METHODS OF BRIDGE

CONSTRUCTION
METHODS OF BRIDGE CONSTRUCTION:
Before a bridge can be built an appropriate method of construction must be
chosen. The decision is made by the design team. The principle factors
considered by the design team when chosing a suitable method of
construction are given below:

1. The scale of the bridge

2. The obstacles to be crossed
3. The regularity of the span lengths
4. The horizontal and vertical profiles of the bridge decks
5. The nature of the soil strata
6. The local weather
7. The local cost of materials
8. The local labour market
9. The accessibility of the site
10. The time allowed for construction.
Following are the methods of bridge construction:

1. Cast-in-situ Method of Bridge Construction

2. Balanced Cantilever Method Of Bridge Construction
3. Precast Method of Bridge Construction
4. Span by Span Casting method of Bridge Construction
5. Incremental Launching Method of Bridge Construction
6. Cable Stayed Method of Bridge Construction
7. Arch Method for Bridge Construction
Cast-in-situ Method of Bridge Construction:
Cast-in-situ method of construction of bridges is a flexible method in which the
demands of more unusual geometrical shapes can be easily coped with. This
method is commonly used for short span bridges for the cost effective
construction of solid, voided or ribbed reinforced concrete slab bridges. Each
bridge type is build by designing the decks to allow each span to be cast in
one continuous pour. Construction is simplicitic in form consisting of a
birdcage scaffold with plywood formwork.

Where cast-in-situ construction is used for longer span bridges, the falsework
system required becomes more sophisticated. Semi or fully mechanical
falsework will require a specialized contractor. Semi-mechanical falsework will
generally consists of steel beams or trusses which are then spanned between
temporary towers. Fully mechanical falsework system is where a self
launching gantry with steel lined shutters is used.

The type of false work system used will also have a bearing on the rate of
span construction. For semi mechanical system each span will take between
2 to 6 weeks to construct. While for fully mechanical systems a span may be
placed within 1 to 2 weeks.

Balanced Cantilever method of Bridge Construction: Balanced cantilever

method of bridge construction is chosen where a bridge has few spans which
range from 50 to 250m. Construction begins at each bridge pier. Special
formwork is positioned and cast-in-situ pier segment is begun. The complete
pier segment is then used as an erection platform and launching base for all
subsequent travelling formwork and concrete segment construction. Cast-in-
situ segments range between 3mm to 5m in length with formwork moving in
tandem with each segment. Segment construction is continued until a joining
midpoint is reached where a balanced pair is closed.

Stability of the end cantilever is maintained by using temporary pier supports

as the end span is begun. The length of the end spans is equal to between
0.55 and 0.65 times the length of the typical span in the bridge.
Although this is a flexible method with its repetitive construction cycle
improving efficiency it is still relatively slow. This restriction was improved in
1962 with the introduction of precast segments.

Precast Method of Bridge Construction:

(i) Precast Beams:
Precast beam decks are generally used for short span bridges ranging
between 5m to 50m – these may be railway or motorway bridges. Standard
inverted tee beams or M-beams are chosen and positioned by crane.

Where precast beams are considered for a motorway bridge construction, the
bridge cross-section for a typical carriageway will generally consist of four
beams. Erection time of such bridge should have a rate of construction of four
beams per day. A cast-in-situ slab top deck is normally used with an expected
rate of construction of one span a week.

(ii) Precast Decks: Precast deck construction is often used for the
construction of long viaducts. It is a time saving method which is beneficial for
long bridges where construction time for the final completion stage is tight.
A long viaduct can have a complete precast deck speedily placed with this
method. The decks are positioned using either a large crane or purpose made
gantry. A rate of construction of two spans per day is considered normal
where a gantry system is in use, if this pace is maintained a one kilometer
deck can be placed in three weeks.

However, if this method of construction is chosen it is imperative that the

engineer has clearly organized the deck construction schedule. The speed of
this method depends on the timely delivery of prefabricated decks, the
engineer and deck contractor must set out a rate of construction which allows
the supplier to produce a sufficient decks to time while the deck contractor
must be ready to place and store decks on receipt of delivery.

