Bridge Construction Plan and Cost Estimate

FOR INTERNAL USE ONLY Final Report Volume III Design Manual
DIVISION III BRIDGE CONSTRUCTION PLAN AND COST ESTIMATE
CONTENTS
CHAPTER I GENERAL ........... ...... ..... . 3- I
CHAPTER 2 CONSTRUCTION PLAN
2. 1 Objective of Construction Plan 3-2

2.2 Procedure of Construction Plan ... ... ..... . 3-2
2.2 . 1 Preliminary Study 3 -2
2.2.2 Items of Construction Plan ......... . 3-3
2.3 Flow Chart of Major Works 3-5
2.4 Construction Programme
2.5 Construction of Substructures .... 3 -10
2 .5. 1 Structure Excavation 3 -10
2.5.2 Flasework and Form ....... .. ... ... .. . 3 -I I
2.5 .3 Concrete . 3 -14
2.5.4 Pile Driving ..... .. .......... ...., 3 -18

2.5.5 Pile Loading Test "' 3 -22
2.6 Construction of Superstructure .. ....... ...... . 3 -23
2.6.1 Manufacturing Pre-tensioned Beam 3 -23
2.6. 2 Fabrication Yard for Post-tensioned Beam .... 3 -25
2.6.3 Form ....... .... . 3 -25
2.6.4 Concrete ......... 3 -26
2.6.5 Prestressing .. 3 -28
2.6.6 Handling and Launching ... .... ............. . 3 -32
2.6.7 Public Relations ..... 3 -41
2.7 Quality Control .............................. . 3 -42
2.7.1 Importance of QuaJity Control 3 -42
2.7.2 Quality Control Checks .. 3 -43
CHAPTER 3 COST ESTIMATE
3.1 Objective of Cost Estimate ...... 3 -46

3.2 Type of Cost Estimate 3 -46
Cawangan Jalan, Ibu Pejabat JKR, K.L Page 21

3.2.1 Approximate Cost Estimate 3 -46

3.2.2 Detailed Cost Estimate "0" 3 -47
3.3 Structure of Total Project Cost .... 3 -47
3.3. I Direct Cost.. 3 -50
3.3.2 Indirect Cost... 3 -52
3.3 .3 Project Cost .... 3 -54
3.4 Major Work Classification ...... . 3 -54
3.4.1 Clearing and Grubbing .. 3 -54
3.4.2 Structure Excavation and BackfilL .......... .. ......... ............. . 3 -54
3.4.3 Concrete ........... ............. ........... . 3 -56
3.4.4 Reinforcing Steel ... .... . 3 -57
3.4.5 Furnishing Precast Beam and Spun Concrete Pile ... 3 -57
3.4.6 Pile Driving ...... ...... . 3 -57
3.4.7 Prestressing ... 3 -58
3.4. 8 Handling and Launching ...... . 3 -58
3.5 Unit Cost of Major Item of Work 3 -58
3.5.1 Unit Rates and Prices ..... 3 -58
J.S.2 Unit Cost of Major Item of Work .. 3 -59

DIVISION III BRIDGE CHAPTER 2 CONSTRUCTION PLAN

CONSTRUCTION
PLAN AND COST 2.1 Objective of Construction Plan
ESTIMATE
The construction plan is important and
vital to the successful implementation of
CHAPTER I GENERAL
the works, and suitable construction plan
will facilitate the construction.
This manual is prepared to assist engineers
in understanding the construction
Prior to starting actual construction, the
plan/method and estimating procedure of
construction plan should be studied for
standard bridge construction project.
possible problems in order to complete
the project in accordance with the
The construction plan presents mainly
Drawings and Specifications within the
current practices and problems on
contract period and with sound
construction method and work approach of
engineering practice and government's
bridge construction, and it will relate to the
budget.
cost estimate. However, materials and
workmanship stipulated in the
The construction plan should be
specifications are not described in this
reviewed from time to time during
manual. Technical matter concerning
construction, in accordance with the
concrete products and ready-mixed
prevailing circumstances on the site,
concrete are stipulated in Malaysian
also if change in the contract or design
Standard (MS). Also, the following manual
are required during construction, the
and guideline will be referred for site
construction plan should be modified or
management and quality control of
corrected to meet the requirement. The
concrete.
cycle of construction plan is illustrated
below.
- Construction Supervision Manual for
Contract Roadworks (JKR, 1990)
- Guideline for Inspection and Testing of

Roadworks (JKR, 1990)
- Manual on Quality Assurance in

Concrete Works (JKR, 1991)
Bridge construction costs, even though the

same in size, are varied depending on site
condition, environment, construction
method and location of the site. The
accuracy of any cost estimate will depend
on the amount of information known about
the project. This cost estimate presents
fundamental method and procedure which
are universally applicable.

2.2 Procedure of Construction Plan ......... location and size

- Electricity and water supply
2.2.1 Preliminary Study - Survey and laboratory equipment
The construction plan will be provided (3) Construction Methods and Work
taking into account the scope and Approach
quantity of works, and site condition
including environment. - Temporary works
Form and falseworks
(1) Scope and Quantity of Works Cofferdams Temporary water
- Scope of works control
- General drawings Temporary bridge and road
- Major quantities - Structure excavation and backfill
- Removal of existing structure
(2) Site Condition and Environment - Driving foundation piles
- Topography Test pile of loading test Driving
Topographic condition equipment
Drainage condition - Concrete
- Geology Ready-mixed concrete or site mix
Geographic condition Transportation and placing
Soil condition and soil profile - Prestressing
Assumed depth of foundation Force and elongation of tendons
- Climate - Handling and launching beams
Annual rainfall and density Launching method
Dry and wet season - Miscellaneous works.
- River Bearing
Highest and lowest water level Handrail
Stream velocity Expansion joint
- Environment Drainage pipe
Housing, hospital and school
around the site (4) Construction Plant and Equipment
Road traffic and railways
- Public utilities - Selection and delivery to the site
Water, electricity, telephone, - Kinds, numbers, period of use of
sewers, oil and gas equipment required
- Layout on the site
2.2.2 Items of Construction Plan - Workshop
The following items are to be (5) Site Organization and Supervision

considered in planning decision to be
made. - Work assignment and their duties
- Nominated or specialist suppliers
(1) Materials and Products - Nominated or specialist sub-
- Sources and availability contractors
- Route of delivery - Committee and communication
- Scheduling of labour requirement
(2) Preliminary Works (Preparatory
Works) (6) Work Programme
- Site office, storage and laboratory - Sequence of works

- Production rate
- Effect of major public holidays
and weather constraints
- Site traffic and traffic pattern
(7) Quality Control
- Technical inspection
- Quality control testing
(8) Construction Safety

- Cofferdams
- Handling and launching beams
(9) Public Relations

- Utilities........Diversion or protection
- Road traffic management
- Railways/highways ............
Construction operation of flyover

2.3 Flow C hart of Majo r Works
The flow charts of major works of bridge construction, substructure and

superstructure (posHensioned beam) are shown in Fig. 3.1 and Fig. 3.2
respectively.
PREPARATION WORKS
Site Survey
Temporary road and bridge
Temporary water channel
Relocation of public utilities
STRUCTURE EXCAVATION
Open excavation or cofferdam
j
PILE DRlVING
Test pile
j Pile driving
j Splicing of piles
Pile cut·off
FOOTING
Leveling concrete
j Formwork
j Reinforcing steel
j Concrete placing
Curing
ABUTMENT AND PIER BODY
Falsework and formwork
j Reinforcing steel
j Concrete placing
Curing
BACKFILL AND APPROACH ROAD
Compaction of soil
j Road base and subgrade
j Slope protection
RlVER BANK PROTECTION

Stone masonry
Concrete block
Grouted riprap
Fig. 3.1 Work Flow of Substructure

PREPARATION WORKS
Site Sunrey
j Manufacturing base
j for PC beams
MANUFACTuruNGPCBEAM
Formwork
j Reinforcing steel and ducts
j Concrete placing
Curing
PRESTRESSING
Installing prestressing steel
j Calibration of jack
j Prestressing
Grouting
HANDLING AND LAUNCHING
Setting bearings
j Lifting and transportation
j Launching and placing
CROSS BEAM
Fonnwork
j Reinforcing steel
j Tendons
j Concrete placing
j Curing
Prestressing
RC.SLAB
Formwork
j Reinforcing steel
j Concrete placing
Curing
MISCELLANEOUS WORKS
Parapet and handrail
j Drainage pipes
j Expansionjoints
PAVEMENT
Base course
Wearing course
Fig. 3.2 Work Flow of Superstructure

2.4 Construction Programme The schedule control curve which is

called S-cures or Bell-curves for road
In order to estimate the programme of construction was produced by the
construction, the quantities of each statistical analysis in the California
works should be determined. It will Division of Highway, USA is shown
estimated at the probable rate of the below.
work to be performed considering
available labour and equipment, The lower line in this figure gives
allowing for estimated loss in time due allowable progress rate, i.e. at 30% of
to weather conditions, site condition or time passing, an allowable rate of
any other causes. From this information progress is 16-35%. If the progress of
it will be possible to estimate the total work is under 16%, it is necessary to
time required to complete each work. take measures to recover from the
critical condition, and if the progress is
The estimated starting date and over 35%, present incorrect work
completion date for each work will be programme is to be reviewed.
determined. In scheduling the activities
it will consider the desirable sequential An example of work programme for
relationship between the activities. For road construction is shown in Fig. 3.4.
example, in constructing a concrete
foundation, it will be necessary to
complete the excavation before
concrete is placed, and concrete can not
be placed until the forms have been
erected and the reinforcing steel has
been placed. Work programme will be
presented usually in Bar Charts or
Critical Path Method. Typical work
programme of construction of pre-
tensioned and posttensioned concrete
bridge are shown in Fig. 3.3.

