b150 erection of pretensioned precast concrete members · process held: erection of pretensioned...

Edition 3 / Revision 3 TRANSPORT FOR NSW

June 2020

TRANSPORT FOR NSW (TfNSW)

QA SPECIFICATION B150

ERECTION OF PRETENSIONED PRECAST CONCRETE MEMBERS

NOTICE

This document is a Transport for NSW QA Specification. It has been developed for use with

roadworks and bridgeworks contracts let by Transport for NSW or by local councils in NSW. It is not

suitable for any other purpose and must not be used for any other purpose or in any other context.

Copyright in this document belongs to Transport for NSW.

REVISION REGISTER

Ed/Rev

Number

Clause

Number Description of Revision

Authorised

By Date

Ed 1/Rev 0 First Issued GM,CMS 03.05.91

Ed 2/Rev 0 Clause numbers and structure have been

changed to suit new Word 6 format. Revised

title.

GM, RNIC (W Ho)

11.09.97

1.2, 3 Reference to RTA B110 added.

2.1 New Hold Point, more detailed certificate

with drawings

2.3 Joint Survey of supports required for girder

bridges

4.1 Supervision specified. Direct placement of

girders on some bearings disallowed

4.2 More detailed requirements for bracing

5.1, 5.2 Local Government Act changed to Roads Act

6 Survey to comply with RTA Q, Hold Point is

now in RTA Q.

8 Each type of member shall be a separate pay

item

Annexure

B150/1

Revised in accordance with Clauses 2.1, 2.3

and 6.

Ed 2/Rev 1 Annexure

R150/1

Schedule of Identified Records added GM, RNIC (J

Woodward)

14.04.00

Ed 3/Rev 0 Various Clauses & annexures rearranged

Text revised to direct imperative style.

”Superintendent” replaced by “Principal”.

Reformatting and minor editing

“Shall” replaced by “must”.

GM, RNIC 23.12.04

Foreword New clause after the Table of Contents

ii

Ed/Rev

Number

Clause

Number Description of Revision

Authorised

By Date

Ed 3/Rev 0

(cont’d)

1.2 References transferred to Annex B150/M

with minor changes.

New introduction to annexures

1.3 Definition for Engineer added

4.1 Hold Point amended to include regulations

and standards

4.3 Adjustment for hog variations required

5 Removal of limitation on hog and submission

of proposal for accommodating excess hogs

6.2 New clause for lifting added

6.4 New clause on tolerances added

Ed 3/Rev 1 4.3, 8, C1 Survey references changed to G71 GM, RNIC 25.02.05

Ed 3/Rev 2 9 Revised and lifting devices included for

removal

GM, RNIC 21.06.05

Ed 3/Rev 3 Global References to “Roads and Maritime

Services” or “RMS” changed to “Transport

for NSW” or “TfNSW” respectively.

DCS 22.06.20

Edition 3 / Revision 3 TRANSPORT FOR NSW

June 2020

QA SPECIFICATION B150

ERECTION OF PRETENSIONED PRECAST

CONCRETE MEMBERS

Copyright – Transport for NSW

IC-QA-B150

VERSION FOR:

DATE:

Erection of Pretensioned Precast Concrete Members B150

Ed 3 / Rev 3 i

CONTENTS

CLAUSE PAGE

FOREWORD ............................................................................................................................................... II TfNSW Copyright and Use of this Document ............................................................................... ii Revisions to Previous Version ....................................................................................................... ii Project Specific Changes ............................................................................................................... ii

1 GENERAL ........................................................................................................................................ 1 1.1 Scope .............................................................................................................................. 1 1.2 Structure of this Specification ........................................................................................ 1 1.3 Definitions ...................................................................................................................... 1 1.4 Additional Project Quality Plan Requirements .............................................................. 2

2 (NOT USED) .................................................................................................................................... 2

3 (NOT USED) .................................................................................................................................... 2

4 PRE-ERECTION REQUIREMENTS ..................................................................................................... 2 4.1 Certification of Erection Methods .................................................................................. 2 4.2 Conformity of Structural Members ................................................................................ 3 4.3 Pre-Alignment ................................................................................................................ 3

5 HOG IN MEMBERS .......................................................................................................................... 3

6 ERECTION ....................................................................................................................................... 3 6.1 General ........................................................................................................................... 3 6.2 Lifting ............................................................................................................................. 4 6.3 Bracing of Girders .......................................................................................................... 4 6.4 Tolerances in Position and Alignment ............................................................................ 4

