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SDI
For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project
7/30/2015
Strukuras DF International Co. Ltd
January 9th, 2014
SDI’S EXPERTISE IN SHEIKH JABER CAUSEWAY PROJECT
SDI
For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project
Contents
1. Project General Information
2. FSLM Equipment Introduction
• Design
• Manufacturing
• QA/QC
• Factory Load Test
• Painting& Packing
• Spare Parts
3. On Site Services
• On-site Assembly & Commissioning
• 3 Times Modifications/Relocations of LG&T/P on Deck
• 24 Months Maintenance
SDI
For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project
7/30/2015
Project General Information
SDI
For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project
PROJECT LOCATION
-Name of Project: FSLM Equipment Supply and Services for the Use of Sheikh
Jaber Al-Ahmad Al-Sabah Causeway Project – Main Link, in Kuwait
-Client: Hyundai Engineering & Construction Co., Ltd.
-Location: Kuwait/From Shuwaikh Port to Subiyah New Town
SDI
For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project
CONDITION OF CONSTRUCTION:
Bridge Name
Depth
(H) 2.5m 4.0m
Span(L) 35m 40m 45m 45m 60m
30m or
31.14m
60m or
63.86m
Shuwaikh Port Br. 14 30 8
Shuwaikh Port I/C Br. 72
Shuwaikh Br. 202
South App. Br. 2 146
Main Br. 4 4
North App. Br. 4 300
Subiyah Br. 8 258
Sub Total 14 304 8 14 704 4 4
Total 326 726
(1) Bridge Information
SDI
For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project
CONDITION OF CONSTRUCTION:
(2) Minimum radius of Horizontal alignment :
• H =2.5m PC Girder Bridges : R =1200m
• H =4.0m PC Girder Bridges : R =25000m
• Temporary Transport Road (18m width) at Subiyah Job Site : R=1200m
• Temporary Access Ramp (30m ~ 45m width ) at Bay Island south : R=200m
(3) Maximum longitudinal slope:
• H =2.5m PC Girder Bridges : S = 0.53%
• Bridge with height 4.0m PC Girder : S = 0.02%
• Temporary Transport Road at Subiyah Job Site : S = 2%
• Temporary Access Ramp at Bay Island south : S = 2%
Bay Island south Temporary Access Road
SDI
For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project
CHALLENGES
Since the 21st century, the bridge construction equipment and technology are developed rapidly,
and kind of large-scaled bridge equipment had performed very important roles for the bridge
construction in many large projects.
Around 2005, the worldwide famous Korea Incheon Bridge and China Hangzhou Bay bridge
were built by adopting FSLM Method in turn, for which project the max.PC Box Girder to be
erected is of 50m span, 1400t weight, meanwhile launching gantry had developed with a
capacity suit for the erection of 50m, 1400t PC box girders.
And for the use of Kuwait Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project, the FSLM
equipment we made are designed for the lifting and erection of up to 60m, 1800t PC box
girders.
This shall be a new breaking record for FSLM bridge erection Construction, and also
big challenges to develop such large-capacity full set of FSLM equipment and
construction.
CONDITION OF CONSTRUCTION:
SDI
For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project
China Hangzhou Bay Bridge- LG &T/P for erection of 50m&1400t PC Box Girder
Korea Incheon Bridge- LG &T/P for erection of 50m&1400t PC Box Girder
SDI
For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project
CHALLENGES
Comparing to the Korea Incheon Bridge and China Hangzhou Bay bridge, the Kuwait Sheikh
Jaber Al-Ahmad Al-Sabah Causeway Project is not only to be built with a bigger span and
weight (increased from 50m /1400t to 60m/1800t), but existing much more complicated
construction conditions and requirements, which put forward much higher requirements
and challenges for the full set of FSLM equipments.
Major Complicated and Special Construction Conditions:
a) Variable spans from 35m to 60m, with complicated and irregular span combinations
b) Existing Min. Curve Radius: 1200m bridge;
c) Several times relocation and modifications over the sea are required for the L/G and
T/P; ..
d) S-shaped access with 200m small curve radius are existed on the South Bay Island, the
Transporter on deck is required to carrying the PC box girders to be erected and LG for
relocation to pass through for many times;
e) Many times construction for the first & last spans and variable spans;
f) Existence of Widen flanged box-girder and construction of bridge with variable deck
width.
CONDITION OF CONSTRUCTION:
SDI
For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project
SDI’s Working Scope In This Project
 Design, Manufacture, DAP shipment of Full Set of FSLM Equipment to Subiyah Jobsite.
 Site assembly & commissioning of All FSLM Equipment.
 3 Times Modification & Relocation of FSLM Launching Gantry and Transporter on Deck.
 FSLM Equipment Buy-back unpon Completion of PC Girder Erection.
Full Set of FSLM Equipment, including:
 Launching Gantry(LG)
 Transporter On Deck (T/P on Deck)
 Transporter On Land (T/P on Land)
 Straddle Carrier at PC Yard(SC at PC Yard)
 Straddle Carrier at Jetty(SC at Jetty)
SDI1800 Launching Gantry DCY1800II Transporter On Deck
DCY1800II Transporter On Land
SDI
For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project
1800Ton Straddle Carrier at PC Yard
1800Ton Straddle Carrier at Jetty
SDI
For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project
Independent from SDI
Project Organization Structure
High Rank Management
(SDI)
Project Manager
Design
Manager
NDF design
team
STK design
check team
Korea KOSHA
consultant
Fabrication
manager
SDI
fabrication
Supervisor
NDF
fabrication
manager
Procurement
manager
QA/QC
Manager
QA/QC
engineers
SDI internal
QA/QC
3rd party
NDT
Korean
supervisor
A/S Manager
On-site
assy.&commis
sioning
Equip.Modific
ation Team
Onsite
Maintenance
PM team office
consultant team
of experts
SDI
For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project
7/30/2015
SDI
For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project
Design
Working Environment
• Ambient temperature: 0 ℃ ~+60℃
• Wind Speed
under work : ≤20m/sec
non-work : ≤42m/sec
• Equipped with lamps enough for Night Work
General Design Standard
 1) Steel Structure
All the Steel Structure conforms to European Design Codes:
EN1990, Eurocode 0: Basis of Structural Design
EN1991, Eurocode 1: Actions on structures.
EN1993, Eurocode 3: Design of steel structures.
EN13001 : Cranes, General design
EN13001-1: Cranes, General design
EN13001-2: Cranes, General design
SDI
For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project
Design
General Design Standard
 2) Electrical and Hydraulic Systems
Electrical System: accordant with “CEI EN 60204.1” requirements, and Motor
Protection Index is above IP55.
The Design and assembly of the Hydraulic System follows ISO,UNI and CETOP relevant
standards and requirements.
