Professional Documents
Culture Documents
Key words: Long-span, steel through arch, structural behaviors, erection control
Abstract: The Chongqing Chaotianmen Yangtze River Bridge is a three-span steel through
arch bridge currently under construction. By the time of its completion at the end of 2008,
it will become the longest steel arch bridge in the world with a record span of 552 m. This
paper describes some of its design characteristics and challenges in the construction
control. Time dependent analyses with 3D models were carried out to study the structure
behavior at each erection stage and to identify potential problems as well as applicable
solutions during erection. Based on the results from analyses, a reasonable and practical
scheme of erection stages and controlling procedures was proposed for structure to safely
and accurately achieve its final design configuration at closure.
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Xiang, Zhang, Du, Mao & Yu: STUDY ON ERECTION CONTROL SCHEME FOR LONG SPAN STEEL ARCH BRIDGE
1. INTRODUCTION
Technology of designing and building a steel arch bridge has been significantly advanced in
the nineteen century. It took about 42 years for the span length to increase from 158.6 m in
1874 (St. Louis Bridge) to 297 m in 1916 (Hell Gate Bridge), an increase of 90% in span
length. The construction of Bayonne Bridge in 1931 further extended span length to 504 m,
representing an increase of 70% in 15 years. In 1977, New River Gorge Bridge was built
with a record span of 518.3 m. However, it is only a meager 3% increase in span length
comparing with that of Bayonne Bridge. No new steel arch bridges built after was able to
break this span record for more than twenty-five year until LuPu Bridge in Shanghai was
completed in 2003 with a new record span of 550 m as shown in Table 1.
Main span
No. Bridge name Location Year Completed
(m)
1 New River Gorge Bridge America 1977 518.2
2 Bayonne Bridge America 1931 504
3 Sydney Harbor Bridge Australia 1932 503
4 Fermont Bridge America 1973 383
5 Port Mann Bridge Canada 1964 366
6 Sint Michielsbrug Bridge Panama 1962 344
7 Livio Lotte Bridge Canada 1967 335
8 Runcorn Bridge England 1961 330
9 Zdakov Bridge Czech 1967 330
10 Birchenough Bridge Zimbabwe 1935 329
11 Roosevelt Lack Bridge America 1990 329
Table 1: Abroad list of long-span steel tied-arch bridges
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Xiang, Zhang, Du, Mao & Yu: STUDY ON ERECTION CONTROL SCHEME FOR LONG SPAN STEEL ARCH BRIDGE
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Xiang, Zhang, Du, Mao & Yu: STUDY ON ERECTION CONTROL SCHEME FOR LONG SPAN STEEL ARCH BRIDGE
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Xiang, Zhang, Du, Mao & Yu: STUDY ON ERECTION CONTROL SCHEME FOR LONG SPAN STEEL ARCH BRIDGE
The main-span arch trusses are erected by cantilever method using movable crane on
standing on the completed panels. As the cantilevered arm gets longer, the overturning
moment increases and the stability of structure reduces. Counterweights are thus applied
on side-spans to balance the overturning moment and guying cable systems are added to
improve the structure stability.
At the erection of main-span arch truss, the bearings on main-span piers (P7, P8) are fixed,
and longitudinally freedoms of side-span bearings (P6, P9) are released.
(3) Position adjustment of main-span arch at closure
The closure sequence for main arch is the following: bottom chord, top chords, diagonals,
and lateral bracings. Temporary closure hinge is used to speed up bottom and top chord
closure. The closure of diagonals and laterals after top and bottom chord closure requires
the release of temporary bearing fixity at pier P8. Jacking forces at main-span piers and
side-span piers are applied to adjust bearing position and achieve final no-stress closure.
(4) Installation of the temporary tie bar
After the main-span closure, temporary tie bar is installed at joint E17 of the bottom
stiffening chord of mid-span and stressed. The side-span bearings are then adjusted to the
final design elevation and remove the guying cable-stayed system and the counterweights
in a reversed order.
(5) Installation of the permanent rigid tie girders and final main-span closure
Permanent tie girders for the main-span can then be installed in a sequence from top down,
panel by panel using fully rotary deck derrick crane. After the closure of permanent tie
girder, the temporary tie bar is removed, and the bridge deck system is placed.
