracing members required to resist the forces and distortions on a structure
resulting from wind pressure.
The wind bracing consists of lightweight horizontal cross-braced frames, formed of
steel tension rods that are adjustable by turnbuckles, that are located below the
deck of the truss span (on some Allan and all De Burgh and Dare trusses). Each
cross braced frame joins the upstream and downstream bottom chords together,
one cross brace per bay of the truss.
The wind bracing is designed to stiffen and stabilise the truss span against lateral
movements between the ends of the trusses, hence keeping the trusses straight.

108 Ed 1/Rev 2
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Timber Truss Repairs - Construction M757


M.5 TERMINOLOGY USED IN CAMBERING

M.5.1 Defined Terms - Cambering


 APPROVED CAMBER The Final Camber to be achieved after the truss repairs, truss fabrication or during
remedial cambering, as approved by the Principal. This is a best fit for the DESIGN
CAMBER for the relevant truss.
The APPROVED CAMBER applies when the truss carries the full dead load of the
truss span, but no live load.
For truss repairs, the APPROVED CAMBER is the camber intended to apply upon
completion of all truss repairs and removal of the TSS (i.e. after completion of
fabrication and erection stages, camber adjustment and transfer of dead load from
the TSS to the truss), making allowance for slack and bedding in of truss
connections under service loads.
The APPROVED CAMBER is provided after completion of truss repairs, by final
cambering of the truss.
 CAMBER CORRECTION The required amount of camber adjustment, calculated as the difference between
the existing camber and required camber (INITIAL CAMBER or APPROVED CAMBER).
The CAMBER CORRECTION is normally carried out in two stages:
 From existing camber to INITIAL CAMBER
 From INITIAL CAMBER to APPROVED CAMBER.
For truss repairs supported at the INITIAL CAMBER, the CAMBER CORRECTION is the
difference between the INITIAL CAMBER and the APPROVED CAMBER.
The CAMBER CORRECTION must be based on consistent loading conditions, the
standard condition being when the truss carries the full dead load of the truss span
but no live load.
 DESIGN CAMBER The camber of the truss that is intended in the original design and applies when
the truss carries the full dead load of the truss span, but no live load. Normally, the
DESIGN CAMBER will be a smooth circular vertical hog curve over the length of the
span.
The DESIGN CAMBER is normally shown on the Original Drawings of the bridge. It
should also be shown on the Construction Drawings or structural drawings,
together with the INITIAL CAMBER.
 INITIAL CAMBER The camber provided during the fabrication and erection stages of truss repairs
(refer Clause 4.4) and for truss adjustments and for commencing final cambering.
The INITIAL CAMBER is provided in the truss fabrication while the truss is in fully
supported condition. INITIAL CAMBER is zero camber for all truss types.
 TOTAL DEAD LOAD DEFLECTION The maximum dead load deflection including truss self weight, transfer of full truss
span dead load from TSS to the truss and further changes to the truss span dead
load after dead load transfer (e.g. cross girders, deck or footway).
Refer Clause 4.4.

M.5.2 Definitions - - Cambering

Term Alternative Definitions


Term
 Camber The vertical alignment of the bottom chord of the truss, measured relative to the
Camber Baseline (i.e. a straight line between the ends of the bottom chord).

Ed 1/Rev 109
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M757 Timber Truss Repairs – Construction

Term Alternative Definitions


Term
 Cambering Any work that changes the camber of the truss. It does not include prefabrication
off the bridge to the INITIAL CAMBER.
 Camber Cambering The process of changing the existing camber of a truss to achieve the required
Adjustment camber.
 Camber A straight line between the camber measurement points (i.e. end panel points) at
Baseline each end of the truss.
 Existing Camber The as-is camber of an existing truss (before truss repairs or remedial cambering)
Camber that applies when the truss carries the full dead load of the truss span, but no live
load.
 Final Camber The camber of the bottom chord achieved after truss repairs, truss fabrication or
remedial cambering. This is normally the APPROVED CAMBER, achieved by means
of camber adjustment.
 Final Cambering The process of achieving the Final Camber after truss repairs or truss fabrication,
Cambering or during remedial cambering.
 Hog Camber Positive Camber A camber profile that is above the Camber Baseline.
 Localised A local deviation at a panel point from the generally smooth, circular camber
Camber profile (i.e. curve of best fit) generated by the other panel points. Measured as
Irregularity the vertical offset from the continuation of the matching smooth profile.
 Nominal Nominal Camber The apparent CAMBER CORRECTION, calculated as the difference between the
Camber Adjustment existing camber and the DESIGN CAMBER.
Correction
 Remedial Camber The process of restoring the camber of an existing truss to achieve the APPROVED
Cambering Adjustment CAMBER, where no component replacements or other truss repairs are planned.
CAMBER A TSS may not be necessary for Allan, De Burgh and Dare trusses (refer
CORRECTION Clause 4.11.1.5).
 Required Required The actual CAMBER CORRECTION to be applied, based on the difference between
CAMBER Camber the existing camber and the APPROVED CAMBER, after allowing for localised
CORRECTION Adjustment camber irregularities.
 Sag Camber Negative A camber profile that is below the Camber Baseline.
Camber
 Zero Camber INITIAL CAMBER The INITIAL CAMBER provided during the fabrication and erection stages of truss
repairs, for truss adjustments and for final cambering.
In remedial cambering, it is only practical to provide a best attempt for the Zero
Camber. This includes camber irregularities (e.g. due to pre-existing bottom chord
permanent deformation) that cannot be corrected during remedial cambering and
may not be symmetrical (about midspan).

….

110 Ed 1/Rev 2

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