4/6/2017 1 Prepared and presented by : Tan Chee Kean 1 Tan Chee Kean Penolong Jurutera Bahagian Pemulihan Jambatan Prepared and presented by : Tan Chee Kean 2 Ia merupakan satu kondisi semasa dimana komponen jambatan telah mula atau telah berada dalam keadaan kekurangan atau tidak lagi sempurna bila dibandingkan dengan keadaan asal. Situasi dimana keutuhan jambatan telah mula atau telah merosot ketahap yang boleh menjejaskan fungsi jambatan mengikut kehendak rekabentuk atau daya penahan beban tanggungan.
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4/6/2017
1
Prepared and presented by : Tan Chee Kean 1
Tan Chee KeanPenolong Jurutera
Bahagian Pemulihan Jambatan
Prepared and presented by : Tan Chee Kean 2
Ia merupakan satu kondisi semasa dimana komponen jambatan telah mula atau telah berada dalam keadaan kekurangan atau tidak lagi sempurna bila dibandingkan dengan keadaan asal.
Situasi dimana keutuhan jambatan telahmula atau telah merosot ketahap yang bolehmenjejaskan fungsi jambatan mengikutkehendak rekabentuk atau daya penahanbeban tanggungan.
4/6/2017
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Prepared and presented by : Tan Chee Kean 3
Punca-punca Kerosakan Komponen Jambatan
1. Secara Tindakan Mekanikal.2. Secara Tindakbalas Kimia.3. Secara Tindakbalas Fisikal.
Punca-punca Kejadian Kerosakan
Prepared and presented by : Tan Chee Kean 4
Punca-punca Kerosakan Komponen Jambatan
1. Secara Tindakan Mekanikal.a) Impakb) Tanggungan Beban Berlebihanc) Penggerakand) Pemendapane) Gegaranf) Letupan
2. Secara Tindakbalas Kimia.a) Alkali-aggregate reaction.b) Serangan Sulphate.c) Serangan Chloride.d) Delayed Ettringite Formation (DEF).e) Biological activity.
Punca-punca kejadian kerosakan
AAR
DEF
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Prepared and presented by : Tan Chee Kean 5
Punca-punca Kerosakan Komponen Jambatan
1. Secara Tindakan Mekanikal.2. Secara Tindakbalas Kimia.3. Secara Tindakbalas Fisikal.
Akan mengurangkan keupayaan dan keutuhanstruktur jambatan untuk terus berfungsi mengikutkehendak jangka hayat yang telah direkabentukkan.
Ketahanlaksakan struktur akan terjejas.
Kos penggantian jambatan akan meningkat.
Kekerapan kerja pembaikan akan meningkatkemudian hari.
Keselesaan dan keselamatan pengguna jalanrayaakan tergugat.
Kelancaran trafik akan terganggu.
Prepared and presented by : Tan Chee Kean 8
Teknik dan Operasi Penyenggaraan
Jambatan
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Prepared and presented by : Tan Chee Kean 9
Teknik dan Operasi Penyenggaraan Jambatan
1. Ketahui jenis bahan komponen.
2. Fahami jenis sistem jambatan.
3. Kenalpasti jenis kecacatan, tahapkerosakan dan punca kejadiannya.
4. Laksanakan ujian jika perlu.
5. Pintar tentangan kegunaan bahanpemabaikan yang bersesuai danekonomi.
Kefahaman asas sebelum melaksanakan operasipenyenggaraan dan kerja pembaikan:-
Prepared and presented by : Tan Chee Kean 10
Teknik dan Operasi Penyenggaraan Jambatan
1. Penyenggaraan biasa.
2. Pembaikan biasa.
3. Rehabilitation.
4. Strengthening.
Jenis-jenis skop kerja
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Prepared and presented by : Tan Chee Kean 11
1. Penyenggaraan biasaa) Penyenggaraan biasa jambatan oleh
konsesi mengikut kontrak. (R05)
b) Operasi penyenggaraan , pemulihandan penggantian komponenbersekala kecil.
Teknik dan Operasi Penyenggaraan Jambatan
Prepared and presented by : Tan Chee Kean 12
A. Penyenggaraan biasa jambatan oleh konsesimengikut kontrak. (R05)i. Kerja Pembersihan di atas deck jambatan.ii. Pembersihan weep holes.iii. Pembersihan laluan air pembetung.iv. Pembuangan semua tumbuhan.
B. Operasi penyenggaraan , pemulihan danpenggantian komponen bersekala kecil:-i. Steel Parapet.ii. Corrugated guardrail di jalantuju jambatan.iii. Drainage pipe.iv. Bridge obstruction marker.v. Bridge structure number.vi. Reflector marker.vii. Greasing of mechanical bearing.viii. Cleaning of expansion joint.
