COMPARATIVE STUDY ON THE SUPERSTRUCTURES OF EXISTING RAILWAYS IN THE PHILIPPINES – LRT LINE 1, LINE 2
AND LINE1 NORTH EXTENSION
RONALDO REAVELES ALVAREZ 2005-48284
SUBMITTED TO THE FACULTY OF THE
COLLEGE OF ENGINEERING AND AGRO-INDUSTRIAL TECHNOLOGY UNIVERSITY OF THE PHILIPPINES LOS BAÑOS
IN PARTIAL FULFILLMENT OF THE REQUIREMENTS FOR THE
DEGREE OF
BACHELOR OF SCIENCE IN CIVIL ENGINEERING
MARCH 2010
The report attached hereto entitled COMPARATIVE STUDY ON THE SUPERSTRUCTURES OF EXISTING RAILWAYS IN THE PHILIPPINES – LRT LINE 1, LINE 2 AND LINE 1 NORTH EXTENSION, prepared and submitted by Ronaldo R. Alvarez in partial fulfillment of the requirements for the degree of Bachelor of Science in Civil Engineering is hereby accepted.
_____________________ _________________________________
ENGR. JENNYL R. ESTIL ENGR. PAUL JOHN ROSS L. NARCISO Panel Member Panel Member
___________________ ____________________
Date Signed Date Signed
_______________________
PROF. MARLOE B. SUNDO Adviser
___________________
Date Signed
_______________________
PROF. MARLOE B. SUNDO Chairman, CE Department
___________________
Date Signed
__________________________
DR. ARSENIO N. RESURRECCION Dean
College of Engineering and Agro-Industrial Technology University of the Philippines Los Baños
___________________
Date Signed
vi TABLE OF CONTENTS
Title Page i
Acceptance Sheet ii
About the Author iii
Acknowledgment iv
Table of Contents vi
List of Tables ix
List of Figures x
1. INTRODUCTION
1.1. Background of the Study 1
1.2. Significance of the Study 2
1.3. Objectives of the Study 3
1.4. Scope and Limitation of the Study 4
1.5. Date and Place of the Study 4
2. REVIEW OF RELATED LITERATURE
2.1. Means and Evolution of Philippine Transportation 5
2.1.1. Light Rail Transit 6
2.2. Railway Construction 7
2.2.1. Elevated Railway 7
2.2.2. Tracks At-grade 8
2.2.3. Underground Railway 8
2.2.4. Bored Tunnels 9
2.3. Parts of an Elevated Viaduct 10
2.3.1. Substructure 10
2.3.2. Superstructure 11
2.4. Types of Railway Tracks 12
2.4.1. Ballasted Track 12
2.4.1.1. Materials for Ballast 13
2.4.2. Non-ballasted Track 13
2.4.2.1. Structural Principles of Non-ballasted Track 14 2.4.2.2. Non-ballasted Track Structural Types 15 2.5. Existing Railway Transit in the Philippines 15
2.5.1. Light Railway Transit Line 1 16
2.5.2. Light Railway Transit Line 2 17
2.5.3. Metro Rail Transit or Line 3 18
2.6 Comparative Construction Costs of the LRT Lines 18
3. STUDY METHODOLOGY 4. OBSERVATION
4.1. Construction of Pre-cast Girder 22
4.1.1. Preparatory Works 22
4.1.2. Lay-out 22
4.1.3. Rebar Assembly 23
4.1.4. Post-tension Ducts and Strands Installation 24
4.1.5. Formworks System 24
4.1.6. Formworks Assembly and Installation 25
vii
4.1.7. Pre-Pour Final Inspection 26
4.1.8. Concrete Placement 26
4.1.9. Curing and Stripping 27
4.1.10. Post tensioning and Grouting of Girders 28
4.1.11. Stressing and Grouting of Girders 28
4.1.12. Transfer and Stocking of Girders 30
4.1.13. Delivery of Girders 30
4.2. Girder Installation 31
