Construction Practices Webinar Series

February 2022

Overview of
Segmental Bridge Construction
What is Segmental Bridge Construction
 What is Segmental Bridge Construction
Overview
• What is segmental construction?
• Major Types of Segmental Bridges
• Casting Yard
• Geometry Control
• Post-Tensioning
• Erection Equipment
What is Segmental Bridge Construction
 What is Segmental Bridge Construction
• Fabrication and Erection of a
Structural Element Using Individual
Elements (Segments), Which May
be Either Precast or Cast-in-Place
• The Completed Structural Element
Acts as a Monolithic Unit Under
Some or All Design Loads
• Post-Tensioning is Typically Used to
Connect the Individual Elements
• Individual Superstructure Elements
are Typically Short Box-Shaped
Segments with Monolithic Flanges
That Comprise the Full Width of the
Structure
 What is Segmental Bridge Construction

Terminology
• Typical Segment
• Pier Segment
• Diaphragm
• Variable Depth Segment
• Precast Substructure
 What is Segmental Bridge Construction
Terminology
• Segment Joint
• Top Flange / Slab
• Bottom Flange / Slab
• Web
• Shear keys
• Tendon Anchors
• PT Blisters
• PT Bar Blisters
Segmental Bridge Types
 Segmental Bridge Types
Cast-in-Place Segmental
• Segments Cast In-Situ
• Usually Progressive Placement on Previously Built Structure
• Specialized Forming Required
 Segmental Bridge Types
Balanced Cantilever
• Often Single Crossings of Difficult
Terrain / Congestion
• Segments are Built Out from
Central Pier, Limiting Unbalanced
Weight
• Adjacent Cantilevers Meet in the
Middle, are Connected with a
Closure
 Segmental Bridge Types
Balanced Cantilever
• Top “Cantilever” tendons resist
negative bending while the
cantilever is built outwards.
 Segmental Bridge Types
Balanced Cantilever
• Bottom “Continuity” tendons
provide positive bending
resistance in the completed
structure.
 Segmental Bridge Types
Cable-Stay Segmental
• Major Crossings
• Similar in Concept to
Balanced Cantilever
• Wider Variety of Sections
• Specialized Equipment and
Forming to Accommodate
Cables
 Segmental Bridge Types
Cable-Stay Segmental
• Stay Anchorage
 Segmental Bridge Types

CIP Arches
• Single Direction Cantilever
• Relatively Uncommon
• Sure Do Look Good
 Segmental Bridge Types
Incremental Launch
• Segments Cast in Fixed Form at
Abutment
• After Each Cycle, Bridge is
Pushed Forward
• Typically Shorter Spans Where
Falsework is Impossible
 Segmental Bridge Types
Incremental Launch
• Post tensioning is heavier,
primarily axial compression.
 Segmental Bridge Types
Cast-in-Place Segmental
• Continuous rebar across joints
 Segmental Bridge Types
Pre-Cast Segmental
• Segments Precast Off-Site
• Segments Transported to Site and Assembled
• Specialized Equipment for Casting and Erection
• Used in High Volume / Low Access Situations
 Segmental Bridge Types
• Span-by-Span, Simple
• Single, Simple Span Erected
Between Piers
• Simplest, Fastest Way to
Build
• Span Lengths on the Shorter
End of the Spectrum
 Segmental Bridge Types
• Span-by-Span, Simple
• Articulation
 Segmental Bridge Types
Span-by-Span Continuous
• Spans Erected One at a Time but
Made Continuous with Post-
Tensioning
• Slightly Longer Erection Cycle but
Increases the Span Length Due to
Continuity
 Segmental Bridge Types
Span-by-Span Continuous

Exp. CIP CIP CIP CIP

Jt. Closure Closure Closure Closure

Span 1 Span 2

Pier

Pier
Pier

CIP CIP CIP CIP

Closure Closure Closure Closure Exp.
Jt.