7 POST-ERECTION LOADING OF PLANKS AND GIRDERS ................................................................... 5 7.1 Prior to the Placement of the Deck Concrete ................................................................. 5 7.2 After the Placement of the Deck Concrete ..................................................................... 5

8 PROFILE DIAGRAM ......................................................................................................................... 5

9 REMOVAL OF TEMPORARY WORKS ............................................................................................... 5

ANNEXURE B150/A – (NOT USED) .......................................................................................................... 6

ANNEXURE B150/B – PAYMENT .............................................................................................................. 6

ANNEXURE B150/C – SCHEDULES OF HOLD POINTS AND IDENTIFIED RECORDS ................................... 6 C1 Schedule of Hold Points ................................................................................................. 6 C2 Schedule of Identified Records....................................................................................... 6

ANNEXURE B150/D – PLANNING DOCUMENTS ....................................................................................... 7

ANNEXURES B150/E TO B150/L – (NOT USED) ....................................................................................... 7

ANNEXURE B150/M – REFERENCED DOCUMENTS .................................................................................. 7

LAST PAGE OF THIS DOCUMENT IS ............................................................................................................ 7

B150 Erection of Pretensioned Precast Concrete Members

ii Ed 3 / Rev 3

FOREWORD

TFNSW COPYRIGHT AND USE OF THIS DOCUMENT

Copyright in this document belongs to Transport for NSW.

When this document forms part of a contract

This document should be read with all the documents forming the Contract.

When this document does not form part of a contract

This copy is not a controlled document. Observe the Notice that appears on the first page of the copy

controlled by TfNSW. A full copy of the latest version of the document is available on the TfNSW

Internet website: http://www.rms.nsw.gov.au/business-industry/partners-

suppliers/specifications/index.html

REVISIONS TO PREVIOUS VERSION

This document has been revised from Specification TfNSW B150 Edition 3 Revision 2.

All revisions to the previous version (other than minor editorial and project specific changes) are

indicated by a vertical line in the margin as shown here, except when it is a new edition and the text

has been extensively rewritten.

PROJECT SPECIFIC CHANGES

Any project specific changes are indicated in the following manner:

(a) Text which is additional to the base document and which is included in the Specification is

shown in bold italics e.g. Additional Text.

(b) Text which has been deleted from the base document and which is not included in the

Specification is shown struck out e.g. Deleted Text.

http://www.rms.nsw.gov.au/business-industry/partners-suppliers/specifications/index.html

http://www.rms.nsw.gov.au/business-industry/partners-suppliers/specifications/index.html

(TfNSW COPYRIGHT AND USE OF THIS DOCUMENT - Refer to the Foreword after the Table of Contents)

Ed 3 / Rev 3 1

TfNSW QA SPECIFICATION B150

ERECTION OF PRETENSIONED PRECAST CONCRETE MEMBERS

1 GENERAL

1.1 SCOPE

This Specification sets out the requirements for the erection of pretensioned precast concrete girders

and planks in bridges. This Specification does not apply to piles.

1.2 STRUCTURE OF THIS SPECIFICATION

This Specification includes a series of annexures that detail additional requirements.

1.2.1 Payment

Payment is in accordance with Annexure B150/B.

1.2.2 Schedules of HOLD POINTS and Identified Records

The schedules in Annexure B150/C list the HOLD POINTS that must be observed. Refer to

Specification TfNSW Q for the definition of HOLD POINTS.

The records listed in Annexure B150/C are Identified Records for the purposes of TfNSW Q

Annexure Q/E.

1.2.3 Planning Documents

The PROJECT QUALITY PLAN must include each of the documents and requirements listed in

Annexure B150/D and must be implemented.

1.2.4 Referenced Documents

Unless specified otherwise or is specifically supplied by the Principal, the applicable issue of a

referenced document is the issue current at the date one week before the closing date for tenders, or

where no issue is current at that date, the most recent issue.

Codes, standards, specifications and test methods are referred to in abbreviated form (eg AS 1234).

For convenience, the full titles are given in Annexure B150/M.

1.3 DEFINITIONS

The terms “you” and “your” mean “the Contractor” and “the Contractor’s” respectively.

The following definitions apply to this Specification:

“Engineer”. An Engineer eligible for Corporate Membership of the Engineers Australia, who is

experienced in the type of work for which certification for compliance with regulations, Australian

Standards and/or specifications is required.



2 Ed 3 / Rev 3

“Erection”. The process whereby precast concrete members are lifted, aligned, and placed in their

final positions as shown on the Drawings. It includes all temporary supporting and bracing measures

required to keep the member stable at all times until it takes up the correct final position in the

permanent structure.