Analysis based on the installed bearing positions can be carried out to determine additional
adjustment needed to the bearing position in vertical, longitudinal, and transverse direction
to ensure the closure within required tolerance.
(6)Control of the construction geometry of bridge
The steel girder geometry is guaranteed primarily by the quality of fabrication and the
accuracy field connection.
3.7 Bridge construction process
The construction flowchart is shown in Figure 3.
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Xiang, Zhang, Du, Mao & Yu: STUDY ON ERECTION CONTROL SCHEME FOR LONG SPAN STEEL ARCH BRIDGE
Preparation of construction
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Xiang, Zhang, Du, Mao & Yu: STUDY ON ERECTION CONTROL SCHEME FOR LONG SPAN STEEL ARCH BRIDGE
5) External lifting forces are required to achieve system transfer at zero stress at closure.
6) Combination of rigid arch and flexible tie girders in the design makes its structure and
stress analysis difficult. Precision in initial position establishment and final position
adjustment of middle pivot is highly required.
7) QZ145000kN cast iron spherical bearings are used for the main span support. It is
one of the largest bearings in the world.
4.2 Construction challenges
1) With limited experience in erection process, providing adequate monitoring and
control becomes more crucial.
2) Large size of the structural components requires heavy lifting equipment. It is
difficult to install and maintain the stability of lifting equipment.
3) Special considerations such as zero stress length and selection of bolt-hole locations in
fabricating panels are required to ensure that erection tolerance is not exceeded.
4) To improve stability and reduce cantilever deflection of partially erected arch,
counterweights are added at side span. In addition, inclined guying cable system is also
provided.
5) No initial stress at closure of main span is required.
6) To ensure zero-stress (natural) at closure, lifting forces need to be applied at the side
and middle fulcrums.
7) Structure system transferring from initial cantilevered condition to completed arch
system after closure, and then to tied arch system requires applying of external lifting forces
for bearing adjustment.
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Xiang, Zhang, Du, Mao & Yu: STUDY ON ERECTION CONTROL SCHEME FOR LONG SPAN STEEL ARCH BRIDGE
the designer. They can be amended, modified, and altered according to real situation if
necessary.
6.3 Process control of steel truss at side span in cantilever setup
For the need of fulcrum setup at the side spans and closure of the middle span, surface
position for truss erection at the side fulcrum is obtained by analysis. The safety and
stability of the fulcrum is monitored and balancing loads are determined. Meanwhile,
according to process simulation analysis, longitudinal position, and its pre-deviation of the
temporary middle fulcrum are determined.
6.4 Forming control of steel truss at side span
Control focuses on the transfer process of cantilever erection from no support to simple
support. Observation is needed to the displacement of the bracket at the side spans.
6.5 Process control of fulcrum setup at middle span
Control focuses on surface position, height of the fulcrum at the middle span, by adjusting
with a jack and by adjusting the height of the side fulcrum, respectively.
6.6 Process control of steel truss arch in cantilever erection at middle span
Included various external factors such as temperature and wind force, comparison of real
and theoretical heights and stresses provides judgment to the stability and safety of the
structure, possibility of problems in non-stress closure of the main span, and alert to these
issues. Modification can be made accordingly. Observation should be taken to structural
stress and strain of steel truss. Setup outline of trussed arch needs to be controlled.
In the process of truss arch setup, measurement should be taken to the down deflection of
the beam, and, side curve and vertical curve due to environmental temperature change.
Structural correction coefficient (= real change/theoretical change) needs to be calculated,
since it is the basic material for precise adjustment of the middle span before closure.
6.7 Control of tilted buckling and load balancing at side span
Based on theoretical analysis and real measurements, position of the tilted buckling and
force in its cable can be determined in the process of cantilever erection of the steel truss at
the middle span. Temporary cable tower, force in the tilted cable and its adjustment are
monitored to ensure anti-overturn stability. Force non-homogeneity is monitored as well as
the force. Meanwhile, time and magnitude of the balancing loads need to be controlled.
