CHAPTER 16 - GANTRIES

DS Temple

16.1 SCOPE

This section covers the inspection of Sign Gantries as specified in the applicable chapter of the
Specifications. It also covers the special attention which must be given by the engineers monitoring
staff to the specific requirements of setting out, excavations foundations, backfill and, manufacture
and erection of the structural steel gantries.

16.2 FOUNDATIONS

16.2.1 Setting Out (Refer to Chapter 4)

The setting out of the gantries should be carried out in accordance with Chapter 3 of this document.
However the following points should be noted.

16.2.1.1 Location

The gantry location (e.g. km distance) on the structural drawings must tie in with the location given
on the road works drawings.

16.2.1.2 Horizontal Clearances

Horizontal clearances must be checked prior to the casting of the gantry foundation plinths.

16.2.1.3 Vertical Clearances

The vertical clearances as specified on the design drawings should be checked by the Monitoring Staff
on site.

Photo 16.1: Gantry foundation

16.2.2 Excavations (Refer to Chapter 4)

Note that it is preferred that the foundation concrete is cast directly against the sides of the excavation.

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16.2.3 Formwork & Falsework (Refer to Chapter 6)

16.2.4 Steel Reinforcement (Refer to Chapter 7)

16.2.5 Concrete (Refer to Chapter 8).

Note that durability concrete should be used only in extreme situations.

16.2.6 Built-in Items

The Monitoring Staff should confirm the orientation of the Holding Down Bolt Groups.
Confirm the position of ducts, gantry number and any other built-in items indicated on the
drawings.

Photo 16.2: Completed gantry foundation

16.3 STRUCTURAL STEEL GANTRIES

16.3.1 Materials

The Engineers Monitoring Staff should ensure that the contractor submits a certificate of compliance
for:

Structural steel for manufacture of gantry

Holding down bolts

16.3.2 Corrosion Protection

The corrosion system as specified on the drawings must be confirmed with the Contractor. The
Monitoring Staff should ensure that the manufacturers Quality Assurance records are made available
with the delivery of the gantries. Hot dip galvanizing could be specified as a corrosion protection
measure but should be used with caution as this process is still in the experimental stages. Buckling
of thin plates occurs during the dipping process due to stress relief in the plates and therefore extreme
care should be taken before using this method of corrosion protection.

Gantries 16-2
16.3.3 Shop Drawings

The Monitoring Staff should ensure that shop drawings of the gantry and holding down bolts are
submitted for review timeously.

16.3.4 Factory Inspection

It is a requirement that monitoring staff inspect the structural steel during the manufacturing process.
The following important aspects should be checked and verified against the design drawings:

Dimensions and thicknesses of the steel plates.

Number and spacing of the beam and column stiffener plates.
Type, size and quality of all the welds as specified on the drawings.
Diameter and length of anchor bolts, as well as the dimensions of the anchor bolt cage.

The Monitoring Staff should ensure that the correct grade steel for the anchor bolts and structural steel
gantry structure is used. All certificates pertaining to the grade and quality of the steel should be
obtained from the manufacturer for construction record purposes.

Photo 16.3: Gantry manufacturing

16.3.5 Erection

The Monitoring Staff should ensure that the Contractor submits for review a complete method
statement for the erection of the gantries.
Accommodation of traffic measures should be submitted in accordance with Road Traffic Signs
Manual, Chapter 13.
Monitoring Staff should ensure that the gantry is erected within the specified tolerances.

16.4 CHECKING AND TESTING

The Monitoring Staff should visit the manufacturing facility during manufacture to ensure that the
gantries are being manufactured according to the Manufacturers Quality Plan.

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16.4.1 Corrosion Protection

Reference should be made to the notes on the Detailed Design drawings for the corrosion
system to be used.
Surface preparation to SA 2.5 should be checked prior to the application of any corrosion
protection.
Ensure that the contractors proposed system for the painted, galvanized or sprayed metal
coating conforms to specified requirements.
Random testing of the thickness of the various coats of the corrosion protection system should
be carried out in the paintshop as well as on the delivered elements and especially on the site
painted areas (welded site connections on gantry beams).
Records of the tests carried out on the dry film thicknesses (DFT) should be kept.

16.4.2 Welding

The Monitoring Staff should ensure that the process control adopted by the manufacturer complies
with the Project Specification. This can be achieved by including notes on the shop drawings for
welding procedures. All QA records of process control of the welds should be provided to the
Engineer.

Proof of the welders qualifications should be provided.

Ultrasonic testing should be carried out on the following welded connections:

Column & base plate connection

Column & beam haunch connection
At least 10% of the seam welds in the columns*
At least 10% of the seam welds in the beams*
Gusset plate connections*
Site welds**

*Where ultrasonic testing is not possible magnetic particle testing should be carried out on at least
50% of the seam welds.

**At the very least site welds should be inspected and approved by an independent qualified person.
Where possible ultrasonic testing (preferable) or magnetic particle testing should be carried out. It
should be noted that these must be done before painting and after the steel has cooled.

Gantries 16-4
 Photo 16.4: Gantry erection

16.5 GANTRY STRUCTURES - CONSTRUCTION MONITORING CHECK LIST

The Monitoring Staff should use the Gantry Structures - Construction Monitoring Check List as far
as possible to ensure the quality of the gantry structures.

