RGBS / ABDC

Document review

Ref. letter number

Date

Name

Drawing number

Approval sheet number

Date

Checked
Approved

Status of approval
A
Approved
AN
Approved except Noted
RR
Returned for correction and Resubmission

The approval of the drawings will not exonerate the Contractor from any
responsibility in connection with the works

po:Koenig
2
1
Ind

2013-08-05
2013-05-25
Date

E. BLACHE
E. BLACHE
Prepared

N. KOENIG
JL. PEREZ
Checked

A. ROUSSIN
N. KOENIG
Reviewed

ISSUED FOR OBSERVATION

ISSUED FOR OBSERVATION
Amendments

OBS
OBS
Status

ARAB REPUBLIC OF EGYPT

Ministry of Water Resources and Irrigation
Reservoirs and Grand Barrages Sector (RGBS)
ASSIUT BARRAGE DEVELOPMENT CONSULTANTS (ABDC)

NEW ASSIUT BARRAGE AND HYDROPOWER PLANT

LOT 1 CIVIL WORKS

EGYPTIAN FRENCH NEW ASSIUT BARRAGE

JOINT VENTURE

CONCRETE WORKS
PREFABRICATION ANALYSIS
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EGYPTIAN FRENCH NEW ASSIUT BARRAGE JOINT VENTURE

EGYPTIAN FRENCH
NEW ASSIUT BARRAGE

TECHNICAL
DOCUMENTS
JOINT VENTURE
NUMBERING SYSTEM

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L1 1J JN OC 00 00 Q0 00 00 17 A2

Table of Index

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11

12

13

14

15

16

17

18

19

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List of Contents
1

Abbreviations ...................................................................................................................................................... 4

Reference documents ........................................................................................................................................ 4

Scope ................................................................................................................................................................... 5

Precast slabs ....................................................................................................................................................... 6

4.1

Precast slabs location ........................................................................................................................................ 6

4.2

Precast slabs characteristics ............................................................................................................................ 9

4.3

Installation programme request and fabrication assumptions ...................................................................... 9

4.4

fabrication storage............................................................................................................................................ 10

Technical galleries precast slabs.................................................................................................................... 11

5.1

Electrical galleries location.............................................................................................................................. 11

5.2

Electrical galleries characteristics .................................................................................................................. 12

5.3

Installation programme request and fabrication assumption ...................................................................... 12

5.4

Fabrication and storage ................................................................................................................................... 12

Technical gallery precast slab ......................................................................................................................... 13

6.1

Location ............................................................................................................................................................. 13

6.2

Characteristics .................................................................................................................................................. 13

6.3

Installation programme request and fabrication assumption ...................................................................... 13

6.4

Fabrication and storage ................................................................................................................................... 13

Precast channels .............................................................................................................................................. 14

7.1

Precast channels location................................................................................................................................ 14

7.2

Precast Channels Characteristics ................................................................................................................... 14

7.3

Installation programme request and fabrication assumptions .................................................................... 14

7.4

Fabrication and storage ................................................................................................................................... 15

Precast stairs .................................................................................................................................................... 16

8.1

Precast stairs location...................................................................................................................................... 16

8.2

Precast stairs characteristics .......................................................................................................................... 17

8.3

Installation programme request and fabrication assumption ...................................................................... 18

8.4

Fabrication and storage ................................................................................................................................... 18

Conclusion......................................................................................................................................................... 19

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1
NL
NL
NL
PH
PH
SW
SW

ABBREVIATIONS
DS
MP
US
EP
WP
EP
WP

Navigation Locks,
Navigation Locks,
Navigation Locks,
Powerhouse,
Powerhouse,
Sluiceway,
Sluiceway,

Downstream Head
Middle Part
Upstream Head
East pier
West pier
East pier
West pier

REFERENCE DOCUMENTS

General:

(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)

1JN C00 0002-1: Concrete Works, Concrete blocks database

1JN C00 0003-2: Formwork surfaces analysis
1JR C03 1101-4: Construction joints, Powerhouse piers, Plan views & sections
1JR C03 3001-1: Construction joints Powerhouse, central pier & units 1 to 4 Plan views & sections
1JR C04 1001-2: Construction joints, Sluiceway pier axis 16, Plan views & sections
1JR C04 3001-1: Construction joints, Sluiceway pier axis 1, Plan views & sections
1JR C05 1001-4: Construction joints, Navigation locks Downstream head, Plan views & sections
1JR C05 1002-4: Construction joints, Navigation locks Upstream head, Plan views & sections
1JR C05 2001-1: Construction joints, Navigation locks Middle part, Plan views & sections

