AASHTO CHBTW _1995_Construction Handbook for Bridge Temporary Works - Revision 1
February 1, 2017 | Author: David Rodriguez | Category: N/A
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A A S H T O T I T L E CHBTW 95
= 0639804
0033532 OLA
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Ob39804 0033533 T 5 4
A A S H T O T I T L E CHBTW 95
American Association of State Highway and Transportation Officials Executive Committtee 1994-1995
Voting Members Officers: President: Wayne Shackelford,Georgia Vice President: Bill Burnett, Texas Secretary/Treasurer: Clyde E. Pyers, Maryland
Regional Representatives: Region I
Patrick Garahan, Vermont
Region II
Ben Watts, Florida
Region III
Darre1 Rensink, Iowa
Region IV
Larry Bonine, Arizona
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Non-Voting Members Executive Director: Francis B. Francois, Washington, D.C.
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I
Ob37804 0031534 7 7 0
AASHTO T I T L E CHBTW 75
AASHTO Highway Subcommittee on Bridges and Structures 1995 JAMES E. SIEBELS, COLORADO, Chairman G. CHARLES LEWIS, GEORGIA, Vice Chairman STANLEY GORDON, FEDERAL HIGHWAY ADMINISTRATION, Secretary
PENNSYLVANIA, Mahendra G. Pate1 PUERTO RICO, Jose L. Melendez, Hector Camacho RHODE ISLAND, Kazem Farhournand SOUTH CAROLINA, Rocque L. Kneece SOUTH DAKOTA, John C. Cole TENNESSEE, Ed Wasserman TEXAS, Charles C. Terry U.S. DOT, Stanley Gordon (FHWA), Nick E. Mpars (USCG) UTAH, David L. Christensen VERMONT, Warren B. Tripp VIRGINIA, Malcolm T. Kerley WASHINGTON, M. Myint Lwin WEST VIRGINIA, James Sothen WISCONSIN, Stanley W. Woods WYOMING, David H. Pope ALBERTA, Dilip K.Dasmohapatra MANITOBA, W. Saltzberg NORTHERN MARIANA ISLANDS, John C. Pangalinan NEW BRUNSWICK, G.A. Rushton NEWFOUNDLAND, Peter Lester NORTHWEST TERRITORIES, Jivko Jivkov NOVA SCOTIA, C.Y.S. Nguan ONTARIO, Ranjit S . Reel SASKATCHEWAN,Lome J. Hamblin ENGLAND, Philip J. Andrews MASS. METRO. DIST. COMM., David Lenhardt N.J. TURNPIKE AUTHORITY, Wallace R. Grant PORT AUTHORITY OF NY & NJ, Joseph K. Kelly NY STATE BRIDGE AUTHORITY, William Moreau BUREAU OF INDIAN AFFAIRS, (vacant) U.S. DEPARTMENT OF AGRICULTURE-FOREST SERVICE, Steve L. Bunnell MILITARY TRAFFIC MANAGEMENT COMMAND, (vacant) U.S. ARMY CORPS OF ENGINEER-DEPT. OF THE ARMY, Paul C. T. Tan
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ALABAMA, William F. Conway ALASKA, Steve Bradford, Ray Shumway ARIZONA, William R. Bruesch, F. Daniel Davis ARKANSAS, Dale F. Loe CALIFORNIA, James E. Roberts COLORADO, A.J. Siccardi CONNECTICUT, Gordon Barton DELAWARE, Chao H. Hu D.C., Gary A. Burch, Charles F. Williams, Jacob Patnaik FLORIDA, Jerry Potter GEORGIA, Paul Liles HAWAII, Donald C. Ornellas IDAHO, L. Scott Stokes ILLINOIS, Ralph E. Anderson INDIANA, John J. White IOWA, William A. Lundquist KANSAS, Kenneth F. Hurst KENTUCKY, Richard Sutherland LOUISIANA, Wayne Aymond MAINE, Larry L. Roberts, James E. Tuley MARYLAND, Earle S. Freedman MASSACHUSETTS, Joseph P.Gill MICHIGAN, Sudhakar Kulkarni MINNESOTA, Donald J. Flemming MISSISSIPPI, Wilbur F. Massey MISSOURI, Allen F. Laffoon MONTANA, William S . Fullerton NEBRASKA, Lyman D. Freemon NEVADA, Floyd I. Marcucci NEW HAMPSHIRE, James A. Moore NEW JERSEY, Robert Pege NEW MEXICO, Martin A. G a r n i c k NEW YORK, Michael J. Cuddy, Amn Shirole NORTH CAROLINA, John L. Smith NORTH DAKOTA, Steven J. Miller OHIO, B.David Hanhilammi OKLAHOMA, Veldo M. Goins OREGON, Terry J. Shike
...