Span 3 Span 4
Pier

Pier

Pier
 Segmental Bridge Types
Span-by-Span Continuous
 Segmental Bridge Types
Pre-Cast Segmental
• Similar in Concept to CIP
Balanced Cantilever
• Precast Segments Used Instead
• Erected in Balanced Pairs
• Segment Transportation is the
Limiting Factor
 Segmental Bridge Types
Balanced Cantilever on Land
• Segment / span typical
• Lengths up to ~300’
• Closure pours where
cantilever tips meet
• Potentially closures at pier
segment interface
• Delivery often limiting
factor
 Segmental Bridge Types
Balanced Cantilever Over Water
• Delivery of much larger segments
possible

• Opens the door to longer spans

with fewer segments
 Segmental Bridge Types
Pre-Cast Cable-Stayed
• Major Crossing
• Similar to Balanced Cantilever
• Segment Transportation
Planning a Must
 Segmental Bridge Types

Substructures
• Columns Can be Precast and
Assembled Vertically
• Typically in Low-Seismic
Environments
 Segmental Bridge Types
Pre-Cast Segmental
• Shear and alignment keys
 Segmental Bridge Types
Epoxy
• Currently required for all precast bridges
 Segmental Bridge Types
Epoxy Squeeze
• Wet epoxy is compressed to create a tight match with no gaps
 Casting Yard
Applies to Precast
 Casting Yard
Forms
• Short-Line vs. Long Line
• Short-Line Far More Common
 Casting Yard
Forms
• Long line forms mimic the entire span
 Casting Yard
Forms
• Short line forms capture one
segment at a time
 Casting Yard

Short-Line Forms
• Fixed Bulkhead
• Exterior Forms
• Core Forms
• Hydraulics
• Manipulator
 Casting Yard

Match Casting
• The “Fourth Wall” of the
Form is the Adjacent or
Match Cast Segment
• This Ensures the Segments
Will Fit Together in the Field

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Casting Yard

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 Casting Yard

Rebar Jigs
• Minimal Cycle Time is
Important in the Casting
Yard
• Reinforcement is Pre-Tied
in Steel Jigs That Mimic
Segment Geometry
• They Are Then Lifted Into
an Adjacent Form

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 Casting Yard
Storage
• Segments are Moved from the Forms to
Storage – and from Storage to Transportation

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 Casting Yard
Storage
• Segments are Stored on Dunnage
and are Occasionally Stacked* to
Increase Storage Capacity

*AS APPROVED BY THE ENGINEER

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 Casting Yard
Storage
• Three point support
• Prevents permanent
twist

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 Casting Yard
Delivery
• Transport by land on trucks
• Limiting condition for height
• Water transportation has more
flexibility

Don’t forget about

these!

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Geometry Control
 Geometry Control
Concept
• All Types of Segmental Construction Require Special Attention to
Geometry in Order to Achieve the Intended Shape of the Bridge
• CIP Construction is a Moving Target
• Precast Construction Locks in the Bridge Shape One Segment at a Time
Geometry Control
CIP
• Most People are Familiar with Camber
from Traditional Beam Construction
• CIP Balanced Cantilever is Also Swaying
Back and Forth as Segments are Cast
• The Question is “Where Do I Set the
Forms Today, So That This Joint Ends Up
on Profile After the Next 25 Steps?”
 Geometry Control
CIP
• Analytical Procedure,
set tip at “0”
• This gives the total
movement over time
• That value is then used
to set the elevation in
construction
• Account for traveler
deflection
 Geometry Control
Precast
• Segments are Cast Miles Away
from the Site, and 10’ at a Time
• The Geometry of the Finished
Product is Mapped Onto the
Form Setup
• Changes in Plan Curvature,
Vertical Curves and Crossfall are
Achieved Through Slight
Adjustments of the Match Cast
Segment
Geometry Control
 Geometry Control

Terminology
• Fixed Bulkhead
• New-Cast or Wet-Cast Segment
• Match-Cast Segment
• Bolts / Hairpins / etc.
 Geometry Control
Camber
• Camber means that you are casting the bridge above or below the theoretical
profile

• This can compensate for anything that will cause displacements over time

• Primary sources include:

– Creep and shrinkage
– Post-tensioning or stay cable effects
– Built-in displacements from the erection sequence
 Geometry Control
Camber
• Camber for precasting means
an adjustment to the target
vertical curve.
• It is combined with the
vertical profile
Post-Tensioning
 Post-Tensioning
Importance of Post-Tensioning
• Heavy use with segmental
• Pre versus post tensioned

Pre- Post-
Pre- or Post- of what? tensioned
stressed

Concrete set.
Pre-stressed is stressed against a form or bulkhead, then released after the
concrete is poured.
Post-tensioned is installed and stressed against the hardened concrete.

