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2015-03-31 I&S Committee - Item 5 - Attachment 2 - Munna Pt Bridge Repairs Design Drawings
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PILE CAPS 3, 4& SONLY :
REMOVE CONCRETE 1000 WIDE x 1200 x
170mm NOM DEPTH. (TO EXPOSE 25mm
FINISHED SURFACE TO BE BEHIND MAIN BARS.) AND REPLACE WITH
10mm ABOVE EXISTING PARCHEM LASS OR EQUAL. 10mm FALL
TOWARDS EDGES TO MATCH FUTURE TOP II
OF PILE CAP PROFILE.
5-32 @ {COLUMN EXISTING DECK UNIT | | EXISTING DECK UNIT
5-32 @ UNDER FINISHED SURFACE
EXISTING 900 DIA COLUMN LAPPED BARS TO MATCH EXISTING EXISTING 900 DIA COLUMN
EXISTING 5-32 @ , 5-32 @ UNDER
—— 5 =< ee ff ele @\e °) EXISTING 1100 x 1100 HEADSTOCK
A|
rN Ea lI
Pe a Ia «COLUMN lI
||
52 DIA x 300 MIN lI
=e _ 1 CORED HOLE lI LOCATE EXISTING REINFORCEMENT IN
@||
oe! onl || HEADSTOCK WITH FERROSCANNER AND
eo” Mle | MARK ON CONCRETE BEFORE DRILLING
“te |e! Ke e| HOLES IN HEADSTOCK
S
|
3165 3165
4x"B" BOLTS. EPOXY INTO 90mm x 1000 DIA NON SHRINK
POSITION. USE FILL HOSE (610 DIA GROUT BED TO TOP PLATE
EXISTING 3-12 @ SITE COATING TYPE 7 EXISTING PILE CAP, EXISTING 3-12 @ LIGS AT 100 CRS EXISTING 3-12 @ AND AIR BLEED HOSE TO
LIGS AT 100 CRS "A" BOLTS "B" BOLTS : PILE CAP REINFORCEMENT SHOWN IS < NEW 610@ X 15.9 GRADE 350MPa LIGS AT 100 CRS INSTALL EPOXY. DO NOT LIFTING LUGS OR PIN MOUNT
A/M30 DE 316 INDICATIVE ONLY. STRUCTURAL GRADE BARS IM Yl D STRENGTH DAMAGE REINFORCEMENT. TO SUIT EXCAVATOR GRIP
Re (230 MPa YIELD STRENGTH TO AS AQ2) PROTECTIVE COATING TYPE 5 ee
CL SS 50, THR AADED ROD x 500 LONG NEW 610@ X 15.9 SINGLE SEAM
(AS PER ORIGINAL DESIGN) 40TK (MIN GRADE 250) BASE PLATE (SHOP APPLIED) TO FULL WELDED PIPE GRADE 350MPa
GRADE 316 STRENGT! ae GRADE 316 SS STRENGTH CLASS 80, NEW STEEL COLUMN - PLAN VIEW FSBW TO COLUMN, DRILL FOR 4 - 30 EXTERIOR INCLUDING MINIMUM YIELD STRENGTH
CLASS 80 WASHERS. LOCKING NUT. LOCTITE TO THREAD -
(4mm THICK) PRECOAT REFER TO NO01 - NOO3 DIA GR 316 THREADED ROD, UNDERSIDE OF BASE PLATES. (WELDABLE)
STRENGTH CLASS 5. SUPPLY WITH
WITH 75 MICRON DFT GRADE 316 SS STRENGTH CLASS 80, 1:40 UNREDUCED AT A3 ADDITIONAL HOLES FOR IF CONCRETE CRACKED 4x "A" BOLTS. EPOXY INTO
EPOXY. NUT 1:20 UNREDUCED AT At ALTERNATIVE BOLTING POSITIONS. 3/ 0.5mm THICK GRADE 316 (PILE CAPS 3, 4 &5 ONLY): POSITION.
ah FILL UNUSED HOLES WITH EPOXY TO SS SHIMS (IF REQUIRED) REMOVE CONCRET, 080 90mi 1008 DIA NON SHRINK
40TK BASE PLATE OF H AD: QCK OVE PREVENT MOISTURE BUILDUP. 4/ 1mm THICK GRADE 316 WIDE x 1200 (TO 50 | GROUT
DEPTH BED TO BASE PLATE.
NOTED) AND RE! LACE DO NOT USE VELLING NUTS.
p
38mm HOLE DIAMETER. 6102 PIPI NDI SS SHIMS WITH PARCHEM ASS USE GR 316 ST, INLESS SHIMS.