3) Safety and Test Criterions
Safety: in accordance with EEC89/392 General Safety Criterion & Latest Regulations
Test: after completing the trial assembly, Load testing will be conducted
(110% dynamic load; 125% statistic load)
SDI
For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project
Design
Specification Data of the FSLM Equipment
1) SDI1800 LG
• Equipment Type : Overhang type ( without under bridge)
• Applicable Launching length : Variable PC Girder with 35m, 40m, 45m, 60m span
• Minimum applicable radius : 1200m
• Adaptable longitudinal gradient : 1%
• Lifting capacity : 1800ton
• Min. lifting height under the hanger : 12m
• Lifting mode : Hoisted by 4 points with 3 points supporting system
• Winch Trolley driving type : Chain pulling system ( long. running and side shift )
• Winch Trolley running speed : 0~5m/min(full loading), 0~10m/min(unloading)
• Lifting speed : 0~0.5m/min(full loading), 0~1m/min(unloading)
• Launching Gantry forward speed: 0~10m/min
SDI
For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project
Design
Specification Data of the FSLM Equipment
2) DCY1800II Transporter on Deck
• Purpose of use : Feeding PC Girder to Launching Gantry for the erection.
• Load capacity : 1800ton
• Running mode : 4 sets trolleys, 2 sets trolleys to be operated synchronously
• Driving mode : Hydraulic motor and reducer
• Driving speed : 0~5km/h (full loading), 0~8km/h ( unloading)
• Steering structure : Hydraulic cylinder driving shaft for steering
• Braking Mode : Hydraulic system
• Braking function : Driving brake, Parking brake, emergency brake
• Tire type : Radial tire
• Applicable Loading length : Variable PC Girder with 35m, 40m, 45m, 60m span
• Minimum applicable radius : 200m (at Bay Island south ), 1200m(at Subiyah Job Site)
• Adaptable gradient : 2% ( longitudinal), 3% (transversal)
SDI
For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project
Design
Specification Data of the FSLM Equipment
3) DCY1800ITransporter on Land
• Purpose of use : Transport PC Girder between Stock Yard and Jetty.
• Load capacity : 1800ton
• Running mode : 4 sets trolleys, 2 sets trolleys to be operated synchronously
• Driving mode : Hydraulic motor and reducer
• Driving speed : 0~5km/h (full loading), 0~8km/h ( unloading)
• Steering structure : Hydraulic cylinder driving shaft for steering
• Braking Mode : Hydraulic system
• Braking function : Driving brake, Parking brake, emergency brake
• Tire type : Radial tire
• Applicable Loading length : Variable PC Girder of 35m, 40m, 45m, 60m and 63.5m span
• Minimum applicable radius : 1200m(at Subiyah Job Site)
• Adaptable gradient : 2% ( longitudinal), 3% (transversal)
SDI
For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project
Design
Specification Data of the FSLM Equipment
4) Straddle Carrier PC Yard
• Purpose of use : Carry PC Girder out from casting bed
• Type of PC Girder : Variable ( 35m, 40m, 45m, 60m, 63.5m and hybrid girder)
• Lifting capacity : 2uints x 900ton
• Synchronized operation of two units
• Leg Span : 45m
• Minimum lifting height under the hanger : 18m
• Minimum height under the main girder : 20m
• Driving mode : hydraulic motor and reducer
• Braking Mode : hydraulic system
• Operation mode : Remote control and cabin
• Running speed : 3km/h(full loading), 6km/h(unloading)
• Lifting speed : 0~0.5m/min(full loading), 0~1.5m/min(unloading)
• Tire type : Radial tire
SDI
For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project
Design
Specification Data of the FSLM Equipment
5) Straddle Carrier at Jetty (Subiyah Temporary Jetty)
• Purpose of use : Shipping of PC Girder
• Type of PC Girder : Variable ( 35m, 40m, 45m, 60m, 63.5m and hybrid girder)
• Lifting capacity : 2uints x 900ton
• Synchronized operation of two units
• Leg Span : 45m
• Minimum lifting height under the hanger : 18m
• Minimum height under the main girder : 20m
• Driving mode : Hydraulic motor and reducer
• Braking Mode : Hydraulic system
• Operation mode : Remote control and cabin
• Running speed : 3km/h(full loading), 6km/h(unloading)
• Lifting speed : 0~0.5m/min(full loading), 0~1.5m/min(unloading)
• Tire type : Radial tire
SDI
For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project
1. Control to the Construction Loads– the Biggest Difficulty , the Key to Overall Proposal
Control to the Construction load of the LG and T/P on deck is the most difficult point for this
project and it determines the success of overall construction proposal.
For the bridge, the construction load(deadweight of LG and T/P) is far bigger than the running
loads on the bridge from vehicles after construction completion. Bridge design should consider
and check the construction loads are satisfying the bearing capacities of the PC girder and
Piers/Abutment.
The Construction Loads are quite difficult to control mainly due to below factors:
a) Self weight of the LG is quite big, almost equal to the weight of one piece of the PC Girder
b) The relative bigger construction loads on the bridge deck must be reacted around the area
near the pier caps.
c) The LG and T/P on deck is designed to satisfy the construction loads for the erection of 60
spans, and also has to meet that requirements for the erection of 40mspans.
d) Construction loads caused by relocation of the LG&T/P, the erections of the first, last and
variable spans.
e) Impact caused by erection the widened flanged box-girder and construction of bridge with
variable deck width.
Design Challenges – Launching Gantry
SDI
For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project
1. Control to the Construction Loads– the Biggest Difficulty , the Key to Overall
Proposal
We had taken below measures to control the construction loads for reducing the impact to
bridge piers and the PC girders:
a) Optimize the design proposal and construction procedures, and make the loads
b) concentrating on the pier caps or above the web areas/cross walls of the PC girders.
c) Arrange the supporting positions of each legs of LG properly longitudinally or
transversally to distribute the concentrated loads.
d) To avoid any bigger concentrated loads may occurred to the erected deck during LG
launching operations.
e) Through the transporter on deck to transmit and distribute the loads onto 4 pieces of
erected PC girders.
f) Modify and shorten the main girder when to erect the smaller spans
Design Challenges – Launching Gantry
SDI
For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project
2. Girder Erection at Small Curve Radius – 1200m
Through side-shit the main supports/legs to realize deflection adjustment during LG
launching operation.
The key is to control and realize the legs supports on the pier caps and bridge deck.
And Main Girder of the LG is required to rotate horizontally and position during launching
operation, this also raises high requirements for the design of LG mechanisms.
Design Challenges – Launching Gantry
SDI
For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project
3. Girder Erection at Variable Spans
The no.2# leg, no.3# leg and no.4# leg are longitudinally movable along the main girder, this is
the basic requirements to realize girder erections for the variable spans.
There are variable spans(30m, 40m, 45m and 60m) in the project, how to arrange LG
supports/legs reasonable to satisfy the requirements of girder feeding and erection, and
meanwhile to ensure the construction loads to be approved by bridge designer?
This is another key and difficult points for LG Design.
Design Challenges - Launching Gantry
SDI
For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project
4. The First Span and the Last Span Girder Erection
For Girder Erection of the first span or the last span, it is not just a simple operations to
support the LG Legs onto the abutment or roadbed.
 How to arrange the main supports/legs and transmit the construction loads?
