E18 Grimstad-Kristiansand Efficient Construction of 61 Bridges. Bridge Conference, Oslo, 10. November 2009 Carsten Lehmann

Transcription

1 E18 Grimstad-Kristiansand Efficient Construction of 61 Bridges Bridge Conference, Oslo, 10. November 2009 Carsten Lehmann

2 Contractual Organisation Concession Contract (PPP / OPS) Sundt AS Design & Construction Contract Seite 2

3 Scope of Works Roads: 38,5 km 4-lane Motorway E18 > 60km Side and Access Roads 11 Departures to Side Roads > 22 Deposits for Surplus Material 5 Deposits for Sulphuric Rock 2600 acre Tree-Cutting 5 Mio m³ Solid Rock to Explosives ton asphalt Seite 3

4 Scope of Works Tunnels: 7 Excavated Tunnels (Excavation by Blasting) 3 Drill & Blast Units Total Excavated Length: 12km Longest Tunnel: 2.200m m³ Blasted Rock Rock Bolts m³ Shotcrete m² Lining Elements Seite 4

5 Scope of Works Bridges and Structures: 61 Bridges 30 Concrete Structures 1 Cut & Cover Tunnel m³ Concrete to Reinforcement Steel 600to Prestressing Steel m² Formwork 28 Tower Cranes Seite 5

6 General Information Key Element of the Transport Corridor between Norway and the European Continent Largest Infrastructure Project in Norway Seite 6

7 Time Schedule 38,5 km 38 Months Seite 7

8 Bridge Construction Reddelskanalen und Tjore Bru 2x 4-span Prestressed Concrete Bridges 2x 3-span Concrete Bridges Bridge Length: Max. Pier Height: 115m and 38m 15m Seite 8

9 Bridge Construction Verven Bru 2x 5-span Prestressed Concrete Bridges Bridge Length: Max. Pier Height: 260m 55m Seite 9

10 Bridge Construction Kaldvell Bru 2 Composite Bridges with Steel Arch and Concrete Deck Bridge Length: Arch Span: 128m 93m Seite 10

11 Bridge Construction Bjellandsvad Bru 2 Prestessed Concrete Bridges Bridge Length: 400m Max. Height: 55m Seite 11

12 Bridge Construction Nottangen bro Prestressed Concrete Bridge Bridge Length: 220 m Max. Height: 20 m Seite 12

13 Work Preparation 1. Evaluation of Constraints Check contractual requirements, access to site, rig area, environment, traffic management 2. Classification of Bridges Standardization of bridges (Design), Classif. by bridge type, geometry and resources 3. Scheduling a. Detailed Bridge Schedules b. Fitting to Overall Schedule (consideration of bottlenecks and requirements from other trades) c. Grouping and Linking of Bridges d. Scheduling of Resources Cranes, scaffolding and formwork based on final work order e. Scheduling of Design just in time Seite 13

14 Evaluation of Constraints Contract SVV Handbooks, Norwegian Standard Traffic Management PPP Contract, Appendix A (Functional Description) PPP Contract, Appendix B (Technical Description) PPP Contract Technical Solutions Exceeding Scope Of Handbooks Technical Solutions Deviating from Handbooks Seite 14

15 Evaluation of Constraints Contract SVV Handbooks, Norwegian Standard Traffic Management PPP Contract, Appendix A (Functional Description) Technical Solutions Clarified in Design Approval Process, Technical Clarification with VD PPP Contract, Appendix B (Technical Description) Technical Solutions Determined in Design Process PPP Contract PPP Contract, Appendix H (Technical Specification) Technical Solutions Predetermined by Contract Seite 15

16 Evaluation of Constraints Contract Traffic Management Risdal Bridge Phase 0 Oct Traffic on existing E 18 In Construction Under Traffic Completed Seite 16

17 Evaluation of Constraints Contract Traffic Management Risdal Bridge Phase 1 Nov In Construction Under Traffic Completed Diversion Risdal Bridge Seite 17

18 Evaluation of Constraints Contract Traffic Management Risdal Bridge Phase 2 Dec Jan In Construction Under Traffic Completed Traffic on North side existing bridge E18 Widen the E 18 on the north side Risdal Bridge Local Road Build South side on new alignment Seite 18