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AASHTO T I T L E
CHBTW 95 œ Ob39804 0033535 827 œ
PREFACE
This construction handbook has been developed for use by contractors and construction engineers involved in bridge consíruction on Federal-aid highway projects. This document may also be of interest to faisework design engineers, and supplements information found in the Guide Design Specgcation for Bridge
Temporary Works.") The content is construction-oriented, focusing primarily on standards of material quality and means and methods of construction. The handbook contains chapters on falsework, formwork, and temporary retaining structures. For more indepth discussion on a particular topic, related literature and references are identified. This study was conducted under FHWA Contract No. DTFH61-91-C-O0088by Wiss, Janney, Elstner Associates, Inc., Northbrook, Illinois. The project was directed by the Scaffolding, Shoring, and Forming Task --``,`````````,``,`,``,,`,``,``,-`-`,,`,,`,`,,`---
Group of the FHWA, whose comments and review were very helpful in the preparation of this document. The
task group consisted of the following Federal, State, and industry representatives: Sheila Rimai Duwadi, Federal Highway Administration James R. Hoblitzeii. Federal Highway Administration Donald W. Miller, Federal Highway Administration William S. Cross, Federal Highway Administration Ian M. Friedland, Transportation Research Board James M. Stout, California Department of Transportation Donald Flemming, Minnesota Department of Transportation Nick Yaksich, Associated General Contractors Kent Starwait, American Road and Transportation Builders Association Ramon Cook, The Burke Company Robert Desjardins, Cianbro Corp. Richard F. Hoffman, McLean Contracting Robert T. Ratay, Consulting Engineer Additional information and input was solicited from other individuals and indusuy associations in their fields of interest. Special recognition is extended to representatives of the Shoring and Forming Engineering Committee of the Scaffolding, Shoring, and Forming Institute: L.Edwin Dunn, California Department of Transportation (Retired); Robert G. Lukas, Ground Engineering Consultants, Inc.; Alan D. Fisher, Cianbro Corporation: Mark K. Kaler, Dayton-Superior Corporation: Harry B. Lancelot, Richmond Screw Anchor Company; Donald F. Meinheit and Raymond H.R. Tide.
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AASHTO
TITLE CHBTW 95
Ob39804 003L53b 7b3
TABLE OF CONTENTS Page
Chapter 1.
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . .
...........................
SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RELATED PUBLICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.
FALSEWORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
...........................
MATERIALS AND MANUFACTURED COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . Structural Steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Timber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Manufactured Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FOUNDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shallow Foundations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DeepFoundations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Protection of the Foundation Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONSTRUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TimberConstruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vertical Shoring Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cable Bracing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bridge Deck Falsework . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Traffic Openings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LOADING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Loads During Falsework Erection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Concrete Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Load Redistribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OtherConditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VerticalTake-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection During Concrete Placement ............................... Inspection After Concrete Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.
FORMWORK
.........................................................
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FORM COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sheathing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Structural Supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Form Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LOADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FORMWORKTYPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Job-Built Formwork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Modular Formwork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stay-in-Place Formwork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gang Forms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Plate Girder Forms .............................................. CONSTRUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FORM MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
V --``,`````````,``,`,``,,`,``,``,-`-`,,`,,`,`,,`---
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1 1 1 2 3
3 3
7 10 12 12 13 14 19 19 19 21 24 25 27 30 30 30 30 32 32 32 32 33 33 35
35 35 36 40 43
47 49 50 50 51 51 53 54 56
AASHTO T I T L E CHBTW 95 W 0 6 3 9 8 0 4 0033537 LTT
TABLE OF CONTENTS (Continued) Chapter 4
.
