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SEMINAR ON EUROPEAN RESEARCH & DEVELOPMENT FOR STEEL FLYOVER TECHNOLOGY

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MAINTENANCE

DIREKTORAT JENDERAL BINA MARGA

4. MAINTENANCE



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MAINTENANCE


• Maintenance

– Painting

– Bearings

– Connections

– Expansion Joints

– Frequency

– Easiness of Repair


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MAINTENANCE


COAT MATERIAL MINIMUM DRY FILM

THICKNESS REMARKS

Surface Preparation Blast Cleaning GRADE 21/2 According to

EN ISO 8501-1

1st COAT - BLAST PRIMER TWO COMPONENT EPOXI

PAINT 120

HEMPADUR QUATRO 17634 or

equivalent

2nd COAT UNDERCOAT TWO COMPONENT EPOXI

PAINT 120

HEMPADUR QUATRO 17634 or

equivalent

3rd COAT - GLOSS FINISH TWO COMPONENT

POLYURETHANE TOP COAT 80

HEMPATHANE HS 55610 or

equivalent

At surfaces where slip critical connections are designed (High strength friction grip), Alkali-zinc silicate

paint or equivalent with minimum 0.4 slip coefficient shall be applied with a minimum thickness of 50-80

m dry film thickness.

Final colour shall be selected by Employer among the standard RAL colours offered by the paint

supplier.

The protective system shall be C5.M.H (High Durability) according to EN-ISO 12944-6, type of paint,

dry film thickness ranges shall be as specified in following table:

Paint Maintenance


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MAINTENANCE


• C5.M.H (High Durability)

• Flyover Paint designed for: • Marine environment and High Durability (worst condition) • No Maintenance for 15 years (certified) • Touch up Maintenance as described below

Durability Range: Low (L):2 to 5 years Medium (M): 5 to 15 years High (H): > 15 years.

Paint Maintenance


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MAINTENANCE


Paint Maintenance

• Preparation of the surface (Abrasive blasting)

• 1st: Prime Coat

• 2nd: Intermediate Coat

• 3rd: Final Coat

• Drying time

• Control total thickness


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MAINTENANCE


Paint Maintenance

• Rajagiriya: RAL 9003 - White • Ganemulla & Polgahawela:

RAL 7001 - Gray


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MAINTENANCE


• TOUCH-UP AND REPAIR OF SHOP COATING

• GENERAL

– DAMAGED AREAS OF SHOP COATED SURFACES, ALL FIELD WELDS, UNPAINTED AREAS ADJACENT TO FIELD WELDS AND STRUCTURAL JOINTS SHALL BE PAINTED WITH A "TOUCH-UP" LAYER

• SURFACE PREPARATION

– THE SURFACE TO BE REPAIRED SHALL BE TO GRADE ST-3 ACCORDING TO STANDARD UNE-EN ISO 8501-1. WHEN ABRASIVE-BLASTING OR POWER-TOOL CLEANING IS NOT PRACTICAL, HAND-TOOLS MAY BE USED.

• TIMING OF APPLICATION

– PAINTING SHOULD TAKE PLACE AS SOON AS POSSIBLE AFTER SURFACE PREPARATION AND PRIOR TO DEVELOPMENT OF VISIBLE OXIDES.

• MIXING

– WHEN MAKING A REPAIR OF A PREVIOUSLY DAMAGED SURFACE WE SHALL APPLY TWO DIFFERENT LAYERS, A FIRST REPAIRING LAYER BASED ON EPOXI PAINT AND A FINISHING LAYER.

– THE FIRST REPAIRING LAYER HEMPADUR, IS USED WHEN THE COATING HAS SUFFERED SERIOUS DAMAGE.

– THE SECOND FINISHING HEMPATHANE LAYER IS APPLIED. AT LEAST 3 HOURS SHALL BE WAITED BETWEEN THE APPLICATION OF THE FIRST AND SECOND LAYER TO ALLOW THE PAIN TO DRY.

Paint Maintenance


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MAINTENANCE


APPLICATION PROCESS

·PAINT HEMPADUR MASTIC IS ROLLED OR BRUSH APPLIED TO A CLEAN, DRY STEEL SURFACE. BRUSHING / ROLLING SHOULD BE IN A DOUBLE APPLICATION ACCORDING TO THE PAINT MANUFACTURER INSTRUCTIONS.