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 INDEX TO APPENDICES

16A - GANTRY STRUCTURES

Gantries 16-6
 APPENDIX 16A
GANTRY STRUCTURES
CHECK LIST(1/4)
CONSTRUCTION MONITORING CHECKLIST
PROJECT NO. / NAME: .......................................................................................................................................
INSPECTORS NAME(S): ....................................................................................................................................
STRUCTURE: ........................................................... ELEMENT: ..............................................................
APPROVAL
ACTIVITY AND DETAILS SIGNED DATE
Y/N N/A Comment
1. EARTHWORKS
1.1 Setting out
Km distance
Depth of excavation relative to edge of
road
Distance from edge of road to
foundation centre
Can foundation be cast directly against
side of excavation as is preferred
If not has work space been agreed
with Engineer
1.2 Bearing pressure
DCP Tests done
Is soil improvement required
If so describe
Soil improvements tested
Provide estimated foundation bearing
capacity in kPa
1.3 Blinding layer
Depth to blinding layer relative to
edge of road
Plan area of blinding layer
2. REINFORCEMENT
2.1 Footing Bars parallel to road
Are they Top 1 and Bottom 1
Bar spacings - 125mm
Bar type bottom
Bar type top
Alternative bar reversed (top bars)
2.2 Footing Bars perpendicular to road
Bar spacings - 250mm
Bar type bottom
Bar type top
Alternative bar reversed (top bars)
2.3 Plinth
Are there the correct number of "U"
bars
Orientation
Location
Bar projection height
Secondary bars, i.e. clips & stirrups
Checklist continues on next page

Gantries 16-7
 APPENDIX 16A
GANTRY STRUCTURES
CHECK LIST(2/4)

APPROVAL
ACTIVITY AND DETAILS SIGNED DATE
Y/N N/A Comment
3. ANCHOR BOLTS
3.1 In workshop
Diameter
Steel Grade of bolt
Bolt cage dimensions
3.2 On Site
On site orientation
Location within plinth
Projection of bolts
Top portion of bolt corrosion
protected
4. FORMWORK
4.1 Footing plan dimensions
4.2 Is footing formwork required and
approved
4.3 Footing thickness
4.4 Plinth plan dimensions (parallel and
perpendicular to road)
4.5 Height of plinth
4.6 Level difference between top of
plinth & road edge
4.7 Cover to rebar - footing 50mm
bottom, 75mm sides
4.8 Cover to rebar - plinth 50mm sides
and top
4.9 Plinth shutter - adequately propped
4.10 Plinth off shutter surface finish OK
5. SPECIAL CAST IN ITEMS
5.1 PVC ducts provided if detailed on
the drawings
5.2 Location in plinth (plan)
5.3 Projection above plinth concrete
Checklist continues on next page

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 APPENDIX 16A
GANTRY STRUCTURES
CHECK LIST(3/4)

APPROVAL
ACTIVITY AND DETAILS SIGNED DATE
Y/N N/A Comment
6. CONCRETE
6.1 Pre concrete inspections
Concrete as per specification & mix
design (obtain copy of delivery note)
Concrete Class W30MPa
Plinth concrete: 50mm < slump <
70mm
Proposed curing method
Proposed curing period
6.2 Post concrete inspections
Cracks
Spalling
Honeycomb
Shutter kick
Repair method
7. STRUCTURAL STEEL
7.1 Prior to dispatch to site
Steel grade certificate and markings
Column height plust the beam section
Beam length (less the beam section
attached to column/s)
Column cross section dimensions
Beam cross section dimensions
Plate thicknesses columns
Plate thicknesses beams
Special attachment size & plates
Stiffener plates, thickness, spacing,
fitment
Welds visually acceptable and
according to drawing
Chamfering and preparation for
welding
Holes setting out
Ultrasonic testing of welds - certified
7.2 On site
Method of erection approved
Traffic accommodation approved
Site welding method approved
Site welding quality approved
Anchor bolt tightening torque (provide
Nm)
Grout under base plate - type approved
Grout under base plate - installed
correctly
Checklist continues on next page

Gantries 16-9
 APPENDIX 16A
GANTRY STRUCTURES
CHECK LIST(4/4)

APPROVAL
ACTIVITY AND DETAILS SIGNED DATE
Y/N N/A Comment
8. CORROSION PROTECTION
Inland or coastal specification
Paint specification approved
8.1 Prior to dispatch to site
Abrasive blast cleaning
Primer - paint type and DFT certified
Approval of application of second coat
prior to dispatch
8.2 On site
Patch repairs- paint type and DFT
certified (NB repairs at site welds)
Second coat - paint type and DFT
certified
Final coat - paint type and DFT
certified
Final coat colour
Anchor bolts corrosion protected
9. AS-BUILT DATA
Name and address of Main Contractor
Name and address of Steelwork
Fabricator
Name and address of Painting
Contractor
Paint system used
Foundation material and safe bearing
capacity
Date of steel structure erection
Least favourable results of test certificates:
9.1 Structural steel
Steel grades
Ultimate tensile strength (MPa)
Yield strength (MPa)
Elongation at fracture (%)
9.2 Anchor bolts
Steel grades
Ultimate tensile strength (MPa)
Yield strength (MPa)
Elongation at fracture (%)
9.3 Data included an As-built
drawings

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