How to design the leg structure to satisfy the supporting requirements?
How to launch the LG in position and ready for Girder erection? Etc.
All the requirements should be considered during the design stage.
Design Challenges - Launching Gantry
SDI
For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project
5. Assy. and Relocation/Modification over the Marine Area
 The LG & T/P on deck shall be assy. On deck oversea.
 And due to the construction and Girder erection requirements of the North &
South Bay Islands, the LG& T/P on deck are required to relocated/modified on
the marine for 3 times.
Design Challenges - LG&T/P on Deck
SDI
For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project
5. Assy. and Relocation/Modification over the Marine Area
Thus the working conditions as below for the assy., modification/relocation works
are required to be considered, i.e.:
• Assy. and dismantling of the LG and T/P by Floating Crane on the deck;
• LG transported by T/P for relocation;
• Transportation of the main parts and or the LG and T/P by marine barges.
Design Challenges - LG&T/P on Deck
SDI
For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project
5. Assy. and Relocation/Modification over the Marine Area
Design Challenges - LG&T/P on Deck
SDI
For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project
6. Assy. and Relocation/Modification over the Marine Area
The last spans near the South Bay Island and North Bay Island are designed to be
widened PC box girders, distance from the center to the web flange of the box girders
are increasing from 8.5m to 11.8m gradually. And no.4# leg of the LG is required to
satisfy the requirements to support and launching at these area.
Design Challenges - LG&T/P on Deck
SDI
For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project
7. S- shaped Access of 200m Curve Radius at South Bay Island
.
Design Challenges - LG&T/P on Deck
The T/P on deck carrying the PC Girder or
the whole LG is required to pass through
this area.
SDI
For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project
8. Variable Bridge Width/ Center Distance
Launching Gantry and Transporter shall be suitable to pass Shuwaikh Port Bridge
where the lateral center distance of the deck are changed from 19m to 18m
around STA 103+352.(Pier P077 to P076),accordingly the pier center distance are
changed from 18.872m to 17.782m.
.
Design Challenges - LG&T/P on Deck
P(077)Pier P(076) Pier
19000
18000
SDI
For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project
8. Variable Bridge Width/ Center Distance
When the Transporter carrying with heavy load is passing through this area, the
lateral center distance between two trolleys is required to be adjusted to suitable
the change from 19m to 18m(center distance of the deck), to ensure that center
of the Transporter is in line with the deck center , and wheel loads be
symmetrical reacting on deck.
.
Design Challenges - LG&T/P on Deck
19000 18000
SDI
For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project
8. Variable Bridge Width/ Center Distance
When the LG is launching through and operating at this area, the transversal
distance of each legs/supports are required to be adjusted continuously to satisfy
the supporting requirements of each leg and proper load transmission.
.
Design Challenges - LG&T/P on Deck
SDI
For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project
9. Other Key Design Points
 Synchronous control of 2 units Straddle Carriers of one set
 Synchronous Control technology of 4 trolleys of the Transporter
 Equipment Reliability and Safety Design
 Design to ensure reliability of equipment Mechanism, Electric System and
Hydraulic System under high temperature ambient.
Other Design Challenges - SC&T/P
SDI
For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project
9. Other Key Design Points
4 transporters to work simultaneously on bridge deck or embankment with small
radius is a technical challenge.
We carried out tests on 4 transporters’ simultaneous control and succeed.
Please see a short video.
Other Design Challenges - SC&T/P
SDI
For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project
7/30/2015
Strong Design Capacity - A joint design team with over 50 experienced
engineers from NDF and STK are participated in the project.
Design input
Design
Design Check
Compliance with European
Standards
NDF
NDF+SDI
Strukturas AS
Consultant team
Design Capacity
SDI
For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project
7/30/2015
3-dimension design model
Finite Element Method for Structure Calculation
Design Capacity
SDI
For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project
7/30/2015
Finite Element Method for Structure Calculation
Design Capacity
SDI
For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project
7/30/2015
Design Capacity
Currently, the detailed design of all the FLSM equipment is near completion,. and
through continuous realizable design, optimization and effective communication with
client , almost all the design challenges have been overcame successfully and
approved by bridge designer and client.
And Straddle Carrier at PC yard has been put into fabrication since Feb.10th,
2014.
SDI
For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project
7/30/2015
Manufacturing
Manufacturing Capacity
SDI carries out most equipment fabrication and almost all factory acceptance testing
at the workshops of it’s major shareholder, Zhengzhou New Dafang Heavy Industry
Science & Technology Co.,Ltd. (NDF).
NDF’s headquarters and main workshopsoccupy 254,000 square meters of land.
Facilities include :
 Workshop area is over 80,000 square meters;includes 3 Steel Structure shops, 3
machining shops, 2 final assembly shops.
 Loading test fields are over 45,000 square meters.
Annual manufacturingcapacity:
 Over100sets of large-scaled bridge building equipment.
 Annual steel processing capacity: over 50,000 tons.
SDI
For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project
Factory Workshop Annual Capacity
DF Heavy Industry 86,500m2 12,000tons
Liuye 26,000m2 30,000 tons
Dongfang metal structure 20,000m2 50,000 tons
Hangxiao steel structure 51,440m2 Over 24,000tons
Zhongkai-changjian 40,500m2 12,000 tons
Manufacturing
Manufacturing Capacity
SDI also has several affiliated and long-term cooperating workshops for
fabrication.
The major affiliated / partner workshops are:
 DF Heavy Industry(subsidiary of NDF)
 Liuye
 Dongfang metal structure
 Hangxiao
 Zhongkai – Changjian
Steel Processing Workshop Area and Annual Capacity
SDI
For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project
7/30/2015
Manufacturing
Manufacturing Capacity
As the workload of each factory is changing time to time, and its capacity
available to SDI for this project is also changing time to time.
Refer to the real-time steel structure fabricating capacity available to SDI, the
major affiliated / partner workshops to be involved to the project are:
 DF Heavy Industry(subsidiary of NDF)
 Liuye
 Dongfang metal structure
 Hangxiao
 Zhongkai - Changjian
SDI
For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project
7/30/2015
Manufacturing
Manufacturing Arrangement & Location
FSLM Equip. Item Manufacturing Factory
SC at PC Yard Steel Structure of MG&Supports, etc Liuye
Machining Parts, Running System,
Winch Trolleys
NDF
Purchased Parts Delivered to NDF
FAT(load test) NDF
SC at Jetty Steel Structure of MG&Supports, etc Dongfang/or Hangxiao(spare)
Machining Parts, Running System,
Winch Trolleys
NDF
Purchased Parts Delivered to NDF
FAT(load test) NDF
SDI
For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project
7/30/2015
Manufacturing
Manufacturing Arrangement & Factories
FSLM Equip. Item Manufacturing Factory
T/P on Land Main Frame/Steel Structure Dongfang
All Other Parts NDF
Purchased Parts Delivered to NDF
FAT(load test) NDF
T/P on Deck Main Frame Dongfang
All Other Parts NDF
Purchased Parts Delivered to NDF
FAT(load test) NDF
L/G Steel Structure of MG&Supports,etc. Liuye
All Other Parts NDF
Purchased Parts Delivered to NDF
FAT(load test) NDF
SDI
For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project
7/30/2015
Detailed Manufacturing and Assembly Schedule
Manufacturing
SDI
For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project
7/30/2015
QA/QC Control
Design Quality Control
1st control
Design Quality is subjected to NDF’s design quality control system, as mentioned
in SDI Introduction.
