Construction Method

1. CONCEPTUAL DESIGN AND PLANS OF TEMPORARY FACILITIES

1.1Camp Layout
The camp of the project, living and production facilities are arranged on the right
bank (Sta. 1+000).Concrete batching plant and aggregates screening field will be
independently arranged at Sta. 0+500 of the right bank. For details, see
Conceptual Design and Plan of Temporary Facilities
1.2Construction of temporary Roads
Onsite transportation includes all roads connecting to the existing highways and
temporary construction roads .The temporary roads are constructed with crushed
stones, 20cm thick and 7m wide. At the same time, the top of cofferdam is also
used as the temporary road. A 2km road for construction area.
1.3Concrete Batching Plant
The concrete of this project is produced in the batching plant. The concrete
batching plant is located at the upper
Right bank of the dam, equipped with 2 HZS75EII compulsion type concrete
mixers, each with a productivity of 150m3/h, which can meet the requirements of
the construction. For details, see Conceptual Design and Plan of temporary
Facilities
1.4Water Supply
Construction water id from the Agno water for life is from the local water supply
network or deep water well.
1.5Electricity Supply
Electricity for construction is from the electricity power station located in the
upriver (2.5km). The electricity is transmitted to the site transformer (2X630kvA)
by the 10kv cables and then supplied to the site and temporary facilities. The
construction and living area is equipped with a 200kw generator for standby
power supply and the batching plant is equipped with a 200kw generator for
standby power supply.
1.6Air Supply System
Compressed air for this project is mainly used for rock excavation. Based on the
feature rocks to be excavated, air will be supplied by the compressed air station.
Air supply will be accomplish by using 4 seamless steel pipes as the main pipe
and 3 seamless steel pipes as the branch pipe.
1.7Workshops and Warehouses
(1) Formwork Workshop

The formwork processing plant is located in the main camp. The concrete
construction uses fixed-beam formwork. Storage yard and maintenance
workshop formwork are set-up. And the area of the formwork processing
plant is 400m2.
(2)Rebar Workshop
It is located beside the formwork processing plant, with an area of 400m 2.
(2) Concrete Pre-cast Yard
(3) The precast concreting work will be arranged after the completion of
installation of the batching plant on the right bank, to meet the
requirements of construction. The precast yard is 800m 2.
(4) Other workshop and warehouses
Other plants located in the site include machinery repair shop, M&E
assembling area, power distribution room, on- site laboratory, cement
warehouses and other warehouses, which covers an area of 4000m 2
(5) Powder House
Powder house is located on the mountain of the left river bank, with 300m
safe distance to other facilities. It covers an area of 150m 2.
1.8Office, First-aid Clinic and living Facilities
Office and living facilities located on the right bank. Living facilities
include on-site office, dormitory, recreation room, first aid clinic,
canteen, bathroom, toilet, sewage treatment plant, etc. The office and
dorm are set up with brick walls, steel sheet roof and cement floor.
In order to make sure that employees have a sanitary and safe
environment for rest, the office and living area is separated from the
production area by wall. Each dorm building is equipped with adequate
fire extinguishers according to safety. Living area is provided with
rubbish bins and certain designated people will be responsible for the
cleaning and the maintenance of the area.
1.9Table of Main Temporary Works
Table of Main Temporary Works

10
11
12
13
14
15
16
17

No.

Item

1
2
3
4
5
6
7
8
9

Temporary Roads
Power Supply line 10kv
Power Supply line 80v/220v
Aggregate Screening Field
Concrete Batching Plant
Aggregate Stock Yard
Concrete Pre-cast Yard
Laboratory
Rebar Workshop

Formwork Workshop
Repair Shop
Hardware Warehouse
Equipment Parking Area
Fuel Station
Air Compression Station
Power Distribution Room
M&E Assembling