1. Pre-tensioned Concrete Bridge Bridge length: 3-span x 22.7m = 68.1m

No. of beam : 3x 11 =33nos.
Work Items Month

1 2 3 4 5 G 7
Mobilization and preparation

Manufacturing PC beam
Bearing -
Transportation & launching -
Hanging scaffolding f-
Cross beam --
RC slab
Miscellaneous works I-
Pavement -
Demobilization - f-
Remarks : Manufacturing PC beams in factory : 30 davs
2. Post-tensioned Concrete Bridge Bridge length: 3-span x 28.7m,. 86.1m

No. of beam : 3x 7 =21nos.
Work Items Month

1 2 3 4 5 G 7 8 9 10 11 12
Mobilization and preparation

Manufacturing PC beam
Bearing - --
Launching - - - f--
Hanging scaffolding 1-
Cross beam
RC slab
f--
Miscellaneous works
Pavement
Demobilization
-
Remarks Manufacturing PC beams on site

(16 davs x 21 nos.) /3 - manufacturing bases - 112 da s
Fig. 3.3 Work Programme of PC Bridge

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FOR INTERNAL USE ONLY Final Report Volume II Design Manual
FINAL REPORT VOLUME III

DESIGN MANUAL
2.5 Co nstruct iOIl of Substructures
2.5.1 Stru cture Excavation
Foundation of substructures are constructed in open excavation if ground-water

level is low, and if necessary, a cofferdam will be constructed to exclude earth and
water from an area in order that work may be performed there under reasonable
dry condition. Temporary water control consists of dikes, by-pass channels and
flumes are carried out specially in dry season.
(1) Open Excavation
The following critical slope grade of excavated surface and depth may be
maintained during excavation works, without any cofferdam and falseworks, if
the ground-water level is low.
Ta bl e 3.1 Critical Slote Gra de and Depth Dunno ExcavatIOn

Type of Ground Depth of Excavation Slope Grade
(D) (a)
Rock or D<5m a<90·
Hard Clay D2:5m a<75·
D<2m a <90·
Other Soil 2m~D<5m a<75"
D2:5m a <60·
Sand D<5m a<35·
Generally, the depth of open excavation is taken from the fo llowing equation if
ground-water level is low:
D=2cJr • tan(4S" + </>/2)
where; D Depth of open excavation

C Cohesion of soH (tlm2)
r Unit weight of soil (tlm3)
</> Coefficient ofintemal friction C)
,
--
.-

(2) Temporary Cofferdam sufficiently high, it may agitate the sand

and cause boils at the bottom of the pit,
Cofferdam should be safety designed as indicated.
and constructed, and be made as water
tight as it is necessary for the proper If an impervious blanket is placed
performance of the work which must be outside and a berm of earth is placed
done inside. It is usually cheaper to inside a sheet-pile cofferdam as
permit some flow of water into the illustrated in Fig.3.5., the increased flow
working area wherein water can be distance will reduce the value of the
removed with pumps than to make the hydraulic gradient which will reduce the
cofferdam watertight. velocity and quantity of water flowing
under the cofferdam. In addition to
The interior dimensions of cofferdam reducing the flow of water, the berm
should have sufficient clearance for the adds horizontal stability to the
construction of forms for inspections cofferdam.
and to permit pumping from outside the
forms. Types of cofferdam are as 2.5.2 Falsework and Form
follows:
(1) Loads.
Land Cofferdam - Wooden plate
- H-beam pile with Falseworks and forms are to be designed
wood plate to have sufficient strength and stiffness
- Steel-sheet pile for the forces which are likely to act on
Water Cofferdam- Earth or rock fill them.
- Steel-sheet pile
(a) Vertical Forces
There are cantilever type and supported
with crib type for wooden plate, Hbeam Weight of forms, concrete, workmen
and steel-sheet pile, according to depth and equipment (including their
of excavation, kind of soil and water impact) from concrete placing,
level. temporary installations, and others.
As a single wall of steel-sheet pile has (b) Horizontal Forces

limited strength in resisting the
horizontal pressure of water or earth, it Compaction of concrete, eccentric
is necessary to provide an internal load and others.
system of bracing to resist the pressure. Load act for falsework is generally
If the dimensions across a cofferdams assumed as 5% of the sum of dead
are not too great, rows of wales and loads.
cross braces will be satisfactory and eco
nomical. When manufactured devices are
employed, the design where in loads
The paths followed by particles of water on such devices do not exceed the
flowing under a sheet-piling cofferdam load ratings recommended by the
are illustrated by lines 1, 2, 3, and 4 in manufacturer.
Fig.3.5. As line 1 offers the shortest
path, the velocity of flow will be the
greatest along this line. If the velocity of
the water entering the cofferdam is

(2) Falsework Steel support - Steel support 0.5 to

1.Om/m
Timber or manufactured devices Steel support - Wood support 1.0 to
which are steel in frames, pipe 2.0m/m
supports, I or H shaped steel beam
and truss beams are used for Wood support - Wood support 1.0 to
falsework. 2.0m/m
Falseworks are to be constructed so (3) Forms

as to transmit acting loads to the
foundation, to allow its anticipated Forms to be made of wood,
settlement and deflection and set plywood, steel or other materials
camber for the vertical alignment. To shall be mortar tight and of sufficient
adjust falsework with setting camber rigidity to prevent distortion due to
strips should use between falsework pressure during concrete operations.
beams and soffit forms or screw
jacks should use at each posts. Frequency of use (repeating use) of
forms depend on handling and
Foundation for falsework maintenance degree, however it is
usually as follows:
- Concrete (thickness is 30 to
40cm) Anticipated settlement Kind of Forms Frequency of Use
- Timber sleeper to be 10 to 30 Wood 3 to 5
m/m Plywood 5 to 10
- Pile depend on soil condition Steel 40
- On footing ........ no settlement Aluminum alloy 100
Settlement of falsework itself is to be (4) Lateral Concrete Pressure on Forms

desirable within IOrn/m.
Displacement of joints of falsework The pressure on a vertical surface is
is as follows: less than hydrostatic pressure of the
concrete. This may be due to the

stiffening of the concrete as the 2.5.3 Concrete

cement hydrates and to the arching
of the concrete against opposite (1) Mixing Concrete
vertical surfaces. For design of
forms, concrete pressure is to be Concrete may be mixed at the site of
determined as follows: construction, at a central plant, or
wholly or part in truck mixers. When
(a) In columns concrete will be mixed at the
construction site, the mixers may be of
P=0.8+(80R)/(T+20) ; the tilting revolving drum or non-tilting
Maximum 15t/m2 or 2.4h t/m2 revolving drum type.
(b) In walls, with rate of placement
not exceeding 2m/hr Table 3.2 presents the maximum output
of various concrete mixers which may
P=0.8+(80R)/(T+20) ; be useful to estimate the number of
Maximum IOt/m2 or 2.4h t/m2 mixers needed at the site and the
duration of concrete production.
(c) In walls, with rate of placement
greater than 2m/hr (2) Transportation of Concrete
P=O. 8+(120+25R)/(T+20) Once the mixed concrete arrives or

batch mixing is finished at site, the fresh
If the revibration, the extyernal concrete shall be handled in such a
vibration of forms, the retarding manner that will maintain plasticity and
admixture, the pozzolanic additions avoid segregation. The transportation
are used, appropriate adjustment for may be accomplished in several ways,
increased pressure can be made. depending upon the distance, elevation
and other constraints imposed, as shown
where: in Table 3.3.
P : Lateral pressure of
concrete (t/m2)
R : rate of concrete placing
(m/hr)
T : temperature of
concrete in the forms
(deg.C)
h : height of fresh concrete
above point considered
(m)

Relationship between rate of placement and lateral concrete pressure in shown Fig. 3.6
Table 3.2 Concrete Mixer

Wet Batch Not-Titling Type Titling Type
Capacity Power Output per Power Output per
(m3) (kW) hour (m3) (kW) hour (m3)
0.10 - - 1 2
0.15 - - 2.5 4.5
0.20 5 6 4 6
0.30 7 7.5 6 7.5
0.40 11 12 9 9
0.75 18.5 23 15 18
1.50 30 42 23 36
2.30 45 61 30 55
3.00 56 80 37 73

Table 3.3 Transportation Method

Maximum
Direction Capacity Distance Power Remarks
(m3) (m)
Truck Horizontal 1 to 10/no 10,000 Engine Access road
Fork lift Horizontal 0.5 to 1.0/no 200 Motor Access road
Agitator Horizontal 1 to 10/no 20,000 Engine Long distance
Buggy Horizontal 0.5 to 0.2/no 50 Manual Runway
Engine
Bucket Vertical 0.5 to 1.0/no 50 with Crane
25 Crane
Pump Horizontal 1.5 to 80/hr 200 Engine Bulk
Vertical 40 Volume
(3) Placing Concrete
To avoid segregation of the concrete

materials and the displacement of the
reinforcement, the long troughs, chutes,
and pipes for conveying the concrete
from the mixer or bucket to the forms
will be used for placing concrete.
Fig. 3.7 demonstrate correct and

incorrect handling method, and also
show how to avoid segregation in
placing concrete.
(4) Compaction of Concrete
The vibrators shall be inserted and with

drawn out of the concrete slowly and be
of sufficient duration and intensity to
thoroughly consolidate the concrete, but
shall not be over vibrated so as to cause
segregation. Fig. 3.8 demonstrate correct
and incorrect compaction of concrete
method.

CHUTE
..... BUGGY
CORRECT INCORRECT
Separation is avoided discharging pemlitting concrete from chute or

concrete into hopper feeding into drop buggy to strike against from and
chute. This arrangement also keeps ricochet on bars and foml faces
forms and steel clean until concrete causes separation and honeycomb
covers them. at the bonom.
CORRECT INCORRECT
Concrete should be dumped into face Dumping concrete away from

of previously placed concrete. previously placed concrete
causes separation.
Fig. 3.7 Methods of Placing Concrete

(from ACI Manual of Concrete Practice)

:~
-
" ~
....". .-';'..-;:'.;"".
' ' "
-:-.,: .. . ....
....
'-,...
"
CORRECT INCORRECT
Start placing at bottom of slope When placing is begun at top of

so that compaction is increased by slope the upper concrete tends to pull
weight of newly added concrete. apart especially when vibrated below
Vibration consolidates the concrete. as this starts flow and remo ....es suppon
from concrete above
o·
_. I ,. 1/~., <1•
, ".'0".0: . ".
•• _
\ .... ," ';
,.,0,'
4 ·... 'JQ'/<3.
f ." • 4 Q':0 ~~;0 ' ,' ' : ' ''
6 ~ J., .. ... • 0 ,. ..... \) :
.' 0
CORRECT INCORRECT
Vertical penetration of vibrator Haphazard random penetration

a few inches imo previous lift of the vibrator at all angles and
(which should not yet be rigid) spacing without sufficient
at systematic regular intervals depth will not assure intimate
will give adequate consolidation. combination of the two layers.
Fig.3.8 Methods of Compaction of Concrete

(from ACI Manual of Concrete Practice)