2nd control
Fully Independent Design Check will be carried out by Strukturas for this project
to ensure compliance with relevant Euro codes.
3rd control
Equipment experts from outside of SDI, NDF AND Strukturas are invited to review
and comment.
SDI
For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project
7/30/2015
QA/QC Control
Design Quality Control
SDI
For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project
QA/QC Control
SDI QUALITY CONTROL PLAN
SDI’s QA/QC DEPARTMENT
Monitoring
3rd PARTY NDT
Information
INSPECTION AND TEST PLAN (ITP)
WORKSHOP INTERNAL QA/QC
AS-BUILT DOCUMENTATION
Clinet’s Superintendent
Supervision&Cooperation
Manufacturing Quality Control
Below Control Plan shall be followed to ensure the Manufacturing Quality
SDI
For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project
Manufacturing Quality Control
Steel Fabrication Quality Control Plan, covers the following items:
- Material (Purchase, Receipt, Marking, Checking & Testing)
- Welding (Qualifications, Procedures, Inspection)
- NDT (Operator Qualification, Extent of Testing, Repair Welding, Dimensional Survey)
- Surface Preparation (Shot Blasting, Visual Inspection, Temperature / Dew Point /
Humidity Readings)
- Trial Assembly (After all welding has been completed)
- AS Built Documentation (Quality Documentation to be supplied to Client)
QA/QC Control
SDI
For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project
QA/QC Control
Purchased Parts Quality Control
Besided conform to the RFQ of HDEC and requirements, all purchased parts shall be
of the reliable ones and be appoved by client/HDEC before P.O.
SDI
For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project
7/30/2015
Each one nos of each kind of FSLM equipment as below shall be tested and accepted by
client before EXW.
FAT (Load Test )for:
 SDI1800 Launching Gantry
 DCY1800II Transporter On Deck
 DCY1800I Transporter On Land
 Straddle Carrier at PC Yard
 Straddle Carrier at Jetty
FAT Criteria:
Load Test shall be carried out on completion of assembly in the factory:
 110% dynamic load;
 125% static load
Factory Acceptence Test
SDI
For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project
7/30/2015
FAT/ load tests for the FSLM equipment on completion of assembly shall be carried out at
below testing yards in NDF, SDI’s Main factory.
Factory Acceptence Test
20,000m2 15,000m2
SDI
For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project
7/30/2015
General Plan and layout of loading tests
Factory Acceptence Test
SDI
For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project
7/30/2015
General Plan and layout of loading tests
Factory Acceptence Test
SDI
For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project
Loading test capacity up to 2000 ton:
SIMULATE CONCRETE BEAM OF 60M
We prepared 60m MSS main girder used as main
beam structure in loading test.
We prepared 2000 ton concrete blocks used as
load for in loading test.
Factory Acceptence Test
SDI
For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project
7/30/2015
General tests plan of straddle carriers
Factory Acceptence Test
SDI
For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project
7/30/2015
General tests plan of transporters
Factory Acceptence Test
SDI
For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project
7/30/2015
General tests plan of launching Gantry
Factory Acceptence Test
SDI
For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project
 Painting:
Steel shall be pretreated before cutting-off;
Painting after Blasting in accordance with
outdoor working Requirements:
 Blasting comply with Sweden SA2 standards
 The first coat: inorganic zinc coating, 60 microns thick.
 Intermediate coat: epoxy paint, 60 microns thick.
 Min. total painting thickness = 120 microns
Study on “good paint for 60 Celsius degree” is carried
out.
Painting and Packing
SDI
For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project
7/30/2015
Packing :
Oversized structure parts of the
equipment shall be shipped in bulk
after sound and reliable packing,
e.g. below figs .
MG500 GC to Korea
SDI has experience to pack and ship
bridge building equipment to Korea,
Taiwan, Middle East, Russia.
We tried and found out the ways to
reduce damages to the least!
Painting and Packing
SDI
For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project
7/30/2015
Standard-sized structure and fragile parts
are to be loaded and well fixed into 40’OT
containers to ensure no damages during
long-sea voyage
Fragile parts like motors, reducers and
cylinders are to be well packed into boxes
before loading and fixing in 40’OT
containers to ensure no damages during
long-sea voyage
Painting and Packing
SDI
For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project
7/30/2015
Spare Parts :
 Additional Repair Parts as property of SDI shall also be delivered to site to ensure
timely repairs under warranty and emergency repairs out of warranty if any.
 We have considered and listed some necessary spare parts to be supplied
together with the equipment.
Repair Parts :
Spare Parts and Repair Parts
SDI
For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project
7/30/2015
Section 3 – On Site Services
SDI
For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project
To complete the assembly, commissioning and modification works of FSLM equipment supplied
in a safety, high-quality and scheduled manner, a professional management team(dispatched in
batches, about 60 staffs in total) with high professional level, rich construction experience shall
be launched. And adequate technical workers and qualified construction equipments will also be
put in the project.
Assembly &Commissioning of FSLM equipment
Assembly of all FSLM equipment and conducting commissioning as below:
 Erection of 3 span (6 number of PC Girder) of Subiyah Bridge by Launching Gantry and
Transporter on Deck.
 Transportation of 6 number of PC girder by Transporter on Land from PC Yard to Subiyah Jetty
 Lifting and stock of 6 number of PC girder by Straddle Carrier at PC Yard from PC Factory to
PC Yard.
 Lifting and unloading of 6 number of PC girder on the transportation barge by Straddle
Carrier at Jetty.
On-site Assembly & Commissioning
SDI
For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project
Assembly Plan for equipment’s first site assembly
On-site Assembly and Commissioning
SDI
For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project
3 times modifications of FSLM equipment:
① Transportation of L/G and T/P from Subiyah bridge to Shuwaikh r Bridge after the
completion of PC Girder erection of Subiyah Bridge, including erection of 2 spans of
Shuwaikh Birdge after modification.
② Transportation of L/G and T/P from Shuwaikh r Bridge to Bay Island South arera after the
completion of PC Girder erection of Shuwaikh r Bridge .
③ Transportation of L/G and T/P from Bay Island South arera to Bay Island North arera.
3 times Modifications
SDI
For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project
More detail plan has to be made according to site
condition and construction demand.
LG and T/P on deck Relocation Plan
3 times Modifications
SDI
For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project
We shall mobilize and operate an experienced and professional maintenance team at site to
maintain the FSLM Equipment for the required duration -24 months warranty.
Maintenance team shall consist of:
one supervisor, one electrician and two mechanics (Hydraulic and mechanic)
Our maintenance team shall provide any required maintenance and repair work under warranty
and technical assistance to Client /equipment operators.