19 Evaluation of Constraints Contract Traffic Management Risdal Bridge Phase 3 Jan Jun In Construction Under Traffic Completed Traffic on North side existing bridge E18 Widen the E 18 on the north side Risdal Bridge Local Road Build South side on new alignment Seite 19

20 Evaluation of Constraints Contract Traffic Management Risdal Bridge Phase 4 15 Jun Oct In Construction Under Traffic Completed Traffic on North side existing bridge E18 Widen the E 18 on the north side Risdal Bridge Local Road Build South side on new alignment Seite 20

21 Evaluation of Constraints Contract Traffic Management Risdal Bridge Final Situation In Construction Under Traffic Completed Seite 21

22 Classification of Bridges Bridge Type Bridge Geometry Site Resources Installation Total Along E18 Across E18 Outside E18 Type 1. Concrete slab bridge Concrete beam bridge Concrete box girder Concrete arch Steel arch w/conc. Slab Copy of existing Extension exiting Seite 22

23 Classification of Bridges Bridge Type Bridge Geometry Resources Similar cross section Similar length Similar Substructure Seite 23

24 Classification of Bridges Bridge Type Bridge Geometry Resources Due to the similarities of the bridge structures they could be built in a chain by using the same equipment: Formwork according cross section Scaffolding due to similar span length and height Crane with same requirements Same working team (supervisor and labour) Seite 24

25 Scheduling Detail Schedule Overall Check Grouping Resources Design Construction time approx. 5-6 month per bridge => a chain of 4 bridges is possible! Seite 25

26 Scheduling Detail Schedule Overall Check Grouping Risdal Bridge: Part of section 1 Handover July 2008 Bridge is part of traffic management => internal milestone for Finalization June 2007 => 1. bridge of the chain Resources Design Brønningsmyr Bridge: Part of section 5 Handover July 2009 Bridge is independant of any traffic => internal milestone for Finalization Dec 2007 => 3. or 4. bridge of the chain Langåsen bridge: Part of section 5 Handover July 2008 Old E18 has to be relocated before start Sep => Internal milestone for earliest start => 4. bridge of the chain Morholt bridge: Part of section 1 Handover July 2008 Bridge is independant of any traffic => Internal milestone March 2008 due to Handover => 2. bridge of the chain Seite 26

27 Scheduling Detail Schedule Overall Check Grouping Resources Design Risdal Morholt Use of same: Formwork according cross section Scaffolding due to similar span length and height Crane with same requirements Working team (supervisor and labour) Brønningsmyr Langåsen Seite 27

28 Scheduling Detail Schedule Overall Check Grouping Resources Design Seite 28

29 Scheduling Detail Schedule Overall Check Grouping Resources Design Remaining bridges are built independant due to the long construction period or their special design Seite 29

30 Scheduling Detail Schedule Overall Check Grouping Resources Design Add Schedule for e.g. use of scaffolds Seite 30

31 Scheduling Detail Schedule Overall Check Grouping Resources Design Add Schedule for e.g. use of scaffolds Seite 31

32 Scheduling Detail Schedule Overall Check Grouping Resources Design Due to the short preparation time between Contract Award and Start of Construction the design had to be done parallel to the construction - just in time The target was to have the final design available 3 months before the construction start of a bridge Strong link between construction schedule and design schedule! Advantages: + Time saved by parallel Design and Work Preparation + Generative feedback between parallel work preparation and design process improves the opportunities of value engineering + Experiences from construction progress can be considered in the ongoing design progress Seite 32

33 Construction Phase 1. Organisation - Organisation chart - Labour 2. Scheduling / Controlling - Update of detail schedules - Feedback to overall schedule - Update of the schedules 3. Interface Management - Delays - Mass transports Seite 33