m2
m2
m2
m2
m2
m2
m2
m2

Uni
t
km
km
km
m2
m2
m2
m2
m2
m2
400
300
300
600
300
200
100
1500

Quantity
4
4
1.5
800
1000
10000
10000
140
400

Remarks

18
19
20

Powder House
Cement Warehouse
Office and Living Facilities

m2
m2
m2

150
2000
7850

2 CONSTRUCTION DIVERSION & CARE OF RIVER

2.1 Diversion Method and Construction Plan
Based on the features of the project and considering the climate, hydrological,
geological and topographical conditions in the local area, the diversion works will
be divided into stages, the construction of the concrete dam is also accordingly
divided into two stages.
In the first stage, right bank cofferdam will be set up, which could encloses the
right bank gate dam, right bank intake structures and half of fixed dam on right
bank. In this stage, the river water will flow on the left bank river bed which is
not enclosed, and the construction of the above mentioned structures will be
conducted. While the concrete works of the right bank dam reaches 98.0m level,
the first stage cofferdam could be removed.
The second stage cofferdam on the left bank will be built upon removal of the
first stage cofferdam. The river water will flow on the right bank river deb and
could fall off along the built right bank fixed dam. In this stage, the structures of
left bank fixed dam, left bank gate and left bank intake will be constructed up to
98.0m level.
After these two stages, the fixed dam has been basically completed, the river
water could flow through it and the construction of upper structures could be
executed without cofferdam.
Please refer to the Construction and Diversion Plan
2.2 Type of Cofferdam
The first and second stage cofferdam will adopt the earth dam with clay core
wall. The section is as shown below:

2.3 Construction of Cofferdam

The equipments used for cofferdam construction are dump truck, bulldozer,
backhoe and roller. Excavate the river bed along the location of cofferdam up to
74.0m elevation, and backfill with clay by dump truck. While the elevation of the
clay core will reach the original river bed level, embank gravel along the two
sides of the clay core wall simultaneously. The embankment should be conducted
layer by layer to ensure a good quality of the cofferdam. The thickness of every
layer should be no more than 30cm. After spreading of material on every layer, it
should be compacted properly with roller.

2.4 Dewatering During Construction

The underground water, waste water from construction as well as rain water
should be treated and drained out of foundation pit in time and properly during
the construction. The following measures will be adopted.
(1) Prior to the excavation of the side slope, a cut-off drain shall be built along
the bank to prevent soil erosion and the collapse of foundation side slopes.
(2) Use backhoe to excavate a drainage along the slope foot of the cofferdam,
and then divert the water into the sump pits which are set in every 100m,
the depth of the sump pit is 2.5m, with dimension of 6mX6m.
(3) Submersible pumps will be used to pump out the water.
(4) The waste water shall be deposited before discharge.

3 CONSTRUCTION METHOD OF MAIN WORKS

3.1 Construction Method of Earthwork

3.1.1 Cleaning and Grabbing

Bulldozer will be used to take the cleaning and grabbing work, loader will be
used to load the top soil to the dump truck. The dump trucks will transport the
material to the appointed disposal area.

3.1.2 Excavation of Earthwork

The backhoe will be used to excavate the and load materials to the dump truck,
dump truck transport the materials to the designated disposal area. The
construction procedures are as follows:

Preparation

Measurement

Site Cleaning

Excavation

Measurement of
the base level

Proceed to the next

procedure

3.1.3 Excavation of Rock

(1)General requirement
To protect the integrity of the base rock and the surface roughness after
excavation, different blasting techniques shall be employed according to
different excavation sections. For the surrounding area of the foundation pit,
presplit blasting shall be employed to control the excavation limits. The alveolus
slope in the foundation pit shall be excavated by smooth blasting. Shallow hole
blasting shall be employed to excavate by smooth blasting. Shallow hole blasting
shall be employed to excavate large-volume (above the protection level) rock.
For the protection level, small hole blasting shall be employed. The depth of hole
in the protection layer shall not exceed the bottom of construction base.
Pneumatic coal pick and crowbar digging shall be integrated to level up the base
level. The blasting excavation of the protection layer is the key point to the
quality of the construction of the structure base level.
RC401-1 Down-hole drill and the 7655 hand-pneumatic drill shall be employed to
conduct the drilling operations. 2 # anti-water rock ammonium nitrate explosive,
millisecond electric detonators or detonating explosive shall be used to ignite the
explosion.
Before the excavation of rocks, trial explosion shall be conducted. The drilling
and blasting settings and the parameter of the wire bound explosives density
shall be verified. After approval, the trail results will be taken as the construction
quality control parameters.
(2) The procedures of the excavation of rocks are as follows:

Preparation

Inspection

Installing
explosives

Drilling Test

Drilling

Set blasting
parameters

Layout

Blasting Hole
enclosing

Connecting the
blasting network

Disposal of
rocks

Rock
explosion

Check

3.1.4 Embankment and Backfilling

3.1.4.1 Work Scope

The embankment and backfilling construction of this project include structure
backfilling, embankment of flood protecton dike, clay blanket, and road
embankment.
3.1.4.2 Work Procedures
The work procedure of embankment and backfilling construction follows the flow
chart below:

Failed

Land Preparation

Passed
Compaction
Pased

Inspection

Surface
Treatment

Passed
Water Content Test

Soil Spreading

Failed
Failed
Tedding or
humidifying

Sampling

Passed
Spraying
water

Scarifying

Next layer
construction

3.1.4.3 Points of Quality Control

(1) The eluvial soil should be cleaned up before construction to ensure the
stability of the side slope of the foundation pit. The caves, cannels and wells on
bottom and both sides of the grooves should be filled.

(2) If the water table is higher than the bottom of the foundation pit, barreldrains must be arranged to lead the water into the sump pit to ensure the
dryness of the founddation pit.
(3) The back filling of the gravels of the strudctures should be constructed with
vibrators. The construction must be done layer by layer. The thickness of the
pavement of each layer should be 30cm and water sprinkling should be applied
during construction. The gravel layer under slope protection should be laid from
the bottom layer and be stamped with standing rammers.
(4) The dry densiy should be determined by cutting ring sampling method and
watering douching methods. The close-grained should not be less than that of
the designed regulation.
3.2 Construction Method of Concrete Works
3.2.1 Procedures of Concrete Works
The procedures of concrete work is shown in the flow chart below:
Construction Preparation

Formwork
fabrication

Steel Bars
Fabrication

Steel Bars test

Self -checkingSampling tests of cement,

aggregate, sand, water,
admixture, and other materials

Inspection and approval by

Engineer

Mixed Design

Concrete mixing in the mixing

Concrete pouring
plant

Concrete transportation with

mixer
Manual concrete spreading

Concrete Vibration

Surface cleaning and

smoothening
3.2.2 Construction
Method
Concrete
curingof Sourcing Sluice
(1) Layer and Block Division of Sluice Chamber Concrete Pouring
Left bank and roght bank scouring sluice each has one unit of sluice gate without
design expansion joint.For the vertical construction, 1.5m for each layer for
sluice bottom, 3m for each layer for sluice pier. The upper traffic bridge is
regarded as a pouring layer by itself; vertical beams and slabs of the control
room will be poured at the same time whilr cylinders between slabs are deemed
to be a pouring layer.
(2) Layer and Block Division of Concrete Wall (such as retaining wall and guide
wall concrete)
Horizontal span of the wall are divided in accordance with the design
joints.Vertical layer is 3m each; under parts will be poured in one time.
(3) Concrete Pouring
Stepped pouring is adopted here with every 40cm high layer. Concrete pump will
be use to concrete to every part. Pouring shall be continuous so that cold joints
can be avoided and construction quality could be ensured. Force balance of the
formwork shall be taken into consideration while concrete pouring is carried out
on load-bearing formwork of the sluice gate and upper layer`s concrete
construction cannot be started until poured layer`s strength reaches 80% or
above of the concrete`s design strength.
Manuals spreading is adopted and high-frequency vibrator is used to compact
the concrete.In order to ensure the formwork`s stability, penetrating vibrator is
used to compact the concrete in the place where is near the formwork.
Flat-plate vibrator is used to flatten and compact the bottom slab`s surface, after
that workers will smooth and polish it. Since bottom slab pouring will take long
time, the surface flattening and polishing should be done according to the setting
time of poured concrete. By doing so, appearance quality of the concrete could
be guaranteed.
Various pre-embedded parts shall be protected when concrete pouring is going
on. Staff shall be appointed to regularly check the position of pre-embedded
parts during construction so that displacement of those parts can be avoided.
3.2.3 Construction Method of Fixed Weir
(1) Layer and Block Division of the Weir`s Concrete Pouring
Horinzontally: divided according to structuraql joints. Construction is carried
out in a skipping manner.
Vertically: the thickness of upstream connection parts is 50cm and one-time
pouring is adopted here. Downstream connection part is divided into three
sections along water flow and concrete pump will be used. Layers for concrete
pouring are as follows: for the first and second sections, surface layer is 1.2m
concrete Type-A, the elevation is form EL.8200~ EL.8080; for parts below
EL.80.80, every 1.5m is regarded as one pouring layer. For the third section, the