Page
TEMPORARY RETAINING STRUCTURES
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLASSIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Woodsheeting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SoldierPiles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steel Sheet Piles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tangent Piles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SELECTION OF COFFERDAM SCHEME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RELATIVECOSTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SELECTION OF SUPPORT METHOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SEALING AND BUOYANCY CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SEEPAGE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PROTECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONSTRUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Timber Sheet Pile Cofferdam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Soldier PileAiVood Lagging Cofferdam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steel Sheet Pile Cofferdam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Soiland Rock Anchors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Internal Bracing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
59 59 62 62 66 67 68
70 70
71 72 75 76 76 77 78 80 83
APPENDIX A . SECTION PROPERTIES OF STANDARD DRESSED (S4S) AND ROUGH SAWN LUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
89
APPENDIX B. FALSEWORK AND FORMWORK DESIGN EXAMPLES
91
.
APPENDIX C RECOMMENDED THICKNESSES OF WOOD LAGGING APPENDIX D. STEEL SHEET PILE DATA
..................
113
........................................
115
.............................................................
121
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REFERENCES
....................
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A A S H T O T I T L E CHETW 95 W Ob39804 0031538 5 3 6
LIST OF FIGURES
Figure No.
Page
1.
Acceptable and unacceptable weld profiles
2.
Shapes in which knots appear in various structurai members and methods of measuremen.t
3.
Determination of combined slope of grain...........................................
4.
Frame and braced tower buckling modes
5.
Adjustable horizontal shoring beams spanning between bridge piers and temporary timber bents
6.
Adjustable overhang bracket for precast concrete stringer ...............................
7.
Analysis of plate bearing tests
..................................................
15
8.
Analysis of pile loading tests
..................................................
16
9.
Washout under sill support
..........................................
7
. . . . . . . .9
..........................................
9
11
.... 11 12
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10.
.................................................... 17 Sole plate and bracing details for falsework supported on a sloped surface ...................17
11 .
Timber cross-bracing between longitudinal stringers
12.
Cantilevered ledger beam at temporary pile bent
13.
Examples of plan bracing of modular frames
14.
Bracing detail for screw leg supporting a sloped soffit
15.
Typical installation of wire rope clip..............................................
25
16.
Bridgedeck falsework
.......................................................
26
17.
Traffícopenings
18.
Deformation of spans subject to post-tensioning
.....................................
31
19.
Formworkcomponents .......................................................
35
20.
Plywood sheathing for horizontal formwork
........................................
36
21.
Form ties
................................................................
45
22.
Coil tiesystem
23 .
Exterior and interior formwork hangers
24.
Distribution of concrete pressure with form height
25 .
Lateral pressure of concrete on formwork
..................................
20
.....................................
20
.......................................
22
.................................
...........................................................
23
28
.............................................................
...........................................
47
....................................
48
..........................................
49
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A A S H T O T I T L E CHBTW 95
28.
m
Page
......................................................... 50 Assembled gang form ............................................. ......... 52
Job-buiit formwork
32.
................................................ 52 Plate girder form spanning between two supports .................................... 53 Plate girder forms used to fom a bridge pier ....................................... 54 Vibration of concrete ........................................................ 55 Installation of wedges .......................................................55
33.
Coilboltassembly ..........................................................
34.
Typicalcofferdams
35 .
Internally braced cofferdam systems
36.
Self-supporting and externally anchored cofferdam systems
37 .
Types of timber sheet piling
38 .
Louver effect for woad lagging
39.
Steel soldier piles
40.
Concrete in-fill between soldier piles
41.
Wood lagging to front flange
42.
Typical steel sheet-piling sections
...............................................
66
43 .
Typical pile arrangements .....................................................
67
44.
Peneiration of sheeting required to prevent piping in isotropic sand
........................
73
45 .
Penetration of sheeting required to prevent piping in stratified sand
........................
74
46.
Wood sheeting systems
......................................................
76
47 .
Soldier pile retained with soil anchors
............................................
78
48.
Sheet pile àriving procedure
...................................................
79
49.
Sheet pile installation
........................................................
84
50.
Typical framing arrangements
..................................................
86
51.
Typical connection for inclined brace and horizontal wale
..............................
87
29. 30. 31 .
Gang form for wali construction
......................................................... .............................................
56
60 60
............................. 61
...................................................
63
.................................................
64
..........................................................
64
.............................................
