David H Moloney

Bridge Construction, Project Execution Plan 8th August 2016

Details of how a Bridge is constructed, and how the progress, safety and quality will be monitored
and controlled. Also the measures to ensure that the site is environmentally friendly.

Brief Description

The purpose of this presentation is to give an understanding of the Methods, Plant and Sequence to
construct an insitu concrete bridge.

This presentation can be used to engage Stakeholders and to get the Site Teams commitment to the
programme. Also can be used for Induction Training and as a way to capture and share knowledge.

Project Execution Plan (PEP) details how a project will be executed, monitored and controlled. High in
Educational Value and easily understood. Recommended for Continuing Professional Development (CPD)

This Presentation is innovative and has many beneficial uses.

Table of Contents
Introduction
 Project Location & Nearby National Roads
Introduction
 Location of Bridge on Site
Muscat Airport, Oman
Introduction
 Description & Scope
Introduction

Brief Description & Scope

Four span insitu post-tensioned deck, Piled foundations.

Construction of the Bridge and Handover.
General Items
General Items
Contractors Temporary Site Facilities

To see animations, see my YouTube Film

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General Items Welfare Facilities

Toilets Washing

Canteen, Drying Room, Toilet & Generator

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General Items
Temporary Roads & Entrances

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General Items
Site Hoarding examples

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General Items
Dust Suppression

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General Items
Wheel Wash Drive-through

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General Items Temporary Electricity Supply & Tower Lights

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General Items
Contractors Temporary Site Facilities

Brief Description

Contractors Site facilities comprise:

Offices, Canteens, Toilets, Drying Rooms,
Stores, Plant Yard, generators and
Workshops.

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General Items
Dewatering

Brief Description

Construction dewatering is the removal or drainage of

groundwater and or surface / rain water usually by
pumping to keep the works dry.

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General Items
Dewatering

Brief Description

Construction dewatering is the removal or

drainage of groundwater and or surface /
rain water usually by pumping to keep the
works dry.

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General Items
Dewatering

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General Items Temporary Works
General Items
Falsework
Brief Description

Falsework to support Bridge deck formwork until the deck is post-

tensioned and becomes self supporting
General Items
Sheet Pile Temporary Shaft

Brief Description

Sheet Pile Temporary shaft is used to enable an

excavation for a deep structure.
The construction sequence is:
Install sheet-piles.
Excavate and install bracing.
Excavate to final level.
Construct concrete structure.
Backfill, remove bracing and sheet-piles

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General Items
Sheet pile Temporary Shaft

3D Animation to show Sequence

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General Items
Sheet pile Cofferdam for Piers

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General Items Traffic Management

Brief Description

Traffic management plans are

necessary when working on or beside
roads

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General Items Traffic Management Work on Median

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Earthworks
 Much Shifting
Earthworks

Brief Description

Muck Shifting is the process of moving

large quantities of soil and rock.
 Excavate & Load, Cart, Tip & Return
Earthworks

Brief Description 7 minutes

Cycle Time for 7km haulage distance

using an Excavator 45 tonne weight
and Dumper with a 40 tonne capacity,
the cycle time is 34 minutes

7 km

14 minutes 7 km 14 minutes

3 minutes
Earthworks
Loading Tipper Trucks
Earthworks
Tipping & Spreading Fill
Earthworks
Spreading & Compaction
Earthworks
Spreading & Compaction
Earthworks
Excavation for Trench with Stepped Faces
Earthworks
Excavation for Trench with Battered Faces
Earthworks
Backfill Trench
 Rock - Excavability
Earthworks

Brief Description

The excavability of rock depends

mainly on the rock strength and the
layer thickness. This diagram shows
excavation methods for rock of
various strengths and thicknesses,
with a free face.

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Earthworks
Excavator with Hydraulic Rock-breaker
Earthworks
Excavator with Hydraulic Rock-breaker
Earthworks
Mass Haul Diagram

Brief Description

Shows the quantities and location of

excavation and fill quantities for
motorway.
Concrete
 Concrete Full Scale Trial Castings of Pier
Concrete

Brief Description

The full-scale trial casting(s) shall

demonstrate/document that all
requirements to the concrete and the
execution of the work are fulfilled
simultaneously using the actual
methods and performed by personnel as
for the future production.

BIM 3D Model Shutter Fibreglass

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 Concrete Full Scale Trial Castings of Bridge Deck
Concrete

Brief Description

The full-scale trial casting(s) shall

demonstrate/document that all
requirements to the concrete and the
execution of the work are fulfilled
simultaneously using the actual
methods and performed by personnel as
for the future production.