2.5.4 Pile Driving penetration depth is also difficult so a

soil survey is required before starting
(1) Pile Driving Method the work.
a) Percussion Driving Method d) Hydraulic Method
Many new pile driving methods have Machine manufacturers, etc., are
been developed but this method developing low-noise hydraulic
continues to be the most popular due hammers having the same driving
to its performance, economy and performance as diesel hammer. The
efficiency. Piles may be driven with noise level of all of these hydraulic
a drop hammer, an air/steam hammer hammers is below 80 phones (A) at
or diesel hammer. a distance of 30m from the pile
driving machine. A hydraulic
b) Vibration Method hammer consists of a hammer, a
power unit and a sound-proof cap. It
The force is applied by vibro lifts the ram by hydraulic pressure or
hammer continuously to overcome supplied by the power unit and drops
the skin friction of the pile and thus it freely to hit the pile and penetrate
obtain penetration. This method was it.
developed for driving sheet piles but,
in the case of concrete piles, this (2) Selection of Hammer
method is applied when the required
driving force becomes extreme by Pile driving hammers are to be selected
depending on the soil or when the according to the soil conditions, kind
piles are excessively long. of piles and size of pile. Standard
hammer selection charts for precast
c) Excavation Method concrete piles and steel pile are shown
in Fig. 3.9.
This is one of the methods that have
been developed to prevent the (3) Sequence of Pile Driving
pollution of vibration, noise, etc.
These methods include pre-boring Driving resistance will be gradually
methods and inside boring methods. increased due to compacted soil by
In the pre-boring method, hoes are driving piles. Therefore, pile driving
drilled ahead of time at the locations work should be started from one side of
where piles are to be driven. Piles pile group to the other side or from the
are lowered into these holes and then center of pile group to outside.
driven to refusal in order to obtain
bearing strength. Bentonite or 4) Determination of Bearing Capacity
cement milk are often used to
prevent cave-in of the hole where the When the driving method is adopted for
ground is sandy or soft. precast pile, the bearing capacity can be
estimated from the hammer conditions,
Compared with the percussion also the pile penetration depth and the
method, piles are sometimes bent or rebound can be measured. In general,
broken when the hole is not straight. the length of test pile will be greater
Thus, great care is required in than the estimated length of pile in order
drilling holes. Control of the to provide variation in soil condition.

These method is usually attach to a (m)

recording sheet on the pile and hold a N : Average standard
pencil as shown in Fig. 3.10. The penetration value of
bearing capacity of piles will be soil around pile
determined using following methods. K : Rebound value (m)
eo,ef : Coefficient as follows:
a) Hiley's formula
Ru = (ef o Wh ° H)/(S+1/2K) Ra =
1/3 Ru
Kind of pile eo ef
where;Ru : Ultimate bearing load Concrete (PC,RC) 2*WH/WP 2.5
(t) Bored Concrete (PC) 4 *WH/WP 10
Ra : Allowable bearing load Steel 1.5*WH/WP 2.5
(t) WH: Weight of hammer
WP : Weight of pile
ef : Efficiency of hammer
(diesel hammer 0.5)
(drop hammer 0.7)
Wh : Weight of hammer or
ram (t)
H : Height of hammer
(cm)(diesel hammer
2H)
S : Permanent settlement
(cm)
K : Rebound value (cm)
b) Wave equation formula
The equation is recommended in

"Road Bridge Guideline", Japan
Ru = (A o E o K)/(eo o 1)+(N o
u o 1/ef) Ra = 1/3 Ru
Pile driving work can be stopped

at 2 to IOm/m of penetration
values, if driving work continue
under 2mm of penetration value,
pile will be damaged.
where;Ru : Ultimate bearing load

(t)
Ra : Allowable bearing load
(t)
A : Cross sectional area of
pile (m2)
E : Young’s modulus of
pile (t/m2)
1 : Pile length (m)
u : Distance around of pile

~" P'< -'<; - ,,-

~lO-K
020._. _ _
~-I-f';--
_ _ ._.. _. _____ ~_ .
a- 10· - - - - - --- - - ----_

a 11'.ll, 1.!-11, .,'t-,
',-,-,-.-
1/-)\, ,,-,,\,
w "" w w 100 I"Q gOO 1.000 1.)00 1./00 lOO 00 100 000 NO 100 100 I.tOO 1.100 I.1CO
Dia or rile {mOl} Dia of Pile (",nI)
(a) Steel pile (Il) Concrete Pile
•- -
f-i" 1- - - - l-
•-P'-< - i'" I- I-
·• -f-
• lOO
-+- -,- - - -
--- II" -- - - 1- -
- 1./-/.1'
100 \00
Dia ofPilc
n,
600 100
~\-j.11
.(n"n)
I.I-l.~
-
-
&00 'o~ 1.000 1.1,0 lJOO
(cl Bore Concrete Pile
I
"p,t""
,,
'17m'" I,~ t
C;;-O"~,,o)
:: I
, ,'
"
"
" ,,
, ,'------- ru-==~=HI,
" ,
;.~/
Fig.3.10 Measuring Penetration and Rebound per Blow

(5) Troubles During Pile Driving dried river. Although, it is difficult to

identify these cases from those
Depending on types of soil layers, such caused by other factors,
a phenomena will possibly occur that comprehensive judgment shall be
furthermore driving becomes impossible made by increasing a number of
before a pile reaches an intended bearing boring tests and comparing with
layer of finishing requirements are not driving depth of other piles.
met even when the pile is driven to a
specified depth, as described below. In c) If finishing requirements are not met
such cases, design and construction even by driving a pile to a specified
conditions shall be fully reviewed to depth:
cope with the events.
To cope with this case, an additional
a) If it is impossible to drive a pile pile is often joined and driven. If it is
through an intermediate layer before impossible to splice/joint additional
it reaches a bearing one, or if further, piles due to properties of materials,
driving is difficult due to excessively other measures shall be adopted by
large compacting effect of earth: taking design conditions into
account. It is impossible to
It seems that bearing requirements unconditionally define penetration
are met as far as axial bearing for finishing hammer and an
capacity is concerned. If depth of appropriate hammering frequency to
intermediate layer is more than 5m, drive a pile, by ignoring differences
it is considered as bearing stratum. in types, lengths, and shapes of piles
However, the pile's embedded depth and soil layer conditions. By
may have been determined at the referring to past data, however, it is
design stage by scouring, lateral concluded that penetration for
resistance, consolidated settlement of inishing hammer shall be 2 to
cohesive layers, and other l0 mm.
requirements.It is necessary,
therefore, to take such measures as 2.5.5 Pile Loading Test
using a larger hammer, apply a
pile-boring method in addition to the (1) Purpose of Loading Test
pile-driving method, or mount a
friction cutter at the pile tip. Pile capacity can be estimated by
using various dynamic or static
b) If it is found difficult to make formulas based on site investigation
further driving to reach a specified results. However, due to several
depth, because in intended bearing inherent uncertaines and inaccuracies
layer is located at a shallower depth: in these methods, it is a usual
practice to verify the load carrying
This case in which it is found capacity of piles by loading tests.
difficult to make further driving
because an intended bearing layer is Generally the main objectives of
located at a shallower depth than loading tests are:
expected are often seen when a
construction area extends over a To determine the load-settlement
wide area or when construction is characteristics of piles
effected at a catchment basin of a To check the ultimate capacity

To check the structural soundness The load causing gross settlement

of pile foundation of 10 % of the pile width
(Terzaghi)
(2) Type of Loading Test
Three common types of compressive

loading test on piles are:
Constant Rate of Penetration

(CRP) Test, in which the
compressive force is
progressively increased to cause
the pile to penetrate the soil at a
constant rate.
Maintained Load (ML) Test, in
which the load is increased up to
twice the design load in stages to
some multiple,
settlement curve recorded at each
stage of loading and unloading.
Pile dinamic analysis (PDA) Test.
CRP and ML tests use the same
type of loading arrangements and
pile preparation. Suitable loading
arrangements for applying the
load to the pile by a hydraulic
jack using as the reaction, either
kentledge blocks.
(3) Times before Load Test
As long as possible, sufficient time

shall be allowed before carrying out
the load test after installation because
the skin friction recover in early
stage. "Construction Standard",
Japan recommended that pile in clay
should be tested more than 14 days
after driving piles and for piles in
sand 5 days.
(4) Evaluation of Loading Test
(a) Ultimate Load
The load at which settlement

continues to increase without any
further increase of load.

b) Allowable Load
A criteria for detennination of the allowable working load from loading

test results are: -
Less than allowable stress of pile; or

Yield load x (1/2 to 113); or
Ultimate load x (1/3 to 114) whichever is the lowest value
The test results are summarized in the form of load-settlement curve for
the CRP test and a load-time-settlement curve for the i l l test.
Yield load can be judged from log P-log S curve, S-log t curve and 6S1
610g t - P curve.
2.6 Construction of Superstruct ure
2.6.1 Manufacturing Pre-tensioned Beam
In order to reduce beam sections or dead load of beam, the partial debonded strand
method and deflected strand method are employed for hollow slab and composite
T-beam respectively.
It can avoid tensile stresses at the top at supports by preventing bond for some of
the tendons at a computed length near the ends by covering the strands with plastic
tube. The deflected strand method needs some additional investment on the plant
to provide for hold-downs and special equipment for raising the strands.
Both methods and anchorage for deflected strand are shown in Fig.3. 11 and
Fig.3.I2.
Poniol fkbond Strond Method
------ -.,
8eom 8~ cm
. F-- ~ ...:.----
·1 De!xmd wi'JJ pklstic tube
O~fl eded Strand Method
-7C~ r- - - - - - - - - - -'L-..-,,---Jr- -- - - - - - ---'L-'-"'~~::.

I · Beem I I 8e:lm I
..-= L ___________ J l ___________ J
, I , ,
i , , !
Mcher SliP port Ancher
Fig.3.l1 Partial Debond and Deflected Strand Method

2.6.2 Fabrication Yard for Post-tensioned under the planned bridge.

Beam
The following facilities are provided on
The site of the precasting plant should the plant site and their layout is shown
be of adequate size including transport in Fig. 3.13.
vehicles and handling equipment, and
allow satisfactory manufacture and Girder production yard
storage space of girders. The plant site Girder stock yard
should be flat and trafficable areas, and Concrete plant (if ready mixed
good drainage in the whole site is concrete is not available) - Material
necessary. The energy for operating the Office and storage
plant and water supply for concrete Handling and transport
mixing and curing should be available.
The plant site is usually selected on the
bridge approach road or at the river bed

2.6.3 Form
(1) Preparation of Form
Depending on the frequency of use (number of use of girder), the following types
of formwork can suitably be used for post-tensioned T-beam.
Frequency of Use (number of Plywood Form Steel Form

girders)
n<10 1 set
10 < n <20 2 sets
20 < n <30 1 set
30 < n <60 2 sets
The thickness of form usually are as Since the upper flange and web width of
follows: beams are in same size, a steel form with
height adjusting devices may be used for
beams of varied height. Sample of the forms
are shown in Fig. 3.14.