Teknik dan Operasi Penyenggaraan Jambatan
1. Penyenggaraan biasa
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Prepared and presented by : Tan Chee Kean 13
2. Pembaikan biasa.a) Surface repair.
b) Surface treatment.
c) Non-structural repair.
Teknik dan Operasi Penyenggaraan Jambatan
Prepared and presented by : Tan Chee Kean 14
A. Surface repairi. Kerja pembaikan kecil untuk
kecacatan ringgan seperti:-a. Surface defect and
honeycombing.b. Minor spalling and delamination.c. Non structural surface cracks or
shrinkage cracks.d. Minor surface material
deterioration.
Teknik dan Operasi Penyenggaraan Jambatan
2. Pembaikan biasa
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Prepared and presented by : Tan Chee Kean 15
B. Surface treatmenti. Protective coating for steel members.
a. Mengecat kesemua permukaan komponenstruktur keluli yang terdedah untuk mengatasikekaratan.
b. Membaikpulih dan kemaskini semula kualiti cat pada kesemua komponen struktur keluli.
ii. Protective coating/concrete lining for structural concrete members.a. Mengecat kesemua komponen struktur konkrit
untuk mengatasi impak dari kesan serangan chloride dan carbopnation.
b. Memperkukuhkan permukaan konkrit denganapplikasi concrete lining atau epoxy skim coat.
Teknik dan Operasi Penyenggaraan Jambatan
2. Pembaikan biasa
Prepared and presented by : Tan Chee Kean 16
C. Non- structural repairi. Membaiki atau memasang semula steel
parapet yang telah runtuh.ii. Menggantikan corrugated guardrail yang
telah runtuh.iii. Membaiki atau menggantikan expansion
joint.iv. Pembaikan kecil setempat bukan jenis
kerosakan struktur untuk kesemuakomponen konkrit jambatan.
v. Pembaikan terhadap sistem penahantebing dan cerun jambatan sediada yang rosak.
Teknik dan Operasi Penyenggaraan Jambatan
2. Pembaikan biasa
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Prepared and presented by : Tan Chee Kean 17
A. Merupakan satu proses untuk mengekalkan danmemastikan tahap keupayaan dan keutuhanstruktur jambatan untuk terus berfungsimengikut kehendak jangka hayat yang telahdirekabentukkan.
B. Ia terbahagi kepada 3 ketegori:-i. Structural rehabilitation.ii. Functional rehabilitation.iii. Hydraulic rehabilitation.
C. Pemeriksaan terperinci dan rekabentuk khasperlu dijalankan sebelum kerja-kerja pembaikandilaksanakan oleh specialist contractor.
Teknik dan Operasi Penyenggaraan Jambatan
3. Rehabilitation.
Prepared and presented by : Tan Chee Kean 18
D. Skop-skop kerja pembaikan seperti:-i. Formwork repair to all structural
components.ii. Guniting with additional rebar.iii. Steel plate bonding.iv. Concrete lining with additional rebar.v. Total rehabilitation and replacement of
Expansion Joint.vi. Concrete jacketing of concrete piles and pier
columns.vii. Epoxy injection to all structural cracks.viii. Replacement of walked or bulged bearing
pad.
Teknik dan Operasi Penyenggaraan Jambatan
3. Rehabilitation.
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Prepared and presented by : Tan Chee Kean 19
A. Merupakan satu proses peningkatan keupayaan struktur jambatanuntuk terus berfungsi dan mengekalkan keutuhannya untukmenampung tanggungan beban:-i. Kesatu tahap yang lebih tinggi berbanding dengan kehendak
rekabentuk asal.ii. Kembali kepada keadaan dan kekuatan sediakala mengikut
rekabentuk asal.B. Pemeriksaan terperinci dan rekabentuk khas perlu dijalankan
sebelum kerja-kerja strengthening dilaksanakan oleh specialist contractor.
C. Contoh skop-skop kerja strengthening:-i. Strengthening with CFRP.ii. Steel plate bonding.iii. Additional of splicing plates.iv. External post-tensioning.v. Pile jacketing with additional concrete lining and steel casing
as permanent formwork.vi. Underpining with additional piles.
Teknik dan Operasi Penyenggaraan Jambatan4. Strengthening.
Prepared and presented by : Tan Chee Kean 20
Mengekalkan keupayaan dan keutuhan strukturjambatan untuk terus berfungsi mengikut kehendakjangka hayat yang telah direkabentukkan.
• Routine Condition Inspection Report• Kajian bahan dan Ujian dengan peralatan.
• Material specification• Buku - Bridge Appraisal
Rehabilitation and Maintenance• Keberkesanan Pembaikan
• Document Tender• Method Statement
Terima LaporanStatus Pembaikan
KemaskiniData BMS
• Tender• Pemilihan• Dokumen kontrak
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Prepared and presented by : Tan Chee Kean 23
• Mengenalpasti kekuatan asal.• Melaksanakan pengukuran
perbandingan kualiti.• Meninjau dan menganalisa integriti
setiap komponen.• Mengenalpasti punca kemerosotan
kualiti dan kejadian kecacatan.
