Challenges in Design and Construction of
High Strength Steel Structures
Jewel Changi Airport
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Presentation
• Jewel Changi Airport
• Preview to Domed Roof
• Plunge-in Column
Utilising High-Strength
Steel
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Factsheet
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Site 4.0 hectares
5 Levels and 5 Basements
Extension of Terminal 1
2 Linkbridge connection to T2 & T3
Development GFA about 153,000
sqm
90,000 sqm commercial area
36,000 sqm aviation area
20,000 sqm attraction area at L5
>2500 carpark lots
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TERMINAL 2
TERMINAL 3
LINKBRIDGE TO
TERMINAL 3
LINKBRIDGE TO
TERMINAL 2
JEWEL CHANGI
AIRPORT
TERMINAL 1
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Challenges in Design and Construction of
High Strength Steel Structures
Jewel Changi Airport
Domed Roof
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Domed Roof Factsheet
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Approximate dimension
= 200 m x 145 m
Approximate area
= 25,000 m2
Oculus diameter
= 11.5 m (Area = 104 m2)
Solid milled star nodes
= 4,396 nos. (Each having a unique geometry)
Number of beam
= 12,988 nos.
Number of welded beam
= 3,564 nos. (27.45%)
Number of bolted beams
= 9,424 nos. (72.6%)
Approximate self-weight
= 4,325 tons (approx. 174 kg/m2)
Supported on 14 tree columns (4 branches each) and perimeter “ring” beam.
33 orbits/hoops from oculus to perimeter ring beam.
Bias transition between orbits 3-4, 8-9 and 16-17.
74 types of built-up rectangular sections (150 – 750 deep of various wall thicknesses)
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Domed Roof Preview
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Domed Roof Section
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Domed Roof Internal View
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Domed Roof Edge View
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Domed Roof Perimeter Supports
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Domed Roof Load Path
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Beam Depth Plan
Transition
Transition
Transition
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Beam Depth Section
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Typical Node-Beam Assembly
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Node-Beam Welded Connection
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Node-Beam Bolted Connection
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74 Types of Beam-Connections
22
Depth
(mm)
150
Width
(mm)
120
26
150
120
8
8
WELDED
24
150
120
12
12
WELDED
Mark
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
32/132
200
120
Web
t (mm)
8
8
Flange
T (mm)
8
8
Bolt
4xM24
2xM30
37
200
120
8
8
WELDED
38
200
120
10
10
WELDED
35/534
200
120
12
12
WELDED
36/535
200
120
15
15
WELDED
536
200
120
20
20
WELDED
537
200
120
30
30
WELDED
42
250
120
8
8
2xM30
47
250
120
8
8
2xM36
48/542
250
120
8
8
WELDED
43/143
250
120
10
10
2xM36
543
250
120
10
10
WELDED
44
250
120
12
12
45
250
120
15
15
2xM36
146
250
120
15
30
WELDED
2xM36
51/151
300
120
8
8
2xM36
52
300
120
10
12
2xM36
153
300
120
12
15
2xM36
54/154
300
120
15
30
2xM42
55/155
300
120
15
30
WELDED
61/161
350
120
8
8
2xM36
561/661
350
120
8
8
WELDED
67
350
120
10
10
2xM36
562
350
120
10
10
WELDED
62/162
350
120
10
12
2xM36
63/163
350
120
12
15
2xM42
64/164
350
120
15
30
70/170
Depth
(mm)
450
Width
(mm)
120
Web
t (mm)
8
Flange
T (mm)
8
3xM30
570
450
120
8
8
WELDED
670
450
120
8
8
WELDED
71/171
450
120
10
12
Mark
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
350
120
15
30
WELDED
65
350
120
20
50
WELDED
66
350
120
30
50
WELDED
3xM30
571
450
120
10
12
WELDED
671
450
120