24 month maintenance
SDI
For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project
CONTACT US FOR MORE INFORMATION:
www.sdi-intl.com
sdi_junli@126.com
newdfsharon@163.com
Tel: 0086 (0)371 55635362
We are glad to provide you our
best service.
Thanks for your time!
7/30/2015

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SDI Kuwait Causeway prj.(kusc)

  • 1. SDI For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project 7/30/2015 Strukuras DF International Co. Ltd January 9th, 2014 SDI’S EXPERTISE IN SHEIKH JABER CAUSEWAY PROJECT
  • 2. SDI For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project Contents 1. Project General Information 2. FSLM Equipment Introduction • Design • Manufacturing • QA/QC • Factory Load Test • Painting& Packing • Spare Parts 3. On Site Services • On-site Assembly & Commissioning • 3 Times Modifications/Relocations of LG&T/P on Deck • 24 Months Maintenance
  • 3. SDI For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project 7/30/2015 Project General Information
  • 4. SDI For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project PROJECT LOCATION -Name of Project: FSLM Equipment Supply and Services for the Use of Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project – Main Link, in Kuwait -Client: Hyundai Engineering & Construction Co., Ltd. -Location: Kuwait/From Shuwaikh Port to Subiyah New Town
  • 5. SDI For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project CONDITION OF CONSTRUCTION: Bridge Name Depth (H) 2.5m 4.0m Span(L) 35m 40m 45m 45m 60m 30m or 31.14m 60m or 63.86m Shuwaikh Port Br. 14 30 8 Shuwaikh Port I/C Br. 72 Shuwaikh Br. 202 South App. Br. 2 146 Main Br. 4 4 North App. Br. 4 300 Subiyah Br. 8 258 Sub Total 14 304 8 14 704 4 4 Total 326 726 (1) Bridge Information
  • 6. SDI For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project CONDITION OF CONSTRUCTION: (2) Minimum radius of Horizontal alignment : • H =2.5m PC Girder Bridges : R =1200m • H =4.0m PC Girder Bridges : R =25000m • Temporary Transport Road (18m width) at Subiyah Job Site : R=1200m • Temporary Access Ramp (30m ~ 45m width ) at Bay Island south : R=200m (3) Maximum longitudinal slope: • H =2.5m PC Girder Bridges : S = 0.53% • Bridge with height 4.0m PC Girder : S = 0.02% • Temporary Transport Road at Subiyah Job Site : S = 2% • Temporary Access Ramp at Bay Island south : S = 2% Bay Island south Temporary Access Road
  • 7. SDI For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project CHALLENGES Since the 21st century, the bridge construction equipment and technology are developed rapidly, and kind of large-scaled bridge equipment had performed very important roles for the bridge construction in many large projects. Around 2005, the worldwide famous Korea Incheon Bridge and China Hangzhou Bay bridge were built by adopting FSLM Method in turn, for which project the max.PC Box Girder to be erected is of 50m span, 1400t weight, meanwhile launching gantry had developed with a capacity suit for the erection of 50m, 1400t PC box girders. And for the use of Kuwait Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project, the FSLM equipment we made are designed for the lifting and erection of up to 60m, 1800t PC box girders. This shall be a new breaking record for FSLM bridge erection Construction, and also big challenges to develop such large-capacity full set of FSLM equipment and construction. CONDITION OF CONSTRUCTION:
  • 8. SDI For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project China Hangzhou Bay Bridge- LG &T/P for erection of 50m&1400t PC Box Girder Korea Incheon Bridge- LG &T/P for erection of 50m&1400t PC Box Girder
  • 9. SDI For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project CHALLENGES Comparing to the Korea Incheon Bridge and China Hangzhou Bay bridge, the Kuwait Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project is not only to be built with a bigger span and weight (increased from 50m /1400t to 60m/1800t), but existing much more complicated construction conditions and requirements, which put forward much higher requirements and challenges for the full set of FSLM equipments. Major Complicated and Special Construction Conditions: a) Variable spans from 35m to 60m, with complicated and irregular span combinations b) Existing Min. Curve Radius: 1200m bridge; c) Several times relocation and modifications over the sea are required for the L/G and T/P; .. d) S-shaped access with 200m small curve radius are existed on the South Bay Island, the Transporter on deck is required to carrying the PC box girders to be erected and LG for relocation to pass through for many times; e) Many times construction for the first & last spans and variable spans; f) Existence of Widen flanged box-girder and construction of bridge with variable deck width. CONDITION OF CONSTRUCTION:
  • 10. SDI For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project SDI’s Working Scope In This Project  Design, Manufacture, DAP shipment of Full Set of FSLM Equipment to Subiyah Jobsite.  Site assembly & commissioning of All FSLM Equipment.  3 Times Modification & Relocation of FSLM Launching Gantry and Transporter on Deck.  FSLM Equipment Buy-back unpon Completion of PC Girder Erection. Full Set of FSLM Equipment, including:  Launching Gantry(LG)  Transporter On Deck (T/P on Deck)  Transporter On Land (T/P on Land)  Straddle Carrier at PC Yard(SC at PC Yard)  Straddle Carrier at Jetty(SC at Jetty) SDI1800 Launching Gantry DCY1800II Transporter On Deck DCY1800II Transporter On Land
  • 11. SDI For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project 1800Ton Straddle Carrier at PC Yard 1800Ton Straddle Carrier at Jetty
  • 12. SDI For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project Independent from SDI Project Organization Structure High Rank Management (SDI) Project Manager Design Manager NDF design team STK design check team Korea KOSHA consultant Fabrication manager SDI fabrication Supervisor NDF fabrication manager Procurement manager QA/QC Manager QA/QC engineers SDI internal QA/QC 3rd party NDT Korean supervisor A/S Manager On-site assy.&commis sioning Equip.Modific ation Team Onsite Maintenance PM team office consultant team of experts
  • 13. SDI For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project 7/30/2015
  • 14. SDI For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project Design Working Environment • Ambient temperature: 0 ℃ ~+60℃ • Wind Speed under work : ≤20m/sec non-work : ≤42m/sec • Equipped with lamps enough for Night Work General Design Standard  1) Steel Structure All the Steel Structure conforms to European Design Codes: EN1990, Eurocode 0: Basis of Structural Design EN1991, Eurocode 1: Actions on structures. EN1993, Eurocode 3: Design of steel structures. EN13001 : Cranes, General design EN13001-1: Cranes, General design EN13001-2: Cranes, General design
  • 15. SDI For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project Design General Design Standard  2) Electrical and Hydraulic Systems Electrical System: accordant with “CEI EN 60204.1” requirements, and Motor Protection Index is above IP55. The Design and assembly of the Hydraulic System follows ISO,UNI and CETOP relevant standards and requirements. 3) Safety and Test Criterions Safety: in accordance with EEC89/392 General Safety Criterion & Latest Regulations Test: after completing the trial assembly, Load testing will be conducted (110% dynamic load; 125% statistic load)
  • 16. SDI For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project Design Specification Data of the FSLM Equipment 1) SDI1800 LG • Equipment Type : Overhang type ( without under bridge) • Applicable Launching length : Variable PC Girder with 35m, 40m, 45m, 60m span • Minimum applicable radius : 1200m • Adaptable longitudinal gradient : 1% • Lifting capacity : 1800ton • Min. lifting height under the hanger : 12m • Lifting mode : Hoisted by 4 points with 3 points supporting system • Winch Trolley driving type : Chain pulling system ( long. running and side shift ) • Winch Trolley running speed : 0~5m/min(full loading), 0~10m/min(unloading) • Lifting speed : 0~0.5m/min(full loading), 0~1m/min(unloading) • Launching Gantry forward speed: 0~10m/min