FILL SPACE WITH EPOXY
nN | 3 / 2mm THICK GRADE 316 DO NOT DAMAG
E REO
oS SS SHIMS
100 x 100 GRADE 316 SS EEE
® iS SHIMS TO BE INSTALLED
ZS SYMMETRICALLY
© AROUND JACK x I 5
D \ €
| N N 52@ CORED HOLE. EPOXY gf So 4 \\ HOLE DIAMETER 35mm DRED
N FILLED (REFER TO 8 - HOLES ON 750mm PCD 52 DIA x 300 MIN C)
N N DRAWINGS NO01 - NO03) 2% \ 4- HOLES ON 730mm PCD HOLE EXISTING 1200 1200 PILE CAP
4- HOLES ON 785mm PCD
N N UNUSED HOLES TO BE EPOXY FILLED
N N ve Il 8!
N N tt. PRO OSED SHIM ARRANGEMENT S$ ION
=
y
;* \\ a D (SHIM PLACEMENT - REFER TO NOTE 9, CONSTRUC ENCE) ee al
(0. _@ @ e/
—— <— NTS
"A" BOLT DETAIL ("B" BOLT DETAIL SIMILAR) SF = EXISTING 50 PSC OCTAGONAL PILES
NTS 40TK (MIN GRADE 250) BASE & CAP ~
PLATE FSBW TO PIPE, DRILL FOR 4 -
CONSTRUCTION STEPS 30 DIA GR 316 THREADED ROD, Ww «KS
STRENGTH CLASS 5. SUPPLY WITH
4 LOCATE EXISTING REINFORCEMENT IN PILE CAP AND HEADSTOCK WITH LINE OF HEADSTOCK OVER ADDITIONAL HOLES FOR
ALTERNATIVE BOLTING POSITIONS.
FERROSCANNER AND MARK ON CONCRETE. COLUMN CAP PLATE DETAIL - PLAN FILL UNUSED HOLES WITH EPOXY TO Ke WE u TWEEN
PE (ON
PILE CAPS 3, 4, & 5 ONLY : BREA OUT 1000 200 CONCRETE TO 1:20 UNREDUCED AT A3 (BASE PLATE SIMILAR) PREVENT MOISTURE BUILDUP. © D BE COLUMN
REMOVE CRACKED & DRUMMY CONCRETE. IN; PECT & TREAT 1:10 UNREDUCED AT At SECTION & END PLATES
300
REINFORCEMENT AS PER DRA\ ING NO04.
# INERT NITROGEN / GROUT
139 INJECTION POINTS x 4. (2 AT TOP,
CORE HOLES FOR 4 x "A" "BN LTS, AVOID | | 2 AT BOTTOM) REFER DETAIL.
EXISTING REINFORCEMENT.
USE ALTERNATIVE HOLES TO AVOID HITTING EXIST @32 BARS. IF @12
LIGS ARE IN CONFLICT WITH HO! SEE! ENGINEER APPROVAL BEFORE LINE OF HEADSTOCK OVER oo HEADSTOCK / 2 +/- 5mm (BOTH DIRECTIONS) SECTION (A
CUTTING.
TACK WELD EACH LIG TO EACH MAIN BAR FOR ELECTRICAL CONTINUITY. 4:40 UNREDUCED AT A3 LY
4:20 UNREDUCED AT A1
REPLACE REMOVED CONCRETE WITH PARCHEM LASS OR EQUAL. 100 x 100 GRADE 316 SS H UNDERSIDE OF HEADSTOCK TO BE
CLEANED WITH MECHANICAL WIRE BRUSH
SHIMS TO BE INSTALLED
TO REMOVE ALL SURFACE DEFORMATION
INSTALL NEW STEEL COLUMN AND EPOXY "A" &"B" BOLTS INTO SYMMETRICALLY
POSITION. AROUND JACK —™,_| — WALL OF 610@ COLUMN &COLUMN PROVIDE 130 x 130 X 5 (GRADE 250)
SPREADER PLATE
INSTALL NON SHRINK GROUT TO UNDERSIDE OF COLUMN, TIGHTEN "A" “e SN BELOW CAP TEMPORARY \¢ JACK 30
“a SN
LE
BOLTS AFTER 1 DAY OF GROUT CURING. INSTALL "B" BOLTS NUTS “ey NS ENERPAC JACK : MAXIMUM +/- 5mm a
Ww I<
SS
LOOSE, 10mm CLEAR OF COLUMN CAPPLATE TO ALLOW FOR JACK Cy WN CLOSED HEIGHT = 79mm (BOTH DIRECTIONS) tl
fi \\
MOVEMENT (ENSURE 90mm CLEAR AT TOP OF STEEL COLUMN FOR fi Vy + 5mm SPREADER = 84mm
ie a
JACKING.) CLEAN UNDERSIDE OF HEADSTOCK WITH MECHANICAL WIRE it 4 JACK RANGE 16mm I M30 GR 316 SS NUT (CLASS 50)
ri a I
BRUSH. ° ire} i V4 JACKING FORCE: REFER Lh
i im
= i i NOTE 8 TT UNDERSIDE OF EXISTING IN
Vw 1
a i I HEADSTOCK
USE 1 x ENERPAC (RSM-750) 75 TONNE LOW HEADROOM JACKS TO JACK V ri 1165 Pa)
A ri
BETWEEN HEADSTOCK & TOP OF COLUMN TO 42 TONNES TOTAL vA a
fy
PRELOAD. (WORK CAN BE DONE WITH TRAFFIC ON BRIDGE) \ fi x 139 WIDE
\\ fy
A fy
WN A) NON SHRINK GROUT SPACE :
7
INSTALL GRADE 316 STAINLESS STEEL SHIMS TO TIGHT FIT AND REMOVE SS “ey 90mm BEFORE JACKING.