65
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65
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27.
Ob39804 0033539 472
LIST OF FIGURES (Continued)
.
Figure No
26.
m
AASHTO T I T L E CHBTW 75 --``,`````````,``,`,``,,`,``,``,-`-`,,`,,`,`,,`---
.
= Ob37804
003L540 1 9 4
LIST OF FIGURES (Continued)
Page
Figure No 52.
Typical wale and anchor rod details
..............................................
88
53.
92
54.
............................................ Load-deflection curve for steel overhang bracket ....................................
55 .
Needle beam for slab overhang
56.
Pier cap on friction collar
57 .
Normal interlock swing is at least 10" on arch web and straight web shapes
58.
Steel sheet piling interlocks in the normal position
59.
Slab falsework with overhang bracket
................................................
101
....................................................
105
.................
.................................. Steel sheet piling interlocks in the reverse position (not recommended) ....................
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98
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116
117 117
Ob39404 003l154L O20
A A S H T O T I T L E CHBTW 95
LIST OF TABLES
.
Page
Table No
1.
Early ASTM steel specifications
2.
.................................................
3
Permissible variations in cross section for W and HP shapes
4
3.
Permissible variations in camber and sweep
............................. .........................................
4
4.
Matching filler metal requirements ................................................
6
5.
Referred analysis of carbon steel for good weldability..................................
6
. 7.
Fahework depth and span relationship
8.
Formulas for stress and deflection calculations for plywood
6
............................................
29
Grade-use guide for Plyform sheathing ............................................
37
9.
............................. 38 Section properties for Plyform Class I and Class II. and Structural I Plyform ................. 39
10.
Design stresses for Plyform
11.
Formulas for safe support spacings of joists and ledgers
12.
Beam formulas
13.
Typical equipment for construction of tiebacks
14.
Section properties of standard dressed (S4S) lumber
15.
Section properties of rough sawn lumber
16.
Recommended thickness of wood lagging for various soil types
17.
Standard sheet piling (cuca 1972)
18.
H-pileproperties
...................................................
39
................................
41
............................................................
42
......................................
81
..................................
89
..........................................
90
.........................
113
..............................................
118
..........................................................
119
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A A S H T O T I T L E CHBTW 95 W Ob39804 0031542 Tb7 D
ABBREVIATIONS
AASHTO AC1 AISC
AIS1 AITC
ANSI APA ASCE ASTM AWS BOCA FHWA NAVFAC NDS NFPA OSHA
UBC
American Association of State Highway and Transportation Officials American Concrete Institute American Institute of Steel Construction American Iron and Steel Institute American Institute of Timber Construction American National Standards Institute American Plywood Association American Society of Civil Engineers American Society for Testing and Materials American Welding Society Building Officials & Code Administrators Federal Highway Administration Naval Facilities Engineering Command National Design Specification for Wood Construction National Forest Products Association Occupational Safety and Health Administration Uniform Building Code GENERAL NOTATIONS
in ft
Ibf
m --``,`````````,``,`,``,,`,``,``,-`-`,,`,,`,`,,`---
N kg
inches feet pounds (force) meters newtons kilograms
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A A S H T Q T I T L E CHBTW 95 M Ob39804 0033543 9T3
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AASHTO T I T L E CHBTW 95
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CHAPTER 1. INTRODUCTION SCOPE
This construction handbook has been developed for use by contractors and construction engineers involved in bridge construction on Federal-aid highway projects. This document may also be of interest to falsework design engineers, and supplements information found in the Guide Design Specification for Bridge
Temporary Works.") The content is construction-oriented, focusing primarily on standards of material quality and means and methods. This handbook contains chapters on falsework, formwork, and temporary retaining structures. For more indepth discussion on a particular topic, related literature and references are identified. Chapter Two. Falsework identifies material standards, the assessment and protection of foundations, construction-relatedtopics, loading considerations, and inspection guidelines. Methods for in situ testing of foundations are identified. General guidelines regarding timber construction, proprietary shoring systems, cable bracing, bridge deck falsework, and traffic openings are also discussed. Chapter Three. Formwork identifies and describes the various components and formwork types commonly used in bridge construction. Information on load considerations and design nomogmphs are provided. General guidelines relating to formwork construction and form maintenance are also discussed. Chapter Four. Temporary Retaining Structures focuses primarily on cofferdams and their application to bridge construction. As indicated by the chapter title, however, generai topics relating to a wide range of temporary retaining structures are also addressed. Specific topics include classification of construction types, relative costs, sealing and buoyancy control, seepage control, and protection. The construction of timber sheet pile Cofferdams, soldier pile and wood lagging cofferdams, and steel sheet pile cofferdams is reviewed. Methods of internal bracing, and soil and rock anchorage are also discussed. Section properties of standard dressed and rough lumber, bridge deck falsework design examples, recommended thicknesses for wood lagging, and steel sheet pile data are included as appendixes. Definitions and related publications are identified below.