  • 17. SDI For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project Design Specification Data of the FSLM Equipment 2) DCY1800II Transporter on Deck • Purpose of use : Feeding PC Girder to Launching Gantry for the erection. • Load capacity : 1800ton • Running mode : 4 sets trolleys, 2 sets trolleys to be operated synchronously • Driving mode : Hydraulic motor and reducer • Driving speed : 0~5km/h (full loading), 0~8km/h ( unloading) • Steering structure : Hydraulic cylinder driving shaft for steering • Braking Mode : Hydraulic system • Braking function : Driving brake, Parking brake, emergency brake • Tire type : Radial tire • Applicable Loading length : Variable PC Girder with 35m, 40m, 45m, 60m span • Minimum applicable radius : 200m (at Bay Island south ), 1200m(at Subiyah Job Site) • Adaptable gradient : 2% ( longitudinal), 3% (transversal)
  • 18. SDI For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project Design Specification Data of the FSLM Equipment 3) DCY1800ITransporter on Land • Purpose of use : Transport PC Girder between Stock Yard and Jetty. • Load capacity : 1800ton • Running mode : 4 sets trolleys, 2 sets trolleys to be operated synchronously • Driving mode : Hydraulic motor and reducer • Driving speed : 0~5km/h (full loading), 0~8km/h ( unloading) • Steering structure : Hydraulic cylinder driving shaft for steering • Braking Mode : Hydraulic system • Braking function : Driving brake, Parking brake, emergency brake • Tire type : Radial tire • Applicable Loading length : Variable PC Girder of 35m, 40m, 45m, 60m and 63.5m span • Minimum applicable radius : 1200m(at Subiyah Job Site) • Adaptable gradient : 2% ( longitudinal), 3% (transversal)
  • 19. SDI For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project Design Specification Data of the FSLM Equipment 4) Straddle Carrier PC Yard • Purpose of use : Carry PC Girder out from casting bed • Type of PC Girder : Variable ( 35m, 40m, 45m, 60m, 63.5m and hybrid girder) • Lifting capacity : 2uints x 900ton • Synchronized operation of two units • Leg Span : 45m • Minimum lifting height under the hanger : 18m • Minimum height under the main girder : 20m • Driving mode : hydraulic motor and reducer • Braking Mode : hydraulic system • Operation mode : Remote control and cabin • Running speed : 3km/h(full loading), 6km/h(unloading) • Lifting speed : 0~0.5m/min(full loading), 0~1.5m/min(unloading) • Tire type : Radial tire
  • 20. SDI For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project Design Specification Data of the FSLM Equipment 5) Straddle Carrier at Jetty (Subiyah Temporary Jetty) • Purpose of use : Shipping of PC Girder • Type of PC Girder : Variable ( 35m, 40m, 45m, 60m, 63.5m and hybrid girder) • Lifting capacity : 2uints x 900ton • Synchronized operation of two units • Leg Span : 45m • Minimum lifting height under the hanger : 18m • Minimum height under the main girder : 20m • Driving mode : Hydraulic motor and reducer • Braking Mode : Hydraulic system • Operation mode : Remote control and cabin • Running speed : 3km/h(full loading), 6km/h(unloading) • Lifting speed : 0~0.5m/min(full loading), 0~1.5m/min(unloading) • Tire type : Radial tire
  • 21. SDI For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project 1. Control to the Construction Loads– the Biggest Difficulty , the Key to Overall Proposal Control to the Construction load of the LG and T/P on deck is the most difficult point for this project and it determines the success of overall construction proposal. For the bridge, the construction load(deadweight of LG and T/P) is far bigger than the running loads on the bridge from vehicles after construction completion. Bridge design should consider and check the construction loads are satisfying the bearing capacities of the PC girder and Piers/Abutment. The Construction Loads are quite difficult to control mainly due to below factors: a) Self weight of the LG is quite big, almost equal to the weight of one piece of the PC Girder b) The relative bigger construction loads on the bridge deck must be reacted around the area near the pier caps. c) The LG and T/P on deck is designed to satisfy the construction loads for the erection of 60 spans, and also has to meet that requirements for the erection of 40mspans. d) Construction loads caused by relocation of the LG&T/P, the erections of the first, last and variable spans. e) Impact caused by erection the widened flanged box-girder and construction of bridge with variable deck width. Design Challenges – Launching Gantry
  • 22. SDI For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project 1. Control to the Construction Loads– the Biggest Difficulty , the Key to Overall Proposal We had taken below measures to control the construction loads for reducing the impact to bridge piers and the PC girders: a) Optimize the design proposal and construction procedures, and make the loads b) concentrating on the pier caps or above the web areas/cross walls of the PC girders. c) Arrange the supporting positions of each legs of LG properly longitudinally or transversally to distribute the concentrated loads. d) To avoid any bigger concentrated loads may occurred to the erected deck during LG launching operations. e) Through the transporter on deck to transmit and distribute the loads onto 4 pieces of erected PC girders. f) Modify and shorten the main girder when to erect the smaller spans Design Challenges – Launching Gantry
  • 23. SDI For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project 2. Girder Erection at Small Curve Radius – 1200m Through side-shit the main supports/legs to realize deflection adjustment during LG launching operation. The key is to control and realize the legs supports on the pier caps and bridge deck. And Main Girder of the LG is required to rotate horizontally and position during launching operation, this also raises high requirements for the design of LG mechanisms. Design Challenges – Launching Gantry
  • 24. SDI For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project 3. Girder Erection at Variable Spans The no.2# leg, no.3# leg and no.4# leg are longitudinally movable along the main girder, this is the basic requirements to realize girder erections for the variable spans. There are variable spans(30m, 40m, 45m and 60m) in the project, how to arrange LG supports/legs reasonable to satisfy the requirements of girder feeding and erection, and meanwhile to ensure the construction loads to be approved by bridge designer? This is another key and difficult points for LG Design. Design Challenges - Launching Gantry
  • 25. SDI For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project 4. The First Span and the Last Span Girder Erection For Girder Erection of the first span or the last span, it is not just a simple operations to support the LG Legs onto the abutment or roadbed.  How to arrange the main supports/legs and transmit the construction loads? How to design the leg structure to satisfy the supporting requirements? How to launch the LG in position and ready for Girder erection? Etc. All the requirements should be considered during the design stage. Design Challenges - Launching Gantry
  • 26. SDI For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project 5. Assy. and Relocation/Modification over the Marine Area  The LG & T/P on deck shall be assy. On deck oversea.  And due to the construction and Girder erection requirements of the North & South Bay Islands, the LG& T/P on deck are required to relocated/modified on the marine for 3 times. Design Challenges - LG&T/P on Deck
  • 27. SDI For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project 5. Assy. and Relocation/Modification over the Marine Area Thus the working conditions as below for the assy., modification/relocation works are required to be considered, i.e.: • Assy. and dismantling of the LG and T/P by Floating Crane on the deck; • LG transported by T/P for relocation; • Transportation of the main parts and or the LG and T/P by marine barges. Design Challenges - LG&T/P on Deck
  • 28. SDI For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project 5. Assy. and Relocation/Modification over the Marine Area Design Challenges - LG&T/P on Deck
  • 29. SDI For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project 6. Assy. and Relocation/Modification over the Marine Area The last spans near the South Bay Island and North Bay Island are designed to be widened PC box girders, distance from the center to the web flange of the box girders are increasing from 8.5m to 11.8m gradually. And no.4# leg of the LG is required to satisfy the requirements to support and launching at these area. Design Challenges - LG&T/P on Deck
  • 30. SDI For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project 7. S- shaped Access of 200m Curve Radius at South Bay Island . Design Challenges - LG&T/P on Deck The T/P on deck carrying the PC Girder or the whole LG is required to pass through this area.