Concrete works:
(10) 1JR C00 5002-1: Concrete works, precast slabs forming table
(11) 1JR C05 5003-2: Navigation Locks, precast fill-empty channels mould (standard)
(12) 1JR C05 9101-1: Navigation Locks, precast slabs, fill/empty gallery, layout and principles
(13) 1JR C05 9102-1: Navigation Locks, precast slabs, ballast room, layout and principles
(14) 1JR C05 9201-1: Navigation Locks, precast slabs, fill/empty gallery, schedule
Electrical galleries:
(15) 1JD K05 0109-C: Guide drawing, Navigation Locks, plan view level +54.00, from axis F to axis K
(16) 1JD K05 0110-C: Guide drawing, Navigation Locks, plan view level +54.00, from axis K to axis O
(17) 1JD K05 0111-C: Guide drawing, Navigation Locks, plan view level +54.00, from axis O to axis S
Precast stairs:

(18)
(19)
(20)
(21)
(22)
(23)
(24)
Planning:

(25)

1JD K03 0167-A: Preliminary guide drawing, Powerhouse, stair cases, axes 6-7A, 12-13A
1JD K03 0168-A: Preliminary guide drawing, Powerhouse, stair cases, axes 6-7R, 12-13R
1JD K03 0171-A: Preliminary guide drawing, Powerhouse, precast stairs, details
1JD K05 0170-B: Guide drawing, Navigation Locks, stair cases G17, G20
1JD K05 0171-B: Guide drawing, Navigation Locks, stair cases G18, G19
1JD K05 0172-B: Guide drawing, Navigation Locks, stair cases O17, O20
1JD K05 0173-B: Guide drawing, Navigation Locks, precast stairs, details
1JP J00 0003-A: Working programme, revision (A) dated on 15th July 2013

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SCOPE

This document describes the quantities of workshop prefabricated elements:

- Precast slab for:
o the fill/empty galleries (NL)
o the high rooms, mainly ballast rooms (NL and PH)
o the technical galleries (NL and PH)
- Precast channels (NL)
- Precast stairs (NL and PH)
- Public road bridge deck precast slab (not yet defined)
- Ibrahimia head regulator precast walls (not yet defined)
for following structures:
- Navigation locks (NL-DS / NL-MP / NL-US)
- Powerhouse: intermediate pier axis 7 (PH-WP) & intermediate pier axis 12 (PH-EP)
- Powerhouse: main structure (PH)
- Sluiceway: abutment pier axis 1 (SW-WP) & abutment pier axis 16 (SW-EP)
There are no workshop prefabricated elements in Sluiceway bays and standards piers.

This document doesnt describe in situ prefabrication which includes:

- Sluiceway gantry crane beams
- Sluiceway service gallery
- Public road bridge deck precast beams

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PRECAST SLABS

4.1 PRECAST SLABS LOCATION

Precast slabs for the fill/empty galleries (NL-DS):

Precast slabs for the fill/empty galleries (NL-MP):

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Precast slabs for the fill/empty galleries (NL-US):

Precast slabs for the rooms (NL-US):

Precast slabs for the rooms (NL-DS):

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Precast slabs for the rooms (PW):

Precast slabs for the rooms (PW-WP):

Precast slabs for the rooms (PW-EP):

Precast slabs for the rooms (SW-Pier axis 16):

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Precast slabs for the rooms (SW-Pier axis 1):

4.2 PRECAST SLABS CHARACTERISTICS

Precast slab thickness:

0.07m for the Navigation locks fill/empty galleries top slab

0.12m for the Navigation locks and Powerhouse ballast rooms top slab

Above element:

Wall (mainly gallery)

Slab (shoring height superior to 5m)

Distribution of precast slab quantities:

Workshop prefabrication elements
Th: 7cm

Precast slabs

Th: 12cm

Total

Navigation Locks
Upstream
Downstream
Middle part

552
533
1291

m
m
m

650
305
0

m
m
m

1202
838
1291

m
m
m

0
0

m
m

1854
305

m
m

1854
305

m
m

0
0
0

m
m
m

1967
0
5082

m
m
m

1967
0
7458

m
m
m

Powerhouse
Intermediate piers
Main structure

Sluiceway
Abutment pier axis
Standard piers and bays
Total

4.3 INSTALLATION PROGRAMME REQUEST AND FABRICATION ASSUMPTIONS

Installation programme request:
If first concrete structures start on the 21th August 2013 as per working programme, first installation of precast slabs
will be on the middle of December 2013.
Fabrication assumptions:
Equipment:

Equipment capacity:

3 prefabrication tables of 36m(4.90*7.40m) used currentlyfor about half of capacity

Slab area
Table area
Average ratio table/slab: ~ 0.6
325 m(table) / week

Production assumption:
Lifting assumption:
Installation assumption:

1 batch of precast elements / table / 18h (curing)

fcj 12 MPA minimum for the precast slab lifting
fcj 90% fc28 (~2 weeks between casting and installation in situ)

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Storage assumption:

4.4

Thickness

Dimension

7 cm
12 cm

35m
1.56m

Precast slabs
Storage
Precast slab
superposition
stored
7 elements
105 m
6 elements
54 m

Ratio
(m/m)
3
1.9

Storage area
35 m
28 m

FABRICATION STORAGE

8000

7000

Precast slabs quantities (m)

6000

5000

4000

Sluiceway
Powerhouse
Navigation locks

3000

2000

1000

Progress (in week)

Prefabrication rate:
Storage:
Storage period:
Needed storage area:

to minimise storage (
)
145 m/week from November 2013
30 m/week
from July 2014
2 months
6.5 months
800 m

from November 2013

from July 2014

up to July 2014
up to July 2015
up to July 2014
up to July 2015

If first concrete structures start on the 21th August 2013 as per working programme, prefabrication should start middle
of November 2013 and first installation of precast slabs will be on the middle of December 2013.

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TECHNICAL GALLERIES PRECAST SLABS

5.1 ELECTRICAL GALLERIES LOCATION

Two electrical galleries are present in Navigation locks.

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5.2 ELECTRICAL GALLERIES CHARACTERISTICS

Location:
Level:
Span:
Gallery length
Gallery height
Precast slab surface

G17-Q17
+ 53.45
1.35m
215m
1.90m
294m

Total precast slab surface:

539m

G20-Q20
+53.45
1.35m
17.55m (span: 0.50m) and 173m (span: 1.35m)
1.90m
245m

5.3 INSTALLATION PROGRAMME REQUEST AND FABRICATION ASSUMPTION

Installation programme request: at the end of NL concrete works: February 2015
Fabrication assumptions:
Equipment:

Equipment capacity:

same equipment as precast slabs

3 prefabrication tables of 36m(4.90*7.40m) used currentlyfor about half of capacity
Slab area
Table area
Average ratio table/slab: ~ 0.6
325 m(table) / week

Production assumption:
Lifting assumption:
Installation assumption:

1 batch of precast elements / table / 18h (curing)

fcj 12 MPA minimum for the precast slab lifting
fcj 90% fc28 (~ 2 weeks between casting and installation in situ)

Storage assumption:

Thickness

Dimension

7 cm
12 cm

35m
1.56m

Precast slabs
Storage
Precast slab
superposition
stored
7 elements
105 m
6 elements
54 m

Ratio
(m/m)
3
1.9

Storage area
35 m
28 m

5.4 FABRICATION AND STORAGE

Prefabrication rate:

145 m/ week

Storage:
Storage period:
Needed storage area:

6 weeks
200 m

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TECHNICAL GALLERY PRECAST SLAB

6.1 LOCATION
One technical gallery is present in Power House.

6.2 CHARACTERISTICS
Location:
Precast slab level:
Span:
Gallery length
Gallery height
Precast slab surface

C8-C9 and C10-C11

+ 27.30
1.40m
22.10m (C8-C9) and 21.2m (C10-C11)
1.10m
61m

6.3 INSTALLATION PROGRAMME REQUEST AND FABRICATION ASSUMPTION

Installation programme:
Equipment:

Equipment capacity:

at the beginning of PH concrete works: August 2014

same equipment as precast slabs
3 prefabrication tables of 36m(4.90*7.40m) used currentlyfor about half of capacity
Slab area
Table area
Average ratio table/slab: ~ 0.6
325 m(table) / week

Production assumption:
Lifting assumption:
Installation assumption:

1 batch of precast elements / table / 18h (curing)

fcj 12 MPA minimum for the precast slab lifting
fcj 90% fc28 (~ 2 weeks between casting and installation in situ)

Storage assumption:

6.4 FABRICATION

Thickness

Dimension

7 cm
12 cm

35m
1.56m

Precast slabs
Storage
Precast slab
superposition
stored
7 elements
105 m
6 elements
54 m

Ratio
(m/m)
3
1.9

Storage area
35 m
28 m

AND

STORAGE

Prefabrication rate:
Storage:
Storage period:
Needed storage area:

145 m/ week
2 weeks
25 m

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PRECAST CHANNELS

7.1 PRECAST CHANNELS LOCATION

The precast channels are located in Navigation locks Middle part.

