Bridge Construction

Bridge Construction
‫بسم هللا الرحمن الرحيم‬
BRIDGE CONSTRUCTION
BY
Dr. Ahmed Abdel-Atty Gab-Allah
(Zagazig University)
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Bridge Construction
OUTLINE
1. INTRODUCTION.
2. BRIDGE CONSTRUCTION SYSTEMS.
3. BRIDGE CONSTRUCTION IN EGYPT.
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1. INTRODUCTION
 Importance of bridges.
 Objective:
 Review latest bridge construction systems.
 Scope:
 Highway bridges (90%).
 Prestressed concrete (most recent developments).
 Superstructures.
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2. BRIDGE CONSTRUCTION SYSTEMS

 Classification of Bridges:
 Purpose of Bridge: Highway bridges, railway bridges, foot
bridges, viaducts, elevated roads, etc.
 Material of Construction: Timber, masonry, steel, reinforced
concrete, prestressed concrete, etc.
 Type of Superstructure: Slab, girder, arch, truss, rigid frame, etc.
 Type of Support: Simply supported, continuous, balanced
cantilever, cable-stayed, and suspension bridges.
 Life of Bridge: Permanent and temporary bridges.
 Navigation Requirements: Fixed, movable, and overhead bridges.
 Span Length: Minor bridges (spans of 8 to 30 m), major bridges
(spans of 30 to 120 m), and long span bridges (spans above 120 m).
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Bridge Construction
2. BRIDGE CONSTRUCTION SYSTEMS

 Selection of Bridge Construction Systems:
 Phases of Bridge Construction Projects: Surveying
works, Soil investigation, Bridge layout planning,
Selection of construction system, Design, and
Construction (Construction-Oriented Design).
 Alternative Bridge Designs: (Based on broad
requirements specified by the owner).
 Evaluation Criteria: Economy, Functional
Requirements, Long-Term Performance, Construction
and Design Requirements.
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 Classification of Prestressed Concrete Bridges:
Category Method of Construction
Pre-tensioned Girder 
Erected with Cranes
Bridges 
Erected with Launching
(I- or T- Beam) Girders
Cast in-situ:

On Falsework

Cantilever Segmental

Span by Span
Post-tensioned Bridges
Precast:

Incremental Launching

Cantilever Segmental

Span by Span
Cable-Stayed Bridges 
Incremental Launching

Free Cantilever
Suspension Bridges 
Balanced Cantilever 6
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 Latest Bridge Construction Systems:
System
Description
Code
A Precast, Prestressed Concrete Girders
Incremental Launching Construction
B (Deck Pushing System)
Cast-in-place,
C
Balanced Cantilever Construction
Precast Segmental,
D Balanced Cantilever Construction
E Flying Shuttering System
F Cable-Stayed Bridges
G Suspension Bridges
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 Suitability of Bridge Construction Systems:
Sys. Site Structure Span Lengths Structure Other Aspects
Cond. Level Depth
A Inaccess. High Short Variable Sharp curvatures &

(40 - 80 m) superelevations.
B Inaccess. High Short Constant Straight or slightly-curved
(40 - 80 m) superstructures.
C Inaccess. High Long Variable Crossing navigable
(up to 250 m) waterways.
D Inaccess. High Long Variable Crossing navigable
(up to 200 m) waterways.
E Inaccess. High Short Variable Long viaducts with short
(40 – 70 m) spans.
F Inaccess. Very High Long Variable Crossing deep rivers, deep
(200 to 1,000 m) valleys, and mountains.
G Inaccess. Very High Very Long Variable Crossing deep rivers, deep
(500 to 2,000 m) valleys, and mountains.
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Bridge Construction
(A) Precast, Prestressed Concrete Girders
 System Concept:
 Utilization of precast, prestressed I- of T- girders, on top of
which a deck slab is cast.
 Girders are usually erected by means of mobile cranes.
 However, in case of inaccessible sites, a launching truss may
be used for this purpose.
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Launching Truss – Schematic Diagram 10