Tujuan Melaksanakan Pemeriksaan dan Siasatan Jambatan
Prepared and presented by : Tan Chee Kean 24
Pemilihan Bahan Pembaikan
a. Keserasian dan kebersesuaian.b. Kondisi persekitaran.c. Keberkesanan kos.d. Jangkaan jangka hayat
penggunaan.e. Kewujudan bahan di pasaran.f. Mampu dan senang diguna.
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Prepared and presented by : Tan Chee Kean 25
Proses Pembaikan Komponen Konkrit
Prepared and presented by : Tan Chee Kean 26
Tatacara Untuk Proses Pembaikan Komponen Konkrit
Defective Zone
SurfacePreparation
Concrete/Steel
Repair Work
Crack
Delamination
Pre-packed Shrinkage
compensated Repair
Materials
Bonding of NewTo Old Substrate
Re-bar Cleaning to S.A. 2.5 and apply Zinc Priming
Re-bar
Existing Concrete
Surface preparation and application of bonding agent
Contaminated Concrete With Chlorides Or Carbonation
Spalled Heavily CorrodedRe-bar
Removal OfContaminatedConcrete
Prepared Edge Conditioning
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Prepared and presented by : Tan Chee Kean 27
Langkah 2Gegajikan sempadan kecacatansehingga 15mm dalam dan mulakanpecahan dan pembuangan serpihankonkrit dengan kaedah yang telahdiluluskan.Gantikan besi tetulang yang menghadapi kekaratan yang seriusdan yang telah kehakisan saizdengan saiz tetulang baru dandibekalkan lapping yang mencukupi.
Langkah 1Ketuk dengan tukul untukmengenalpasti sempanandelamination.Tandakan sempadan kecacatandengan cat.Rancang dan memasangkan sistempenyokong dan penyandangmengikut rekabentuk sebelumlaksanakan pecahan konkrit.
Aturcara Penyediaan Permukaan Pembaikan
Langkah 3Sempadan potongan itu mestidalam bentuk yang mudah dibuat.Tujuan pemotongan itu adalahuntuk mengelakkan terjadinyakesan serpihan feather edges.Luas pemotongan itu jika bolehmesti dalam bentuk empat segiuntuk memudahkan kerjapembaikan.
Langkah 4Bersihkan kesemua permukaan besitetulang itu ketahap S.A. 2.5.Tiup dengan pump udara terhadappermukaan yang terdedah untukmembersihkannya dari sebarangansisa bahan serpihan.Pastikan pencapaian tahapcantuman antara permukaan lama dengan bahan pembaikan itu adalahberkualiti.
Prepared and presented by : Tan Chee Kean 28
Surface Preparation - when Corroded Rebar Is Encountered
Blown clean all exposed surface and apply one layer of bonding agent
Surface after loose concrete is removed
Exposing the heavily corroded rebar
●Perimeter of spalled area is saw cut to <15mm deep prior to hacking process
●Concrete is removed to expose rebar
Concrete is removed a minimum of 20mm under corroded rebar
90
• Corroded rebar are cleaned to S.A. 2.5 and apply with one layer of zinc rich primer.
• Heavily corroded rebar with section loss are replaced with new rebar of sufficient lap length.
Continues…..
Spalled area
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Prepared and presented by : Tan Chee Kean 29
Boundary Setting For Surface Repairs
Recommended layout
Boundary layout of loose and delaminated concrete
Recommended layout
Boundary layout of loose and delaminated concrete
Sectional view of loose and delaminated concrete
Note : -Layout should be made as simple as possible.
Recommended Section
Prepared and presented by : Tan Chee Kean 30
Peralatan Untuk Surface Preparation
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Prepared and presented by : Tan Chee Kean 31
Concrete Removal Methods : Partial Depth
1. Pneumatic Chipping Hammer- The 15# to 30# class chipping hammers are the most common removal tools for surface repair.- Hammer larger than 30# can damage encountered reinforcing steel.
2) Hydro Removal- High pressure water (20,000 to 40,000 psi) projected on affected concrete surfaces effectively removes concrete
3) Pneumatic Scabbler- Utilize reciprocating bushing tools hitting the concrete surface.- Effective tools for removal up to 6.5mm of surfaces for preparation of overlay.
4) Rotary Milling Machine- Most utilize carbide-mounted tips on a rotary drum.- Milling is generally used for removing concrete surfaces in preparation for an overlay.
Prepared and presented by : Tan Chee Kean 32
Concrete Removal Methods : Full Depth
1. Hand Held Pneumatic Breaker- 30# to 90# class are effective tools for concrete removal.- Care must be taken not to damage reinforcing steel.
2) Pneumatic/Hydraulic Mounted Breakers- Effective high volume removal tools.- Caution should be exercised to avoid bruising of the concrete surface.