Fresh Concrete Properties Tests

Air Content, Consistence, Density, Initial and Final Setting Time, Temperature
and Bleeding
Chloride Ion Content

Hardening and Hardened Concrete Properties Tests:

Density and Compressive Strength for 1, 3, 7, 14 and 28 Days

Concrete Core Compressive Strength
Tensile Splitting Strength
Modulus of Elasticity
Heat Development
Chloride Migration Coefficient (28 Days)

Reinforcement Cover Measurement Survey

 Concrete Tests
Concrete

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 Trial Grouting of Post-tensioning Duct
Brief Description
Concrete

The full-scale trial of grouting operation shall

demonstrate/document that all requirements to the grout and the
execution of the work are fulfilled simultaneously using the actual
methods and performed by personnel as for the future production.

Pre-trials were carried out in the site laboratory and by way of a

mock-up to check the following in accordance with BS EN 447:
i Fluidity
ii Bleeding and re-absorption
iii Compressive strength (3 cubes at 28 days, all > 30 N/mm2)
iv Mixing ratio (w/c < 0.40)
v Expansion (-1 % - +5 %). For grouts with expanding admixtures
there shall be no decrease in volume

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 Trial for Waterproofing to Bridge Deck
Concrete

Brief Description

. The trial for the deck waterproofing

shall demonstrate/document that all
requirements to the waterproofing and
the execution of the work are fulfilled
simultaneously using the actual
methods and performed by personnel as
for the future production.

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 Trial for Waterproofing to Bridge Deck - Tests
Concrete
 Concrete Batching Plant David H Moloney
Concrete

Brief Description

Concrete batching plant comprises -

concrete mixer, control cabin, silos for
cement and fly ash, aggregate bins and
conveyor belt system to feed the mixer.
Also aggregate storage bays and water
storage tanks.

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 Concrete Batching Plant
Concrete

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 Concrete Batching Plant 3Nr.
Concrete

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 Concrete Batching Plant Computer Controlled
Concrete

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 Concrete Batching Plant - Liebherr Betomix Animation
Concrete
 Concrete Batching Plant David H Moloney
Concrete

Brief Description
.
The mixing is computer controlled
and has a dynamic screen display,
showing the process. The material
storage capacity is, to match two
days concrete production.

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 Concrete Mix Proportions per Cu M
Concrete

Brief Description
.
Details of Mix for C40
1. Concrete Grade C40
2. Cement Type = OPC
Materials Qty Units
3. Slump =125mm Cement 310 Kgs
4. Max size aggregate = 20mm
5. Max water / Cementitious ration =0.42 Fly ash 100 Kgs
Micro-silica 12 Kgs
Washed Sand 670 Kgs
Fine Sand 106 Kgs
10mm Crushed aggregate 400 Kgs
20mm Crushed aggregates 725 Kgs
Water 145 Ltr.
Additive Rheobuild 7.5 Ltr.
General Items Concrete Mix

A concrete mix contains 5 major

elements: cement, water, coarse
aggregates, fine aggregates (sand) and
air in different proportion. Additional
elements such as pozzolanic materials (fly
ash, silica fumes or slag) and chemical
admixtures can also be incorporated to
the mix to increase its properties.
 Quarry & Aggregate Production
Concrete

Brief Description

Quarry and Aggregate Production. Rock is

blasted free from a quarry face and fragmented.

The blasted rock is crushed and screened to

produce different size ranges of aggregates

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 Quarry & Aggregate Production
Concrete

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 Reinforcement Cutting & Bending Yard
Concrete

Brief Description

Reinforcement in 12 m lengths.
Delivery in 3 ton Bundles

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 Reinforcement Cutting & Bending
Concrete

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 Reinforcement Cutting & Bending
Concrete

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 Reinforcement Cutting & Bending Yard David H Moloney
Concrete

Reinforcement in 12 m lengths. Delivery in 3 ton Bundles Reinforcement cut to length by Shearing Machine

Reinforcement Bent to Shape by Bending Machine Reinforcement that is cut and bent is Bundled for delivery to work site
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 Reinforced Wall Construction Sequence
Concrete

Brief Description

The sequence to construct a reinforced concrete wall is as

follows:
Tie the reinforcement.
Erect stop-ends and the wall shutters.
Pour and vibrate the concrete mix.
Remove the shutters after the concrete has hardened.

