1. Application range of HZP1600 segment assembled bridge girder launcher

HZP1600 segment assembled bridge girder launcher is used to erect the prestressed concrete girder with span 50m and 51m. The assembly of girder adopts stub matching precast which assembled on site, the girder is put on the piers simply and then combined span by span firmly. The maximum weight of prestressed segment shouldn’t exceed 130/140t. The construction method of HZP1600 segment assembled bridge girder launcher is the segmental hanging and then construction tensioning after the steel strands are threaded.

2. Main features and advantages of HZP1600 segment assembled bridge girder launcher

● It adopts two-span type；the bearing part of main frame uses box girder structure with good twist resistance; the front and rear guiding girder adopt truss girder structure with light weight.
● it is equipped with 10t crane which lift some small parts on the bridge in order to construction conveniently.
● The layout of whole machine is parallel, so it can travel reversely. The front and rear legs adopt the same structure which can make the leaping backward come true, in order to improve the efficiency.

3. Main technical parameters of HZP1600 segment assembled bridge girder launcher

Product Model	HZP1600
Max. hanging weight(t)	1600
span(m)	50、51
Lifting height of trolley(m)	56
Rated lifting capacity(t)	140
Max. working slope	2％
Max. working transverse slope	2％
Min. curved radius(m)	5500
Traveling speed(m/min)	1
Speed of erection of girder(day/span)	10
The whole machine power(kw)	180
The total weight(k)	750

4. The design basis of HZP1600 segment assembled bridge girder launcher

The bridge girder launcher is designed according to the newest standards and rules in China which are following:
● 《Crane Design Standard》（GB/T 3811）
● 《The technical condition for Beijing-Shanghai passenger dedicated line 》
● 《General Gantry Crane》(GB/T14406)
● 《Code for Design of Steel Structures》（GB 50017）
● 《Code for Construction and Acceptance of Steel Structure》（GB 50205）
● 《The key Purpose of Steel Wire Rope》(GB 8918)
● 《The code of construction and acceptance for Electric equipment installation engineering》( GB50256)
● 《General Technical Conditions of Hydraulic System》 (GB 3766)
● 《Safety technical specification for construction of Railway Engineering(Volume one) 》（TB10401.1）
● 《Mechanical Properties of Fasteners Bolts, Screws and Studs》（GB 3098.1）

5. Main design requirements of HZP1600 segment assembled bridge girder launcher

● Lifting height: 56m
● the lifting tools of trolley: 360°
● Adaptive longitudinal slope: 2%, transverse slope: 2%
● adaptive curve radius R≥5500m；
● The max. hanging weight 1554t(13 segments)，1553t（14 segments）；
● The safety factor of lifting wire rope: n≥6
● The elevating stress safety factor of suspender: n≥6
● Calculation of structural strength safety factor: n≥1.5
● Transmission parts safety factor: n≥1.5
● Resistance overturning safety factor: n≥1.5
● Electrical apparatus and circuitry insulated grade are carried out according to the standards of Ministry of Construction and electrical apparatus insulated grade. Defense grade: electric machine filed IP54, other electrical apparatus ≥IP65.
● Crane using grade: U0
● Crane using state ：Q3
● Crane working grade：A3
● Mechanism working grade of crane：M4
● Low deflection of main girder： S/750；the deflection of cantilever girder： L/400

6. Main mechanical manufacturing technology of HZP1600 segment assembled bridge girder launcher

● It mainly use Q235B steels: the butt welds of cover board and web board, the outer lead weld of cover board and web board adopts Lincoln weld, other welds use CO2 gas shielded welding; welding material: welding rod of Lincoln weld H08A, and HJ431; welding rod of CO2 gas shielded welding: ER50-6; the electrode of tack welding uses J422 when the machine is assembled. The 100% ultrasonic inspection should be done for butt welding, the acceptance standard is GB11345-89, and the grade of welding quality is I grade; the welds between cover board and web board adopt melt thru weld, the 100% ultrasonic inspection is done after welded, and I grade is qualified. All of T joints do X-ray detection, the acceptance standard is GB3323-87, and the grade of welding quality is II grade.
● sand-blasting should be done after the welding is finished, and the derusting grade is Sa2.5; the casting wheel need to do annealing treatment; the NC cutting machine is demanded to cut the steel plate which thickness exceeds 10mm; CNC boring machine is used to process the wheel holes of traveling wheels; the press is used to install the bearing.
● The paint should be the special paint for engineering machinery, the first layer of outer surface is epoxy zinc-rich primer, the middle layer is epoxy cloud iron paint, and the last two layers is polyurethane paint. The total thickness of paint shouldn’t less than 125μm, and the deviation of right and left is 5μm.