3) Splitters- Tools used to fracture concrete into easily removal debris.- Available in 3 types : hydraulic wedges, fluid pressure and expansive cements.
4) Hydro Demolition- Utilizes high pressure water (20,000 to 40,000 psi) projected on to the concrete surfaces.- Can be effective on thin slabs.
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Prepared and presented by : Tan Chee Kean 33
Reinforcing Steel Cleaning
Types Of Heavy Rust And Scale Cleaning Methods
1) Needle ScalesPneumatic tools utilizing a group of small diameter steel rods powered by an internal piston.
2) High Pressure Water CleaningUsing high pressure water 3,000 to 10,000 psi.Fine sands were added for better and faster results
3) Abrasive Blast CleaningAbrasive mixed with pressurised air and projected through a nozzle
4) Power Wire BrushingVery slow and ineffective operation
Prepared and presented by : Tan Chee Kean 34
Reinforcing Steel Cleaning
Needle Scaler
High Pressure Water Gun
Steel needle rods
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Prepared and presented by : Tan Chee Kean 35
Steel Surface Preparation by Abrasive Blast Cleaning
Flexible Abrasive Hose
Concrete Substrate
Abrasive Nozzle
Reinforcing steel
Abrasive Paths
Blind spot
Prepared and presented by : Tan Chee Kean 36
The standard grades of cleanliness for abrasive blast cleaning in accordance with BS EN ISO 8501-1 are:
Sa 1 – Light blast cleaning Sa 2 – Thorough blast cleaning Sa 2.5 – Very thorough blast cleaning Sa 3 – Blast cleaning to visually clean steel
Reinforcement and Steel StructureSurface Preparation Requirement
Sample of blast cleaned steel surface to Sa 2.5 standard
Membaiki Kerosakan Pada Pier di Jambatan Sg. Tebrau, Jalan Lebuhraya Pasir Gudang, Daerah Johor Bahru, Johor.
1500
500
Existing circular r.c. column.
6mm thk. steel casing as a permanent formwork with 150mm thk. Grade 50 pre-packaged, free flowing micro-concrete infill. Normal water
level
10mm thk. steel plate bonding with 5mm thk epoxy infill and 3 rolls of 16mm Ø X 150mm anchor bolts @ 200mm c/c.
Existing river bed level
Typical Sectional View
Pier Column Repair1. All dimensions are in mm unless otherwise
stated.2. Any change of dimensions, shape and concept of
repair shall not be allowed unless otherwise get the approval from the CSFJ.
3. The contractor is only allowed to hack and repair one pier column per location at one time after proper propping and support had been designed and supported as directed by the s.o.
4. Hack and remove all unsound concrete and clean all the corroded rebar to SA 2.5 at defective area of the pier column.
5. Install all necessary anchor bars and new rebar as per detail drawing.
6. Clean all the existing concrete surface with high pressure water jet prior to the installation of water tight formwork.
7. Fix the 6mm thk water tight steel permanent formwork with proper propping system and bracing to keep it in-place.
8. 2 layer of zinc primer coats and 2 layer of epoxy coating shall be applied to all the steel members.
9. Only pre-packed micro concrete of grade 50 shall be used.
10.All propping shall not be remove until the concrete had achieved the desired strength and with approval of the s.o.
Existing r.c. pier cross-head
Z
Z
YY
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Prepared and presented by : Tan Chee Kean 55
Membaiki Kerosakan Pada Pier di Jambatan Sg. Tebrau, Jalan Lebuhraya Pasir Gudang, Daerah Johor Bahru, Johor.
Steel Plate Bonding1. All dimensions are in mm unless otherwise
stated.2. Contractor must do a detail measurement of the
pier crosshead prior to the repair process.3. Any change of shape and concept of repair shall
not be allowed unless otherwise approved by the CSFJ.
4. The contractor must repair all cracks and any other spalling detected prior to steel plate bonding process as directed by the s.o.
5. Carry out cover meter survey to mark points and locations for the installation of the 16mmØ anchor bolts.
6. All the anchor bolt locations shall then be map and transfer it into a detail drawings prior to the drilling of holes on the cut steel plate.
7. Launch and lifting of the steel plate, securing and position it with 16mmØ anchor bolts with 5mm-10mm gaps formed within the interface of concrete surface.
8. Pump in epoxy grouts to fill the 5mm-10mm water tight void and allow it to set.
9. Surface preparation of the entire steel plate to surface quality of S.A. 2.5.
10.Apply 2 layer of zinc primer coats and 2 layer of epoxy top coating to all the steel surface.
1500
500
Existing circular r.c. column.
6mm thk. steel casing as a permanent formwork with 150mm thk. Grade 50 pre-packaged, free flowing micro-concrete infill. Normal water
level
10mm thk. steel plate bonding with 5mm thk epoxy infill and 3 rolls of 16mm Ø X 150mm anchor bolts @ 200mm c/c.
