•  
 
•  
communications and traction power
FUNDAMENTAL CONSTRAINT
Beams to be formed to suit final alignment geometry including
 Architecture – Engineering – Urban Design – Transportation –Marine D&C Contractor
 , , super elevation (cant).
ROLE OF THE FINISHED PRODUCT
The beam carries practically all the E&M services as an integral part of the beam and these are incorporated during casting and interconnected during the installation process.
.
PLANNING & PRE-CONSTRUCTION WORKS
• Design philosophy : (i) minimal disruption to traffic during construction.
  . (iii) maximizing standardization in size for structural members.
• -  Precast post-tensioned concrete beams erected and stitched together with in-situ concrete joints to form continuous frames.
• Sub-structures : Cast in-situ concrete pile caps and piers.
 
 
 
• Non-typical situation (Obligatory Span) :
  guideway beams at some location;
(ii) Long span superstructure may be adopted, e.g: major n ersec on an ra way cross ng up o m;
(iii) Non-typical span arrangement where precast beam transportation is difficult;
(iv) Single beam guideway structure near terminal station; and
 
DESIGN CONCEPT OF GUIDEWAY STRUCTURES cont’d
• In certain circumstances, such as crossing existing railway tracks, bridges or wide road below, special spanning arrangements
sequences of construction may be adopted, in order to minimize disruption to the flow of railway or road traffic. Extra long span bridge   supporting guideway beams may also be designed for 
not viable.
 
PROPOSED STEEL TRUSS BRIDGE FOR 50m SPAN CROSSING THE MAJOR FLYOVER 
• NOTE
RM 15 million.
500 000 extra for the 50 m 
crossing.
• Wind load
• Temperature effects
• Seismic load
Design Loadings
, . .
 
Desi n Loadin s
• Live Loads
The guideway structure shall be designed to carry the axle loads
the train supplier/ rolling stock.
• Train Vehicle Live Load (LL)
2/4/6/8 car modules   with indicated axle load positioned to
produce the maximum load patterns on the structures. The
with the rolling stock proposed for the monorail system. Each
axle load is generally ranging from 100kN to 135kN  with full
passenger load included.
Design Loadings
•  
The dynamic impact factor for vertical load shall be generally taken
as follow:
Concrete beam, I = 20/(50+L)   ≤ 25%
Steel beam, I = 25/(50+L) ≤ 25%
where, L = length of span (m).
Centrifugal loads or longitudinal loads shall not be multiplied by the
dynamic factor. The dynamic impact factor will be considered for 
su erstructure and iers onl . It shall not be a lied to iles and
pilecaps.
•  
Longitudinal loads from braking and traction shall be 18% and 20%
of live load per guideway respectively.
When a structure carries two guideways, both guideways shall be
considered to be occupied simultaneously. Traction load shall act
,
acting in the same direction to produce the worst loading condition.
• un ng orce
Hunting or nosing force is caused by the lateral interaction of the
train vehicle and the guideway   (Snake motion of train).  Hunting
orce s a e o one s ng e ax e oa per car    ac ng
perpendicularly to the track axis at center of bogie.
 
Design Loadings
 
The centrifugal force acting radially through the centre of gravity of the
train at a curve track shall be computed from,
CF = V2 P / R g ≤  0.17 P
where, R = radius of curvature m
g = acceleration due to gravity (m/s2)
P = train weight (kN)
When centrifugal and hunting forces can act simultaneously, only the
larger forces need be considered. Centrifugal force need not be
considered acting simultaneously with seismic load.
.
 
Structural
Element
Concret
 
, cu  
Ec = Young’s modulus of elasticity of concrete
Poisson ratio of concrete shall be taken as 0.2.
 
reinforcement shall be 460 N/mm2, conforming to BS 4449. The
modulus of elasticity  of steel reinforcement shall be taken as 2.
Prestressing Strands
• restress ng stran s s a e o uncoate stress re eve ow
relaxation seven-ply strands conforming to  ASTM A416 or BS
5896. The minimum breaking strength per strand with nominal
.
 