4.2.1. Preparatory Works 31
4.2.2. Traffic Management 31
4.2.3. Survey Check 32
4.2.4. Girder Lifting and Positioning 32
4.2.5. Shear Keys Pouring 33
4.2.6. Diaphragm pouring 34
4.3. Construction of Deckslab 34
4.3.1. Preparatory Works 34
4.3.2. Lay-out 34
4.3.3. Reinforcement 34
4.3.4. Scaffolding 34
4.3.5. Formworks System 34
4.3.6. Pre-fabricated Formworks 35
4.3.7. Pre-fabricated Steel Support and Metal Deck Lifting 35 and Positioning
4.3.8. Screed Rails 36
4.3.9. Survey Check and Pre-Pour Final Inspection 36
4.3.10. Concrete Placement 36
4.3.11. Traffic Management 39
4.4. Stray Current Grid Installation 39
4.4.1. Connection Detail 40
4.4.2. Concreting 40
4.5. Construction of Trackworks 40
4.5.1. Survey 40
4.5.2. Transportation to Site 40
4.5.2.1. Material and Equipment 40
4.5.2.2. Twin-block Concrete Sleeper 40
4.5.2.3. Sleeper Distribution 42
4.5.2.4. EB 50t Rails 42
4.5.3. Rail Distribution 42
4.5.4. Trackworks 43
4.5.4.1. Slab Track 43
4.5.4.2. Track Leveling and Alignment 43 4.5.4.3. Concrete Pouring on the Slab Track 44
4.5.5. Welding of Rails 45
4.5.5.1. Rail Preparation 45
4.5.5.2. Rail Alignment 45
4.5.5.3. Mould Preparation 46
4.5.5.4. Preheating 46
4.5.5.5. Thermic Reaction 46
4.5.5.6. Shearing of Welds 47
4.5.5.7. Rail Grinding 47
viii 5. DISCUSSION AND DISCUSSION
5.1. Types of Girder 48
5.1.1. Girder Design 48
5.1.2. Girder Fabrication 53
5.1.3. Girder Installation and Deckslab 54
5.2. Railings 55
5.3. Railway Track 56
5.4. Qualitative Comparison between Ballasted Track – Line 1 and the 60 Non-ballasted Track – Line 2 and North Extension
5.5. Construction Cost Comparison between Line 2 and 63 Line 1 North Extension
6. CONCLUSION
7. RECOMMENDATION REFERENCES
APPENDICES
Appendix A. Form Layout of AASHTO Girder Type V in the 74 Casting Yard
Appendix B. Cross section of the Installed Formwork of Girder 74 Appendix C. Transfer and Stocking of Precast Girders 75 Appendix D. Set up of Working Area for Girder Installation / 75
Initial Position of Crane
Appendix E. Repositioning of Crane Ready for Installing the Girder 76 Appendix F. Cable Sling Girder Used for Lifting the Girder 76
Appendix G. Detailed Slab Cross Section 77
Appendix H. Concrete Slab Plan 77
Appendix I. Positioning of Transit Mixers for Concrete Pouring of Slab / 78 The Working Area
Appendix J. Sequence of Concreting of Track after Wire Mesh was 78 Installed
Appendix K. Monthly CPI (Year 2004 and January 2010) 79
ix LIST OF TABLES
Table No. Title Page No.
Table 5-1 Location where each type of segmental girder was used 52 Table 5-2 Comparative summary of the physical features of the 59
superstructures of the LRT Line 1, Line 2, and Line 1 North Extension
Table 5-3 Comparative summary of the characteristics of Ballasted 63 Track – Line 1 and Non-ballasted Track – Line 2 and
North Extension
Table 5-4 Data for construction cost comparison of LRT Line 2 64 Table 5-5 Data for construction cost comparison of LRT Line 1 65
North Extension
x LIST OF FIGURES
Figure No. Title Page No.