(2) Base of Form tensioning records.

The instructions are as follows:
During prestressing, the uniform
reaction on base move to both end of Minimum concrete strength at the
T-beam, and at the same time time of tensioning
shortening of beam occur (elastic Whether tendon is stressed from one
deformation). Therefore, the form or both sides
shall be so designed that it does not Tensioning sequence
restrain the shrinkage movement and Tensioning forces and elongation
possible shortening due to
prestressing and that the foundation Tensioning of tendon should be done in
around the end of beam should be sequence to introduce a minimum
strong enough for settlement against eccentric force in the beam section. In
reaction. Structure of base around calculation of anticipated elongation of
end of bearing is shown in Fig. 3.15 each tendons, cable friction, jack and
anchorage friction and elastic
2.6.4 Concrete deformation of the concrete beam are to
be taken into account.
Stirrups and link bars should be tied Prior to the tensioning operation, a
together with tie wire at the correct specialist shall ensure the following
position to avoid displacement during matters:
concreting with heavy vibration,
because ducts are supported and fixed at (a) Understanding on Design
proper location with stirrups. Calculations
Deformation of reinforcement and duct
is shown in Fig. 3.16. Ducts shall be in The relation between design and
smooth alignment without sudden construction work of the prestressed
changes in direction. concrete is much close than that of
other ordinary reinforced concrete.
Concrete for T-beam whose depth is less And particularly, with respect to the
than 2m may be placed in one design requirements and working
continuous operation, however, for drawings, prestressed concrete
depth of 2m or more, may be placed in members are to be prestressed, the
two separate operation; first, web of basic design contents shall be fully
beam, and second, the flange of beam. understood.
2.6.5 Prestressing
(1) Site Tensioning Operation
The tensioning operation will be carried

out by suitably experienced supervisors
and operators (specialist sub-contractor).
The instructions controlling the

tensioning operations are based on the
design of the structure and may be
modified by the engineer as a result of
the information obtained from site

Deformation
, ,
Camber
Concrete Base Bearing Location ~ Roller (din 16m/ lll) for Sliding
Cnmber
Fig.3.15 Structure of Base of Beam End
<D
Deformed Duct Direction of Concrete Placing
I
- - I - - - - I - --I·I---,!;;f
I
I
':.0 .·
Deformed Stirrup Original Position of Duct
Fig3.16 Deformation of Duct and Stirrup

Adjusting Height by Sliding Form

3000 ,.
1000
I
i I I
.,
T
J,. II
J- , J II
, II
I
,,I
II ,,i ""
,
II
II
II
I
!
, II
""
I
I
,I
II
II i
I ""
J
II
II ,,,
,, ""
"
II
II
J.J.
f ,
1\
....., "
II
Adjusting . Portion
Adjusting Height by Additional Form

,. 3000
1 1000 ,.
i I r
,,. I ! I
o -
~ I, -:::
o
.! II II
8~
II II
I II
II
I I Adjusting Form
I, II I, II
, II II
II II
I,
i
II I, II
,,, II
II I
II
II
, U II
Fig. 3.14 Sample of Steel Fonn

(b) Equipment calculated values are in close

agreement, the friction losses
In carrying out the work, the assumed in the design are confirmed.
tensioning equipment should be Where tolerance has not been
appropriate and operated in specified, a realistic value is normally ±
accordance with the system 6%, based on BS and FIP specification.
manufacture's instructions.
Valuation of forces and elongation may
(c) Force Measuring be arised from:
The pressure gauge of jacks are Variation in internal friction in the

required to calibrated by jack
dynamometer in order that the Error in measuring elongation
magnitude of the tensioning forces Variation in cross-sectional area in
can be adequately controlled. This
calibration must be done periodically modulus of elasticity of tendon
since they tend to easily become Difference between design and
inaccurate. actual coefficients of friction
Variation in friction in the anchorage
(d) Safety
(3) Friction Tests
Tensioning works can be dangerous.
If a tendon breaks or slips there is a Two jacks are used for measuring actual
sudden and large release of energy friction, the force is applied via one end
which is likely to cause the tendon to and the other registering the passive
be projected from the duct with a force at the other side of the tendon. The
considerable force. Precautions must distribution of tension along the duct
be taken to ensure that stressing is during prestressing and the relation
carried out safely. between the forces at the tensioned side
and fixed side in the friction
(2) Control of Stressing Operations measurement are shown below.
The recorded force and elongation on

the site should be compared with the
calculated value. If measured and

(4) Failures during Tensioning be occurred during tensioning. If

troubles occur, the wedge or female
Troubles and accidents during cone should be taken out and
prestressing occur mainly on concrete, replaced with new one.
ducts, steel materials to be tensioned,
anchoring devices and connecting (c) Cracks in Concrete
devices, and the causes are the defective
materials, design and construction, or a These cracks are occurred near
combination of these. anchoring portion during or after
tensioning. Cracks are generally
The cause of troubles or accidents caused by insufficient amount of
during tensioning are sometimes clear reinforcing bars, incorrect
(inevitable) and sometimes not clear prestressing (sequence, tension, etc.)
(accidental). The inevitability occurs due incorrect concrete work (mix,
to errors or carelessness during design pouring method, curing, timbering,
and construction work, while the etc.), and combination of these, but it
accidental troubles occur due to is extremely difficult to detect the
irresistible force which is not known by actual cause of the cracks in many
theory or calculations. However, such cases.
irresistible force seems to act when
various kinds of causes with potential In order to avoid the trouble,
problems are overlapped. grid-shaped reinforcing bars shall be
increased around anchor portion.
(a) Broken Wire during Tensioning
(d) Leak of Mortar in Ducts
During tensioning of strand,
individual wire may be broken and During tensioning from both sides,
pulled out, mostly caused by the the operation of pumps is adjusted to
improper installation of ducts and assure the same elongation at both
female cone not aligned after sides. If there is a great difference in
pouring of concrete. elongation even after such
adjustment, or the total elongation is
In case of the area of broken wires extremely small, a leak of mortar and
does not exceed 2% (based on the plugged duct shall be suspected.
AASHTO) of the total area of the
prestressing steel in the member, the Cause of such troubles are
failures may be normally accepted improperly wound tape at the joint of
by the Engineer. If there are some ducts, damaged duct due to improper
allowance in tension, additional handling, break of duct due to
contact of bar-type vibrator during
tension equal to the force should be
applied to the remaining wires as an placement of concrete.
emergency measure.
Measures for this trouble as follows:
(b) Broken of Anchored Portion
Ducts should be placed properly
Broken of anchored portion, such as so as not to damage and
abnormal setting, accident of wedge connecting of ducts should be
and depression of female cone may carried out perfectly.

Immediately after placing the

concrete, the plugging can be
detected by moving the steel
cable back and forth or by
introducing air to the ducts from
an air compressor.
If plugged duct is found after
tensioning, work must be stopped
since occasionally prestress
cannot be given, and the engineer
in charge should take proper
measures in removing the mortar.
For example, if the mortar cannot be

removed even after repeating the
tensioning, probable location of
mortar should be detected by
inserting the steel wire of 0 2.9 from
both ends of beam, and then duct
should be cut out to remove the
mortar.

In this case, full precautions are needed for not damaging steel wires
of the cable. After removal of mortar, this portion should be covered
with new duct and cleaned before pouring concrete.
2.6.6 Handling and Lau nching
(I) Launching Method
The precast prestressed concrete beams are usually launched in position using
truck cranes or launching steel girders with gantry crane or bent. The
following matters are significant for proper selection of launching method for
the precast concrete beams.
Geography of the site

Soil conditions
Condition of fabrication yard (location, width and length)
Weight of beam
Availability ofspeciaJized and/or heavy equipment
Accessibility of the work areas
Obstacles above and below the beam to be launched
Safety of handling and launching
For selecting launching method, the methods in the Table 3.4 are marked ©;,
O and !:::,. in order of their frequency of employment.
(2) Launching by Truck Crane
This method is suitable for bridges where the truck crane can either be
stationed closely to the bridge abutments or piers, or between the bridge pier.
The required capacities of cranes depend on applying of both length and
working radius of crane booms.
(a) Launching by Single Truck Crane
A truck crane can lift beam and launch them on position and it is suitable
for small scale bridge as pre~tensioned concrete beams for weights under
15 tons. In case of truck crane stationed between bridge piers, the lifting
capacity of crane required is about 2 to 3 times of the weight of beams
(30 to 45 tons truck crane). In the case of the truck crane stationed just
behind of bridge abutment, the lifting capacity of crane required is about 6
to 8 times of the weight of the beams (90 to 120 tons truck crane).
Launching method is illustrated in Fig. 3.17.

TahleJ.4 iIi "fl. ,M"hrul o[ Precast Beam

""""...... """ ""
"""""""' i
! ,; ," !" i
,
ii ~
•" •" •" "e ]
CooditiCII
l
• Hit
l ~
.
E
~ l l" ,• ~ [I i.~
l ~, l i• ] . ~
u
•
.
•
~
i
FatriCllliCII yard 10 0 0 0 6 0 6 10 0
0 o 0 0 0 10 10
S!m:f1>"Cf m'<r 10 10 10 0 o 0 6 6 6 10 10
urdcr the brid&e 10 10 10 0
, bridg< 10 10 i 0 0 6
...... PC ...
""..... """ 10 10 10 10
10 10 10 10
o0
10 ' 0
0 0 6
0 0 0 0 0 0 10
lb, 10 10 10 I 0 i 0 0 6 0 0 0 0 0 10
,,00t) 10 10 10 10 ' 0 16 0 0 0 0 10
"""'" ..... ",.
,,~
0 10 10 10 10 10 , 0 . 0 . 0 0 0 6 6
0 10 10 10 10 10 0 0 0 0
6 6 6 10 10 10 10 10 10 0 0 6 6
.,..
Silt and figure 0 10 10 10 10 10 10 10 10 , 0 0
o 0 0 10 10 10 10 10 10 10 10
"'-"" ... "'- o 0 o 0 10 10 10 10 I) 10 0 10 0
o 6 o 0 10 10 10 10 10 10 10 0
"'" '''''
'-"'. o 6 o 0 6 10 10 10 10 10 10 10 6
""'" ,
Owariverocn 10 0 0 10 0
tbt: 0 Frequent
o Soold:ime
6 """"