10
12
WELDED
72/172
450
120
12
15
2xM36
572
450
120
12
15
WELDED
73/173
450
120
15
30
2xM42
75/175
450
120
15
30
WELDED
74
450
120
20
40
3xM42
76
450
120
20
40
WELDED
80/180
600
120
10
12
3xM30
580
600
120
10
12
WELDED
81/181
600
120
12
15
3xM36
15
3xM42
581
600
120
12
15
WELDED
82/182
86/186
600
120
15
30
3xM36
600
120
12
87/187
600
120
15
30
4xM42
89/188
600
120
15
30
WELDED
83/183
600
120
20
40
3xM42
88
600
120
20
40
4xM42
84/583
600
120
20
40
WELDED
185
600
120
20
50
WELDED
85/585
600
120
30
80
WELDED
586
600
120
40
80
WELDED
2xM42
165
Bolt
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90/190
Depth
(mm)
750
Width
(mm)
120
Web
t (mm)
10
Flange
T (mm)
12
97
750
120
10
12
3xM42
590/690
750
120
10
12
WELDED
Mark
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
Bolt
3xM36
91/191
750
120
12
15
98/196
750
120
12
15
3xM42
591
750
120
12
15
WELDED
3xM36
92/192
750
120
15
30
3xM36
99/197
750
120
15
30
4xM42
WELDED
94/198
750
120
15
30
93
750
120
20
40
4xM42
593
750
120
20
40
WELDED
194
750
120
20
50
WELDED
95
750
120
20
50
WELDED
595
750
120
30
80
WELDED
596
750
120
40
80
WELDED
Node-Beam-Bolt Distribution
Nodes
Beams
Welded
Beams
Bolted
Beams
625
1713
474
1239
Bay 2
400
1187
246
941
Bay 3
439
1342
430
912
Bay 4
400
1187
240
Bay 5
428
1270
334
Bay 6
426
1272
Bay 7
433
Bay 8
415
Bay 9
Bay 10
Total
Bay
Oculus
Bay 1
M24
M30
M36
M42
Total
872
2341
3521
891
7625
Bay 2
0
1051
3295
667
5013
Bay 3
0
1298
3368
772
5438
947
Bay 4
0
1119
3320
556
4995
936
Bay 5
0
1245
3286
743
5274
390
882
Bay 6
0
1520
2977
694
5191
1266
342
924
Bay 7
20
1442
3048
835
5345
1243
376
867
Bay 8
32
1303
3004
959
5298
433
1266
338
928
Bay 9
12
1364
2982
997
5355
397
1242
394
848
Bay 10
0
1385
2821
655
4861
4396
12988
3564
9424
Total
936
14068
31622
7769
54395
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Bay
Oculus
Bay 1
Column Top Connection
Pinned
Connection
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Column Base Connection
Spherical
Bearing
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Erection Sequence
Bay 01
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Erection Sequence
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Bolt Tightening Tool
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Bolt Tightening
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Site Progress
January 2017
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February 2017
Site Progress
March 2017
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April 2017
Site Progress
May 2017
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June 2017
Site Progress
August 2017
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Site Progress
August 2017
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Site Progress
September 2017
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Site Progress
October 2017
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Site Progress
November 2017
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Site Progress – Early December 2017
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De-propping Procedure
1.
2.
3.
4.
Install 2 nos of jack to support each node.
Load the synchronized jack to remove the shim plate 5mm.
Proceed to the next ring (orbit).
Continue operation until the roof is self supported.

Deflection will be continuously monitored during the depropping procedure
Deflection control limits have been predetermined. Depropping will be suspended if the values exceed this limit.
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De-propping Sequence
1) Lower nodes at supports
and interface to control
deflection and activate the
tree columns.
2) Release and remove the
node supports from ring
beam and oculus inwards.
3) Release and remove
compression ring node
supports.