End sill (1.2m) is taken as the first pouring layer, for parts below, every 1.5m is
regarded as one pouring layer.
(3) Concrete Pouring
Stepped pouring method is adopted here with each 40cm high layer. After
poured, the concrete will be compacted by penetrating vibrator and highfrequency vibrator. Surface concrete with smooth request will be pressed and
polished by workers after being flattened and compacted.
Skipping pouring is employed here and time interval between two nieghboring
block shall not be less than three days. Interval time of pouring between upper
and below layers shall not be less than five days. Before the pouring of upper
layer, concrete surface of layer below shall be roughened.
Concrete curing shall be conducted as required by the Engineer. Surface of
concrete shall be maintained with thin films while other parts with
water.Concrete surface shall be kept moist all the time.
3.2.3 Construction Method of Right and Left Intake
Building of Right and left Intake can be divided into sluice chamber section,
culvert section and open canal transition section.
(1) Layer and Block Division of Sluice Chamber Section`s Concrete
Horizontally concrete in the lock chamber is divided according to the
designed joints. Base concrete Type-B is divided by the underground water
level, parts below underground water level adopt one-time pouring, parts
above underground water level will be poured in every 1.5m, and every 3m of
the pier is regarded as a pouring layer. In the case of concrete Type-A, layers
are divided according to characteristics of structure lines and thickness of the
layer is controlled within 3m.
(2) Layers and Block- Division of Culvert Section`s Concrete
Culvert`s bottom slab (EL.88 ~ EL.90.0) is the first pouring layer; culvert wall
(EL.90.0~ EL.91.5) is the second pouring layer, culvert wall (EL.90~EL.91.5) is
the third pouring layer and top slab (EL.92.5 ~ EL.93.3) is the forth pouring
layer.
(3) Layer and Block Division of Open Canal Transition Section`s Concrete
Block division of the bottom slab above water level in this section just follow
the design expansion joints. If the bottom slab of the wall is thicker than
1.5m, pour it in every 1.5m; if it is thinner than 1.5m, one-time pouring will be
applied. Wall will be devided into layers with a thickness of 3m. Concrete
lining will be poured in blocks according to the design expansion joints.
(4) Concrete Pouring
Concrete pump is used in left and right Intake to pour the concrete. Stepped
pouring method will be adopted here with each 40cm high layer. After
pouring, the concrete will be compacted by penetrating vibrator and highfrequency vibrator. Surface concrete with smooth requirements will be
pressed and polished by workers after being flattened and compacted.
Curved surface formwork of the open canal transition shall be manufactured
in advance according to the construction drawing to ensure the surface
quality.

Embedded pipe in the weep hole shall be carefully protected during the
pouring process so that pipe blockage and displacement of the embedded
pipe can be avoided.
Concrete curing shall be timely conducted as required by the Engineer.
Surface of concrete shall be cured with thin films while other parts with
water.Concrete surface shall be kept moist all the time.
3.2.4 Temperature Control Measures of Mass Concrete
Temperature crack is the moist common and dangerous crack in mass
concrete. During construction process, temperature stress will appear
beacause of the differences of temperature changes of inner and outer parts,
which will produce surface cracks or even penetrating cracks in concrete and
do harm to the concrete structure in different degree. In this project,structural
concrete including fixed weir, right and left bank scouring sluice, left and right
bank intakes are all mass concrete, as a result, it is imperative to take the
following temperature control measures based on the project`s
characteristics:
3.2.4.1 Reasonable Layer-division of The Structure
Layers of mass concrete are divided according to vertical, transverse and
horizontal joints so as to increase the cooling area, decrease concrete blocks
binding force and make adjusment to temperature deformation. By doing so,
temperature crack can be avoided.
(1) Transverse and vertical joints shall be set up according to requirements of
construction.
(2) Horizontal joints shall be controlled within 1.5m according to requirements
and shall meet the construction strength.
(3) During the concrete pouring process, factors such as mixing, transporting
and pouring abilities shall be taken into consideration. Natural
temperature drop shall also be considered to reduce temperature
difference and the pouring thickness which shall not exceed 40cm.
3.2.4.2 Reducing the Concrete`s Calorific Value
Temperature control mainly means controlling concrete`s maximum
temperature difference T. Reducing calorific value is an important way to
control T, and cement is the main heat source in the concrete, therefore,
adoption of low heat cement and reduction of cement contents become
controlling measures of reducing the calorific value:
(1) Low heat bulk cement can decrease the maximum temperature value
inside the concrete by 20~30%.
(2) Gradation of concrete aggregates shall be improved. Three-graded
concrete shall be used as mush as possible. Coarse aggregate shall be
mixed and weighed strictly the following three gradation: 5~20mm,
20~40mm and 40~75mm.
(3) Fly ash shall be added to reduce the contents of cement and thereby
reduce the concrete`s calorific value. Amount of the fly ash added shall
be 10~25% of the cement.
(4) Lignosulphonate retarding water reducer shall be mixed into the
concrete so as to increase heat dissipation and reduce temperature
difference T of the concrete.
3.2.4.3 Reducing Concrete`s Temperature While Pouring