Trailtr
-;l A •
Truck Crant
i!
IT Truck Crane
iI
--
r
Fig.3 .17 Launching by Single Truck Crane
(b) Launching by Two Track Crane
In this method, the launching girder is usually placed between the bridge
span on which precast bridge beams are carried and placed on abutments
or piers by 2 truck cranes. The lifting capacity of crane usually required is
about L5 to 2.0 times of the weight ofbearn. Taking availability of heavy
truck cranes and safety oflaunching works into consideration, this method
is applicable for weights under 80 tons precast bridge beams. This
method is usually applied for weight of 15 to 70 tons precast beams, and
is used for over 70 tons as in special case. Applicable truck cranes for
launching precast bridge beams are shown in Table 3.5 and launching
method is i!lustrated in Fig. 3.18.
Fig.l lS Launching by Two Track Crane
Table 3.5 Annlicable Truck Crane for Launching Beams

Applicable Lifting
LenallofPC Beam WeiehtofPCBeam Cana~ilies ofTruck Crane
15 - 18m 15 -20 Ions 30-40 Ions)· 2 cranes
20 -22m 25 - 30 Ions (45--60 IOns)· 2 cranes
25 ·30m 50 - 70 Ions 90·]30 tons) * 2 cranes

(3) Launching by Specialized Launching Girder
This method is suitable for launching post-tensioned beams with lengths of

25m up to 45m (weight of 50 - 135 tons) and for specialized launching girders
in succession over several spans. Launching is not influenced by the height of
the piers or the existence of a waterway, and there is no restriction on the
ground condition under the launching girders. Transportation, assembling and
disassembling costs for steel girder are necessary. therefore, it is not
economical for short span beams or a few spans bridge.
Two types of specialized launching girder are shown in Fig. 3.19 and Fig.
3.20.
Sleeper for rail

Ra i 1
Lifting equipment
Lifting equjp~ent
Cross beam
Steel girder Rear support
GUY wire
Forward support
Pi rot truss
Pier
Fig.3.19 Launching by Two Steel Girders
(4) Launching by Gantry Crane
In this method, a pair of gantry crane straddling projected two piers lifts up
and places into position the precast beams which have been delivered by a rail
or a trailer truck running alongside of the projected span.

Cross be:!::>
~
/ o 0 o 0
/:St.e~J zirder ~ lif .~inz
o 0 o 0
,
0
eQuip .. ent
TroJJey~
\
Rear su?port
• I
------ -
-, -------L
f'-For...ard support
GUY Io'j r
f-
•
Liftinz eQuip;ent Lifting eQuip~ent

Cross bea!!!
ilear support forHard support GUY Io'lre
Back cross vie ... Front cross vie ...
GUY Hi re
Tr<lversing Trolley
P.a i J
Steel girder
?ortal crane
Pier
Fig. 3.20 Launching by Single Steel Girder

~ Lifting eQuiplilent
~p(' Lifting device GUY wife
/m~\
I \
.\
I
~Lif_ting equipment
+- ~ G a ntry crane
J
1 liiiZ
IT,G
J
UY 1-'i r.e
/
/ \
17 :-J
1
rd
Fig. 3.21 Fixed Gantry Crane Method
~ Lifting eQujparent
~! .. .
LJf.t1ng deVice
~ Lifting 'Quip•• n'
I . I T Gan try crane
117 ~A
i
I
, .
Sleeper for rail -'- Rad
Fig. 3.22 Self Traveling Gantry Crane Method

A Carring and down method
S.!.e e ?e~
TrO lley::,\ ~pl.llling ".. ire
L-
Pl.llling
...
...i re
,
&1 . ;J; =-± /, " . iI
S tag e
for rail
I / \ / 1\ .=
l/ I/ X, \ Steel beaE!
~~Suppprt
GUY wIre concrete
B Carrying and shifting met hod
T r olley-~ Pulling ...ire

+ P1Jt~~~g,"'ire£lg'h_h_h_l l~for rail
r:mXI~x;rx: 'l'1Tir-~"'9
" . Steel bea~ Support
'--- Sase concrete Support Guy lIire Base concrete
Fig. 3.23 Launching by Bent
Stage of sleepers
Sup port with frace
1rol ley
Fulling
Pulling wire
II ey
Stage of sleepers Support with frame
Ra i I
~~=
Sleeper for rail r o! Ie)'
Fig. 3.24 Launching by Traveling Bent

(a) Fixed gantry crane method. span is necessary.

When the pier height is low and the
In this method, a pair of gantry crane ground under the bent is firm,
is fixed by its legs to the ground so heavier beams can be launched.
that it can lift and place concrete
beams in position. (6) Safety Measures
(b) Self-traveling gantry crane method Since, during transportation, the pre
stressed concrete beams are subjected
In this method, a pair of gantry crane only to the combined stress
is positioned on a track laid on the corresponding to the prestressing and
ground along the bridge spans so that the bending due to the dead load, the
it can freely travel over the bridge tensile stress at the top fiber of the beam
spans. is 10 kg/cm2.
Both methods are shown in Fig. 3.21 If the beam is inclined left or right, the
and Fig. 3.22 respectively. bending moment acts laterally due to its
dead load and the tensile stresses are
(5) Launching by Bent induced on a side and at the top fiber of
the beam.
In this method, steel supports are built
either partially or entirely between the
bridge spans, on which precast beams
are carried to be laid them in place.
(a) Bent-type method
In this method, supports which are

assembled between the entire bridge
spans are utilized, on which the pre
cast concrete beams can be pulled
out.
(b) Traveling bent method
In this method, the end of a precast

concrete beam is received on the
travelling bent running along the
ground rail, and launching can be
accomplished by pulling out the
traveling bent.
Both methods are shown in Fig. 3.23

and Fig. 3.24 respectively.
Characteristics of this method:
Sufficient space for the bent to be

placed and for it to travel over the

FOR INTERNAL USE ONLY Final Report Volume II Design Manual
FINAL REPORT VOLUME III

DESIGN MANUAL
I
II
I
Therefore, appropriate handling and launching study shall be undertaken
specially for long and slender girders, to ensure against lateral buckling or
cracking during various stages of handling and launching.
Position of temporary support

Prestressed beams are only allowed to be suspended or supported
firmly at their bearing points
Inclination of beams
Long and slender beams shall be safeguarded against tilting by means
of auxiliary supports and temporary strutting or bracing.
Wire
!T Block
, I
I Timber StAAt .r-
",~,. I ,
Wire
I ,
I ,
I \ . TroJ
Slee'e.~_I:"'-<';~ '~:_~_~",'~'.'~,' '~', .~_'~_~_'~m~'~.\~,:::::~~R~o~;1

Tronspontotin of Beam l aunChing by Truck Crane
H ~ 1.5m for Pre-tensioned Beam

H ~ 20m Post-tensioned Beam

Allowable Inclination of Beam
The following equation to be satisfied
act' x n + a do' x {I-(Zc')/(Zh) x sin e) '" a cat"

therefore, e= sin -1 {( (] cat"- 0 ct 'x ,, - 0 do') I 0 do' X (Zh/Zc')}
where; e Allowable inclination angle

ocat" Allowable tensile stress due to temporary load during
handling and launching = -25kglcm2
Oct' Tensile stress at top fibre due to prestressing
ado' Compressive stress at top fibre due to girder weight
Zc' Section modulus of X-Xaxis at top fibre
Zh Section modulus ofY -Y axis at flange end fibre
n Effective coefficient of prestressing due to loss = 0.95
Post-tensioned beam PTT-32 (span:32m)
Zc' 442 x l()3cm3

Zh 53 x 1()3 cm3 ocat" = -25 kglcm2
oct' -79 kglcm2 n = 0.95
ado' 69 kglcm2
e = sin -I {(-25+79xO.95-69)i69) x (53xlOJ)i(442xI0J)

= I' -53'
2.6.7 Public Relations
Cooperation should be obtained from the government concerned and private

agencies whose utilities or facilities affect the works, and aJso the inconvenience
and danger to the public are to be avoided.
(I) Utilities
Involved utilities are water, electricity, telephone, sewers and oil/gas pipelines.
These utilities are usuaJly required diversion or protection by the government
concerned or authorities and any damage to the utilities are to be avoided.
(2) Road Traffic
Where temporary diversion bridge or half-width construction is necessary,

they shaH be made safe and suitable, and also traffic management, during that

period, is very important so as to completed structure does not meet

minimize inconvenience to the public. required quality, the structure should be
replaced and reconstructed. That is very
(3) Railway uneconomical and brings loss not only
to the Contractor but also to the
Special care needs to be taken at Government.
intersections with railway tracks, or at
any locations where work has to be In the generality of cases, quality and
undertaken close to railway tracks. It is cost or progress is disagreed to each
essential that very close cooperation others.
with the railway authority and its
regulations are strictly taken and
observed. Construction operation
method and schedule shall be carefully
planned, especially for lifting and
launching operations of prestressed
concrete beams.
2.7 Quality Control
2.7.1 Importance of Quality Control
The objective of quality control is to

ensure and verify the quality of the 2.7.2 Quality Control Checks
materials and the execution of works
shall be in accordance with the contract Flow chart of quality control is shown in
documents and conforms good Fig. 3.25. Quality control shall obtain
workmanship. the level of quality desired by the
Specifications, such as Standard
Two functions of quality control for Specifications for Road Works, JKR,
materials and workmanship are as MS and BS.
follows:
Quality Control Checks for concreting
Technical inspection works is referred "Manual on Quality
Quality control testing Assurance in Concreting Works" - JKR
20700-0035-91. Quality control for
The technical inspection and quality tensioning works and grouting works
control testing to be performed are as follows:
appropriately by suitably experienced
engineers, inspectors and technicians, (1) Tensioning Works
and thoroughly familiar with the
relevant standards and corrected (a) Materials
technical procedures. The construction
quality control is a system which Identification of the
involves the joint but independent steel and checking and filing
efforts on the Government, the of the documents (test
Contractor and Manufacturer to achieve reports, dispatch notes) sent
the level of quality in accordance with by the supplier
the Specifications. When the quality of Checking anchorages and