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Deflection Monitoring Points
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Monitoring of Deflection
During De-propping
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De-propping of BA01 & BA02
Support Brackets at BA02 Completely Removed
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Support Brackets at BA03 Completely Disengaged
Domed Roof at Late December ‘17
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Domed Roof at Early January ‘18
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Challenges in Design and Construction of
High Strength Steel Structures
Jewel Changi Airport
Plunge-in Column Utilising HighStrength Steel
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Topics
Comparison of S355 vs S460 Steel
Effective Yield Strength of Steel to EN10025-4 & BC1
Selection of Buckling Curve for Struts to EN1993-1-1
Typical Elevation of Plunge-in Column in Jewel
Weight Saving in Jewel using S460 (Histar)
Illustrative Sequence of Top-Down Construction in
Jewel
• Process of Installing Plunge-in Column for P62 (1st pile)
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Comparison of S355 vs S460 Steel
S355
S460 HISTAR
Size
Heaviest Section
UC356x406x1086kg/m
Heaviest Section
HD400x1299kg/m
Strength
Reduced strength with
increased plate thickness
Reduced strength only after
plate thickness >80mm
Strut
Unfavourable buckling curve
for built-up section
Favourable buckling curve for
rolled section
Availability
Large stock of available sections
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Limited stock
Long delivery period
Effective Yield Strength
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SS EN 1993-1-1
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Buckling Curve
Buckling curve for rolled S460
Increase in strut
carrying capacity
Buckling curve for
built-up S355
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Comparison of S355 vs S460 Steel
S355
S460
Built-Up Section
1030 kg/m
Area = 1312 cm2
Iz =289900 cm4
Radius of gyration about minor axis = 14.86 cm
Design yield strength, fy = 325 MPa
HD 400x818
818 kg/m
Area = 1043 cm2
Iz =135500 cm4
Radius of gyration about minor axis = 11.4 cm
Design yield strength, fy = 400 MPa
Section Classification : Plastic
Section Classification : Plastic
Cross Section Capacity, Nz,Rd = 42 640kN
Cross Section Capacity , Nz,Rd = 41 720kN
Non-dimensional slenderness, λz = 0.379
Non-dimensional slenderness, λz = 0.548
Buckling curve = d
Buckling curve = a
Reduction factor for buckling resistance, χz = 0.867
Reduction factor for buckling resistance, χz = 0.909
Flexural buckling resistance about minor axis, Nbz,Rd = 36 969kN
Flexural buckling resistance about minor axis, Nbz,Rd = 37 903kN
* Consider flexural buckling about minor axis
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Weight Savings S355 vs S460 (Histar)
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Sequence of Top-Down Construction
in Jewel
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Plunge-in Column
Transfer Plate
2.
3.
4.
5.
L1
Plunge-in columns are designed for construction loads
from B5 up to L5 Deck
Construction Live Loads:
a)
1st Storey
10kPa
b)
B1
20kPa
c)
All other floors
1.5kPa
Superimposed Dead Load is considered for all floors
Plunge-in column design length = 4500mm
Eccentricity in major and minor axis = L/400
B1M
Shear
Head
Drop Panel
Transfer Plate
Shear Head
B1
B2M
B2
Typical Basement Slab
B3
Bored Piles
Typical Basement
Slab
Shear
Studs
B4
250 Slab
500 Drop Panel
1.
1300-2000
Flat Plate
Plunge-in Column Design Parameters
B5
Raft
Bored Piles
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Embedment length
4m
Top-Down Construction
1. Install Diaphragm Wall / Bored Piles / Plunge-in
Steel Columns
Diaphragm
Wall
Plunge-in
Steel Columns
Bored Piles
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2. Construct L1 Transfer Plate
L1 Transfer Plate
Top-Down Construction
3. Excavate below B1 Structure Level
4. Cast B1 Structure
B1 Structure
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Top-Down Construction
5. Excavate below B2 Structure Level
6. Cast B2 Structure
B2 Structure
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Top-Down Construction
7. Excavate below B3 Structure Level
8. Cast B3 Structure
B3 Structure
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Top-Down Construction
9. Excavate below B4 Structure Level
10. Cast B4 Structure
B4 Structure
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Top-Down Construction
11. Excavate below B5 Structure Level
12. Cast B5 Structure
B5 Structure
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Top-Down Construction
Partially Completed Structure
L5
L4
L3
L2
L1
B1
B2
B3
B4
B5
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Process of Installing Plunge-in
Column for P62 (1st pile)
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Plunge-in Column P62
Plunge-in column guide frame
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Plunge-in column guide frame
Plunge-in Column P62
Last concrete truck
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Last concrete truck
Plunge-in Column P62
Re-checking position of bored pile casing
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Lowering guide frame into bored pile casing
Plunge-in Column P62
Leveling the guide frame
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Fixing the guide frame to casing
Plunge-in Column P62
Lifting up the plunge-in column
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Lifting up the plunge-in column
Plunge-in Column P62
Lowering the plunge-in column
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Lowering the plunge-in column
Plunge-in Column P62
Checking leveling of plunge-in column
Lifting eyelet
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Cutting away lifting eyelet
Plunge-in Column P62
Lifting dolly for plunge-in column
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Fixing connecting pin for dolly to plunge-in column
Plunge-in Column P62
Connecting pin for dolly to plunge-in column
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Lowering dolly and plunge-in column
Plunge-in Column P62
Checking level of dolly and plunge-in column
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Spot welding dolly to guide frame
END
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