-
 
• Prepare Mould Setting & Casting Procedure,
• Prepare Mould Setting Data,
• Pre are Heav Lifts Methodolo StudiesPROCUREMENPROCUREMEN
Long Lead Time 
Beam Casting Mould,
Temporary Works Equipment,
Pre-stressing System & Equipment,
• Erection Study ;
• An integrated between
design and construction
operations is essential since
or mistakes.
provide the basis of  multi-
axle hydraulic platform
transporters to manoeuvre
 
The position and capacity of the
crane was driving influence for the
whole operation.
only made possible by the
extensive use of CAD, in order to
simulate every position of the
,
from site boundary conditions.
spans were cantilever beams,
tip since this would cause a
temporary sagg ng moment n
the beam – opposite to the hogging
resistance provided by the
Planning for Casting Yard
Precast Yard is required rational facilities and their arrangement to increase
.
 
Mould Design
• Developing a mould system and a method of converting the al ignment design into
 
Mould Design
• Since the guideway beam also forms the running surface for the monorail, this
results in the warped concrete surfaces, which need to be properly represented
by the formwork skin.
Casting Yard/Mould Design
Casting yard is constructed on ground which should be satisfied prescribed
bearing capacity of ground. Especial ly foundation of gantry crane and beam stock
area had heavy weight of guideway beams
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PLANNING & PRE-CONSTRUCTION WORKS
dimensionally different shapes of guideway
beams to get better understanding about
the beam geometry and to be able to
c ec ma ema ca ca cu a ons a er  
on.
Mould setting using Programmable Logic Control (PLC).
Using third party software (Softdesk ®, Autocad Civil, etc) to
into considerations of the effect due to super-elevations, radius curvature and vertical alignments. The absolute jack  extension/compression coordinates will be reduced from the global coordinates with reference to the local centerline of the
beam castin ard.
The individual beam will be numbered and the coordinated for the respective jacks input into a PLC control to actuate the motorised 24 AC volts jacks into respective positions to form the beam. The loop back to control the jack adjustments will be monitored using linear laser measuring device. The final resting positions o t e jac s wi e monitore on rea time. The Graphical User Interface will be used to plot existing positions of the jacks verses the designed positions using
 
PROJECTION
 
 
 
 
 
QA/QC Procedures - Beam Production Table – (Flow Chart)
The preparation of such flow chart requires the input from many parties
including end users, system supplier, various teams as well as perhaps those
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Production & Storage - Concrete Technology
of monorail so that there is no unevenness. The finish product cannot be altered or modified or swapped.
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• Transportation and Erection
• With beams typically weighing anything from 35 tons to 185 tons and up to 45
meter in length the selection of the equipment to be used and its configuration
must also be worked out with specialist contractors and equipment suppliers.
• The design of the interface between the beam and transporter is crucial since
i t must accommodate the variable geometry, restraining forces required
to stabilize the beam, together with the dynamic movements of the
transporter as it negotiates the bends, gradients and junctions along the route
from casting yard to the city
• It was imperative to design an interface that would not only transmit the huge
loads into the transporter correctly and safely but also had to ensure that
dynamic forces transmitted back into the beam were controlled and
considered by the beam designer.
 
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KEY SERVICE OFFERING
• Setting up casting yard for the monorail guide way beam production,
• Full guide way structures design, design and procurement .
• Provide Project Management for casting, E&M coordination, transport and installation of guide way beams,
crane, concreting pump, bar cutting and bending machine, stressing equipment, special trailer for transport and mobile crane for beam installation,
• Provide construction engineering for transport route survey including shop drawing and alignment data conversion,
• Provide all material for production of guide way beam , , , ,
erection and holding brackets, torsion bearing and all accessories and
 
 
 “ ”   directly and exclusively by the Company. Notwithstanding the same, the information, materials and contents provided by the Company in this presentation are provided on an "as is" basis and are of a general nature and shall be subject to the Shareholder’s obligation to take independent legal, financial or other advise as the Shareholder shall deem necessary. The data and analysis contained in this presentation may, however, be quoted with proper acknowledgement of the Company.
Copyright © 2008 by Worthy Builders Sdn Bhd. All rights reserved. No art of this resentation ma be re roduced stored in or introduced into a retrieval s stem or transmitted in an form or b an means  (electronic, mechanical, photocopying, recording or otherwise) without the prior written permission of the Company.”