ENGINEERING SERVICES FOR THE FINAL DESIGN OF A BRIDGE ACROSS THE CANAL AT THE ATLANTIC SIDE
CONSTRUCTION YARD REPORT
Construction Yard Report
Contract Number 247815: Engineering Services for the Final Design of a Bridge Across the Canal at the Atlantic Side
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Construction Yard Report
1
Segment Casting Yard Consideration for Component A (Section A-B)
The proposed Panama Canal 3rd Bridge comprises a main cable stayed bridge, east approach bridges,
west approach bridges and access roads on the East and West sides. This estimation is for the location
and size of the casting yard required for the production of segments in the east approach, west
approach and main bridge.
The determination of segment casting yard location and size governs by the factors including
accessibility of Limon Bay for the segment transportation, allowed construction period for segment
casting and land acquisition / availability. Option evaluation was conducted to assess the required areas
of segment casting yards. Option 1 assumes that Limon Bay is accessible for transportation, only one
casting yard required at the East of canal. Option 2 assumes that Limon Bay is not accessible for
transportation, two casting yards shall require at both east and west. Summary of evaluation finding is
tabulated as below.
Option
1
2
Location of Casting Yard
East side of canal
East side of canal
West side of canal
Required Size of Casting Yard
18165m2
15608m2
14292m2
The size and location of casting yards are estimated from the currently available information to the
designer. The exact location and required size shall be determined by the future segment casting
contractor to suit their construction.
1.1
Deck Erection Method and Sequence
1) The span arrangements of main bridge, east approach and west approach are summarized in the
table below. Figure 1-1 indicates the span arrangement of East Approach, West Approach and the Main
Bridge.
East
Approach
Location
Bridge A
Bridge B
Bridge C
Bridge A’
Bridge B’
Span Arrangement
12x45m
74m + 125m + 74m
4x78m
West
7x78m
Approach
8x45m
Main Bridge
79m + 181m + 530m + 181m + 79m
Note: The main bridge deck structure will be cast in place concrete box girder.
Construction Yard Report
Contract Number 247815: Engineering Services for the Final Design of a Bridge Across the Canal at the Atlantic Side
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2) In the approach bridges, for modules with span lengths 45m only, the span by span deck erection
method using launching gantry is proposed. These include Bridge A on the East Approach, Bridges B’ of
West Approach. For the remaining modules with 78m or 125m spans, the balanced cantilever deck
erection method using launching gantry is proposed. The direction of deck erection will be from the low
level abutment positions at the two ends towards the main bridge.
3) For the main cable stayed bridge, balanced cantilever method will be adopted for the deck erection.
The main bridge deck structure will be cast in place concrete box girder.
1.2
Bridge Deck Segmentation
1) In the approach bridges, there are a maximum 1025 numbers of precast segments if all the
provisional span modules are required. If all such provisional are not needed, the number of segments is
867. (See Table 1 for the summary) The length of each segment is 3 to 4m. There are three segment
types with various box girder depths for typical span lengths 45m, 78m and 125m, namely type A, B and
C respectively.
Table 1: Summary of Segment Numbers at Approach and Chargres River Bridges
Location
Nos. of Segments
Segment Type
East
Bridge A
157
A
Approach
Bridge B
33+18*2
C&B
Bridge C
93
B
West
Bridge A’
163
B
Approach
Bridge B’
105
A
Total
587
2) From the above, the numbers of each segment type are:
Segment Type
A
B
C
Number of Segments
262
292
33
From the above, at least three sets of casting molds shall be required for the segment production in
approach viaducts.
1.3
Determination of Segment Casting Yard Location and Size
The determination of segment casting yard location and size governs by the following factors:
1) Accessibility of Limon Bay for the segment transportation
2) Allowed construction period for segment casting
3) Land acquisition / availability
Construction Yard Report
Contract Number 247815: Engineering Services for the Final Design of a Bridge Across the Canal at the Atlantic Side
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In view of above factors, the accessibility of Limon Bay will affect the provision of whether one or two
casting yards. In the approach spans of this project, there are 268 segments at the west side of the Canal
and 319 segments at the east side of Canal. If the Limon Bay is accessible for segment transportation, it
is logical to have one single casting yard located at the Eastern side. Alternatively, two segment casting
yards shall be provided at both the west and east sides of the Canal. Therefore, there are two possible
casting yard options.
1.3.1 Option 1: One single casting yard at the East side of Canal
This option is on the basis that the Limon Bay is accessible for the segment transportation. If land
availability is not an issue, the best position for casting yard will be the area of Mindi A. The proposed
location and size of casting yard are determined on the basis of the following premise:
1) Raw materials for the production of segments are assumed to be delivered to the casting yard from
the Eastern side of the Canal.