·THE MINIMUM DRY FILM THICKNESS OF THE TOUCH-UP HEMPADUR MASTIC SHALL BE 80-90 µM PRIOR TO THE APPLICATION OF THE SECOND COAT OF HEMPATHANE WITH DRY FILM THICKNESS OF 80-90 µM. TOTAL DRY FILM THICKNESS OF THE TOUCH-UP SHALL BE 160-190 µM

·THE DRY FILM THICKNESS OF THE COATINGS WILL BE MEASURED BY MAGNETIC-TYPE GAUGES OR EQUIVALENT GAGE.

TOUCH-UP OF FAYING SURFACES

·FAYING SURFACES ARE THOSE IN WHICH THERE IS A BOLTED FRICTION CONECTION, SPECIAL PAINT TO GUARANTEE FRICTION, IS APPLIED TO THESE SURFACES

·FAYING SURFACES SHALL SATISFY REQUIREMENTS FOR THE SPECIFIED SLIP FRICTION COEFFICIENT OF 0.40. THE PAINT COATING SHALL BE ALKALI-ZINC SILICATE WITH A THICKNESS OF 50µm TO 80µm HEMPEL GAVOSIL OR EQUIVALENT.

Paint Maintenance


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MAINTENANCE


TOUCH-UP OF BOLTS, NUTS AND WASHERS AT SITE

• THE BOLTS ARE HOT DIP GALVANIZED, TWO LAYERS OF PAINT ARE APPLIED AT SITE.

• BEFORE THE APPLICATION OF SITE PAINT THE BOLTS, NUTS AND WASHERS SHALL BE CLEANED BY MEANS OF THINNER, TO REMOVE GREASE AND OTHER TYPES OF DIRT, PREVIOUS TO PAINT APPLICATION.

• APPLY A FIRST LAYER OF HEMPEL EPOXY PRIMER, FOLLOWED BY A FINAL LAYER OF POLYRETHANE PAINT HEMPATANE.

Paint Maintenance


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MAINTENANCE

DIREKTORAT JENDERAL BINA MARGA Pot Bearings

• Individual design

• Movement Free/Fixed

• Delivered in boxes


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MAINTENANCE

DIREKTORAT JENDERAL BINA MARGA POT BEARINGS MAINTENANCE

• POT bearings are designed and manufactured so as to make it almost maintenance free.

• Opening of POTS at the installation temperature is required to guarantee correct functioning of the bearings.

• All the POT bearings of the flyover shall be opened at the same installation temperature

• POT Installation temperature is selected in order that temperature expansion and temperature contraction of the bridge are similar

• Suitable easy access to the bearing shall be provided for inspection and maintenance. Provision shall be made for jacking up the superstructure so as to allow repair/replacement of the bearings.


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MAINTENANCE


POT BEARINGS MAINTENANCE

• Periodic nominal maintenance of bearing shall be carried out in order to ensure better performance and longer life. The bearings are required to be inspected at an interval of one year for the first five years and at an interval of two years thereafter.

• Bearings shall also be examined carefully after unusual occurrences, like movement of abnormal heavy traffic, earthquakes, cyclones, etc.


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MAINTENANCE

DIREKTORAT JENDERAL BINA MARGA POT BEARINGS MAINTENANCE

Elements of Inspection

• Measurement of movement - During inspection at site, measurements are required to be taken and documented to compute its movement and rotation. The recoded value of movement shall be compared with the design values.

• Measurement of dimensions - Overall dimensions of the bearings are required to be measured and compared with the actual dimensions to ascertain any excessive stress or strain on the bearing.

• Evidence of lock in condition- If any moveable or rotating part of a bearing is found to be in locked-in/jammed condition, necessary rectification measures shall be taken immediately.

• Evidence of corrosion - If corrosion of any part of exterior exposed steel surface of the bearing is detected the following measures may be taken.

• i. Detect affected part

• ii. Wire brush the affected portion to clean the rust.

• iii. Apply protective coating as per manufacturer’s specifications.


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MAINTENANCE


POT BEARINGS MAINTENANCE

RESULTS AND ACTIONS

• i) No action

• ii) Further measures/long-term monitoring or design analysis needed

• (e.g., considering extreme temperatures/exposures, variation of

• loads, etc.).

• iii) Minor repair works e.g. cleaning, repainting etc.

• iv) Repair or replacement of entire bearing or parts of the bearing.