Post-tensioning required special embedded hardware to transfer the force.

 Post-Tensioning
Terminology
• Strand
• Duct
• Anchor / Trumpet
• Wedge Plate / Wedge
• Spiral / Confinement
• Cap
 Post-Tensioning

Anchorage Hardware Life Cycle

 Post-Tensioning
Internal and External
• Internal  Duct is Surrounded
by Concrete

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 Post-Tensioning
Internal
• Blocks / blisters
• Internal deviations /
curvatures / detailing

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 Post-Tensioning
Internal
• Duct are corrugated plastic
(now typical) or galvanized
(older, or maybe in California)

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 Post-Tensioning
Internal
• Duct Couplers
• Used as part of a more
aggressive corrosion
protection system
• Seal the ducts at the joints
• Decrease potential for water
intrusion or grout
communication
 Post-Tensioning
Internal and External
• External  Duct is Not Part of
Concrete Section, but is Inside
the Box Girder for Protection

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 Post-Tensioning
External
• Deviator Segments

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 Post-Tensioning
External PT
Diabolos 

 Pipes

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 Post-Tensioning
External
• Smooth HDPE Duct

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 Post-Tensioning
Transverse Post-Tensioning
• Compresses deck in
transverse direction
• Smaller tendons, 4-strand
commons
• Oval duct to reduce
thickness

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 Post-Tensioning
Post-Tensioning and Grout
• Grout Fills the Space Between the
Tendon and the Duct
• It is a Key Component of the
Corrosion Protection
• Cementitious Grouts are Frequently
Pre-Packaged to Ensure Quality and
Performance
• Flexible Fillers (Wax and Grease) are
an Emerging Technology

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 Post-Tensioning
Post-Tensioning and Grout
• Anchorage Protection
• Varies by location and owner
• Usually has a plastic, grout-
filled cap
• May also include a secondary
pour-back and / or coatings

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 Post-Tensioning
Post-Tensioning and Grout
• Shameless ASBI plug

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Basic Erection Equipment
 Basic Erection Equipment
Form Traveler
• Forms the Segment in CIP
Construction
• Is Advanced Forward with Each
Cycle and Secured
• Often Accommodates Varying
Geometry
• Horses
 Basic Erection Equipment

CIP Cable-Stayed
• Similar Concept
• Increased Complexity
• Accommodating Stays – Both
as Forces and as Obstacles
 Basic Erection Equipment
Gantry
• Used in Span-by-Span and Balanced
Cantilever Construction
• Holds Segments In Place Until Post-
Tensioned and Self-Supporting
• Moves Segment Along Length,
Adjusts Geometry
• Self-Launches Forward to Next Span
 Basic Erection Equipment
Overhead Gantry
• Simple span versus BC gantries
 Basic Erection Equipment
Gantry
• Construction cases are significant
 Basic Erection Equipment
Underslung Gantry
• Similar Function as Overhead
• Supported on Brackets
• Can be Relatively Low Tech (and
Cheaper) When Circumstances
Allow
 Basic Erection Equipment
Overhead Gantry
• Typically self-
launching
• Supports move with
the gantry
 Basic Erection Equipment
Articulated Gantry
• Variation of overhead gantry
• Has articulated joint in middle
• Allows tighter turns in congested
areas
Basic Erection Equipment
 Basic Erection Equipment
Lifter (Beam and Winch)
• Single Segment Lifts on Balanced
Cantilever or Cable-Stayed
• Usually on Larger Bridges
• Lower Investment, but Limited
Reach
 Basic Erection Equipment
Segment Hauler
• Sometimes Customized Segment
Movements are Needed
• May Need to be Tailored to
Bridge Geometry to Minimize
Forces
• Nothing Wrong with a Flatbed
Truck and Crane – If They Work
 Basic Erection Equipment
Segment Handling
• Integrate equipment
Questions?

Ben Soule, PE, SE