Figure 1-1 Project location and existing operational railways 2 Figure 2-1 Different means of transportation in Metro Manila 6
(a to c – from past to present)
Figure 2-2 Elevated railways 7
Figure 2-3 At-grade railways 8
Figure 2-4 Underground railways 9
Figure 2-5 (a) Bored tunneling and (b) Tunnel railways 10 Figure 2-6 Common design and components of a ballasted track 12
railway
Figure 2-7 Non-ballasted track construction layer 14
Figure 2-8 Several types of non-ballasted track depending on the 15 construction method
Figure 2-9 Routes of the three railway tracks and their stations 16 Figure 2-10 Rail track and light rail vehicle in Line 1 17 Figure 2-11 Line 2 rail track features in the station 17 Figure 2-12 Rail track in MRT Line 3 and Metrostar train’s operation 18
Figure 3-1 Flowchart of the study 21
Figure 4-1a Alignment and leveling of casting beds 23
Figure 4-1b Casting bed ready for rebar assembly to be carried 23 Figure 4-2 Assembly of reinforcement bars after being lifted in the 24
casting beds
Figure 4-3 Ducts installation for the pre-stressing strands of girder 24 Figure 4-4a Formwork ready to be lifted and fixed to the rebar assembly 25 Figure 4-4b Formwork already aligned and installed in the rebar assembly 26 Figure 4-5 Pouring of concrete mix to the installed formwork 27 Figure 4-6 Stripping of formworks at the casting yard 27 Figure 4-7 (a) Initial pre-stressing of the lower hole (b) Final stressing 29
of upper hole
Figure 4-8 Girders after final stressing, ready for grouting 29
Figure 4-9 Grouting of the holes of girder 30
Figure 4-10 Two 60-tonner crane loading the girder to the trailer and 30
xi dolly truck ready for delivery
Figure 4-11 Arrival of girders at the site at exactly 10 PM 32 Figure 4-12 Surveyor checking the alignment and elevation of the 32
bridge seat
Figure 4-13 Lifting and positioning of four girders between piers (a to d) 33 Figure 4-14 (a) Workers fixing the side formworks (phenolic plywood) 35
(b) Metal deck formwork already installed
Figure 4-15 Slab rebars and formworks in place ready for concrete 36 pouring
Figure 4-16 Concrete placement using pumpcrete 37
Figure 4-17 Workers making sure that the concrete mix was consolidated 38 well through vibrators
Figure 4-18 Leveling of concrete to the design thickness 38 Figure 4-19 Welded wire mesh already installed underneath the sleeper 39 Figure 4-20 (a) Formworks/mould of sleeper (b) Finished concrete twin- 41
block sleeper
Figure 4-21 Microcellular pads and rubber boots pre-installed on the 41 sleeper
Figure 4-22 Rails from Belgium already lifted in the viaduct ready 42 for installation
Figure 4-23 (a) Rail pad placed at the concrete sleeper (b) Elastic clip 43 e-1809
Figure 4-24 Aligning and leveling of tracks using the positioning 44 equipment (a, b, c)
Figure 4-25 Already poured slab track 44
Figure 4-26 Rail ends already cleaned ready for Thermit welding 45 Figure 4-27 Laborers preaheating the welded cavity inside the mould 46 Figure 4-28 Rail already welded and allowed to cool before rail grinding 47
Figure 4-29 Finished welded rail ready for service 47
Figure 5-1 (a) Typical end section and (b) Longitudinal section of 49 AASHTO Girder Type V used in Line 1
Figure 5-2 (a) Narrow roads and establishments along LRT Line 2 50 (b) Wider roads along LRT Line1 North Extension
Figure 5-3 Cross sections of the four segments of girder of Line 2: 51
xii (a) Type I Girder (b) Type II Girder (c) Type III Girder
(d) Type IV Girder
Figure 5-4 Distribution of four different types of segmental girder 52 on Line 2
Figure 5-5 Segmental girders of Line 2 ready for delivery 54 Figure 5-6 (a) Concrete parapet wall as railings of Line 1 (b) Cast Iron 55
as railings of Line 2 (b) Galvanized iron pipe serves as railings of Line 1 North Extension
Figure 5-7 Crushed stones as ballast of the existing Line 1 56 Figure 5-8 Railway assembly of Line 2 (Direct Fixation Track) including 57
the concrete plinth, rail, and rail fastenings
Figure 5-9 LRT Line 1 North Extension as new railway design in 58 the Philippines (Slabtrack)