Cycle Time
Pour per Day

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 Reinforced Wall Construction Sequence
Concrete

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 Vibrating Concrete
Concrete

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 Bridge & Post-tensioning
Concrete

Brief Description

The sequence to post-tension a bridge

deck is as follows;
Fix the ducts and anchorages.
Install the stressing strand.
Concrete the deck.
Stress the strands and lock at
anchorages.
Grout the ducts.
 Bridge & Post-tensioning
Concrete
 Bridge & Post-tensioning
Concrete
 Bridge Concrete Deck
Concrete
 Bridge Concrete Deck
Concrete
 Bridge Post Tensioning Deck Install Strand
Concrete
 Bridge Post Tensioning Deck
Concrete
 Bridge Construction Sequence David H Moloney
Concrete

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Piling
Piling
Piling Construction - Plant & Methods

Brief Description

Piling Plant, Equipment and Material;

Crawler Crane, Piling Hammer, Temporary Casing,
Piling Rig, Concrete Pump, Concrete Mixer Trucks,
Tremie Pipe and Reinforcement Cage
Piling
Piling Construction - Plant, Methods & Sequence
Piling
Piling Construction - Plant & Methods
Piling
Piling Construction - Vertical Piles
Piling
Piling Construction - Raking Piles
Piling
Piling Construction - Raking Piles
 Pile Load Test
Piling

Brief Description

A jack is used to load the pile in steps and

gauges measure any settlement.

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 Pile Load Test
Piling

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Roads & Pavings
 Asphalt Batching Yard
Roads & Pavings

Brief Description

Asphalt Batching Yard

Capacity of main batching plant is
250 tonnes per hour .
 Asphalt Batching Yard
Roads & Pavings
 Asphalt Batching Yard
Roads & Pavings
 Asphalt Batching Yard
Roads & Pavings
 Asphalt Batching Yard
Roads & Pavings
 Asphalt Batching Yard
Roads & Pavings
 Road Construction
Roads & Pavings

Brief Description

Sequence, methods and plant to construct a

motorway on a high embankment
 Road Construction
Roads & Pavings
 Road Construction
Roads & Pavings
 Asphalt Pavement - Tests
Roads & Pavings
Miscellaneous Works
 Fencing
Miscellaneous

Brief Description

Fencing.
Sequence of construction;
1. Clear and grade the ground.
2. Fix corner and straining posts.
3. Fix intermediate posts.
4. Fix line wire, chain-link and razor wire.
5. Construct concrete ground beam
Miscellaneous
Fencing
Miscellaneous
Fencing
Miscellaneous
Fencing
Miscellaneous
Fencing
Setting out & Surveying
Setting out & Surveying
Setting out & Surveying
Safety & Environmental
 Emergency Phone Numbers & Response
Health, Safety & Environment
 Dashboard is a single page, graphical representation of
HSE Monitoring & Reporting - Dashboard current HSE Issues and historical trends
Health, Safety & Environment
 Site Safety Posters examples
Health, Safety & Environment
 Trench - Safety Measures
Health, Safety & Environment

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 The purpose of safety training is to provide the knowledge necessary to
Safety Training on Site perform a job safely
Miscellaneous
 The purpose of safety training is to provide the knowledge necessary to
Safety Training Matrix perform a job safely
Miscellaneous
 Emergency Response Drill Drills and exercises are used to rehearse anticipated emergency scenarios
HSE
 Safety Documents
Health, Safety & Environment

Safe System of Work.

To provide a safe system of work is a legal requirement. What this means is that before you ask an employee to do a
job. You ensure that he has received training, has the appropriate personal protective equipment, the work area is safe
and he is unlikely to be injured or cause damage by carrying out the assigned task.

Project Management Plan for Health, Safety, Security and Environment. also Known as (HSSE Plan)

The Project HSSE Management Plan details how safety on site will be managed.

Project Procedures for Health, Safety, Security & Environment

Details the safe way to undertake a task

Methods Statements

Are prepared in advance of starting work, to plan a Safe System of Work on site for all activities that carries a risk. The
contents of a Method Statement, typically include:- Scope & Location of the Works, Programme, Roles & Responsibilities
of Staff. Resources, Work Methodologies and Risk Assessment.

Slide 1 of 2
 Safety Documents
Health, Safety & Environment

Safety Risk Assessments

Are prepared to identify and evaluate risks, to adopt control measures to reduce or eliminate risks.

COSHH Sheet

The purpose of the Control Of Substances Hazardous to Health sheet is to identify how to prevent or adequately control
workers exposure to hazardous substances.

Permit to Work.