2) In terms of segment delivery for the West Approach, temporary jetty shall be provided across the
Limon Bay for the segments transportation by barge. For the East Approach, segments can be
delivered directly by land.
3) The overall construction period of the approach bridges is 900 days. For the main cable stayed
bridge, as it is a complex structure, the period is slightly stretched 6 months to 1080 days. Assuming
the set up of the casting yard would require 90 days, the segment casting can start at 3 months after
the commencement of construction period. In general, the deck furniture would need 90 days for
installation. Therefore, the net time remained for segment casting and deck erection is equal to 720
days. In our design, we assumed the segment concrete age is 90 days during the erection. As such,
the maximum time allowed for segment casting is 630 days. Below table illustrate the key timeframe
within the construction period.
Activity
Overall construction period
Casting yard set up
Segment casting
Last segment cast to attain 90 days age
Last day for deck erection
Deck furniture construction
Time
900 days (Day 1-Day 900)
Day 1-Day 90
Day 91-Day 720
Day 721-Day 810
Day 810
Day811-Day 900
4) There are three segment types A, B, C and at least three sets of casting moulds are required. If the
casting operation is smooth, one set of mould can produce one segment each day. However,
segment type A has 262 nos. which may be marginal if only one set of mould is used for the 630
days period. We propose to adopt two sets of moulds for segment type A and one set each for
segments type B, C.
Calculation of casting yard size for segment types A, B & C
The area of casting yard depends on:
Construction Yard Report
Contract Number 247815: Engineering Services for the Final Design of a Bridge Across the Canal at the Atlantic Side
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a)
b)
c)
d)
e)
f)
Number of moulds
Area for reinforcement fabrication
Area for segment storage
Area for material storage
Access road inside the casting yard
Site office and survey towers
Option 1A: Calculation of casting yard size for segment types A, B & C
Zone
Calculation of Area
Mould
Type A/B/C
Segment A/B/C width = 21m
Match cast + wet cast segment lengths =
8m
Fixed bulkhead = 1m
Working space =5m
Clearance from mould to mould = 5m
Area required for each mould for type
A/B/C= (21+5) x (8+1+5) = 364m2
Required Area
For 4 nos. of moulds of type
A/B/C, area = 4 x 364 = 1456
m2
Reinforcement fabrication
Type A/B/C
Segment A/B/C width = 21m
Segment length = 4m
Working space 3m on each side
Area required for each type A/B/C
reinforcement cage fabrication =
(21+3+3)x(4+3+3)= 270m2
For 4 nos. of reinforcement
fabrication for type A/B/C,
area required = 4 x 270m2 =
1080m2
Segment storage
Type A/B/C
Segment width= 21m
Segment length = 4m
Clearance on each side = 1m
Area required for each segment = (21+1+1)
x (4+1+1) = 138m2
Assume to be 10m width and length equals
to the extent of the 5 moulds and
reinforcement fabrication area, which is
equal (21+5)x4+(21+3+3)x4 = 212m
Assume 100 segment types
A/B/C stored on site and
batching in two layers, area
required = 50 x 138m2 =
6900m2
Material storage
Access road
Area of storage area = 212 x 10 = 2120m2
2 access roads, each 10m width. Length of
access road covers the extent of the 5
moulds and reinforcement fabrication area,
which is equal (21+5)x4+(21+3+3)x4 =
Area= 2120m2
For 2 access road, area
required = 4240 m2
Construction Yard Report
Contract Number 247815: Engineering Services for the Final Design of a Bridge Across the Canal at the Atlantic Side
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212m
Area required for each access road = 212 x
10 = 2120m2
Site office, survey towers 15% of above items = 0.15 x (1456+
2369m2
2
and other miscellaneous
1080+6900+2120+4240)= 2369m
Total
18165m2
Note: The above calculation assumes ready mix concrete available and concrete batching plant not
required at casting yard.
1.3.2 Option 2: Two casting yards
This option is on the basis that the Limon Bay is not accessible for the segment transportation. Segment
casting yards have to set up at both east and west side of the canal. At the East side, the proposed
casting yard position is Mindi A, same as option 1. The means of transportation is the same as that
described in option 1. For the West side, the casting yard is proposed to be at the Black Tank North
adjacent to the alignment and direct transportation for deck erection.
For the casting yard at the east side, 319 segments of the approach bridges will be produced. Segment
types A, B and C are 193 nos., 33 nos. and 93 nos. respectively. For the segment production within the
maximum timeframe 630 days as discussed in option 1, total three sets of moulds are required in the
east side casting yard.