6.8 Control of steel truss arch closure (the first system transfer)
Based monitored temperature variation, the closure time, temporary lifting locations was
estimated. According to monitoring pre-temperature change, positions of temporary side
and middle fulcrums at closure are analyzed and lifting adjustments to them are presented,
and sensibility of the lifting to cantilever structure is also analyzed. The process of the
adjustment is monitored until the first system transfer, i.e., natural closure of the steel truss
arch is accomplished. Disbenefit of various external factors should also be monitored
after the transfer.
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Xiang, Zhang, Du, Mao & Yu: STUDY ON ERECTION CONTROL SCHEME FOR LONG SPAN STEEL ARCH BRIDGE
6.9 Control of span adjustment of steel truss arch and temporary bowstring setup
Determine adjusting magnitude of the surface position at the side fulcrums for span
adjustment. The process of the adjustment and setup of temporary bowstring should be
monitored. Also, force in the bowstring and its non-homogeneity should be monitored.
6.10 Process control of steel truss setup of main span trail
Procedure of steel truss setup of main span trail, stresses and deformations of steel structure
and longitudinal displacement of the middle fulcrum in the formed three spans are main
objects to be monitored and controlled.
6.11 Control of steel truss for trail (the second system transfer)
Steel truss for trail is permanent bowstring itself. According to temperature and other
factors, when the three spans are formed, positions of the side and middle fulcrums (i.e.
permanent fulcrum positions) should be analyzed and determined, magnitude of adjustment
should be presented, and sensibility of the jack lifting to cantilever structure should also be
analyzed. The process of the adjustment is monitored until the second system transfer,
i.e., steel truss for trail closures.
6.12 Setup control of compliant bowstring
According to design and temperature, setup time and tension of compliant bowstring
(pre-stressed cable outside the body) is determined. Effect of the forming process of
bowstring to the structure is monitored.
6.13 Monitor stressing of booms
The key point is to ensure that the stressing of booms is in accordance with the design,
meanwhile, to ensure its length exerts effect on bridge surface outline adjustment.
6.14 Control of trails and adjustment of bridge surface outline
The key point is the effect of construction procedure of trails (including lower trail and
automotive path) and their weights to the stress and deformation of the three spans steel
bowstring arches. Control to longitudinal and transverse geometry of the bridge is also
needed.
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Xiang, Zhang, Du, Mao & Yu: STUDY ON ERECTION CONTROL SCHEME FOR LONG SPAN STEEL ARCH BRIDGE
The main-span arch closure, which is the first system transfer, in the zero stress condition,
depends on the accuracy of stress prediction from analytical model, member fabrication
accuracy and temperature control, as well as bearing position adjustment.
Bridge closure control of trussed-steel beam (the second system transfer) in addition to
relying on the accurate theoretical analysis of conversion state, precision machining of the
structural members and accurate temperature control, with the change of the vertical
position in the middle support (using Jack) to achieve.
7.2 The establishment of the construction control systems
The scale of the bridge is very large,the procedure is very complicated,and the
technology is very difficult. It is important to establish a practical and effective control
system for the bridge construction. The diagram of the system represents in Figure 4.
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Xiang, Zhang, Du, Mao & Yu: STUDY ON ERECTION CONTROL SCHEME FOR LONG SPAN STEEL ARCH BRIDGE
(b) Stage 2 (Removed temporary piers 1# and 2#, and side-span erection)
(c) Stage 3 (Removed all temporary piers and erection of main-span arch to panel joint #21)
(e) Stage 5 (Installation of tie girders with temporary tie rods installed)
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Xiang, Zhang, Du, Mao & Yu: STUDY ON ERECTION CONTROL SCHEME FOR LONG SPAN STEEL ARCH BRIDGE
REFERENCES
[1] Scientific Research and Design Institute of Chongqing Jiaotong · Design Institute of
China Railway Bridge Bureau. Design Documents of the Chongqing Chaotianmen
Yangtze River Bridge.
[2] Chongqing Jiaotong University & Harbour Design and Research Institute in Wuhan.
Construction Controlling Scheme of the Chongqing Chaotianmen Yangtze River Bridge.
[3] Department of Construction of Chongqing Chaotianmen Yangtze River Bridge. Design
of Construction Organization of the Chongqing Chaotianmen Yangtze River Bridge.
[4] Xiang Zhong-Fu. Control Technology of Bridge Construction [M]. Beijing: People's
traffic Press, 2001.
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