DEFINITIONS For the purpose of this manual, the following definitions apply. These definitions are not intended to be exclusive, but are generally consistent with the common usage of these terms. Falsework - Temporary construction work used to support the permanent structilre until it becomes selfsupporting. Falsework would include steel or timber beams, girders, columns, piles and foundations, and any proprietary equipment, including modular shoring frames, post shores, and adjustable horizontal shoring. Shoring - A component of falsework such as horizontal. vertical, or inclined support members. For the purpose of this document, this term is used interchangeably with falsework. Formwork - A temporary structure or mold used to retain the plastic or fluid concrete in its designated shape until it hardens. Formwork must have enough strength to resist the fluid pressure exerted by plastic concrete and any additional fluid pressure effects generated by vibration.
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Cofferdam - A temporary watertight enclosure that allows construction of the permanent structure under
dry conditions. RELATED PUBLICATIONS
California Falsework Manual, California Department of Transportation, Sacramento, CA, 1988. Certifcation Program for Bridge Temporary Works (FHWA-RD-93-033), Federal Highway Administration, Washington, DC,1993. Formwork for Concrete (SP-4, Fifth Edition, American Concrete institute, Detroit, MI, 1989. Foundation Construction, A. Brinton Carson, McGraw-Hill, New York, NY, 1965. Guide Design Specification for Bridge Temporary Works (FHWA-RD-93-032). Federal Highway Administration, Washington, DC,1993. Guide Standard Specificationfor Bridge Temporary Works (FHWA-RD-93-031), Federal Highway Administration, Washington, DC, 1993. Haridbook of Temporary Structures in Construction, R. T. Ratay, Ed., First Edition, McGraw-Hill Book Company, New York, 1984. Lateral Support Systems and Underpinning, Vols. I, II, III (FHWA-RD-75-I28, 129, 130). Federai Highway Administration, Washington, DC. 1976. Soil Mechanics, Foundations, and Earth Structures (NAVFAC DM-7), Depanment of the Navy, Alexandria, VA, May 1982. Standard Specijications for Highway Bridges, American Association of State Highway and Transportation Officials, Washington, DC (Readers are cautioned to use latest edition). Syrühesis of Falsework, Formwork, and ScafJolding for Highway Bridge Srructures (FHWA-RD-91-062). Federal Highway Administration, Washington, DC, November 1991. Temporary Works, J.R. Illingworth, Thomas Telford, London, England, 1987.
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CHAPTER 2. FALSEWORK MATERIALS AND MANUFACTURED COMPONENTS
Structural Steel Quality of Steel - Steel grades greater than ASTM A36 are generally not recommended for faisework construction. The Guide Design Specification for Bridge Temporary Works permits the use of higher working responsibility. if steel properties are unknown and test samples are not taken, steel can generally be assumed to
be ASTM A36. For reference, some of the more common steel designations predating ASTM A36 are provided in table 1.