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MAINTENANCE

DIREKTORAT JENDERAL BINA MARGA Expansion Joints

Free Abutment

Fixed Abutment

• Allows more displacement (Elongations produced by

temperature variations)


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MAINTENANCE


Expansion Joints

Free abutment expansión joint Fixed abutment expansión joint


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MAINTENANCE


EXPANSION JOINTS MAINTENANCE

• Guided Expansion Joints are generally used in Steel flyovers

• Manufactured of elastomer and Steel plates

• Allow for long displacements in longitudinal direction, allowing big energy dissipation during Earthquake

• Do not transfer big lateral loads to the bearings at abutments

• Correct installation of expansion joints is critical to minimize maintenance


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MAINTENANCE



• EXPANSION JOINTS SHALL BE INSTALLED WITH THE CORRECT GAP BETWEEN THE ABUTMENT BACK WALL AND THE DECK OF THE SUPERSTRUCTURE.

• THIS GAP SHALL BE ACHIEVED AT THE CENTER OF THE DEFORMATION RANGE OF THE STEEL SUPERSTRUCTURE, AT THE INSTALLATION TEMPERATURE.

• THE EXPANSION JOINT INSTALLATION TEMPERATURE IS SELECTED IN ORDER THAT TEMPERATURE EXPANSION AND TEMPERATURE CONTRACTION OF THE BRIDGE ARE IN ACCORDANCE WITH THE DISPLACEMENTS OF THE EXPANSION JOINT.

• WHEN PLACING THE BACKWALL FORMWORKS, WE SET THE REQUIRED GAP WHEN THE STEEL STRUCTURE IS AT THE CENTER OF THE DEFORMATION RANGE, WHICH HAPPENS AT THE RECOMMENDED INSTALLATION TEMPERATURE.

• IF POTS HAVE BEEN INSTALLED CORRECTLY AND OPENED AT THE INSTALLATION TEMPERATURE, THE EXPANSION JOINT REQUIRED GAP SHALL BE SET WHEN THE POTS ARE IN THE NEUTRAL POINT OF THEIR DEFORMATION RANGE.

• THE INSTALLATION OF THE EXPANSION JOINT SHALL BE CONDUCTED AT THE INSTALLATION TEMPERATURE. WE MARK THE POSITION OF THE ANCHOR RODS TO DRILL THE HOLES AT THE INSTALLATION TEMPERATURE.


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MAINTENANCE

DIREKTORAT JENDERAL BINA MARGA EXPANSION JOINTS MAINTENANCE


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MAINTENANCE


• With correct design and installation maintenance is minimized

• Concrete and asphalt damage might need to be repaired

• Expansion joint substitution is required, in case of excesive wear or damage due to extreme event



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MAINTENANCE


Connections Maintenance • Slip resistant connections • Silicate Painting


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MAINTENANCE


Bolts have to be tightening to correct tension using lubrication.

While inspecting the bridge, bolt tension can be checked using Bolt Calibtrating machine.

If bolts are below the required load and still can absorb more torque without plastifying they can be retightened within the elastic range.

If bolts cannot be retightened and requiered design loading cannot be achieved bolts shall be substituted.

>>MAINTENANCE >>ITEMS>>SUPERSTRUCTURE>>BOLTS


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MAINTENANCE


Baut harus dikencangkan sesuai tegangannya dengan melumuri dengan pelumas.

Ketika melakukan inspeksi jembatan, tegangan baut dapat dicek menggunakan Mesin Kalibrasi Baut.

Bila baut tidak sesuai dengan beban yang diminta dan masih dapat lebih menyerap torque tanpa plastifying maka baut dapat dikencangkan dalam rentang elastis.

Jika baut tidak dapat dikencangkan dan design loading yang diminta tidak tercapai maka baut harus diganti.

>>PEMELIHARAAN >>ITEM>>SUPERSTRUCTURE>>BOLTS


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MAINTENANCE


– Standard Bolted Connections M24 10.9

– Friction Connections

– Silicate painting for increased friction

– Standart Inspection and Maintenance

CONNECTION MAINTENANCE


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MAINTENANCE


• Frequency of Maintenance

– Frequency for Steel Structures including:

• Bolted Connections

• POT Bearings

• Expansion Joints

• Paint Major Maintenance after 15 years


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MAINTENANCE


• Easiness of Repair

– C5M.H Paint

– Bolted Connections

– Open Sections for steel beams

– Simple Expansion Joints

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