  • 31. SDI For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project 8. Variable Bridge Width/ Center Distance Launching Gantry and Transporter shall be suitable to pass Shuwaikh Port Bridge where the lateral center distance of the deck are changed from 19m to 18m around STA 103+352.(Pier P077 to P076),accordingly the pier center distance are changed from 18.872m to 17.782m. . Design Challenges - LG&T/P on Deck P(077)Pier P(076) Pier 19000 18000
  • 32. SDI For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project 8. Variable Bridge Width/ Center Distance When the Transporter carrying with heavy load is passing through this area, the lateral center distance between two trolleys is required to be adjusted to suitable the change from 19m to 18m(center distance of the deck), to ensure that center of the Transporter is in line with the deck center , and wheel loads be symmetrical reacting on deck. . Design Challenges - LG&T/P on Deck 19000 18000
  • 33. SDI For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project 8. Variable Bridge Width/ Center Distance When the LG is launching through and operating at this area, the transversal distance of each legs/supports are required to be adjusted continuously to satisfy the supporting requirements of each leg and proper load transmission. . Design Challenges - LG&T/P on Deck
  • 34. SDI For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project 9. Other Key Design Points  Synchronous control of 2 units Straddle Carriers of one set  Synchronous Control technology of 4 trolleys of the Transporter  Equipment Reliability and Safety Design  Design to ensure reliability of equipment Mechanism, Electric System and Hydraulic System under high temperature ambient. Other Design Challenges - SC&T/P
  • 35. SDI For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project 9. Other Key Design Points 4 transporters to work simultaneously on bridge deck or embankment with small radius is a technical challenge. We carried out tests on 4 transporters’ simultaneous control and succeed. Please see a short video. Other Design Challenges - SC&T/P
  • 36. SDI For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project 7/30/2015 Strong Design Capacity - A joint design team with over 50 experienced engineers from NDF and STK are participated in the project. Design input Design Design Check Compliance with European Standards NDF NDF+SDI Strukturas AS Consultant team Design Capacity
  • 37. SDI For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project 7/30/2015 3-dimension design model Finite Element Method for Structure Calculation Design Capacity
  • 38. SDI For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project 7/30/2015 Finite Element Method for Structure Calculation Design Capacity
  • 39. SDI For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project 7/30/2015 Design Capacity Currently, the detailed design of all the FLSM equipment is near completion,. and through continuous realizable design, optimization and effective communication with client , almost all the design challenges have been overcame successfully and approved by bridge designer and client. And Straddle Carrier at PC yard has been put into fabrication since Feb.10th, 2014.
  • 40. SDI For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project 7/30/2015 Manufacturing Manufacturing Capacity SDI carries out most equipment fabrication and almost all factory acceptance testing at the workshops of it’s major shareholder, Zhengzhou New Dafang Heavy Industry Science & Technology Co.,Ltd. (NDF). NDF’s headquarters and main workshopsoccupy 254,000 square meters of land. Facilities include :  Workshop area is over 80,000 square meters;includes 3 Steel Structure shops, 3 machining shops, 2 final assembly shops.  Loading test fields are over 45,000 square meters. Annual manufacturingcapacity:  Over100sets of large-scaled bridge building equipment.  Annual steel processing capacity: over 50,000 tons.
  • 41. SDI For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project Factory Workshop Annual Capacity DF Heavy Industry 86,500m2 12,000tons Liuye 26,000m2 30,000 tons Dongfang metal structure 20,000m2 50,000 tons Hangxiao steel structure 51,440m2 Over 24,000tons Zhongkai-changjian 40,500m2 12,000 tons Manufacturing Manufacturing Capacity SDI also has several affiliated and long-term cooperating workshops for fabrication. The major affiliated / partner workshops are:  DF Heavy Industry(subsidiary of NDF)  Liuye  Dongfang metal structure  Hangxiao  Zhongkai – Changjian Steel Processing Workshop Area and Annual Capacity
  • 42. SDI For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project 7/30/2015 Manufacturing Manufacturing Capacity As the workload of each factory is changing time to time, and its capacity available to SDI for this project is also changing time to time. Refer to the real-time steel structure fabricating capacity available to SDI, the major affiliated / partner workshops to be involved to the project are:  DF Heavy Industry(subsidiary of NDF)  Liuye  Dongfang metal structure  Hangxiao  Zhongkai - Changjian
  • 43. SDI For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project 7/30/2015 Manufacturing Manufacturing Arrangement & Location FSLM Equip. Item Manufacturing Factory SC at PC Yard Steel Structure of MG&Supports, etc Liuye Machining Parts, Running System, Winch Trolleys NDF Purchased Parts Delivered to NDF FAT(load test) NDF SC at Jetty Steel Structure of MG&Supports, etc Dongfang/or Hangxiao(spare) Machining Parts, Running System, Winch Trolleys NDF Purchased Parts Delivered to NDF FAT(load test) NDF
  • 44. SDI For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project 7/30/2015 Manufacturing Manufacturing Arrangement & Factories FSLM Equip. Item Manufacturing Factory T/P on Land Main Frame/Steel Structure Dongfang All Other Parts NDF Purchased Parts Delivered to NDF FAT(load test) NDF T/P on Deck Main Frame Dongfang All Other Parts NDF Purchased Parts Delivered to NDF FAT(load test) NDF L/G Steel Structure of MG&Supports,etc. Liuye All Other Parts NDF Purchased Parts Delivered to NDF FAT(load test) NDF
  • 45. SDI For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project 7/30/2015 Detailed Manufacturing and Assembly Schedule Manufacturing
  • 46. SDI For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project 7/30/2015 QA/QC Control Design Quality Control 1st control Design Quality is subjected to NDF’s design quality control system, as mentioned in SDI Introduction. 2nd control Fully Independent Design Check will be carried out by Strukturas for this project to ensure compliance with relevant Euro codes. 3rd control Equipment experts from outside of SDI, NDF AND Strukturas are invited to review and comment.