(iii) Precast segmental decks:

Precast segmental deck construction is used for long bridges where the deck
depth is difficult for cast in situ construction. Box girder deck segments are
generally used where the segment can be 2m or less deep, between 2.5m
and 4m long carrying a deck upto 15m wide are generally used.
Where in-situ post-tensioning is favoured the segments can be prestressed
either internally or externally. Internal tendons must be protected from
moisture attack.

The repetitive nature of this method allows for a variety of modern placement
techniques to be used, though balanced or free cantilever about a pier is a
preferred choice. With this method a crane or self launching gantry system
can place upto six segments per day.

The rate of construction for internally prestressed segments is considered to

be a span per week. If externally prestressed tendons are used it should be
feasible to complete three spans per week.

Span by Span Casting method of Bridge Construction:

Span by span is a relatively new construction technique historically associated
with cantilever construction but the advancement in external prestressing has
enabled its own potential use to grow. Today it is considered to be the most
economic and rapid method of construction available for long bridges and
viaducts with individual spans upto 60m.

Decks are begun at one abutment and constructed continuously by placing

segments to the other end of the bridge. Segments can be positioned by
either a temporary staying mast system through more commonly using an
assembly truss.

Before segments are placed the truss with sliding pads is braced over two
piers. Depending on the bridge location the segments are then transported by
lorry or barge to the span under construction. Each segment is then placed on
the sliding pads and slid into its position. Once all segments are in position the
pier segment is then placed.

The final stage is then begun by running longitudinal prestressing tendons

through segments ducts and prestressing entire span. Deck joints are then
cast and closed and ducts grouted. When the span is complete the assembly
truss is lowered and moved to the next span where construction cycle begins
until the bridge is complete.
Incremental Launching Method of Bridge Construction:

For bridge decks greater than 250m in length, the method of incremental
launching can be considered. With this method of construction the bridge deck
is built in sections by pushing the structure outwards from an abutments
towards the pier. It is most suited to the rapid construction of bridges with a
constant radius of curvature such as constant depth of box girder segments.

The construction sequence begins behind one abutment where a highly

mechanized prefabrication deck mould is set up removing the need for
temporary supports with this method. A rigid framework is then attached
enabling the production of cast-in-situ segments. In-situ deck segments range
in length from 5m to 30m. when each segment is complete it is placed on
sliding bearings and pushed through into the span.

A steel nose is also positioned at the front of the first span formwork. This
allows for the necessary deck cantilever length as the span approaches the
first pier.

Bridge decks of 1km can be built by this method with a rate of construction of
30m per week.
Cable Stayed Method of Bridge Construction: The technique of cable-
stayed construction has been used and continually developed over the last
50years. It is the most common construction choice today when a bridge is
required to span more than 300. Cable-stayed bridges can be either concrete
or steel though a combination of both materials is often chosen.

Fig: Stay cable anchorages on a concrete deck

For concrete cable stayed bridges free cantilever construction is considered

economical. With this method the deck segments can be either precast or
cast-in-situ by travelling shutter arrangement.

In ca cable stayed bridge, depending on its design, the cables carry the bridge
deck from one or both sides of the supporting tower. The stay cables carry the
deck and transfer all bridge loads to the foundations. This is done by
transmitting the cable stay forces, through its extremeties, at it anchorage
points. Stay cables are firmly attached to the anchorages which are designed
to resist the buckling forces of the loads.
Detailing of all anchorages should allow for their safe construction and
accessibility for inspection and maintenance on completion. In concrete stay-
cabled anchorages are placed under the deck.

Arch Method of Bridge Construction:

he arch is the most natural bridge shape in nature. Originally constructed of
stone, today such bridges are built of reinforced or precast concrete. They are
often the most economical choice where a bridge is required to cross over
inaccessible landscapes.

The development of modern arch construction methods has made the use of
arch construction more economical by removing the need of expensive
centring formwork. Though abutments still must be well founded on rock or
soild ground.

Two construction techniques are most commonly used today.

(i) Cast-in-situ free cantilever method

This method involves the partially built arch tied back to rock anchors in the
valley side slopes.

(ii) Slip formed sections

This method involves half arch sections being held vertically over each
abutment and then rotating each arch section into position.

Tee-beams are generally used for arch bridge decks for their functionality and
self weight.