Existing river bed level
Typical Sectional View
Existing r.c. pier cross-head
Z
Z
YY
Prepared and presented by : Tan Chee Kean 56
3 Dimension View of Column Repair
6mm thk. steel casing as a permanent formwork with 150mm thk. Grade 50 pre-packaged, free flowing micro-concrete infill.
2000
T25 vertical main bars to be placed @ 175 c/c
T16 @ 175 c/c links
T16 hook with 150 embedded length @ 300 c/c for holding the vertical main bars
Before
During
After
Membaiki Kerosakan Pada Pier di Jambatan Sg. Tebrau, Jalan Lebuhraya Pasir Gudang, Daerah Johor Bahru, Johor.
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Prepared and presented by : Tan Chee Kean 57
Beam-Column Moment Capacity Strengthening
A
Beam/Slab
Column
Section A-A
Steel plate assembly compositely fastened to existing concrete members
A
Steel plate assembly compositely fastened to existing concrete members
High tensile fastening bolts
High tensile fastening bolts
Site Elevation
Sectional View
Beam
Column Concrete shear walls added to existing column and beams
Footing
Prepared and presented by : Tan Chee Kean 58
External Post-Tensioned Reinforcement
Sectional View
Flexural cracks are pressure epoxy grouted prior to stressing
End bearing assembly
Bridge Pier Bent
I-beam
Side Elevation
End anchorage
Beam
ColumnExternally mounted post-tensioned strand on each side of beam
Reaction frame
External post-tensioned threaded bar Bridge deck
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Prepared and presented by : Tan Chee Kean 59
Strengthen by Pultruded CFRP Plates
Sectional View
All shear and flexural cracks are pressure epoxy treated prior to application of CFRP
Bridge deck
Bridge Pier Bent
Pultruded CFRP plates
I-beam
a) Surface preparation of affected substrate to remove oil, grease, dust, cement laitance and any coated materials.
b) Apply one coat of primer epoxy resin to prepared concrete surface.c) Apply one coat of epoxy resin to prepared concrete surfaced) Cut the pultruded CFRP plates to required length and place onto applied
epoxy resin with a roller according to the fiber direction to spread even fabric so as to ensure a proper adhesion.
e) Apply one coat of epoxy resin onto the fixed CFRP surface after it had archived sufficient strength as per recommendation by the supplier.
Pier Cross-head
Prepared and presented by : Tan Chee Kean 60
Steel Plate Bonding
Sectional View
Steel plate secure with threaded anchor bolts and bonded with epoxy adhesive
New composite member
See Detail ‘A’
Detail ‘A’
Concrete flexural member
Apply epoxy sealant and allow to set prior to pumping of epoxy adhesive
32mm Ø threaded anchor rod provides additional shear capacity and erection support
15mm thks. steel plate bonding with zinc primer and epoxy paint as top coat
Epoxy adhesive pressure grouted into plate concrete interface
steel plate bonding
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Prepared and presented by : Tan Chee Kean 61
Reconstruction of Underdesigned or Nonfunctioning Corbel
Before Reconstruction
Existing corbel
Inadequate reinforcement
Frozen bearing
After Reconstruction
Fill reconstruct corbel with dual shrinkage compensated grout
Additional steel reinforcement doweled into existing concrete
Jack and lifting of beam
New rubber bearing
Prepared and presented by : Tan Chee Kean 62
Pembaikan TerhadapCorbel Approach Slab
Yang Rosak AkibatPemasangan Dowel Bar
Yang Salah
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Prepared and presented by : Tan Chee Kean 63
Stage-1
• Mark, saw cut to required length and depth.
• Hack to required depth and remove all the unsound concrete.
• Use high pressure water jet to clean the prepared surface.
• All hacking should be executed alternately at the maximum repair length of not exceeding 1.5m at any one go.
Reconstruction of Wrongly Constructed Corbel
Prepared and presented by : Tan Chee Kean 64
Stage-2
• Scan to locate the existing rebar with concrete scanner prior to the marking of proposed location of the new dowel bars at the soffit of the approach slab.
• Drill at the pre-marked location to required size and depth as per detail design.
• Blow clean all the holes with air-jet.
• Cut and prepare the new dowel bars to required size and length as per design.
• Pump in approved epoxy sealant, insert and fix the new dowel bars, allow it to set as per recommendation by the supplier.
Reconstruction of Wrongly Constructed Corbel
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Prepared and presented by : Tan Chee Kean 65
Stage-3
• Scan to locate the existing rebar with concrete scanner prior to the marking of proposed location of the new dowel bars at the soffit of the approach slab.
• Drill at the pre-marked location to required size and depth as per detail design.
• Blow clean all the holes with air-jet.
• Cut and prepare the new anchor bars to required size and length as per design.