“Girders”. Pretensioned precast concrete members forming part of the bridge superstructure, spaced

at intervals as shown on the Drawings.

“Planks”. Pretensioned precast concrete members which are placed side by side in the span to form,

together with a cast-in-place concrete topping, a completed deck as shown on the Drawings.

1.4 ADDITIONAL PROJECT QUALITY PLAN REQUIREMENTS

Include the following information as part of its PROJECT QUALITY PLAN:

(a) details of any cranes, falsework and/or other equipment proposed for lifting, positioning and

temporary support of the members;

(b) details of the method to be used for erection; and

(c) for girder bridges, details of the method to be used for distributing the load to the girders when

loads are applied prior to the completion of the in-situ deck, together with the method of

keeping the girders upright without twisting or buckling occurring.

2 (NOT USED)

3 (NOT USED)

4 PRE-ERECTION REQUIREMENTS

4.1 CERTIFICATION OF ERECTION METHODS

HOLD POINT

Process Held: Erection of pretensioned precast concrete members.

Submission Details: Prior to the commencement of any erection, submit a certificate from an

Engineer, certifying the structural adequacy and compliance of the proposed

method of erection (including all supporting and bracing measures) and the

falsework with any applicable regulations, Australian Standards, this

Specification and relevant design requirements. The certificate shall be

accompanied by any drawings necessary to clearly describe the proposed

method of erection including detailed drawings of any supporting and

bracing measures.

Release of Hold Point: The Principal will consider the details submitted, prior to authorising the

release of the Hold Point.



Ed 3 / Rev 3 3

4.2 CONFORMITY OF STRUCTURAL MEMBERS

Do not erect any member until:

(a) full conformity records for that member have been made available to the Principal;

(b) the concrete in the supporting members has attained at least 80% of the specified strength, and

(c) the supporting formwork for these members has been removed,

unless specified otherwise on the Drawings.

4.3 PRE-ALIGNMENT

Set all bearings to achieve the correct final levels and inclinations, making allowance for and taking

into account for variations in hog from design, as specified on the Drawings. All falsework and

temporary supports must have adequate provision for adjustment to achieve the required profile

detailed on the Drawings.

To allow for the change in length of members due to temperature variations, position the bearings so

that the horizontal distance between the centres of base plates will result in the distance being as

shown on the Drawings for the specified temperature.

At least one working day prior to erection, submit a certificate verifying that the location and levels of

all permanent and temporary supports are in accordance with the profile shown on the Drawings.

For a girder bridge, apply the requirements in TfNSW G71 for Joint survey to the verification of

locations and levels of all permanent and temporary supports and the certification must conform to the

requirements of TfNSW G71 for Product Conformity Survey. Apply the associated Hold Points.

5 HOG IN MEMBERS

If the members are not expected to be loaded with deck concrete until they are older than 50 days from

casting, advise the Principal of the anticipated increase in hog due to creep and measures you propose

to accommodate these increases. These measures must not affect deck finished levels.

Place members so as to minimise variations in hog between adjacent members.

6 ERECTION

6.1 GENERAL

Take necessary actions, preparation and set up of cranes, equipment and site so as to comply with the

relevant statutory regulations and to maintain safe working conditions at all times.

The erection operation must be supervised by an Engineer.

Ensure that:

(a) each member is placed in position safely, without damage to the member or the structure; and

(b) the intended permanent structural action of the member is not:



4 Ed 3 / Rev 3

(i) restrained; or otherwise

(ii) adversely affected by the process of erection or by movements which occur due to

environmental or construction-related forces,

before the member is finally integrated with the adjacent parts of the structure.

Do not place girders by crane directly on the following types of permanent bearings:

(i) Pot type bearings;

(ii) Spherical bearings;

(iii) Steel roller bearings; or

(iv) Steel rocker bearings

For these types of bearings, use temporary supports during placement and alignment of girders. The

method of subsequently transferring the girder load onto the permanent bearings must be certified as

safe, by an Engineer.

Give the Principal 5 working days' notice of the proposed date to commence erection.

6.2 LIFTING

For the purpose of erection, lift members only by the devices specified on the Drawings, unless

approved otherwise by the Principal. The angle of the lifting sling must be as specified at all times.

The mass of the units to be lifted must be within the safe capacity of the equipment, as certified by an

Engineer. Position the lifting equipment such that any required turning radius does not endanger the

stability of the equipment.

6.3 BRACING OF GIRDERS

Effectively support and brace the girders so as to prevent overturning, unintended sliding and any

other unintended movement, when subjected to any loads, including loads induced by handling and

environmental factors.