7.2 PRECAST CHANNELS CHARACTERISTICS

Quantity of elements:

96 elements with:
80 elements done with standard mould (
)
16 elements done with mould and extension (

7.3 INSTALLATION PROGRAMME REQUEST AND FABRICATION ASSUMPTIONS

Installation programme request:
Starting of Middle Part casting:
Installation period:
Installation period assumption:

23th October 2013

March / September 2014 (6 months)
Installation of pier axis 20
Installation of pier axis 18-19
Installation of pier axis 17

24 units
48 units
24 units

Beginning of March
Beginning of May
Middle of July

Fabrication assumptions:
Equipment:
Production assumption:
Lifting assumption:
Installation assumption:

1 mould & extensions set

1 precast channel / 18h (curing)
fcj 12 MPA minimum for the precast slab lifting
fcj 90% fc28 (~ 2 weeks between casting and installation in situ)

Storage assumption:

3 elements stored on 3*3m area

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7.4 FABRICATION AND STORAGE

Channels installation
100

90

80

Channel quantities (unit)

70

60

50

40

30

20

10

0
Oct-13

Nov-13

Jan-14

Mar-14

Apr-14

Jun-14

Jul-14

Sep-14

Nov-14

Programme of installation

Prefabrication:
Prefabrication rate:
Prefabrication period:
Starting of prefabrication:

Storage:
Maximum storage period:
Maximum precast channels stored:
Needed storage area:

3 channels / week
32 weeks ~ 7months
Mid of November
45 elements have to be produce before the beginning of period installation
(14 weeks before)
6 months
45 elements
200 m

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PRECAST STAIRS

8.1 PRECAST STAIRS LOCATION

Precast stairs (NL-DS, axis O17/O20):

Precast stairs (NL-DS, axis G17/G18/G19/G20):

Precast stairs (PH-EP, axis 12-13R):

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Precast stairs (PH-EP, axis 12-13A):

Precast stairs (PH-WP, axis 6-7R):

Precast stairs (PH-WP, axis 6-7A):

8.2 PRECAST STAIRS CHARACTERISTICS

Quantities:

34 units with:
o 16 units in Navigation Locks
Precast stair type PCS 9:
Precast stair type PCS 10:
Precast stair type PCS 10A:
Precast stair type PCS 11:
Precast stair type PCS 11A:
o 18 units in Power house
First flight of stairs:
Precast stair type PCS 7:
Precast stair type PCS 7A:
Precast stair type PCS 8:
Precast stair type PCS 10:
Precast stair type PCS 12:

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8.3 INSTALLATION PROGRAMME REQUEST AND FABRICATION ASSUMPTION

Installation programme request:
NL precast stairs:
October 2013 to March 2014
PW precast stairs:
November 2013 to December 2015
Fabrication assumptions:
Equipment:

1 mould & extensions set

Production assumption:
Lifting assumption:
Installation assumption:

1 precast channel / 18h (curing)

fcj 12 MPA minimum for the precast slab lifting
fcj 90% fc28 (~ 2 weeks between casting and installation in situ)

Storage assumption:

3 elements stored on 3*3m area

8.4 FABRICATION AND STORAGE

Fabrication:
Prefabrication rate:
Prefabrication period:

1 precast stairs a week

34 weeks ~ 7.5 months

Storage:
Maximum storage period:
15 months
Maximum precast stairs stored: 16 units
Needed storage area:
150 m

Precast stairs installation

40

35

Precast stairs (unit)

30

25

20

15

10

Programme of installation

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CONCLUSION
2013

Prefabrication programme
Precast slabs
Prefabrication
Storage
Installation in situ
Electrical galleries (NL)
Prefabrication
Storage
Installation in situ
Technical gallery (PW)
Prefabrication
Storage
Installation in situ
Channels
Prefabrication
Storage
Installation in situ
Precast stairs
Prefabrication
Storage
Installation in situ

10

11

2014
12

145 & 30 m/week

() peak : 800m
continuous

2015
8

10

11

12

10

11

12

3 channels/week
() peak : 100m
discontinuous

Recommendations:
- Storage area peak:
- To be considered:

1000m (January to April 2014)

Mould fabrication
Precast slabs design (done by JV)
Precast stairs design (done by designer)
Concrete formula ad hoc which authorizes 12 MPA for the
precast lifting

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PREFABRICATION ANALYSIS

145 m/week
() peak : 100m
continuous

CONCRETE WORKS

145 m/week
() peak : 100m
continuous

3 stairs/week
() peak : 150m
discontinuous

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