• Pump in approved epoxy sealant, insert and fix the new dowel bars, allow it to set as per recommendation by the supplier.
Reconstruction of Wrongly Constructed Corbel
Prepared and presented by : Tan Chee Kean 66
Stage-4
• Cut and prepare the new rebar to required size and length as per design.
• Fix and tire all the additional new rebar as per approved detail drawing.
Reconstruction of Wrongly Constructed Corbel
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Prepared and presented by : Tan Chee Kean 67
Stage-5
• Prepare and assembly of water tight formworks with pre-fixed injector pipe at the lower most location and overflow outlet pipe as per directive and approval by the S.O.
• Pump in shrinkage compensated micro concrete as per approval by the S.O.
• All formwork must be properly support to prevent any happening of segregation.
Outlet pipe
Injector pipe
Reconstruction of Wrongly Constructed Corbel
Prepared and presented by : Tan Chee Kean 68
Stage-6
• Remove all the formwork when the micro concrete achieved the required strength.
• Repeat the same process until the repair work reached the full length of the defective corbel.
Reconstruction of Wrongly Constructed Corbel
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Prepared and presented by : Tan Chee Kean 69
Pengukuhan Pier Dengan Kaedah
Tambahan Lateral Cross Tie-beam
Prepared and presented by : Tan Chee Kean 70
MEMBAIKI Jambatan No. FT001-454-50, Kerling, Daerah Hulu Selangor, Selangor.
Lateral bracing dengan pemasangan rasuk konkrit tambahantelah dibina bagi membaiki jambatan yang menghadapi
pemendapan dan keretakan rasuk.
Keadaan jambatan sebelum kerjapembaikan.
Cadangan kerja pembaikan
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Prepared and presented by : Tan Chee Kean 71
Kaedah PembaikanDengan Menggunakan
Carbon Fiber Reinforced Plastic
Prepared and presented by : Tan Chee Kean 72
Sequence on installation of Carbon Fibre Reinforced Plastic (CFRP)
Concrete Substrate
Primer
Epoxy Putty Filler
1st Resin Coat
Carbon Fibre2nd Resin Coating Epoxy based
Protective Coating
a) Surface preparation of affected substrate to remove oil, grease, dust, cement laitance and any coated materials.
b) Apply one coat of primer epoxy resin to prepared concrete surface.
c) Apply one coat of epoxy putty filler prior to the application of 1st layer of epoxy resin for installation of CFRP.
d) Cut and place CFRP onto applied epoxy resin with a roller according to the fiber direction to spread even the fabric so as to ensure a proper adhesion.
e) Apply 2nd coat of epoxy resin onto the fixed CFRP surface after it had archived sufficient strength as per recommendation by the supplier.
f) Top one layer of epoxy based protective coating to protected the applied CFRP from damages.
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Prepared and presented by : Tan Chee Kean 73
Pembaikan Jambatan Merdeka di Seberang Perai Selatan,
Pulau Pinang.
Prepared and presented by : Tan Chee Kean 74
Pemasangan CFRP di Jambatan Merdeka (FT001/782/10), Daerah S.P. Selatan.
CFRP Pultruded plates Part A & B Epoxy adhesive
Application of epoxy primer
Securing of CFRP plates using roller
Finished fixing condition of CFRP plates
Cutting of CFRP plates Removing of protective wrap
Mixing of Part A & B Epoxy adhesive
Control application to required thickness of Part A & Part B Epoxy adhesive in progress
Fixing and gluing CFRP Pultruded plates
Repeat process of securing of CFRP plates using roller
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Prepared and presented by : Tan Chee Kean 75
Pemasangan CFRP di Jambatan Merdeka (FT001/782/10), Daerah S.P. Selatan.
CFRP Fabric Epoxy Primer Epoxy Primer Surface preparation
Application of Epoxy Primer
Cutting of CFRP Fabric to required size
Epoxy Resin part A & part B components
Mixing of part A & part B components
Application of Epoxy resin for CFRP
Application of CFRP pultruded plates
Application of CFRP fabric wraps
Finished application of CFRP fabric wraps
Prepared and presented by : Tan Chee Kean 76
Pemasangan CFRP di Jambatan Merdeka (FT001/782/10), Daerah S.P. Selatan.
CFRP Fabric Epoxy Primer Epoxy Primer Surface preparation
Application of Epoxy Primer
Cutting of CFRP Fabric to required size
Epoxy Resin part A & part B components
Mixing of part A & part B components
Application of Epoxy resin for CFRP
Application of CFRP pultruded plates
Application of CFRP fabric wraps
Finished application of CFRP fabric wraps
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Prepared and presented by : Tan Chee Kean 77
Crack Repair Technique
Prepared and presented by : Tan Chee Kean 78
• Keretakan akan terjadi apabila tekanantegangan terhadap komponen konkrit itu telahmelebihi kemampuan untuk menampung.