For the casting yard at west side, 268 segments of approach bridges will be produced. Segment types A
and B are 105 nos. and 163 nos. respectively. Production of segment type C is not needed in this casting
yard. For the segment production within the maximum timeframe 630 days as discussed in option 1,
total 2 sets of moulds are required in the west side casting yard.
For the easy comparison, calculations of the size of casting yard for segment types A, B and C involved
two different combinations, which are given under options 2A and 2A’.
Option 2A: Casting yard at east side of Canal
Option 2A’: Casting yard at west side of Canal
Option 2A: Calculation of the Area of Casting Yard at East Side of Canal
Zone
Calculation of Area
Required Area
Mould
Type A/B/C
For 4 nos. of moulds of type
Segment A/B/C width = 21m
A/B/C, area = 3 x 364 = 1092
Match cast + wet cast segment lengths =
m2
8m
Fixed bulkhead = 1m
Working space =5m
Clearance from mould to mould = 5m
Area required for each mould for type
Construction Yard Report
Contract Number 247815: Engineering Services for the Final Design of a Bridge Across the Canal at the Atlantic Side
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A/B/C= (21+5) x (8+1+5) = 364m2
Reinforcement Type A/B/C
fabrication
Segment A/B/C width = 21m
Segment length = 4m
Working space 3m on each side
Area required for each type A/B/C
reinforcement cage fabrication =
(21+3+3)x(4+3+3)= 270m2
Segment
Type A/B/C
storage
Segment width= 21m
Segment length = 4m
Clearance on each side = 1m
Area required for each segment = (21+1+1)
x (4+1+1) = 138m2
Material
storage
Access road
Site office,
survey towers
and other
miscellaneous
Assume to be 10m width and length equals
to the extent of the 5 moulds and
reinforcement fabrication area, which is
equal (21+5)x3+(21+3+3)x3 = 159m
Area of storage area = 159 x 10 = 1590m2
2 access roads, each 10m width. Length of
access road covers the extent of the 3
moulds and reinforcement fabrication area,
which is equal (21+5)x3+(21+3+3)x3 =
159m
Area required for each access road = 159 x
10 = 1590m2
15% of above items = 0.15 x
(1092+810+6900+1590+3180)= 2036m2
For 3 nos. of reinforcement
fabrication for type A/B/C,
area required = 3 x 270m2 =
810m2
Assume 100 segment types
A/B/C stored on site and
batching in two layers, area
required = 50 x 138m2 =
6900m2
Area= 1590m2
For 2 access road, area
required = 3180 m2
2036m2
Total
15608m2
Note: The above calculation assumes ready mix concrete available and concrete batching plant not
required at casting yard.
Option 2A’: Calculation of the Area of Casting Yard at West Side of Canal
Zone
Calculation of Area
Required Area
Mould
Type A/B
For 2 nos. of moulds of type
Segment A/B width = 21m
A/B/C, area = 2 x 364 = 728
Match cast + wet cast segment lengths =
m2
8m
Fixed bulkhead = 1m
Working space =5m
Construction Yard Report
Contract Number 247815: Engineering Services for the Final Design of a Bridge Across the Canal at the Atlantic Side
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Clearance from mould to mould = 5m
Area required for each mould for type A/B
= (21+5) x (8+1+5) = 364m2
Reinforcement Type A/B
fabrication
Segment A/B width = 21m
Segment length = 4m
Working space 3m on each side
Area required for each type A/B
reinforcement cage fabrication =
(21+3+3)x(4+3+3)= 270m2
For 3 nos. of reinforcement
fabrication for type A/B/C,
area required = 3 x 270m2 =
810m2
Segment
storage
Type A/B
Segment width= 21m
Segment length = 4m
Clearance on each side = 1m
Area required for each segment = (21+1+1)
x (4+1+1) = 138m2
Assume 100 segment types
A/B stored on site and
batching in two layers, area
required = 50 x 138m2 =
6900m2
Material
storage
Assume to be 10m width and length equals
to the extent of the 3 moulds and
reinforcement fabrication area, which is
equal (21+5)x2+(21+3+3)x3 = 133m
Area= 1330m2
Access road
Site office,
survey towers
and other
miscellaneous
Area of storage area = 133 x 10 = 1330m2
2 access roads, each 10m width. Length of
access road covers the extent of the 5
moulds and reinforcement fabrication area,
which is equal (21+5)x2+(21+3+3)x3 =
133m
Area required for each access road = 133 x
10 = 1330m2
15% of above items = 0.15 x (728+
810+6900+1330+2660)= 1864m2
For 2 access road, area
required = 2660 m2
1864m2
Total
14292m2
Note: The above calculation assumes ready mix concrete available and concrete batching plant not
required at casting yard.
Construction Yard Report
Contract Number 247815: Engineering Services for the Final Design of a Bridge Across the Canal at the Atlantic Side
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