period, is very important so as to completed structure does not meet

minimize inconvenience to the public. required quality, the structure should be
replaced and reconstructed. That is very
(3) Railway uneconomical and brings loss not only
to the Contractor but also to the
Special care needs to be taken at Government.
intersections with railway tracks, or at
any locations where work has to be In the generality of cases, quality and
undertaken close to railway tracks. It is cost or progress is disagreed to each
essential that very close cooperation others.
with the railway authority and its 2.7.2 Quality Control Checks
regulations are strictly taken and
observed. Construction operation Flow chart of quality control is shown in
method and schedule shall be carefully Fig. 3.25. Quality control shall obtain
planned, especially for lifting and the level of quality desired by the
launching operations of prestressed Specifications, such as Standard
concrete beams. Specifications for Road Works, JKR,
MS and BS.
2.7 Quality Control
Quality Control Checks for concreting
2.7.1 Importance of Quality Control works is referred "Manual on Quality
Assurance in Concreting Works" - JKR
The objective of quality control is to 20700-0035-91. Quality control for
ensure and verify the quality of the tensioning works and grouting works
materials and the execution of works are as follows:
shall be in accordance with the contract
documents and conforms good (1) Tensioning Works
workmanship.
(a) Materials
Two functions of quality control for
materials and workmanship are as Identification of the
follows: steel and checking and filing
of the documents (test
Technical inspection reports, dispatch notes) sent
Quality control testing by the supplier
Checking anchorages and
The technical inspection and quality
control testing to be performed accessories Condition of the
appropriately by suitably experienced ducts.
engineers, inspectors and technicians, Geometric tolerances of
and thoroughly familiar with the anchorages and accessories.
relevant standards and corrected
technical procedures. The construction (b) Before Tensioning Stage
quality control is a system which
involves the joint but independent Placing the formwork
efforts on the Government, the Checking the condition of the
Contractor and Manufacturer to achieve tendons after storage and
the level of quality in accordance with handling. Checking to ensure that
the Specifications. When the quality of the positioning tolerances have

been complied with. (2) Grouting Works

Checking the number and rigidity
of fasteners. (a) Before Grouting Stage
Availability of full instructions
issued by the designer Sequence Results of preliminary and suitability
of tensioning the tendons. tests.
Tensioning procedure (from one Continuity of the ducts (no breaks in
end or both ends, increments in them), liquid-tightness of couplings,
the tensioning force to be applied, availability of unobstructed bent
maximum pressure at the jack, holes and weep holes.
corresponding theoretical tendon Making the grout (mix proportions
extension, tolerances on such and tolerances in the proportions,
extension). sequence of adding the constituents,
Availability and proper condition mixing time, speed of the agitator,
of the necessary equipment etc.).
Calibration of the acks. Grouting (adapted to the climatic
Quality of the concrete conditions, blowing through with
compressed air or flushing the ducts
(information check test results) and tendons with water, grouting
and other materials concerned, pressures, closure of bent holes).
(e.g. jointing materials)
Degree of freedom (b) Grouting Stage
To enable the prestressed Observing the pressure and detection

concrete member to deform when of any leakage.
the prestress is applied. Checking the volumes: quantity of
To enable the cables to move in grout and time that elapses before it
their ducts. emerges from the bent holes.
Taking samples for quality control
(c) Tensioning Stage check.
Measurements for determining (c) After Grouting Stage

transmission coefficients, if Checking that all bent holes and
necessary. other openings have been properly
Records of the forces and sealed and that the permanent
extensions corresponding to each anchorages are suitably protected.
increment of the tensioning force.
(plotted in a diagram).
Supervision of any re-tensioning
operations and of the installation

of anchorages and accessories.
Measurements of slip of cable in
relation to the anchorages.
(d) After Tensioning
Visual inspection of the concrete

of the structure.

CHAPTER 3 COST ESTIMATE to perform the works in accordance with

the final contract documents.
3.1 Objective of Cost Estimate
3.2.1 Approximate Cost Estimate
The purpose of cost estimate is to
determine the forecast cost required to Approximate cost may be estimated
complete a project in accordance with according with the statistical contract
the Specifications and preliminary rate of the similar projects. It may be
construction plan. There are so many estimated to multiply the number of
variations and factors that can influence square meter of bridge surface area for
the cost of construction, such as superstructure, and the concrete volume
geology, topography, site environment, for substructure excluding pile.
workmanship and construction
difficulties. The construction cost should The unit cost to be obtained from a
be estimated according to site condition, weighting of the data that emphasizes
construction plan and construction time the average value yet it account for the
which were clarified in plan and design maximum and minimum values as
stage. shown by the equation below.
The estimated cost shall be reasonably UC = (A+4B+C)/6

enough to allow the contractor to where;UC : Proposed unit cost per m2
complete the project with a reasonable A : Minimum unit cost of
profit, yet low enough to be within the previous bridge
Government budget. B : Average unit cost of
previous bridge
Because construction estimates are C : Maximum unit cost of
prepared before a project is constructed, previous bridge
an estimate is to be close approximation
of the actual cost. The true construction It is necessary to adjust the cost
cost will not be known until the project information from previous completed
has been completed and all costs have bridge, such as year built, location and
been recorded. bridge size.
3.2 Type of Cost Estimate The adjustment should be present the

relative inflation or deflation of costs
Cost estimates may be divided into at with respect to year built, and relative
least two different types, depending on costs of materials, equipment, and
the purpose as approximate estimates labour with respect to the geographic
(preliminary estimate) and detailed location of bridge under construction.
estimates. Although the total construction cost of
bridge will increase with size of bridge,
Early in a project, prior to the however, the unit cost per square meter
design, the Government may wish to of bridge surface area may decrease.
know the approximate cost of a project.
At the detailed design stage, the Proposed cost = Previous cost x fy x f 1
Consultants will estimate the cost in x fs x fc
detail in order to finalize the design to where;fy : Adjusting factor of year
satisfy the Government's budget. The built
Contractor must know the costs required

and contingencies.
fs : Adjusting factor of
location Construction cost is subdivided into
fc : Adjusting factor of bridge direct cost and indirect cost. Direct cost
size, such as span length consists of labour cost, material cost and
and number of span equipment cost. Indirect cost comprises
fc : Adjusting factor of of general cost, preliminary cost and,
construction difficulty contractor's overhead and profit.
3.2.2 Detailed Cost Estimate Structure of total project cost is charted

in Fig. 3.28.
A detailed estimate is prepared by
determining the cost of the materials, 3.3.1 Direct Cost
labour, equipment, subcontract work,
overhead, profit, and some (1) Labour Cost
contingencies. The process of estimate
begins with a thorough review of the Labour Cost is calculated as follows:
contract document - contract
requirements, drawings and technical Labour Cost = Number of Labour
specifications. It is necessary to visit the x Labour Rate
project site to clarify factors that can
influence the cost of construction, such = Quantity of work
as site conditions, control of traffic, item x Production
security, and existing underground rate x Labour rate
utilities.
Labour rate includes wages, income
There are two distinct tasks in tax, insurance and all fringe benefits,
estimation; to determine the probable such as vacation, sick leave,
real cost and to determine the probable medicare and workmen's
real time to construct the project. It is compensation. The labour
required to provide production rates, rate is estimated on the basis of data
crew size, equipment and the estimated researched from the market
time to perform various individual work investigation.
items for planning and scheduling of the
project. This information concerning Production rate is the number of unit
costs can cover an integration of the of work produced by a person in a
estimating and scheduling function of specified time, usually an hour or a
construction project management. day. Production rate may also specify
the time in labour-hours or labour-
Flow chart of cost estimate and work days required to produce some unit
schedule are shown in Fig.3.26 and Fig. of works.
3.27 respectively.
Such data may be obtained by
3.3 Structure of Total Project keeping accurate records of the
Cost production of labour on projects
during the progress of construction.
Total project cost consists of
construction cost and project cost, such
as administration cost, engineering cost,
land acquisition and compensation cost,

I. Review of Information and Data

Contract Documents onstruction Conditio Construction Plan
-Natural Environment
-Condition of Contract
-Electricitv & Water -Temporary Facilities
-Drawings -Construction Method
-Teclmical Specification -Transportation -Equipment
-Materia] & Labour
-Quantities -Social Envirorunent -Construction Schedule
2. Determine Unit Price - Material

- Labour
- Equipment
,
>. Determine Production Rate
-Labour
-Equipment
4. Estimate Direct Cost
-Material cost = Quantity x Unit price

-Labor cost = (Quantity)lLabour production rate X Labour rate
-Equipment cost =(Quantity)JEquipment production rate X Equipment rate
5. Estimate Construction Schedule
6. Estimate Indirect Cost
-Preliminary -Design & Supervision

-Overhead -Administration
-Profit -Contingency
7. Construction Cost
Fig. 3.26 Flow Chart of Cost Estimate

l. Sequence of Main Works
2. Work Items and Elements
3. Operation Days of Work Items

~ (Quantity of Work Item)
/ (Average Dai ly Work Quantity)
4. No Working Days
-Daily weather pathems and seasonal weather contraints

-Sunday and public holidays
-Other factors
5. Necessary Operation Day of Work Items
~ Item 3 x (Calender days) / (Calender days - No working days)
6. Mobilization and Demobilization Period
7. Whole work Schedule arranging Item 1 to Item 6
Fig. 3.27 Flow Chart of Work Schedule

(2) Material Cost (a) Depreciation
Material cost is calculated as In general, depreciation is a tax

follows: term referring to the legally
permitted decline in value from
Material Cost = Quantity x Unit the original purchase price of
price equipment for the depreciation
= Designed periods from the view point of
quantity x (1 + economical life of equipment.
Rate of loss)
x (Material unit Depreciation = (Net
price + depreciation
Transportation value)
cost) / (Depreciation
period in hours)
The quantity of material can be taken
from the drawings, however, loss of = (Purchase price
material due to storage and - Salvage value)
construction should be considered. / (Depreciation
period in hours)
Construction materials are delivered
by the supplier or producer directly (b) Interest, Insurance and Taxes
to the project site in trucks, however,
some materials may be obtained by Whether or not purchased
the Contractor at the storage yard of equipment is actually in
the supplier. operation, its owner must pay
interest, insurance and taxes.
(3) Equipment Cost Interest refers to the interest on
the investment, when the
There are two types of equipment investment is covered by the
costs: ownership costs and operating owner's own fund or to the
costs. Ownership costs refer to the interest on the debt, when the
costs incurred even if the machine is investment is covered by a debt.
not working. They include In either case, the interest will be
depreciation, interest, taxes, an equal amount.
insurance, and maintenance and
repair. Operation costs are the costs Calculation is made of the
incurred in operating the machine. average value of the residual
They include costs for repair, fuel, value at the beginning of each
lubricants, tires, consumable parts year within the depreciation
and operator's wages. Composition period, and interest, insurance
of equipment cost is shown in Fig. and taxes are imposed on this
3.29. value. By dividing this value by
the number of hours and expects
The equipment cost is calculated in to operate the machine in one
unit of hourly cost (M$/hour) which year, the hourly value can be
is suitable for use on any project. calculated.