• Faktor kejadian keretakan adalah sepertiberikut:– shrinkage – thermal– alkali aggregate reaction– corrosion of reinforcement – applied load– differential settlement
• Jenis keretakan itu akan dibahagikanmengikut lokasi, corak, saiz dan masakejadian.
Types Of Crack
Structural Crack
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Prepared and presented by : Tan Chee Kean 79
Crack Repair By Epoxy Injection
Mechanical Packers – for high and low pressure injection where hole drilling is possible. Used for
repair the structural cracks.
Surface Packer – for low pressure injection where hole drilling is not possible and is
used to repair surface cracks.Mechanical Pressure Pump
a) Surface preparation with approved tools to all the marked crack lines as per mapping detail shown in the drawing.
b) Fixed injector nipples with epoxy sealant to all marked crack lines at desired spacing as per specification.
c) Sealed all the marked crack lines with epoxy sealant.
d) Mix and inject epoxy resin as per specification with proper approved pumping system.
e) Remove all sealant and injector nipples. Grind and smoothen the affected repaired surface.
Prepared and presented by : Tan Chee Kean 80
Crack Injection Process
1. Use steel wire brush to clean the crack lines.
2. Fixing of injector nipple. 3. Sealing of the crack lines with epoxy mortar.
4. Pump until the epoxy flows out from the second packer, fix the valve quickly. Stop injection and continue pumping at the second packer. Repeat this procedure from packer to packer.
Ujian Ultrasound Pulse Velocity akan dilaksanakanselepas kesemua keretakan itu dibaiki dengantujuan menyemak kualiti pembaikan demi menjadikeutuhan komponen tersebut. Kadar pengukuranbacaannya adalah seperti di atas.
Ultrasound Pulse Velocity
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Prepared and presented by : Tan Chee Kean 81
Contoh KaedahPembaikan Terhadap
Pier Yang MenghadapiMaterial Deterioration
Prepared and presented by : Tan Chee Kean 82
Jambatan No FT0002/210/10 Di Atas Sg. Kepong, Daerah Temerloh, Pahang.
SECTION VIEW
• Clean all exposed surface with high pressure water jet to remove all laitance, dirt and any contaminants.
• Drill, fix and secure 16mm Ø X 175mm long anchor bolts with epoxy (to be placed alternately @ 300mm c/c).
• Cast 75mm thk r.c. wall complete with one layer of BRC-8 with pre-beg free flow shrinkage compensated cementitious grouts.
3000
Concrete lining repair for material deterioration.
New 75mm thkconcrete lining
Concrete surface deteriorated
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Prepared and presented by : Tan Chee Kean 83
Formwork Repair to Material Deteriorated Pile Columns
Before
After
Surface condition before repair
Prepared and presented by : Tan Chee Kean 84
Slope Protection Technique
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Prepared and presented by : Tan Chee Kean 85
MEMBAIKI JAMBATAN NO FT003/522/20, DI ATAS SG. RINTING,SEBERANG MARANG, TERENGGANU.
PLAN VIEW
3m 3m
16
.0m
Existing boundary of gabion layers to be removed, trimmed and set back as indicated for the laying of new gabions
Existing embankment2 stacks of 1m x 1m x 2m Wire Mesh Rock Filled Gabions (5 Tilted)
150mm x 150mm x 5000mm H.W. Timber Piles At 2000mm c/c
25mm Ø X 200mm Anchoring Bars Complete With Zinc Rich Primer
N.W.L.
100mm
Prepared and presented by : Tan Chee Kean 104
Membaiki Kerosakan Pada Pier di Jambatan Sg. Tebrau, Jalan Lebuhraya Pasir Gudang, Daerah Johor Bahru, Johor.
1500
500
Existing circular r.c. column.
6mm thk. steel casing as a permanent formwork with 150mm thk. Grade 50 pre-packaged, free flowing micro-concrete infill. Normal water
level
10mm thk. steel plate bonding with 5mm thk epoxy infill and 3 rolls of 16mm Ø X 150mm anchor bolts @ 200mm c/c.
Existing river bed level
Typical Sectional View
Notes:-1.All dimensions are in mm unless otherwise stated.2.Any change of dimensions, shape and concept of
repair shall not be allowed unless otherwise get the approval from the CSFJ.
3.The contractor is only allowed to hack and repair one pier column per location at one time after proper propping and support had been designed and supported as directed by the s.o.
4.Hack and remove all unsound concrete and clean all the corroded rebar to SA 2.5 at defective area of the pier column.
5.Install all necessary anchor bars and new rebar as per detail drawing.
6.Clean all the existing concrete surface with high pressure water jet prior to the installation of water tight formwork.
7.Fix the 6mm thk water tight steel permanent formwork with proper propping system and bracing to keep it in-place.
8.2 layer of zinc primer coats and 2 layer of epoxy coating shall be applied to all the steel members.