(1) Natural temperature drop shall be taken into consideration.

Aggregate stacking site shall be properly piled up to 5m and aggregates shall be
kept for more than 5 days. Direct exposure shall be avoided. (2) Cold water shall
be considered to be used to mix the concrete.
(3) After the
concrete comes out of the batching plant, transformation shall be quick, transfer
shall be avoided whenever possible, and concrete pouring shall be continuous.
(4) Concrete pouring should as far as possible not to be conducted in high
temperature
period.
3.2.4.4 Accelerating the Heat Dissipation of Concrete
Natural heat dissipation is the main method to accelerate the heat dissipation,
this includes decreasing the thickness of pouring layer and prolonging the
pouring time. Thickness of concrete pouring shall be less than 1.5m, pouring
time interval between two neighboring blocks shall not be less than 3 days and
time interval between upper and lower layers shall not be less than 5 days.
3.2.4.5 Preventing Adverse Effects of Temperature and Applying Surface
Protection
Adverse effects of the temperature includes summer dryness or cold waves
attraction. Great temperature difference of the concrete caused by temperature
rise due to the lacks of necessary cooling or ignorance of heat preservation can
both lead to the surface cracks or even penetrating cracks. Therefore, apart from
the above-mentioned measures, the following three measures shall also be taken
to prevent adverse effects of temperature in the initial stage:
(1) in high temperature, surface of the poured concrete shall be paved with
damp sand, damp sawdust or cured by water (the formwork shall also be
frequently sprinkled with water). In this way, both moisturizing and curing can be
applied simultaneously.
(2) When
cold waves attack, straw bags shall be used to cover the concrete surface to
protect
it
and
isolated
it
from
exterior
cold.
(3) Under normal temperature, great attention shall also be taken to the poured
concrete so as to create favorable hardening condition.
3.3
Construction
Methods
o9f
Steel
Sheet
Piles
3.3.1
General
Instruction
The steel sheet piles of the project are used as cut-off walls for the
upstream flood protection dike. According to the design, there are two
kinds of steel sheet piles: from Stake 0+000~0+384, 9mx0.4m type will
be used at elevation 77.0m~86.0m. The total length of this type is 8,640
linear meters. From stake 0+384~89.0m. The total length of this type is
33,456 linear meters. The total length of these types of steel sheet piles
used
in
this
project
reaches
33,456
linear
meters.
3.3.2 Construction Procedures of Steel Sheet Piles

3.3.3
Selection
of
Pile
Driver
According to the geological conditions of the project, on-site operating
environment, as well as the type of steel sheet pile, we propose to use
mobile crane (50t) to hang ZD-45-type diesel vibrating hammering to
drive
the
steel
sheet
pile
3.3.4
Construction
Method
(1)
Construction
Preparation
1. Examination of steel sheet pile Appearance: Including surface defects,
length, width, thickness, height, end/square ratio, flatness and locking
shape. The new steel sheet piles shall meet the quality standards,
otherwise
it
shall
be
corrected
before
driving.
2. Lifting and Stocking: Two points lifting will be used while loading and
unloading of steel sheet pile. The lifting members of the steel sheet pile
every time should not be excessive, and attention should be paid to
protect the interlock edge from damage. Steel sheet pile should be piled
on flat solid ground
3. Cleaning and Layout: Within the working scope of the vibrating pile
driver, barriers on and under the ground shall be cleared away, the site
should be leveled, drains and temporary roads should be constructed.
Setting out and positioning shall be conducted according to the design
drawing, and the control network and benchmarks should settled.