34 on Jan To rka Jan Kor sgaar d B er nhard P awlitschko Natasja Smits Project Dir ector Contract Director Technical Director As sistant E 05/07 09/09 28 E 11/07 10/09 24 E 01/08 09/09 21 L 08/06 09/09 38 Admin.+Finance Department Liv Roeyneland Dagmar Lange Beate Snemyr Ass istant Adm in.+financ e M anager As sis tant L 01/07 10/09 34 E 11/07 05/10 31 L 08/06 05/10 46 Surv ey Contrac t Scheduling + Wor k Prep. PR M anagement Claim Management Design D epartment Design Contract Environment D epartment HSE Depar tment QA Department Final Documentation Department Controlling Department IT M anagement Carsten Lehmann Kyrre Lian Peter R edgrave Meike G ehrke Andres Zachlehner A nette Falkum M ar tin Schreck Naveed Hussain Michael Schütte Bertram Tantz Guntram Feder Ole K. Thomassen Sc heduling + Work Preparation PR M anager Claim Manager Survey Coordinator Des ign Manager As s is tant OpEnv. Manager QA-HSE M anager Project Controller IT Manager ITAdminis trator IT Adminis trator E 08/06 01/09 30 E 06/06 09/09 39 E 04/08 04/09 13 S 09/06 08/09 36 E 07/06 12/08 30 L 10/06 06/08 20 L 08/06 04/09 33 E 03/07 11/09 32 E 11/06 05/09 31 E 07/06 01/09 30 E 07/06 11/09 40 L 02/07 12/08 23 M aximilian Tr ommer Martin M agerl Lisa Kr istjandottir Lone Sørensen Katar zyna A lfsen Anne Gundersen Anja Sørensen Bertram Tantz Carola Hüge G rit Schütte Vibeke M agnussen Marie Sunnarvik NN Work Preparation Dep. Surv. C o./cad G en. DCC Design DCC Road and E&M Environmental Engineer HSE Engineer+Reporting Doc ument Control IT Work Estim ate Senior Ac countant Senior A cc ountant Junior Ac c ountant Ac countant E 08/07 01/09 17 S 09/06 08/09 36 L 08/06 06/08 22 L 07/07 06/08 12 L 09/07 12/08 16 L 12/06 11/09 36 L 12/06 06/08 19 E 08/06 09/09 38 E 08/06 11/09 40 E 09/06 08/09 36 L 09/06 01/09 28 E 05/08 01/09 9 Niels Roesgaard Nancy Koedderitz DC E18 Des ign JV Vera Stroth Geor ge Lessak Anke Str ich Anke Strich Elise Bjørneseth Erika Fr itsch Lucyna Arnvar d Pooja Sood Contrac t Adm inistration CAD Drainage and E& M Landsc ape Architec t Doc ument Control Adminis tration Reporting Pers onnel Adm inis tration PersonnelAdm inistration Pers onnel Adminis tration PersonnelAdm.As s. E 10/06 04/10 43 S 02/07 12/08 23 L 04/08 07/09 16 L 08/07 08/09 25 E 09/06 09/09 37 L 08/06 12/08 28 E 11/06 12/08 26 L 05/07 12/08 20 L 02/08 12/08 10 Steffen G iese Sven M ueller Tzu-Yun (Sonia) Huang Joanna Gucw a ElinA ndersson Elin Andersson Daniel M artens Christina Zeh NN Dan S ør ensen Contrac t Adm inistration CAD Road Des ign as -built /G eolog. Laboratory As s is tant Ass istant As sistant Proc urement Procurem ent Proc urement Procurem ent E 09/07 12/08 16 S 10/07 06/09 21 E 11/07 09/09 23 L 07/07 12/08 18 L 08/06 10/09 39 E 02/08 04/09 14 E 11/06 12/08 26 L 05/08 12/08 8 E 09/06 12/08 27 Markus Kemme Andreas Weidemann Sebastian Wollnik Inger M yrlund Thea van Gemerden CAD as -built CAD as -built CAD as -built Rec eptionis t Receptionis t S 04/08 08/09 17 S 02/08 07/08 5 E 02/08 09/09 19 L 07/07 01/09 19 L 11/07 03/08 4 André Martaler Elena Tscherkassow Lilian G onzales Michael Nowak Ivana Ondrackova Mirella Nowak Survey ing Unit as -built CAD as -built CAD as -built Offic e Ass istant Offic e As sis tant Offic e Ass istant S 03/08 08/09 17 S 04/08 07/08 4 L 03/08 09/09 19 L 08/06 09/09 37 L 08/07 12/08 16 L 11/07 12/08 14 Matthias Wals Surveying Unit Fixpoints S 01/08 05/09 17 Asphalt Section Karl Ludw ig K ley Har ald Weidinger Jürgen Mohs DC E18 Karin Mikkelsen Jeanette Birkholm Steffen Höppner SebastianG löckner Christian Lausch Construction M anager Coordinator Road Des ign Coord. Reg. 1 on request HSE Engineer QA Engineer Laboratory M anager Estimator Com mercialadmin. E 06/07 10/09 29 S 09/07 06/09 22 S 11/07 08/08 10 E 10/07 12/08 15 E 09/06 07/09 34 E 08/07 05/09 22 E 09/07 12/08 16 E 12/07 09/09 22 Thomas Süssmeier Kim Eriksen Oliver Kias Christoph Wagner Lars Kramper Ørjan Lerbak Jörg Neef F. N.