SS ar
SS
JACK AND SPREADER PLATE. TIGHTEN "B" BOLT NUTS TO FINGER TIGHT. ENERPAC JACK —— 91mm AFTER JACKING. somm DIA HOLE THRU _ 7
REFER POSITIONING
10 INSTALDNON SHRI OUT FO TO) OF COLUN APTER DAY PLAN COLUMN WALL M30 GR 316 SS (CLASS 50) BOLT
oy
CURING, FULLY TIGHTEN "B" BOLT NUTS. x 30 LONG. (SUPPLIED LOOSE)
— 40TK (MIN GRADE 250) BASE
11 REMOVE LIFT LUGS IF REQUIRED. MAKE GOOD ANY COATING DAMAGE. & CAP PLATE FSBW TO WALL OF 610@ COLUMN 6mm AIRTIGHT F.W.
COLUMN. {COLUMN
12. 10% OF "A" AND "B" BOLTS TO BE SUBJECTED TO PULLOUT TEST USING
HOLLOW CYLINDER JACK (ENERPAC RCH - 302 OR EQUAL) TEST LOAD =
162kN LINE OF HEADSTOCK OVER ENERPAC JACK POSITIONING ON COLUMN - SECTION WALL OF 610@ COLUMN
13 LOCK "A" BOLT &"B" BOLT NUTS WITH LOCK NUTS. FIX WITH LOCTITE NOTES : (ENERPAC JACK - JACKING FORCE 42 TONNES REFER TO NOTE 7 & 8,
PER OTE; Noo4 - NOQ4. Fl L
POXY 6 PR MO ALL SPAI EBA EPLATE HOLES WITH CONSTRUCTION STEPS)
D SHIM POSITIONING ON COLUMN CAP - PLAN 4 PLEASE PRINT IN COLOUR. 4:20 UNREDUCED AT A3 NITROGEN / GROUT INJECTION POINT DETAIL
4:10 UNREDUCED AT A1
(SHIM PLACEMENT - REFER TO NOTE 9, CONSTRUCTION SEQUENCE) 2 REFER TO DRAWINGS NO01 - N004 FOR PROJECT SPECIFIC NOTES. (FOR LATER USE DURING CONSTRUCTION. 4 REQUIRED PER COLUMN.
4:20 UNREDUCED AT A3 3. REFER TO DRAWINGS NO01 - NO03 FOR STEELWORK COATINGS. ALIGN INJECTION POINTS FOR EASY ACCESS FROM PILE CAP)
4:10 UNREDUCED AT A1
COPYRIGHT © Associated Consultants Client TOD = Drawn Verified Project Drawing Title
This drawing is subject to P COOKE C DOWDING BRIDGE REMEDIAL WORKS - REFERENCE |NEW COLUMN
copyright in accordance with the 5.9.14 AMENDED AS CLOUDED NV x SCONE Designed Verified DESIGN - MUNNA POINT, NOOSA INSTALLATION DETAILS
agreement between Tod
Consulting pty Itd (tc) and tc's 02.7.14 | ISSUED FOR TENDER PC C DOWDING MAY 2014 Drawing Number
client. This drawing shall only be 26.6.14 | ISSUED FOR REVIEW PC consulting engineers Approved RPEQ No RDP OPTION 1: STEEL 02600 -S005
used for this specific project.
17.6.14 | PILE TYPE, REPAIR DEPTH, INJECTION PC Noosa: 07 5449 9600 DOWDING 8339 LOCAL AUTHORITY NOOSA SHIRE COUNCIL
This drawing shall not be used 22.5.14, COLUMN OPTIONS PC Sunshine Coast: 07 5329 3190 Mackay: 07 4840 2337 Sit Date MCU APPROVAL HORIZ DATUM 0 10 20 30 40 50 60
for construction until irked as PO Box 61, Noosaville, QLD 4566
‘issued for construction’ in the 28.3.14| ISSUED FOR COMMENT PC [email protected] www todconsulting.com 20.10.14 ROL APPROVAL VERT DATUM AHD Aid|
revision description. Rev| Date |Revision Description Drawn ABN. 39 128 805 336 OPW APPROVAL RL MEASUREMENT BAR - INCREMENTS IN mmSee the original
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