4. Antirust Painting: Before application, the groove mouth at the tip of the
pile shall be closed and the locking edges should be coated with Antirust
paint.
(2) Driving of steel sheet piles
1. Pile caps should be placed between the pile hammer and the top of
steel sheet piles so as to ensure even distribution of the pressure of the
hammer onto the sheet pile and to protect the pile from damage.
2. Setting of pile guide frame: To ensure the vertically of pile driving and
the flatness of the sheet pile walls, guide frame should be set before the
application of the sheet piles, as is shown below. For the double sides
guide frame, the space between the two sides should be 8~10mm larger
than the width of the steel sheet pile. The guide frame support usually
consist of profiled bar, such as H-shaped steel, I-shaped steel C-shaped
steel and so on. The depth of guide frame support driven into the ground
is around 6~8m with spacing 2~3m, the supports should be connected by
welded connecting steel sheet.

(a) layout;

(b) section

1-pile for frame purlin; 2-purlin; 3-steel sheet pile; 4-connecting steel
sheet
(3) Driving of steel sheet piles
a. Use a 30t mobile crane to lift the steel sheet pile to the driving point.
After located, each pile should be capped and hammered slightly.
b. When hammering, two theodolites shall be set two direction to ensure
the
verticality
of
the
steel
sheet
piles.
c. To prevent displacement of the locking centerline, lock plates shall be
located in the interlock edges the piles. At the same time, calculation of
the location of each pile shall be conducted for calibration at any time.
d. Accuracy of the location and direction of the first piles applied be
ensured to make a good starting of the steel sheet wall. Therefore,
measurement shall be conducted every time when the pile driven 1m
deep. When the pile is driven at the expected depth, it should be welded
to the guide frame immediately.
(4)
The closing up and adjusted of steel sheet piles. Sometimes the designed
length of the sheet pile walls is not of integral multiple of the standard
width of steel sheet piles and the axis of the sheet pile walls might be
complicated. The lock of the pile might have gaps when the pile is driven.
All of these conditions will make it difficult to close the walls. In these
cases, the special-shaped piles will be adopted and axis adjustment will be
applied.
(5) Screening method is used for the construction of steel sheet piles.
Every 10~20 steel sheet piles form a construction section. When driven
into the soil to a certain depth, the section forms a short screen wall. The
piles at the both ends shall be driven first up to its length, and the

verticality of those piles shall be controlled and ensured. The two piles
shall be fixed onto the guide frame by welding. The rest of the piles shall
be driven in a sequence up to their to 1/3 height, taking on the shape of
a ladder. The adoption of this method can serve to prevent excessive tilt
and reverse, reduce cumulative tilt error and facilities the closure of the
piles. Since the piles are driven section by section, the construction of
their adjacent piles will not be affected.
3.4 Manufacture & Installation of Metal Works
4.4.1 Manufacture
Metal Structures shall be manufactured in
the metal works plant, transported by trailer after passing pre-delivery
inspection and set up at the site. Gates, gate slot embedded parts and
trash racks shall be fabricated in whole or in sections according to the
technical specifications. Fabrication and installation of metal structures
shall be arranged according to the respective construction schedule.
1) Manufacturing Process of Gate Slot
Embedded Parts
Preparation work Blanking
Welding Deformation Correction Machining (rail surface or sealing
seat surface) Preassembly Inspection Corrosion Prevention
Acceptance
Transportation and machining conditions shall be taken into consideration
when processing all the welded gate slot embedded parts. The length of
gate slot built-in parts shall be limited within a range of 6.0m. Preassembly
shall be made in manufactory for each set of gate slot, its dimensional
deviation and joint interleaving should be in accordance with the drawings
and the specification. Distinct markings and serial numbers shall be in the
joints after inspection is passed. After spot welding, gate slots shall be
welded in sections, bilateral symmetry or skip methods will be used in
order to avoid stress concentration and tracks deformation of built-in
parts.
Rectification and quality inspection for
welding shall be made on the platform with the help of water level, angle
square, steel ruler and chalk line. After acceptance and approval by the
Engineer, anti-corrosive treatments shall be carried out for the gate slot
built-in parts in different places according to the requirements before
warehousing.
2) Manufacturing Process of Plane Gate Leaf
1. Blanking and Assembly of Girder System
For the welded composite beams gate leaves, the composite beams shall
be firstly manufactured. Semi-automatic gas cutting will be used for
blanking of composite beams. Slag removal and corrective treatment shall
be done after panel cutting. Reserved welding shrinkage and counterdeformation pre-compression allowance shall be left in advance for main
beams, edge beams and longitudinal beams. All the beams shall be
assembled according to the inspections. Welding shall be made in the
same direction. Inspection and tests shall be carried out for each single
part of the girder system.
2.
Blanking
and
Assembly
of
Gate
Leaves
Blanking and assembly of gate leaves shall be carried out according to the
Panel Layout, in which, 50mm should be reserved for width and the height
of single edge. After full welding of the gate leaves, trim them to design
sizes by semi-automatic gas cutting. Leave seams shall be welded by
automatic submerged arc welding.
3. Lofting and