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 Main System Components:
 Formwork: Forms for precast girders and formwork for deck slab.
(In case of T- girders, the flanges provide support for deck slab).
 Gantry Cranes: Required at fabrication area (to carry girders to
storage area and load them to trolleys, as well as to carry reinforcing
cage to the form).
 Trolleys: Two trolleys are usually required to transport girders to
their spans. Specially designed rubber-tired vehicles may also be used
for this purpose.
 Launching Truss: A steel launching truss, equipped with two
hoists, is required for erecting precast girders into their final
positions.
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 Construction Sequence:
 Casting of girders in a casting yard.
 Transporting girders to their spans by means of trolleys.
 Carrying girders by launching truss which is positioned over
respective span.
 Erecting girders into their final positions.
 Casting of deck slab.
 Moving launching truss forward to next span.
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Bridge Construction
Advantages:
 Economy, speed, and improved quality of mass production.
 Sharp curvatures & superelevations.
 Inaccessible sites.
 No interference with traffic.
Disadvantages:
 Casting yard, transport and erection equipment.
 Unsuitability for complex roadway geometry.
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Post-Tensioning of Girders 14
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(B) Incremental Launching (Deck Pushing)
 System Concept:
 Superstructure segments are cast in stationary formwork in a
casting yard located at one end of the bridge.
 After each segment is completed, the superstructure is pushed
forward to the other end of the bridge.
 In case of long superstructures, two casting yards (one at each
abutment) may be provided.
 In this case, the superstructure is pushed forward from both
abutments towards the center of the bridge.
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Incremental Launching Construction – Schematic 16

Bridge Construction
 Formwork: Rear half consists of forms for bottom slab and lower
part of webs, whereas front half of forms for the rest of box section.
 Lifting and Pushing Equipment: Vertical hydraulic jacks are
used to lift the bridge slightly at the abutment before each advance.
Then, horizontal jacks are used to push the superstructure forward.
 Temporary Bearing Blocks: Concrete blocks covered with thin
stainless-steel sheets, constructed on top of all supports to reduce
friction during launching operation. (Friction forces can be reduced
to about 2% of vertical loading by feeding Teflon sheets between the
bridge soffit and the top of stainless-steel sheets).
 Launching Nose: Lightweight-steel girder, tied to front end of
bridge girder to reduce cantilever moment during launching
operations.
 Intermediate Supports: Temporary supports may be provided
between final piers to reduce bending moments during launching of
superstructure. (Used when span-to-depth ratio > 17:1). 17
Bridge Construction
Temporary Bearing Blocks
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 Construction of casting yard(s), including formwork and
launching nose.
 Installation of pushing and/or pulling systems, and temporary
bearing blocks.
 Construction of superstructure.
 Disassembling of formwork, pushing and pulling systems, and
launching nose.
 Demolition of casting yard(s).
 Erection and stressing of post-tensioning cables in
longitudinal girders (webs).
 Replacement of temporary bearings by permanent bearings.
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Bridge Construction
Advantages:
 Riding learning curve (Repetitive operations).
Disadvantages:
 Casting yard and pushing equipment.
 Increase in longitudinal prestressing (cantilever moments).
 Large labor force during launching.
 Unsuitability for complex roadway geometry.
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Construction Sequence 21
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Inc. Launching Construction 22

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(C) Cast-in-Place, Balanced Cantilever
(Cantilever Carriage System)
 System Concept:
 Superstructure is cast in segments in traveling forms.
 These forms are supported from one end on completed part of
superstructure, while the other end is a free cantilever.
 After concrete reaches required strength, forms are moved
forward and prepared for next segments.
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Bridge Construction
 Form Travelers: Consist of main frames, guide rails, and
suspended platforms. Main frames run on upper guide rails and both
frames and rails are attached to finished portion of superstructure by
means of tie-down anchors. Forms are suspended from main frames;
they can be stripped in a single operation by lowering main frames.
 Pier Brackets: Used to provide support for the formwork of pier
tables. If a pier is low, pier brackets may be supported on pier footing
or directly on the ground. But if a pier is high, pier brackets are
usually built out from the pier cap and pier shafts.
 Local Bracings: Required for closure pours.
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Form Travelers - Schematic Diagram 25

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 Construction Sequence (Contd.):
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Cantilever Carriage System – Closure Pour 28

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Advantages:
 Long navigation channels.
 No interference with traffic or navigation.
 High labor efficiency.
Disadvantages:
 Special equipment and skilled labor.
 High precision required.
 Increase in reinforcement (cantilever moments).
 Limited length of segments.
 Low construction rate.
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Bridge Construction
Bridge Construction
Cantilever Carriage Construction 31