-Farzian / S. Rand. Asphalt Prod.+Cons truc tion Site Engineer Supervisor As phalt Surv ey ing Unit Roads 1 Des ign Coord. Reg. 2 Quality Controller Laboratory Engineer EW Laboratory Eng. As phalt E 11/07 12/09 26 E 01/08 01/09 12 E 01/08 05/09 17 S 01/07 06/09 30 L 01/07 10/08 21 L 12/07 12/08 Road Fur niture Section M arkus Ecker t Wolfgang H artw ig Tarjei Ravn NN NN Jesper M agnussen Surveying Unit Roads 2 Design Coord. Reg. 3+4 Quality Controller Laboratory Technican EW Laboratory Eng. Asphalt Sec tion M anager / Team Leader S 01/08 06/09 18 S 11/07 08/08 10 L 08/07 09/08 14 E 05/08 12/08 8 L E 06/06 10/09 41 Uwe Warkentien Norbert Döberl Mariam Jamshed NN Ola Johansson Marco S tegert Sigbjørn B oye Jan Winnberg Bernd Lewandowski Surveying Unit Roads 3 Design Coordinator Document Handling Laboratory Ass. Asphalt Site Engineer Servic e Team Superv is or Service Team Sup. Natural Stone Wall Supervis or A sph. / Defor. Forem an S 09/07 06/08 9 E 02/08 10/08 9 L 10/07 12/08 15 L E 12/06 12/08 25 E 10/07 12/08 15 L 01/08 12/08 11 L 04/07 05/09 26 E 08/07 12/08 17 Michale Reinhart Dirk Fouquet Surveying Unit Roads 4 Traffic Management E S Peter Wagner Earthworks Section Surveying Unit Roads 5 Hagen Escher Sec tion M anager / Team Leader Rainer Kiessling Sven Helmich E 09/07 12/08 16 Geologist Surveying Unit Roads 6 JohannRiedl Meike Züllighoven S 11/07 08/08 10 S Supervis or Work Preparator E 08/07 08/09 25 E 09/07 12/08 15 Georg B inder Karl-Heinz Bielmeier Walter Noack ChristianNagl Heiko K raus Region ManagerSec t. 1 Site Engineer Site Engineer Site Engineer Supervis or Earthworks E 01/08 06/08 5 E 08/07 09/09 26 E 08/07 08/09 25 E 02/08 08/09 18 E 09/07 01/09 17 Sven Thomas Heiko Töpfer Oskar Kr enner Thomas Lorenz Ulrik Andersen Region ManagerSec t. 2 Site Engineer Supervisor Earthworks Foreman Tec hnic al Serv ic es E 06/07 02/09 21 E 09/07 01/09 17 E 08/07 01/09 18 E 08/07 12/08 17 E 03/08 12/08 10 M artin Häusler Jens Wedemann Uwe Dietz Wilfr ed Schmidt Bernt Wilhelmsen Region ManagerSec t. 3 Site Engineer Supervisor Earthworks Supervis or E arthwork s Supervis or Earthworks E 08/07 02/09 19 E 02/08 01/09 12 E 12/07 01/09 14 E 02/08 05/09 16 L 08/07 01/09 18 Sandro Winter Andreas Kämpfer Dirk Plock Klaus Langkow ski Jøl Arne Suggelia Region ManagerSec t. 4 Site Engineer Site Engineer Supervis or D rainage Supervis or Drainage E 07/07 09/09 27 L 08/07 08/09 25 E 11/07 08/09 21 E 07/07 08/09 26 L 08/07 12/08 16 Poul Wulff Udo Hilbert Plant Manager Site Eng. Asp./Plant Coord. E 02/08 05/09 15 E 01/08 07/09 19 Bettina Müller Uwe K rümmling Lutz Rublack Blast Control Assistant BlastMaster Blast Master L 03/08 12/08 10 E 08/07 12/08 17 E 08/07 12/08 17 Ole Morton Hogås Alexander M oser Torsten Jungtoft Blast Controller BlastController Blast Controler E 09/06 12/08 28 E 08/07 12/08 17 E 10/07 12/08 15 S Structure Section Niklas Vetter Marcel G roebel Jun WenZhu Diana John Ingolf Jensen Anders Häll Christian Ulrich Sec tion M anager / Team Leader on request Survey ing Unit Bridges Struc tural Engineer Environmental Engineer HSE Engineer QA Engineer Com mercialadmin. E 10/06 03/09 30 S 09/06 12/08 28 E 08/07 09/08 14 L 08/07 06/08 11 E 12/06 12/08 25 L 09/07 01/09 17 E 09/07 12/08 16 Kim Laursen NN G. Zehetm./C. Hagen DC E18 Knud Hegelund Gabi Lehmann Lutz N ietner M ario Friedr ich Form work Adminis tration Engineering Des ign Coordinator HSE Engineer QA Engineer Concrete Tec hnology Foreman Concrete R