Table 1. Early ASTM steel specifications,'') ASTM reauirement Date
Specification
Remark
1924-1931
ASTM A I
Structural steel
55,000 to 65,000
M T.S. or not less than 30,000
Rivet steel
46,000 to 56,000
M T.S. or not less than 25,000
Structural steel
55,000 to 65,000
Yi T.S. or not less than 30,000
Rivet steel
46.000 to 56,000
M T.S. or not less than 25,OOO
ASTM A9
Tensile strength, Ibf/in2
Minimum yield point, lbfhn'
1939- 1948
ASTM A7-A9
Structural steel
60,000 to 72,000
Yi T.S. or not less than 33,000
1939-1949
ASTM A141-39
Rivet steel
52,000 to 62,000
M T.S. or not less than 28,000
Conversion: 1,ûOû ibf/in2 = 6.89 N / m 2
Dimensional Tolerances - Rolling smctural shapes and plates involves such factors as roll wear, subsequent roll dressing, temperature variations, etc., which cause the finished product to vary from published profiles. Mill dimensional tolerances are identified in ASTM A6, Standard Specifcation for General
Requirements for Rolled Steel Plates, Shapes, Sheet Piling, and Bars for Structural Use.(') This information is provided in tables 2 and 3 for general reference. Conditioning of Salvaged Steel - ASTM A6 also provides guidelines for the conditioning of plates, structural shapes, and steel sheet piling, as follows: Plate Conditioning - Plates may be conditioned by the manufacturer or processor for the removal of imperfections or depressions on the top and bottom surfaces by grinding, provided the area ground is well faired without abrupt changes in contour and the grinding does not reduce the thickness of the plate by: (1) more than 7 percent under the normal thickness for plates ordered to weight per square fi, but in no case more than
1/8
in (3.2 mm); or (2) below the permissible minimum thickness for plates
ordered to thickness in inches or millimeters.
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stresses for other grades of steel, provided the grade of steel can be identified. Identification is the contractor's
m
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T'
m
T'
T
A, depth, in
Section nominal size, in
T + T',
B, flange width, in
E',
flanges, out over Under over Under of square, theoretical theoretical theoretical theoretical max., in
center, max., in
C, m a , depth at any c m s scction over theordical depth, in
web off
To 12, incl.
1I8
1I8
114
3/16
114
3/16
114
over 12
118
1/8
1I4
3/16
5/16
3/16
114
I H O I i 2 0 " l l l rui1.n
ANGLES
CHANNELS
W SHAPES
Table 3. Permissible variations in camber and Sizes
Permissible variation, in
Length
I
Camber Sizes with flange width quai to or greater than 6 in
All
Sizes with flange width less than 6 in
All
sweep
1/8 in x (total length, ft) 1/8 in x (total length, ft) 10
1
10
1/8 in x (total length, ft) 5 ~
Certain sections with a flange width approx. equal to depth and specified on order as COlUmIIs'
1/8 in x (total length' ft) wiîb 3/8 in max. 10
4
-
3/8 in + 1/8 in x (total length, ft 10
over 45 ft
- 45)
-
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Imperfections on the top and bottom surfaces of plates may be removed by chipping, grinding, or arc& gouging and then by depositing weld metal subject to the following limiting conditions: The chipped, ground, or gouged area shall not exceed 2 percent of the area of the surface being conditioned. After removal of any imperfections in preparation for welding, the thickness of the plate at any location must not be reduced by more than 30 percent of the nominal thickness of the plate.
(ASTM A131/A131M restricts the reduction in thickness to a 20-percent maximum.) The edges of plates may be conditioned by the manufacturer or processor to remove injurious imperfections by grinding, chipping, or arc-air gouging and welding. Prior to welding, the depth of depression, measured from the plate edge inward, shall be limited to the thickness of the plate, with a maximum depth of 1 in (25.4 mm). Structural Shapes and Steel Sheet Piling Conditioning - These products may be conditioned by the manufacturer for the removal of injurious imperfections or surface depressions by grinding, or chipping and grinding, provided the area ground is well faired without abrupt changes in contour and the depression does not extend below the rolled surface by more than: (1) 1/32 in (0.8 mm), for material less than 3í8 in (9.5 mm) in thickness; (2) 1/16 in (1.6 mm), for material 318 to 2 in (9.5 to 50.8 mm) inclusive in thickness; or (3)
118
in (3.2 mm) for material over 2 in (50.8 mm) in thickness.
Imperfections that are greater in depth than the limits previously listed may be removed and then weld metal deposited subject to the foliowing limiting conditions: The total area of the chipped or ground surface of any piece prior to welding shall not exceed
2 percent of the total surface area of that piece. O
The reduction in thickness of the material resulting from removal of imperfections prior to welding shall not exceed 30 percent of the nominal thickness at the location of the imperfection, nor shall the depth of depression prior to welding exceed 1%in (32 mm) in any case except as follows: The toes of angles, beams, channels, and zees and the stems and toes of tees may be conditioned by grinding, chipping, or arc-air gouging and welding. Pnor to welding, the depth of depression, measured from the toe inward, shall be limited to the thickness of the material at the base of the depression, with a maximum depth limit of 2 percent of the total surfaœ area.