- Construction of temporary bridge

This can be calculated by using and road for public
the following formula. - Demolition of existing bridge
- Relocation of existing public
Interest, insurance, tax
= (Factor x Delivered price x utilities Temporary diversion of
Annual rates) / (Annual use in river/waterway
hours)
(2) Preliminary Cost
The factor can be calculated by
the following formula. Preliminary cost includes the
Factor = 1 - {(n-1)(1-r)} / 2n following items and it is assumed to
where; be 10 to 15% of the direct cost
depending on period of the project
n : Depreciation period in and amount of the contract.
year
r : Salvage value rate - Site office and laboratory
=(Machine worth at trade- - Waterhouse
in or resale time) / - Survey
(Delivered price) - Laboratory equipment
- Facilities for electricity and water
(c) Revision of Equipment Cost supply
- Safety measures
The hourly cost of ownership and - Transportation
operating construction equipment - Engineering
will vary with the condition
where the equipment is operated. Preliminary costs of PC bridge are;
If bulldozers are operated on soft
rocks surface, equipment cost Pre-tensioned bridge
will be higher than when the : (Direct cost- Manufacturing
same bulldozers are operated on cost)x(10 to 15%)
common soil surface. Therefore, Post-tensioned bridge
the equipment costs will be : Direct cost x (10 to 15%)
adjusted according to the site
condition where the equipment is (3) Overhead and Profit
to be operated.
The overhead cost is divided into
two categories: job overhead and
general overhead.
3.3.2 Indirect Cost The job overhead can be specifically

charged to a project and general
(1) General Cost overhead can be charged to the
general office of the company.
General cost includes the following
items, which depend on site Job Overhead
condition and construction - Salaries of project staff
requirement: - Site office supplies
- Communication

- Rent cover unforseeable or unavoidable

- Travel expenses and allowance matters during construction, such as
- Insurance and tax temporary land acquisition and some
variations. The contingency is
General Overhead usually considered 5 to 10% of the
- Salaries construction cost.
- Office supplies
- Office rent - Price contingency allows for future
- Welfare price escalation and fluctuation of
- Travel expenses and allowance exchange rates.
- Insurance and tax
(4) Land Acquisition and Compensation
The amount of profit is depending on Cost
the risk involved, desire of the
Contractor to get the job and other A considerable amount of land
factors. acquisition and compensation costs are
required for new bridge construction.
The actual amount of overhead and
profit may be rannged between 20 to 3.4 Major Work Classification
30 % of the direct cost depending on
the risk involved, desire of the 3.4.1 Clearing and Grubbling
contractor to get the work and others.
Prior to staring structure excavation
3.3.3 Project Cost operations, all surface objects and all
trees, stumps, roots and other
(1) Administration Cost obstructions shall be cleared and/or
grubbed. This work will be operated by
Administration cost is an expense of the bulldozers. Measurement will be by area
Goverment arising from implementation basis (hectares) or lump-sum basis or
of the project cost and is assumed to be individual removal of trees (each).
3 % of construction cost.
3.4.2 Structure Excavation and Backfill
(2) Engineering Cost
This work consist of the necessary
Engineering cost consists of detailed excavation for foundations of
design (Geological and topographical substructures and placing backfill with
survey, and detailed design) and free draining granular material in
construction supervision and it is excavated area around structures.
assumed to be 5 to 10% (for example This work may include necessary
2% for the detailed design and 6% for diverting of water streams, bailing,
supervision) of the construction cost.
pumping, draining, and the necessary
(3) Contingency construction of cofferdams or gribs, with
all sheeting and bracing involved.
Contingency is divided into physical
contingency and price contingency as All rock or other hard foundation
described below: material should be cleaned of all loose
material and cut to a firm surface, either
- Physical contingency is mainly to level or stepped. Blinding stone, such as

cobble stone or crushed rock for use

as a foundation to be provided.
(1) Operation of Excavation and

Backfill
The operations of this work are as

follows:
Operation Equipment
Excavation Power shovel (0.35 to

0.6m3)
Bulldozer (15 tons)
Backfill Power shovel (0.35 to
0.6m3)
Compaction Bulldozer (15 tons)
Vibration roller (0.8 to
1.1 tons)
Compactor (60 to
100kg)
Transportation Dump truck (11 tons)

(2) Temporary Works
Operation Material Equipment
Cofferdam Diving Wood plate sheet-pile or Diesel hammer

Removing Steel Sheet-pile or Truck crane
Draining H-shaped pile (20 to 22 tons)
Vibro-hammer
(30 to 40 kW)
Pump
Diversion of Construction of Bulldozer

Water Stream Dikes or Power shovel
By-pass channels
3.4.3 Concrete tons)

Concrete pump
This work consist of the construction of Hopper and chute
portion of structures of portland cement - Compacting Vibrator
concreted which is a mixture of cement, - Finishing
water, admixer, and coarse and fine - Curing
aggregates, and may include temporary
works. (3) Temporary Works
(1) Use of Concrete This work include falsework, form

work and base for manufacturing
The uses of concrete are as follows: post-tensioned beam.
- Post-tensioned concrete girders

- Cross beam
- RC slab
- Abutments and piers
- Curb and parapet
- Approach slabs
- Leveling concrete
(2) Operation of Concrete Work
Operation Equipment
- Trial mix Mixing plant
- Mixing concrete
- Transport Truck
- Handling Cart
- Placing Truck crane (15 to 20

Work Item Use of Concrete Operation Material Equipment
Falsework Abutment Piling or compaction Foundation Truck crane

Pier Erection Pile or concrete (15 bt 16 tons)
RC slab bridges Fixing or timber
Removing Scaffoldings
Timber or
Steel frame or
Steel pipe
Formwork Abutment Fabrication Plywood or steel Truck crane
Pier Erection or aluminium form (15 bt 16 tons)
RC slab bridges Fixing Form tie
Removing Form oil
Base for Post-tensioned Compaction Concrete or
Manufacturing beam Timber or
Beam Briding stone
3.4.4 Reinforcing Steel The cost will depend upon the type,
length and number of purchase, and the
This work consist of furnishing, distance from the manufacture yard of
fabricating (cuttin, bending), splicing, the supplier to the job site. The cost
and placing (erecting, fastening) estimate and other information will be
reinforcing steel bars of the type and obtained from the manufacture
size conformed with Drawings. Tie suppliers.
wires and separators and other materials
used in fastening the reinforcing steel 3.4.6 Pile Driving
bars are included in this work. The work may consist of spun concrete
pile driving, cut and spliced, and loading
3.4.5 Furnishing Pre-tensioned Beam and test. Operation of the work is as follows:
Spun Concrete Pile
Pre-tensioned beams and spun concrete

piles are manufactured and supplied by
manufacturer.
Work Item Operation Equipment

Handling Crawler driving machine
Driving Method Truck crane
- Percussion Vibro hammer
Piling Driving - Vibration Earth auger machine
- Excavation
Splicing
Cut off
Maintained load (ML) test Hydraulic jack
Loading Test or Constant-rate of Steel I-Beam
penetration (CRP) test Timber crib
Kentledge block

3.4.7 Prestressing
This work may consist of furnishing, placing and tensioning of prestressing steel, and
grouting for post-tensioned concrete beams.
Operating of prestressin and 2routiniz are as follows:
Work Item Operation Material Equipment
Prestressing Placing ducts Duct Cutter for strand wire

Placing strand wire Strand wire Tensioning jack
Prestressing Anchorage Tensioning Pump
Supporter of duct
Grid
Grouting Mixing grout Cement Grouting mixer
Injecting grout Admixer Grouting pump
3.4.8 Handling and Launching
This work includes lifting, handling, transporting, launching and placing in position of
pre-tensioned or post-tensioned beams.
Operation of the work are as follows:
Work Item Operation Equipment
Handling Lifting Truck crane

Transportation Gantry crane
Jack
Rail
Trolley
Winch
Launching Launching Track crane
Shifting Launching steel girder
Placing Gantry crane
Bent and rail

3.5 Unit Cost of Major Item of Work
3.5.1 Unit Rates and Prices
The unit rates and prices of labour,

material and equipment in or around
Kuala Lumpur and based on 1995
figures are derived from market
investigation, local contractors and JKR.
These unit rates and prices are shown in

Table 3.6.
3.5.2 Unit Cost of Major Item of Work
To determine the time required to

perform a given quantity of work, it is
necessary to estimate the probable rates
of production of the labour and
equipment. It is, however, difficult to
estimate the accurate production rate
due to lack of records and data in
Malaysia.
Therefore, the production rate being

used in Japan is modified taking into
account labour's skillfulness, efficiency
of equipment, operator's capability in
Malaysia as well as based on those in
similar projects in ASEAN countries.
Finally, the unit cost of each work item
is calcalated using the caliblated
production rate.
Unit costs of major items of work are

shown in Table 3.7.

( The cost shall be calculated after

researching current conditions of the
Table 3.6 Unit Rates and Prices costs.)
1. Labour Unit Rate (M$)
Description Unit Unit Rate
Foreman, Specialist Day 70.00
Skilled Labour Day 60.00
Semi-Skilled Labour Day 55.00
Common Labour Day 30.00
Carpenter Day 60.00
Steel Bar Bender and Fixer Day 60.00
Concrete Worker Day 50.00
Welder Day 60.00
Painter Day 60.00
Mason Day 60.00
Mechanic Day 60.00
Electrician Day 60.00
Pavement Worker Day 40.00
Plant Operator Day 60.00
Driver Day 45.00
2. Material Unit Price (M$)

Description Unit Unit Rate
Portland Cement Kg 0.25
Reinforcing Steel Kg 1.20
Bituminous Material Ton 400.00
Gasoline Litre 1.20
Diesel Oil Litre 0.70
Lubricant Litre 4.50
Fine Aggregate M3 20.00
Coarse Aggregate M3 45.00
Boulders M3 20.00
Plywood t = 1/2" M2 15.00
Timber M3 500.00
H-Shaped Steel Kg 1.80
Angle Steel Kg 1.50
Steel Sheet Pile Kg 1.90
Steel Pipe Pile Kg 2.20


costs.)
Form Tie No 0.40
Separator No 0.20
Spacer No 0.20
PC Strand Wire kg 6.80
PC Anchor 12-RT 15.5 No 400.00
Duct dia. 65mm M 8.00
Ready Mixed Concrete
G30 M3 132.00
G40 M3 154.00
G50 M3 177.00
Spun Concrete Pile
dia. 350m/m M 60.00
dia. 400m/m M 75.00
dia. 500m/m M 110.00
dia.600 m/m M 140.00
Pre-tensioned Tee Beam
L = 7.6m, W = 2.1 ton Each 781.00
L = 9.5m, W = 2.6 ton Each 906.00
L = 12.5m, W = 3.5 ton Each 1,361.00
L = 16.7m, W = 6.6 ton Each 2,565.00
L = 18.9m, W = 8.1 ton Each 3,270.00
Elastomeric Bearing Pad
230 x 200 x 26 2- steel plate Each 71.00
3. Equipment Unit Rate (M$)