Is a management system used to control high risk activities by ensuring safety measures are in place prior to starting
work.
Types of work for which permits will be required include:
Excavation and the digging of trenches.
Working at height, including on roofs.
Working in confined spaces, for example entering a manhole.
Hot work, which is welding, soldering or cutting steel with angle grinders or by gas torch.

Slide 2 of 2
 Hazardous Substances Symbols
Health, Safety & Environment

COSHH stands for the

Control of Substances
Hazardous to Health

Shown are the new

hazard symbols
Health, Safety & Environment
Safety Precautions
Health, Safety & Environment
Signs Examples
 Air, Noise, Water & Soil Pollution
Environmentally Friendly Site
Health, Safety & Environment
 Segregation of Waste
Health, Safety & Environment

Segregation of waste for proper disposal and

recycling. Less waste goes to landfill and
hazardous waste is treated to make it safe.

Colour Code for Skips & Bins

Health, Safety & Environment
Water Pollution Prevention
Health, Safety & Environment
Concrete Washout & Settlement Tanks
 Existing Underground Utilities
Health, Safety & Environment

Brief Description

Before digging establish the

location and route of
underground utilities.

Locator to find Utilities

Spray Paint to mark pavement David H Moloney
 Existing Underground Utilities & Overhead Cables - Safety Measures
Health, Safety & Environment

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Health, Safety & Environment
Trench - Safety Measures
 Trench - Safety Measures
Health, Safety & Environment

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Quality Assurance
 Dashboard is a single page, graphical representation of
Quality Assurance Dashboard current statistics and historical trends
 Runway Asphalt Pavement - Tests
Roads & Pavings
Quality Assurance Tests
 Runway Concrete Pavement - Tests
Roads & Pavings
 Runway Laboratory
Roads & Pavings
 Laboratory
Asphalt Paving

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Administration
Staff Directory

Brief Description

List of staff and their

contact details
Daily Work Record

Brief Description

Daily Work Records showing the

allocation of resources, materials and
work activities carried out daily.
Organogram

Brief Description

Shown are the line and

lateral relationships
between the various team
members and their relative
position in the site
organisation.
Staff Responsibility Matrix
Filing System
Quotations Comparison Sheet
Programme & Progress Monitoring
 Dashboard is a single page, graphical representation of current
Progress Monthly, Monitoring & Reporting - Dashboard progress and historical trends
Programme for Construction
Gantt Charts to plan and schedule projects
 Bridge Construction Stages, Images & Timeline
Concrete
 Bridge Construction Stages, Images & Timeline
Concrete
 Bridge Construction Stages, Images & Timeline
Concrete
 Bridge Construction Stages, Images & Timeline
Concrete
 Bridge Construction Stages, Images & Timeline
Concrete
 Bridge Construction Stages, Images & Timeline
Concrete
 Bridge Construction Stages, Images & Timeline
Concrete
 Bridge Construction Stages, Images & Timeline
Concrete
 Bridge Construction Stages, Images & Timeline
Concrete
 Bridge Construction Stages, Images & Timeline
Concrete
 Bridge Construction Stages, Images & Timeline
Concrete
 Legend
Time Chainage Diagram
Brief Description

The chart has two axis: one for time and the other for location
A legend explains meaning of the colours, symbols and line types
Histogram Charts for Resources & Outputs

Brief Description

Histograms shows resources etc. for each month of a project.

Concrete per Location

Quantity for each month of the Project
Manpower per Discipline

Man-hours for each month of the Project

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Plant & Equipment List & Workers Job Titles
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Other Bridge Projects
Other Projects Kuwait Causeway
Brief Description Marine Piling for Causeway in Kuwait
Other Projects Kuwait Causeway
Brief Description Full Deck Span Precast 1,800 tonnes by 60m long

Precast Yard Straddle Carriers loading Deck onto Multi Wheeled Transporters
Multi Wheeled Transporters moving deck to Jetty

Jetty for loading Barge Barge Crane Placing Deck Barge Crane Placing Deck
Other Projects
Brief Description St. Croix Crossing, Minnesota, USA. Extradosed bridge design
Other Projects - Dubai Metro Viaduct
Brief Description

Overhead Launching Gantry to

Precast Yard for Viaduct Segments Transport Viaduct Segments place Viaduct Segments

Construction Sequence

Completed Project
Other Projects - Dubai Metro Programme
Brief Description
Production by David H Moloney

My YouTube Channel link: https://www.youtube.com/channel/UCeJR9J7svhBd-C0ZoAH2fhQ