Welding - Most of the ASTM-specificationconstruction steels can be welded without special precautions or procedures. The weld electrode should have properties matching those of the base metal. When properties are comparable, the deposited weld metal is referred to as “matching” weld metal. Table 4 provides matching weld metal for many of the common ASTM-designated structural steels. In general, welding of unidentified structural steel is not recommended unless weldability is determined. Most of the readily available structurai steels are suitable for welding. Welding procedures can be bas& on specified steel chemistry because most mili lots are usually below the maximum specified limits. Table 5 shows the ideal chemistry for carbon steels. --``,`````````,``,`,``,,`,``,``,-`-`,,`,,`,`,,`---
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Group Base metal steel specification' I ASTM A36, A53 Grade B, M O O , Mol, A529, A570 Grades 4û,45, and 50 A709 M e 36
II
III
IV
V
Welding fimess* Shielded metal arc Submerged arc Gas metal arc Flux cored arc welding (SMAW) welding (SAW) welding (GMAW) welding WAW) AWS A5.1 or A5.5 AWS A5.17 w A5.23 AWS A5.18 AWS A5.20 EóOXX or E7OXX F6X or Fix-EMLX ER70S-X ESXT-X and E7XT-X (except -2, -3, -10, -GS)
AWS A5.1 or A5.5 AWS A5.17 or A5.23 AWS A5.18 E70XX' Fix-Exxx ER70S-X
ASTMA242P A572 Grades 42 and 50 A588 A709 Grades 50 and SOW ASTM A572, Grades 60 and 65 ASTM A514 (over 2% in thick), A709 Grades 100 and 1OOW (2% in and under)
AWS A5.20 E7XT-X (except -2, -3, -10,
-GS)
ASTM AS14 (2% in and under), A709 Grades I00 and 1oOW (2% ia and under)
AWS A5.5
AWS A523
AWS A5.28
EOXX' AWS A55
FIX-EXXX'
ERBOS'
ElOOXX'
AWS A5.23 F I O X - E ~
AWS A528 ER~OOS~
AWS A5.5 EllOMC
FIIX-~m ER110s'
AWS A5.23
AWS ~ 5 . 2 8
AWS A5.29 E8XT' AWS A5.29 EIOXT' AWS A5.29 E l 1Xl' ~
Notes: (a) When welds are to be stress relieved, the deposited weld metal shall not exceed 0.05 percent vanadium. (b) See AWS Dl.1-92. Sec. 4.20 for electrarlag and electrogas weld metal requirements. (c) In joints involving base metals of two different groups,low-hydrogen filler metal electrodes applicable to the lower strength group metal may be used. "he low-hydrogen processes shall be subject to the technique requirements applicable to the higher strength group. (d) Special welding materials and procedures may be required to match the notch toughness of base metal or for atmospheric corrosion and weathering charactexistics. (e) Low hydrogen classifrcations only. (0 Deposited weld metal shall have a minimum impact strength of 20 ft-lbf (27 J) at O O F (-18 "C)when C h q y V-notch specimens are used. ?his requirement is applicabte only ta bridges. (s) Conversion: 1 in = 25.4 mm
Table 5. Preferred analysis of carbon steel for good weldability.'5) Element Normal Range (96) Carbon 0.06 - 0.25 Manganese 0.35 - 0.80 Silicon 0.10 max Sulfur 0.035 max Phosphorus 0.030 max
Guidance with respect to worlananship, qualification, i d inspection of weldable steel can l x obtained from Structural Welding Code, AWS D1.1-92,'4' Acceptable and unacceptable weld profiles prescribed by AWS are illustrated in figure 1.
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Table 4. Matching fiiier metal req~irernents.'~)
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(B) ACCEPTABLE FILLET WELD PROFILES
(A) DESIRABLE FILLET WELD PROFILES
Note:Convexity. C. of a weid o( individurl suñaca bead SMnot exceed the value of the following table: ~ n d L l g ~ a
wmh of Individual sumcr &ad.
Max. convexity
L
1/16 in (1.6
L
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