  • 47. SDI For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project 7/30/2015 QA/QC Control Design Quality Control
  • 48. SDI For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project QA/QC Control SDI QUALITY CONTROL PLAN SDI’s QA/QC DEPARTMENT Monitoring 3rd PARTY NDT Information INSPECTION AND TEST PLAN (ITP) WORKSHOP INTERNAL QA/QC AS-BUILT DOCUMENTATION Clinet’s Superintendent Supervision&Cooperation Manufacturing Quality Control Below Control Plan shall be followed to ensure the Manufacturing Quality
  • 49. SDI For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project Manufacturing Quality Control Steel Fabrication Quality Control Plan, covers the following items: - Material (Purchase, Receipt, Marking, Checking & Testing) - Welding (Qualifications, Procedures, Inspection) - NDT (Operator Qualification, Extent of Testing, Repair Welding, Dimensional Survey) - Surface Preparation (Shot Blasting, Visual Inspection, Temperature / Dew Point / Humidity Readings) - Trial Assembly (After all welding has been completed) - AS Built Documentation (Quality Documentation to be supplied to Client) QA/QC Control
  • 50. SDI For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project QA/QC Control Purchased Parts Quality Control Besided conform to the RFQ of HDEC and requirements, all purchased parts shall be of the reliable ones and be appoved by client/HDEC before P.O.
  • 51. SDI For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project 7/30/2015 Each one nos of each kind of FSLM equipment as below shall be tested and accepted by client before EXW. FAT (Load Test )for:  SDI1800 Launching Gantry  DCY1800II Transporter On Deck  DCY1800I Transporter On Land  Straddle Carrier at PC Yard  Straddle Carrier at Jetty FAT Criteria: Load Test shall be carried out on completion of assembly in the factory:  110% dynamic load;  125% static load Factory Acceptence Test
  • 52. SDI For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project 7/30/2015 FAT/ load tests for the FSLM equipment on completion of assembly shall be carried out at below testing yards in NDF, SDI’s Main factory. Factory Acceptence Test 20,000m2 15,000m2
  • 53. SDI For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project 7/30/2015 General Plan and layout of loading tests Factory Acceptence Test
  • 54. SDI For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project 7/30/2015 General Plan and layout of loading tests Factory Acceptence Test
  • 55. SDI For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project Loading test capacity up to 2000 ton: SIMULATE CONCRETE BEAM OF 60M We prepared 60m MSS main girder used as main beam structure in loading test. We prepared 2000 ton concrete blocks used as load for in loading test. Factory Acceptence Test
  • 56. SDI For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project 7/30/2015 General tests plan of straddle carriers Factory Acceptence Test
  • 57. SDI For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project 7/30/2015 General tests plan of transporters Factory Acceptence Test
  • 58. SDI For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project 7/30/2015 General tests plan of launching Gantry Factory Acceptence Test
  • 59. SDI For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project  Painting: Steel shall be pretreated before cutting-off; Painting after Blasting in accordance with outdoor working Requirements:  Blasting comply with Sweden SA2 standards  The first coat: inorganic zinc coating, 60 microns thick.  Intermediate coat: epoxy paint, 60 microns thick.  Min. total painting thickness = 120 microns Study on “good paint for 60 Celsius degree” is carried out. Painting and Packing
  • 60. SDI For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project 7/30/2015 Packing : Oversized structure parts of the equipment shall be shipped in bulk after sound and reliable packing, e.g. below figs . MG500 GC to Korea SDI has experience to pack and ship bridge building equipment to Korea, Taiwan, Middle East, Russia. We tried and found out the ways to reduce damages to the least! Painting and Packing
  • 61. SDI For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project 7/30/2015 Standard-sized structure and fragile parts are to be loaded and well fixed into 40’OT containers to ensure no damages during long-sea voyage Fragile parts like motors, reducers and cylinders are to be well packed into boxes before loading and fixing in 40’OT containers to ensure no damages during long-sea voyage Painting and Packing
  • 62. SDI For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project 7/30/2015 Spare Parts :  Additional Repair Parts as property of SDI shall also be delivered to site to ensure timely repairs under warranty and emergency repairs out of warranty if any.  We have considered and listed some necessary spare parts to be supplied together with the equipment. Repair Parts : Spare Parts and Repair Parts
  • 63. SDI For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project 7/30/2015 Section 3 – On Site Services
  • 64. SDI For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project To complete the assembly, commissioning and modification works of FSLM equipment supplied in a safety, high-quality and scheduled manner, a professional management team(dispatched in batches, about 60 staffs in total) with high professional level, rich construction experience shall be launched. And adequate technical workers and qualified construction equipments will also be put in the project. Assembly &Commissioning of FSLM equipment Assembly of all FSLM equipment and conducting commissioning as below:  Erection of 3 span (6 number of PC Girder) of Subiyah Bridge by Launching Gantry and Transporter on Deck.  Transportation of 6 number of PC girder by Transporter on Land from PC Yard to Subiyah Jetty  Lifting and stock of 6 number of PC girder by Straddle Carrier at PC Yard from PC Factory to PC Yard.  Lifting and unloading of 6 number of PC girder on the transportation barge by Straddle Carrier at Jetty. On-site Assembly & Commissioning
  • 65. SDI For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project Assembly Plan for equipment’s first site assembly On-site Assembly and Commissioning
  • 66. SDI For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project 3 times modifications of FSLM equipment: ① Transportation of L/G and T/P from Subiyah bridge to Shuwaikh r Bridge after the completion of PC Girder erection of Subiyah Bridge, including erection of 2 spans of Shuwaikh Birdge after modification. ② Transportation of L/G and T/P from Shuwaikh r Bridge to Bay Island South arera after the completion of PC Girder erection of Shuwaikh r Bridge . ③ Transportation of L/G and T/P from Bay Island South arera to Bay Island North arera. 3 times Modifications
  • 67. SDI For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project More detail plan has to be made according to site condition and construction demand. LG and T/P on deck Relocation Plan 3 times Modifications
  • 68. SDI For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project We shall mobilize and operate an experienced and professional maintenance team at site to maintain the FSLM Equipment for the required duration -24 months warranty. Maintenance team shall consist of: one supervisor, one electrician and two mechanics (Hydraulic and mechanic) Our maintenance team shall provide any required maintenance and repair work under warranty and technical assistance to Client /equipment operators. 24 month maintenance
  • 69. SDI For HYUNDAI E&C-Sheikh Jaber Al-Ahmad Al-Sabah Causeway Project CONTACT US FOR MORE INFORMATION: www.sdi-intl.com sdi_junli@126.com newdfsharon@163.com Tel: 0086 (0)371 55635362 We are glad to provide you our best service. Thanks for your time! 7/30/2015