Equipment Description Specific Unit Unit Rate
Bulldozer (D4) 6ton Hour 65.00
Bulldozer (D6) 15 ton Hour 80.00
Wheel Loader 1.2 sq.m Hour 50.00
Wheel Loader 1.4 s.q.m Hour 50.00


costs.)
Form Tie No 0.40
Separator No 0.20
Spacer No 0.20
PC Strand Wire kg 6.80
PC Anchor 12-RT 15.5 No 400.00
Duct dia. 65mm M 8.00
Ready Mixed Concrete
G30 M3 132.00
G40 M3 154.00
G50 M3 177.00
Spun Concrete Pile
dia. 350m/m M 60.00
dia. 400m/m M 75.00
dia. 500m/m M 110.00
dia.600 m/m M 140.00
Pre-tensioned Tee Beam
L = 7.6m, W = 2.1 ton Each 781.00
L = 9.5m, W = 2.6 ton Each 906.00
L = 12.5m, W = 3.5 ton Each 1,361.00
L = 16.7m, W = 6.6 ton Each 2,565.00
L = 18.9m, W = 8.1 ton Each 3,270.00
Elastomeric Bearing Pad
3. Equipment Unit Rate (M$)

Equipment Description Specific Unit Unit Rate
Bulldozer (D4) 6ton Hour 65.00


costs.)
Backhoe 0.3 sq.m Hour 30.00
Crowler Crane 35 ton Hour 100.00
Truck Crane 5 ton Hour 45.50
Dump Truck 10 ton Hour 40.00
Cargo Truck 6 ton Hour 30.00
Cargo Truck 10 ton Hour 40.00
Trial Truck 30 ton Hour 650.00
Portable Compactor Hour 10.40
Grader 2.5 m blade Hour 40.00
Motor Grader 3.7m blade Hour 75.00
Agigator Truck 2.0 cu.m/hr Hour 20.00
Concrete Truck Mixer 5.0 cu.m Hour 45.50
Concrete Mixer 2.0 cu.m/hr Hour 19.50
Concrete Mixer 0.3 cu.m/hr Hour 9.10
Vibrator 30 m/m Day 10.00
Concrete Pump 30 cu.m/hr Hour 150.00
Diesel Hammer 2.5 Ton Hour 140.00
Vibrating Hammer 60 kw Hour 250.00
Pick Hammer (Jack Hammer) 7 kg Day 35.00
Pile Driver 35 ton Day 1,680.00
Bar Bender max.25mm Day 35.00
Bar Cutter Day 35.00
Winch Purchase 800.00
Tamper 60 - 80 kg Day 35.00
Remarks : These data are based on market research in 1995

Table 3.7 Unit Cost of Major Item ( The cost shall be calculated after
of Work researching current conditions of the
costs.)
No.1 Concrete Work (grade 40) per 10 cu.m
Breakdown of Item Unit Qty Rate Amount Remarks

(M$) (M$)
Skilled labour man 0.3 60 18.00
Semi-skilled labour man 1.2 55 66.00
Labour man 1.4 30 42.00
Truck crane hr 2.3 65 150.00 15 to 16 ton
Ready-mixed concrete cu.m 10.2 160 1,632.00 loss 2% incl. Transporation
Others L.S 1 30 30.00
Total 1,938.00
Per cu.m 193.8
No.2 Concrete Work (grade 50) per 10 cu.m

(M$) (M$)
Labour man 1.4 30 42.00
Truck crane hr 2.3 65 150.00 15 to 16 ton
Ready-mixed concrete cu.m 10.2 184 1,877.00 loss 2% incl. Transporation
Others L.S 1 30 30.00
Total 2,183.00
Per cu.m 218.30


costs.)
No.3 Reinforcing Steel per 1.0 ton

(M$) (M$)
Labour man 2.9 30 89.00
Reinforcing steel ton 1.03 1200 1,236.00 loss 3%
Others L.S 1 30 30.00
Total 1,601.00
No.4 Formwork per 100 sq.m

(M$) (M$)
Carpenter man 29.4 60 1,764.00
Labour man 20.5 30 615.00
Plywood L.S 1 1000 1,000.00
Others L.S 1 40 40.00
Total 3,419.00
Per sq.m 34.20


costs.)
No.5 Falsework per 100 cu.m

(M$) (M$)
Skilled labour man 14 60 840.00
Labour man 6.6 30 198.00
Track crane hr 4 65 260.00 15 to 16 ton
Scaffolding L.S 1 600 600.00 frame type
Totals 1,898.00
Per cu.m 19.00
Foundation of falsework
Per sq.m 15 Cobble or crushed stone
*Area = scaffolding area
No.6 Spun Concrete Pile (600m/m x 30m) per 10 piles

(M$) (M$)
Labour man 7.7 30 231.00
Welder man 7.7 60 462.00
Spun concrete pile No. 30 1,400 42,000.00 600m/m x 10m
Earth auger hr 32 230 7,360
Crowler crane hr 19 115 2,185
Backhoe hr 10 30 300.00
Others L.S 1 4,000 4,000.00 7.5% of above
Total 57,842.00
Per pile 5,784.00


costs)
No.7 PC Cable (12 - dia.12.7 m/m) per 100m

(M$) (M$)
Specialist man 13.5 70 945.00
Labour man 9.8 30 294.00
PC strand m 106 63.2 6,699.00 loss 6 %
Duct m 106 8.5 901.00 loss 6 %
Grout cu.m 0.33 210 69.00 loss 50 %
Others L.S 1 50 50.00
Total 8,958.00
Per m 89.60
No.8 Prestressing (12 - dia. 12.7 m/m ) per 10 cable

(M$) (M$)
Specialist man 7 70 490.00
Labour man 7.2 30 216.00
Anchorage set 20 400 8,000.00
Tensioning jack set-day 3 100 300.00
Grouting pump set-day 4 10 40.00
Others L.S 1 100
Total 9,146
Per cable 914.60


costs)
No.9 Launching by 35 ton Single Truck Crane per day

(M$) (M$)
Foreman man 1.5 70 105.00
Labour m 6 30 180.00
Truck crane m 1 1000 1,000.00 35 ton x 1
Others L.S 1 500.00
Total 2,415.00
* Average launching : 50 ton/day
No.10 Launching by 55 ton Two Truck Crane per day

(M$) (M$)
Foreman man 1.5 70 105.00
Labour man 7.5 30 225.00
Truck Crane day 1 4000 4,000.00 55 ton x 2
Others L.S 1 800.00
Total 5,970.00
* Average launching : 100 ton/day

References
1. Japan Road Association, "Concrete Highway

Bridge Construction Manual", 1984
2. Japan Prestressed Concrete Contractors'

Association, "Guidebook for Construction
Planning", 1995
3. American Association of State Highway and

Transportation Officials, Inc. (AASHTO),
"Standard Specifications for Highway
Bridges, 15th Edition", 1992
4. Federation International de la Precontrainte

(FIP), "Guide to Good Practice: Basic
Reinforced Concrete and Prestressed
Concrete", 1978
5. "Construction Planning, Equipment and

Methods", McGraw-Hill Book Co., 1970
6. Construction Cost Estimate Research Center,

supervised by Engineering Affairs
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Secretariat, Ministry of Construction, Japan,
"Civil Works, Manual for Cost Estimate
Standards, 1994's Edition", Construction
Research Foundation.
7. "Estimating Construction Costs", McGraw-

Hill Book Co., 1989 8. "Specification and
Application Handbook", Komatsu, 1993

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FOR INTERNAL USE ONLY Final Report Volume III Design Manual

DIVISION III BRIDGE CONSTRUCTION PLAN AND COST ESTIMATE

CHAPTER I GENERAL ........... ...... ..... . 3- I

CHAPTER 2 CONSTRUCTION PLAN

2. 1 Objective of Construction Plan 3-2

2.5.4 Pile Driving ..... .. .......... ...., 3 -18

CHAPTER 3 COST ESTIMATE

3.1 Objective of Cost Estimate ...... 3 -46

Cawangan Jalan, Ibu Pejabat JKR, K.L Page 21

3.2.1 Approximate Cost Estimate 3 -46

Cawangan Jalan, Ibu Pejabat JKR, K.L Page 22

DIVISION III BRIDGE CHAPTER 2 CONSTRUCTION PLAN

- Guideline for Inspection and Testing of

- Manual on Quality Assurance in

Bridge construction costs, even though the

Cawangan Jalan, Ibu Pejabat JKR, K.L Page 23

2.2 Procedure of Construction Plan ......... location and size

The following items are to be (5) Site Organization and Supervision

Cawangan Jalan, Ibu Pejabat JKR, K.L Page 24

(7) Quality Control

(8) Construction Safety

(9) Public Relations

Cawangan Jalan, Ibu Pejabat JKR, K.L Page 25

2.3 Flow C hart of Majo r Works

The flow charts of major works of bridge construction, substructure and

RlVER BANK PROTECTION

Fig. 3.1 Work Flow of Substructure

Cawangan Jalan, Ibu Pejabat JKR, K.L Page 26

Fig. 3.2 Work Flow of Superstructure

Cawangan Jalan, Ibu Pejabat JKR, K.L Page 27

2.4 Construction Programme The schedule control curve which is

Cawangan Jalan, Ibu Pejabat JKR, K.L Page 28

1. Pre-tensioned Concrete Bridge Bridge length: 3-span x 22.7m = 68.1m

Work Items Month

Mobilization and preparation

2. Post-tensioned Concrete Bridge Bridge length: 3-span x 28.7m,. 86.1m

Work Items Month

Mobilization and preparation

Remarks Manufacturing PC beams on site

Fig. 3.3 Work Programme of PC Bridge

Cawangan Jalan, Ibu Pejabat JKR, K.L Page 29

Cawangan Jalan, Ibu Pejabat JKR, K.L Page 30

FINAL REPORT VOLUME III

2.5 Co nstruct iOIl of Substructures

2.5.1 Stru cture Excavation

Foundation of substructures are constructed in open excavation if ground-water

(1) Open Excavation

Ta bl e 3.1 Critical Slote Gra de and Depth Dunno ExcavatIOn

D=2cJr • tan(4S" + </>/2)

where; D Depth of open excavation

Cawangan Jalan, Ibu Pejabat JKR, K.L Page 1

(2) Temporary Cofferdam sufficiently high, it may agitate the sand

As a single wall of steel-sheet pile has (b) Horizontal Forces

Cawangan Jalan, Ibu Pejabat JKR, K.L Page 2

(2) Falsework Steel support - Steel support 0.5 to

To check the structural soundness The load causing gross settlement

Constant Rate of Penetration

The load at which settlement