ep. E 02/08 09/08 8 E 04/08 01/09 10 E 10/07 08/08 11 L 11/07 01/09 15 E 01/08 01/09 13 M aren Ber gmann Peter Fr antz en Helmut Fercher Bo Steendahl Site Engineer Superv is or Supervisor Q A Engineer Concrete E 11/06 02/09 28 E 08/07 01/09 18 E 03/08 01/09 11 E Dar uosh M inooei Andreas Wendt M ichael A lburg Site Engineer Supervisor Supervisor S 06/07 02/09 21 E 04/07 04/08 13 E 03/08 01/09 11 M ario Per issutti Rolf Bitter Site Engineer Supervisor E 02/07 02/09 24 E 07/07 12/08 18 Andreas Weinhart Markus Schrieber Site Engineer Supervisor E 03/08 02/09 12 E 02/07 12/08 23 FabianLenz Erik G rønhøj Thorkild Larsen Site Engineer Supervisor Supervisor E 10/07 02/09 17 E 04/07 01/09 22 E 07/07 01/09 19 R.Pellegrini/G. Z ehetm. HermannSattlberger Hans-JuergenKr atz Site Engineer Supervisor Supervisor E 01/07 02/09 26 E 07/07 12/08 18 E 01/07 12/08 24 Silvio Kassin Peter Heller Torsten Henschel Site Engineer Supervisor Supervisor E 12/07 01/09 14 E 05/07 09/08 17 E 10/06 12/08 27 Dieter Herbert Hans Saxler Rudolf H alubek Site Engineer Supervisor Supervisor E 09/07 01/09 17 E 12/07 10/08 11 E 10/06 12/08 27 M artin Rogenhofer Werner Schw ingel Benny Nielsen Site Engineer Supervisor Supervisor E 09/07 02/09 17 E 08/06 01/09 30 E 05/07 07/08 14 ErichM ehring Bronilsaw Bur dz y JanZielinski Yard Manager Storekeeper Storekeeper E 09/07 12/08 16 S 12/07 11/08 12 S 01/08 11/08 11 ChristianSchmidt Uwe H lawatsch Surveying Unit Bridges Machine maint./conc.rep. E 10/06 12/08 26 S 09/07 12/08 16 Tunnel Section A ndreas Reinisch Stefan Degelmann Dirk Niemann Ulrich Ziemann DC E18 M ichael G rausen Siegfried Fleissner Sec tion M anager / Team Leader Chief Geologist Survey ing Unit Tunnel 1 Des ign Coordinator on request HSE Engineer QA Engineer on reques t on reques t E 08/06 03/09 32 E 07/06 04/09 33 S 02/08 11/08 10 E 10/06 07/08 21 E 09/06 03/09 31 S 11/06 04/09 30 Andre Pas Sven Knappe Erw inpartoll Anke Degelmann Silvio Wilke Site Engineer Tunnel Superv is or Tunnel Supervisor Tunnel/Lining Geologis t Survey ing Unit Tunnel 2 E 09/06 10/08 26 E 12/06 10/08 23 E 06/07 03/09 21 L 01/07 04/09 28 S Car stenrosskamp Alois Himpler M ax Fastenmeier Erich Podaber Huber tkalhammer Marcus Zibell Site Eng. Lining/Portals Superv is or Lining Supervisor Portals Supervis or P ortals Geologis t Survey ing Unit Tunnel 3 E 08/06 03/09 31 E 06/07 08/08 15 E 10/07 06/08 9 E 02/08 03/09 13 S 01/08 04/08 4 S Slobodan Martinovic Technical Site Services E Christiane Mögele Geologist L E + M Section Stefan Konetschny Knut Henningsen DC E18 Knud Hegelund NN Sec tion M anager / Team Leader on reques t Des ign Coordinator HSE Engineer QA Engineer on reques t on reques t E 07/06 10/09 39 E 08/07 06/09 23 E KnutHenningsen Sen. Elec tric alengineer E 07/07 05/09 01/08 02/ /07 09/09 28 NN Elec tric al Engineer E 05/08 07/09 15 NN Torsten Jonas Alois Lang Not shown: Trainees E + M Coordinator Superv is or Supervisor E 04/08 09/09 18 E 02/08 07/09 17 E 10/07 07/ /08 09/ /08 11/ /08 04/08 06/ /07 06/08 03/08 03/09 06/ /08 08/ /07 01/ /08 06/09 05/08 06/ Status : Organisation Construction Manager for Interfaces Support team on site: - Logistic: Coordination of formwork, crane, scaffolding, equipment - Survey - Contractual Tea m Roa d - Design Management - Quality (incl. own repair team) - HSE - Environment Section Manager for Structures Tea m Struc ture Construction teams on site: - to construct 61 bridges and 18 culverts - CJV implemented 15 teams with 0,5-1 site engineer, 1 supervisor (and 1 forman) Bridge Section - all employees of CJV Tea m Tunne l additional: - up to 3 Subcontractors for labour teams (more than 300 labour for bridges parallel on site) Tea m E + M Seite 34