Assembly
Assembly
and
See Flow Chart Below.

Production
Welding
Arrangement

of

Material Purchase

Manufacturing Process
Guideline
Components
Fabrication
Beam Grillage
Assembly

Unqualified

Correcting
Adjustment

Repair

a.
System

Girder

Outsourced
Parts process

Parts
Manufacturin
g

Structure & Size

Check

Warehousing
For Use

Qualifie

Welding
Unqualifi
Welding Test
Qualified
Leaves Matching and
Assembly
Welding
Welding Test

Unqualified

Deformation Correction and

Screw & Anchor Holes
Rust-Removing and anti-Corrosion
Whether Gates Dimensions Are Over-Wide
Yes
Reasonable
Sectioning

Final Inspection and

Delivery
Transporting to the
Construction Site
Integral Assemblies of split Gates,
Water seal & roller wheels
assembly and anti -corrosion
repairs
Re-inspections Before installation

No

Water Seal & Roller Wheels

Assembly

3) Manufacturing of Trash Rack

Manufacturing Procedure of Trash Rack is Preparation work Blanking
Assemble, Welding and Inspection of Racks Delivery
Paling of Trash Racks shall be welded with the girder system by using manual arc
welding. Manufacturing of Trash Racks will follow the Drawing and the above
regulations.
4) Painting Works of Gates, Gate Slot Built-in Parts and Trash Racks
Painting work can be carried out with the approval of the Engineer after the
manufacturing and inspections of gate leaves, trash racks and slot built-in parts.
Painting work shall be done according to the requirements of the Contract and
the Technical Specifications.
Work Procedure: Surface cleaning Derusting by sandblast Protecting by
spraying Zinc Painting
3.4.2 Installation
1) Installation of Gate Slot Embedded Parts
Scope of Application
This is applicable to installation of gate slot embedded parts in the Contract,
including main rails, reverse rails, side rails, bottom rails, door inlets (or parapet)
etc.
Installation Process Flow
Anchor bars burying in first stage concrete Slot inspecting, cleaning and
roughening Control points and control lines setting Bottom sill installation
Main rail installation Reverse rail installation Side rail installation Door lintel
installation Inspection and approval of concealed work before secondary
concrete pouring Secondary concrete pouring Cleaning and repetition
measurement.
Installation Procedures
1. Control points and control lines setting. Datum points shall be provided by
the measurement division which are as near to the installation points as
possible. There shall be written documents with the approval of the
Engineer and they shall be properly protected during construction. Control
points shall be introduced from the datum points at a distance of 100-200
mm. Settings of control points shall be double firmed, reliable, correct.
2. Installation of bottom sills. Before hoisting and installation of bottom sills,
the embedded steel dowels should be welded to form a supports.
Elevation of the support top shall be lower than the sill structure for 10-50
mm so as to provide a fitting allowance for sills. To set a steel wire
connected to the control points on both sides of the slot to level-off the
sill. For every 0.5 m, a check point should be made to measure if it comply
with the Specifications. Meanwhile, use water level to measure and check
elevations of sills bottom. Draw-in bolts shall be used to adjust bottom
sills which are basis of all slot structures installation. Reinforcements after
installations are necessary for avoiding vibration displacements during the
second-stage concrete pouring.