9.Only pre-packed micro concrete of grade 50 shall be used.
10.All propping shall not be remove until the concrete had achieved the desired strength and with approval of the s.o.
Existing r.c. pier cross-head
Z
Z
YY
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Prepared and presented by : Tan Chee Kean 105
Notes:-1. All dimensions are in mm unless otherwise stated.2. Any change of dimensions and shape shall not be allowed unless otherwise get the approval from the s.o.3. The contractor is only allowed to hack and repair one pile column per pier location at one time or as directed by the s.o.4. Clean all the existing concrete surface with high pressure water jet prior to the installation of water tight formwork.5. All formwork shall be properly braced, propped, leveled and water tight.6. Provide a minimum concrete cover of 30mm.7. Only pre-packed micro concrete of grade 50 shall be used.8. All propping shall not be remove until the concrete had achieved the desired strength and with approval of the s.o.
T25 vertical main bars to be placed @ 175 c/c
L.L.W.L.
300
2500
100 mm thk grade 50 pre-packed micro concrete
T16 @ 175 c/c
T16 hook with 150 embedded length @ 300 c/c for holding the vertical main bars
100
Keadah Pembaikan Secara Pile Jacketing
Prepared and presented by : Tan Chee Kean 106
Kaedah MenggantikanBearing Pad Yang
Teranjak Dari Kedudukan Asal
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Prepared and presented by : Tan Chee Kean 107
A
B
D
C
E
F
Menggantikan Bearing Pad di FT005-549-10, Daerah Sabak Bernam, Selangor.
Prepared and presented by : Tan Chee Kean 108
D
C
E
F
B
Dari SabakBernam
Expansion joint telah condong
A
Ke Teluk Intan
Dari SabakBernam
Ke Teluk Intan
Dari SabakBernam
Keseluruhan Expansion joint telahtwisted dan parapet terangkat.
Sebahagian Expansion joint telahmendap dan tilted sebelah.
Pandangan dari tebing sungai yang menunjukkan keadaan parapet . Parapet turut mendap sekali
dengan geladak.
Dari SabakBernam
Parapet turut mendap danteranjak secara ufuk (sway).
Menggantikan Bearing Pad di FT005-549-10, Daerah Sabak Bernam, Selangor.
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Prepared and presented by : Tan Chee Kean 109
Menggantikan Bearing Pad di FT005-549-10, Daerah Sabak Bernam, Selangor.
Condition of the pier and bearing shelve.
Most of the bearing pads had walked form its
original position.
Uneven settlement of the bridge deck caused by the
impact of walk bearing pads.
Fixing and assembling of the gantry working platform
system.
Fixing and assembling of the hydraulic jack system in
progress.
Shimming of the thin steel plates on top of the jack to achieve the
required finished level.
Prepared and presented by : Tan Chee Kean 110
Menggantikan Bearing Pad di FT005-549-10, Daerah Sabak Bernam, Selangor.
Fixing and installation of injector hose in progress prior to the jacking process.
Shimming of the thin steel plates along the jacking process to act as
temporary support.
Fixing of the temporary steel girder system for horizontal pushing of the moved deck.
Shimming and fixing of horizontal jack for the pushing
of the moved deck.
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Prepared and presented by : Tan Chee Kean 111
Menggantikan Bearing Pad di FT005-549-10, Daerah Sabak Bernam, Selangor.
Part A (resin) + Part B (hardener) prepacking
epoxy resin
Part C prepacking fine aggregates
Mix Part A + Part B evenly for >2 mins, then add in the Part C.
Continue mixing until homogenous mortar obtained.
Pour to form required thickness and shape it to about the size of
elastomeric bearing pad.
Shape the epoxy mortar to form down stand of beam to
overcome problem of walking bearing pad caused by uneven
seating of beam.
A completed new beam down stand with no gap within the interface between topside of bearing pad and beam soffit
detected.
Prepared and presented by : Tan Chee Kean 112
Kaedah MenggantikanExpansion Joint Rosak
Mengikut Jenis
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Prepared and presented by : Tan Chee Kean 113
Rekabentuk mengikut luas expansion gap.
Lukisan perincian mengikut keadaan tapak.
Method Statement yang cukup jelas.
Material specification mengikut komponen.
Keperluan ujian bahan mengikut komponen.
Quality Control (QC) dan Maintenance manual.
Jangka Hayat Waranti dan jenis tanggungan yang harus dilaksanakan dalam tempuh jeminan.
Keperluan dan syarat-syarat dalampemasangan Expansion Joint
Prepared and presented by : Tan Chee Kean 114
Asphaltic Plug Joint Replacement Sequence
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Prepared and presented by : Tan Chee Kean 115
Elastomeric Joint Replacement Sequence
Mark, cut and breaking out Application of bonding agent prior to leveling process
Bed leveling with epoxy mortar
Drilling of anchor bolt holes Installation and securing of anchor bolts in process