When being placed in position, effectively support and brace the girders before being released by the

crane or other lifting device.

Maintain effective support and bracing at all times during subsequent deck forming and concreting

operations, and until the deck concrete has hardened.

6.4 TOLERANCES IN POSITION AND ALIGNMENT

Place members in their correct position as shown on the Drawings. Align members placed in series

adjacent to one another within specified tolerances.

Unless specified otherwise on the drawings or relevant specification, the following tolerances must not

be exceeded:

(a) Deviation from the correct position must not exceed 20 mm in any direction;

(b) The deviation from plumb or design inclination between any two points must not exceed 1/200

times the distance between the points or 10 mm, whichever is less.



Ed 3 / Rev 3 5

Check all alignment dimensions before final fixing in position.

7 POST-ERECTION LOADING OF PLANKS AND GIRDERS

7.1 PRIOR TO THE PLACEMENT OF THE DECK CONCRETE

Where the spans are simply supported, a vehicle conforming to Ordinance 30C and 30D of the Roads

Act 1993, may travel over bridge planks before the cast-in-place concrete is placed, provided that

timber planks of minimum 125 mm thickness are used to distribute the load uniformly over at least six

planks and the concrete in the piers and/or abutments supporting such members has attained the

specified strength.

Subject to the requirements of Clause 1.4, a girder bridge may be similarly loaded. In this case,

distribute the load to at least three girders.

7.2 AFTER THE PLACEMENT OF THE DECK CONCRETE

Do not impose loads on the deck between the commencement of placing of the cast-in-place concrete

and 7 days after completion of such concreting.

A vehicle conforming to Ordinance 30C and 30D of the Roads Act may travel over the deck between

7 days after completion of the concreting and such time that the concrete has achieved the strength

specified on the Drawings provided that timber planks to distribute the load, as specified in Clause 7.1,

cover the entire track to be traversed by the vehicle.

8 PROFILE DIAGRAM

Before placing of the cast-in-place concrete, submit a diagram that sets out the profile of the

completed member(s) in relation to the profile specified on the Drawings. For girder bridges this

diagram must conform to the requirements of Specification TfNSW G71 for Product Conformity

Survey and apply the associated Hold Point.

9 REMOVAL OF TEMPORARY WORKS

Unless agreed otherwise by the Principal, remove all inserts and fixtures used solely for lifting or

installation, temporary supports, packers, falsework and temporary bracing and carry out any repairs

due to the use of such temporary works using suitable cementitious patching material to the specified

finish as the Works proceed.



6 Ed 3 / Rev 3

ANNEXURE B150/A – (NOT USED)

ANNEXURE B150/B – PAYMENT

In the Schedule of Prices accompanying the Lump Sum component of the Tender, the cost of erecting

pretensioned precast concrete members in accordance with this Specification will be shown as a

separate item. Each type of member will be shown as a separate sub-item. The units are “each”.

ANNEXURE B150/C – SCHEDULES OF HOLD POINTS AND

IDENTIFIED RECORDS

Refer to Clause 1.2.2.

C1 SCHEDULE OF HOLD POINTS

Clause Description

4.1 Certification of Erection Method

4.3 &

TfNSW G71

Notification of Joint Survey of permanent and temporary supports for girder bridges

4.3 &

TfNSW G71

Submission of survey report for permanent and temporary supports for girder bridges

8 &

TfNSW G71

Submission of Profile Diagram for girder bridges

C2 SCHEDULE OF IDENTIFIED RECORDS

The records listed below are Identified Records for the purposes of TfNSW Q Annexure Q/E.

Clause Description of Identified Record

4.3 Certificate verifying that the location and levels of all supports are in accordance with

the Drawings

6 Diagram setting out profile of completed members in relation to profile specified in the

Drawings



Ed 3 / Rev 3 7

ANNEXURE B150/D – PLANNING DOCUMENTS


The following documents are a summary of documents that must be included in the PROJECT

QUALITY PLAN. The requirements of this Specification and others included in the Contract must be

reviewed to determine additional documentation requirements.

Clause Description

4.1 Proposed method of erection together with any associated drawings, and Engineer’s

certificate certifying the structural adequacy

ANNEXURES B150/E TO B150/L – (NOT USED)

ANNEXURE B150/M – REFERENCED DOCUMENTS


TfNSW Specifications

TfNSW G71 Construction Surveys

TfNSW Q Quality Management System

TfNSW B110 Pretensioned Precast Concrete Members