3. Installation of main rails, side rails and reverse rails. Find and fix a central
point on the installed bottom sill and locate the relative positions of the
main rails, side rails and reverse rails. Use hand chain hoist to hang the
gate slot, fix it by spot welding in sections and then fine tune all the
structures to the proper positions by using of draw-in bolts and jacks.
Check points shall be made from the bottom to the top every 0.5 m.
Permissible errors of installation shall follow the design specifications.
Reinforcements shall be done after inspection.
4. Installation of door lintels. Before installation of the door lintels, mark out
the center height line of the lintel on the rails and then fix two brackets
inside the two main rails. Fix the lintel down to the brackets and set a steel
wire along the lintel sealing center so as to adjust its levelness and central
elevation.
5. Repetition measurements of embedded parts. After the installations of
embedded parts and passing the self-checking, ask for the Engineers
inspection and acceptance. Upon approval, carry out the second-stage
concrete pouring as soon as possible .If there is delay or collisions
happening in the concrete pouring, repetition measurements shall be
made again for the Engineers inspection and acceptance .Only with the
Engineers approval can the pouring work be carried out.
6. After removal of formwork for second-stage concrete, carry out repetition
measurement and made corresponding records. Dimensional deviation shall be
corrected.
2. Installation of Gate Leaf
Installation Process Flow
Preparation work- Site assembly of gate leaves- Inspection of assembly qualityOverall acceptance of Gate leaves Installation of gate leaves- Sluicegate test.
Installation of Gate Leaf
Before the installation of gate leaves, a technology report on installation and
welding shall be made in which measure of avoiding welding deformation shall
be described.
Preparation work includes establishing a temporary platform for site
assembling, and the cleaning sundries in the gate slot and the bottom sills.
Assembly and welding of gates shall be carried out on the platform
Installation and adjustment of major supporting parts of the gates (including
sliding support and rollers of the roller-bearing gates etc.) shall be done after
assembly, installation, measurements, corrections and inspections of gates
leaves. All the bearing surface shall be in the same plane and their errors shall
be no larger than the specified in the Drawings.
Allowable deviation of installing gate sealing devices and quality of seal
rubbers shall all conform to Standard and the Technical Specification. While
installation, the rubbers shall be bound first according to the required length and
then bolt holes will be drilled together with gate sealing devices.
After the installation of the gate leaves, sundries on the embedded parts
surfaces and on the gate leaves shall be removed, especially the slurry on the
stainless steel sealing seat surfaces. Lubricates oil or grease shall be applied to
the sliding support surfaces and the roller sleeves.

 After the Engineers approval, paint finishing shall be done to the plain gate
leaves according to the requirements.
Sluicegate test of the plain gate leaves.
Test and check the gates under the instruction of the Engineer after installation
of gates and hoist. Test items includes:
a. The whole trip sluicegates test under anhydrous circumstance. To check if
slide rails and roller wheel are free from any jam. In the full-closed position
of the gates, seal rubber shall free from damages: light leakage test shall
be qualified and water seals shall be done to the seal rubbers and the
stainless steel sealing seat surfaces in order not to damage the rubbers.
b. The whole trip sluicegates test in static water. This shall be carried after
the test in anhydrous circumstances is passed. Items of test and check
shall be the same with those of the test in anhydrous circumstance is
passed .Items of test and check shall be the same with those of test in
anhydrous circumstance (except the checks of seal equipments and light
leakage).
c. General Tests. The whole trip sluicegate test in anhydrous circumstance
shall be carried out for each stoplog gate leave used for various slots and
to make sure that very slot is qualified.
3. Installation of Trash Rack
Pass the re-examination of all the dimensions before installation.
Structure members of the trash racks should be intact and the paint film
on the surface shall not be damaged.
Mobile crane will be used for hoisting and positioning.
Fix the racks with screw bolt after position adjustments.
3.4.3 Design, Manufacture and Installation of Hoists
Hoist will be purchased. They shall be designed and manufactured by
reputable manufacturers according to relevant standards and the
Technical Specification and then be transported to the site for installation.
Purchase and installation of hoist shall be arranged according to the
respective construction schedule.
4. CONSTRUCTION QUALITY CONTROL SYSTEM
4.1Construction quality ensuring system of this project is in compliance
with the quality assurance requirements of ISO 9001:2000, During the
construction of this project, we will have close study of the relevant
rules, regulation and standard in the design drawing, the design
documents and the bidding documents, and work out a detailed
construction program and a construction scheme concerning the key
sections of the work. We shall also compile the construction process,
operating rules, and construction quality management systems as well
as detailed ensuring measures to make strict quality control during the
whole process of construction.
4.2Quality control Organization
We set up a quality control organization according to the project
management program, which consists of the project manager (the first
person liable of the quality), the project engineer of the project (the
direct person liable of the quality), and the quality inspecting
department
Please refer to the Quality Management Organization