7. The quality control in HZP1600 segment assembled bridge girder launcher manufacturing process

● Quality control is executed by ZZHZ QC Department and local Quality Inspection Bureau.

8. Tracing data and leaving factory data of HZP1600 segment assembled bridge girder launcher

● The tracing data of product is made up of contract, review file, drawing , calculation book of design, specification, installation project, raw material quality certificate, product quality inspection record, welding inspection report and purchased certificate.
● leaving factory data is made up specification, installation project, certificate and receiving report etc.

9. The installation method and steps of HZP1600 segment assembled bridge girder launcher

According to the weight of parts, choosing the lifting machine, and installing steps are following:
● the frame of legs are assembled on the ground.
● double main girders are assembled on the ground.
● the legs are lifted and installed.
● the first layer of main girder is lifted and installed.
● the second layer of main girder is lifted and installed.
● lifting trolley and frame are lifted and installed.
● pulley of trolley, winch and lifting tools are lifted and installed.
● front and rear guiding girder , front and rear auxiliary legs are lifted and installed.
● electrical system and hydraulic system are lifted and installed etc.
● other parts are installed.

10. Checking methods after installation of HZP1600 segment assembled bridge girder launcher

After the assembly of components of bridge girder launcher is finished, the workers should do the following tests acceding to geometry size、verticality、horizontality and deflection etc.
● the span deviation of wheel : L＜5mm
● the camber of main girder: AF=（0.9/1000～1.4/1000）S
● diagonal deviation of main girder （D1-D2）≤5mm
● side curvature of main girder: AFP≤S/2000
● gauge deviation of trolley: end of span±2mm, middle of span K≤7mm;the deviation of rail joints of trolley shouldn’t exceed 1mm; the lateral dislocation shouldn’t exceed 1mm.
● the connection of high-strength bolt should base on the standards JGJ82-91---《The design and acceptance specification of high strength bolt connection of steel structures》

11. Operating requirements and attention of HZP1600 segment assembled bridge girder launcher

● It is forbidden to use the equipment in bad weather such as heavy wind, rain and fog, snow and other conditions;
● The equipment is not allowed to work as the wind force is over 7 grade, if the wind force is over 11 grade, take measures to ensure the stability of the equipment;
● Construction in night should be in accordance with safety regulation, provide adequate lighting in work area and passageway to improve visibility and ensure construction safety;
● Keep equipment moving channel smooth, straight and no obstacle;
● Operators must receive professional training and possess equipment operation license.  

12. The maintenance time and item of HZP1600 segment assembled bridge girder launcher

Before using the transporter, be sure to check the vehicle as following guides:
● Make a visual inspection on the vehicle overall appearance, check whether there is external damage and leakage;
● Check oil level of diesel motor;
● When the platform is completely landing, check hydraulic oil level in hydraulic oil tank;
● Check oil level shown on the fuel display table;
● Confirm whether it needs maintenance according to the numerical value on the service hours counter;
● Tighten and seal all pipelines and hoses joints at fixed period in one operation cycle. Operate the hydraulic equipment at least one time every month, operate all pumps;
● Check whether all welding joints have fatigue condition, crack, corrosion and so on. Check whether the paint covers fatigue crack. If the problem is found, be sure to take effective measures immediately. If the paint is destroyed by the rust, clean the rust with brush and re-paint it.

13. The disassembly and site-transferring steps of HZP1600 segment assembled bridge girder launcher

As the transporter is transferred to another site, it usually carry the bridge girder launcher to another site or pass tunnels, transferring sites steps is similar with that of the bridge girder launcher. Disassembling steps are converse to assembly steps:
● Lift suspension oil cylinder, put buttress under the main girder, take bake the cylinder, ensure the tire won’t bear force
● Empty the hydraulic oil in hydraulic oil tank (oil level should be under oil outlet)
● Empty hydraulic oil in hydraulic pipeline
● Close all hydraulic valves
● Dismantle wheels sets one by one
● Begin to remove main girder bolts and connection plates section by section;
● Remove hydraulic pipeline flanges at main girder connection parts section by section
● Dismantle front support leg, rear support leg, engine room and driver’s room;
● Remove girder trailer
● Dismantle the main girder one by one
● Prepare to deliver the goods

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