35 Scheduling / Controlling Progress Reports: 1. Biweekly detail schedules submitted by Site Engineer Seite 35

36 Scheduling / Controlling Progress Reports: 1. Biweekly detail schedules submitted by Site Engineer 2. Main figures => monthly concrete comparison with forecast Seite 36

37 Scheduling / Controlling Progress Reports: 1. Biweekly detail schedules submitted by Site Engineer 2. Main figures => monthly concrete comparison with forecast Update of Schedules 1. Monthly update of detail bridge schedules and overall bridge schedule 2. Monthly recheck of interfaces with Earth-, Road-, Tunnel- and E&M works 3. Update overall schedule Seite 37

38 Interface Management Interfaces with time consequences for bridges: Traffic Management 1. Changes to the original concepts due to local restrictions Earthworks Bridges 1. Delays in accessability 2. Delays in finishing of blasting around the bridges (safety distance) 3. Soil conditions are different and result in changes of the foundation concept 4. Bridges needed for logistic (mass haulage) Tunnel Earthwork - Bridges 1. Tunnel precut and bridge are close together with difficult coordination of the work => Changes in Schedule! Seite 38

39 Interface Management Seite 39

40 Conclusions Efficient Construction of 61 Bridges Preparation 1.Evaluation of constraints 2.Standardization of bridges 3.Detailed work preparation On site 1.Organisation with key personell on site (including design) 2.Controlling of progress and identification of obstruction asap. 3.Check the interfaces to third parties and identify new interfaces 4.Contemporary update of the complete schedule Seite 40

41 E18 Grimstad-Kristiansand Efficient Construction of 61 Bridges Bridge Conference, Oslo, 10. November 2009 Carsten Lehmann