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(D) Precast Segmental, Balanced Cantilever
 System Concept:
 Superstructure is precast and prestressed in segments in a
fabrication area.
 Segments are then transported to bridge site, where they are
erected into their final positions.
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Erection
Procedure
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Erection
Procedure
(Contd.) 34
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 Formwork: Consists of a rigid outer shuttering and a hydraulically
operated collapsible inner shuttering. Inner shuttering can be
completely removed during demoulding.
 Transport Equipment: Precast segments are normally transported
to the site by trailers. Segments should be of transportable size and
weight.
 Erection Equipment: A variety of erection equipment types can be
used (such as truck cranes, crawler cranes, floating cranes, launching
girders, cableways, etc.). However, a launching truss equipped with
hoists is commonly used.
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Bridge Construction
 Fabrication of Precast Segments:
 To achieve a perfect fit between the ends of adjacent segments,
each segment is cast against the end face of the preceding one.
(This is called “Match-Casting” of segments).
 Segments are then erected in the same order in which they
were cast.
 An epoxy resin (about 0.8 mm thick) is normally applied to
the match-cast contact surface. It serves as a bonding and
leveling agent that transfers the shear and bending stresses to
the adjacent segment.
 Shear keys are usually provided in each web of the segments
to handle erection stresses prior to the epoxy achieving final
strength.
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Bridge Construction
 Erection of Precast Segments:
 Precast segments are picked from transport trailer and
launched to their spans by means of launching truss.
 They are then lowered to their level where epoxy resin is
applied to the contact surface with the previously erected
segments.
 They are finally tied to previously erected segments by post-
tensioning cables.
 Segments are erected on either sides of the pier alternatively
(to maintain balanced cantilevers, which will minimize the
out-of-balance moment at the pier).
 After the two cantilevers reach mid-span, the launching truss
is moved forward to next span, where it will be ready for
erecting another pair of balanced cantilevers. 37
Bridge Construction
Advantages:
 Economy, speed, and improved quality of mass production.
 No interference with traffic or navigation.
 Low labor requirement for both fabrication and erection
operations.
 Adaptability to curvatures and superelevation.
Disadvantages:
 Casting yard, transport and erection equipment.
 High precision required.
 Increase in reinforcement (cantilever moments).
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Bridge Construction
Precast Segmental Construction 40

Bridge Construction
(E) Spanwise Construction Using Stepping
Formwork (Flying Shuttering System)
 System Concept:
 Entire span is cast in place in stepping formwork (flying
shuttering), supported on specially designed and fabricated
steel trusses extending over the piers.
 After completion of the span, form trusses carrying the
formwork are moved forward to next span.
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Bridge Construction
(E) Flying Shuttering System
Stepping Shuttering Construction – Schematic Diagram 42

Bridge Construction
 Stepping Formwork: Made of steel panels. Outer formwork is
supported by steel trusses, whereas inner formwork rolls forward on
rails within the box section.
 Form Trusses: Two longitudinal steel trusses are erected beneath
the two side cantilevers of the box girder. They are designed to carry
the forms of entire span.
 Support Frames (or Pier Brackets): Erected on top of piers to
support form trusses. Steel rollers are usually used at support frames
to facilitate launching of trusses.
 Hydraulic Jacks: Used for advancing form trusses. They may be
installed at end of trusses, at next pier, or at finished portion of the
bridge.
 Intermediate Supports: In case of long spans, intermediate
supports for the trusses may be used.
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Bridge Construction
 Erection of support frames.
 Erection of form trusses and outer formwork.
 Concreting of the box girder floor.
 Erection of inner formwork.
 Concreting of webs and top slab at one pour.
 Partial prestressing of longitudinal cables.
 Opening the stepping shuttering, and advancing form trusses
and stepping shuttering to next span using hydraulic jacks.
 Preparation of stepping shuttering to cast the next span.
 Final prestressing of cables after concreting of all spans, to
make the whole bridge continuous.
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Bridge Construction
Advantages:
 Long viaducts with short spans.
 High construction progress rate.
Disadvantages:
 Special equipment.
 Unsuitability for long spans.
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Construction Sequence:
Concreting Phase and Advancing Phase 46
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Flying Shuttering Details 47

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(F) Cable-Stayed Bridges
 System Concept:
 The superstructure is supported at one or more points by
high-tensile steel cables, extending from support towers and
connected directly to the deck.
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Bridge Construction
 Cable Arrangements:
Transverse:
(a) Single Plane – Vertical
(b) Single Plane - Vertical/Lateral
(c) Double Plane – Vertical
(d) Double Plane - Sloping
Longitudinal:
(a) Radiating
(b) Harp
(c) Fan
(d) Star
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Bridge Construction
 Construction Methods:
 The selection of appropriate construction method depends on
many factors (stiffness of pylon, cable anchorage system,
possibility of installing temporary supports, maximum length
of unsupported spans permitted by design, and ease of
transporting materials).
 Balanced cantilever construction is probably the most
favorable construction method for modern cable-stayed
bridges.
 However, other construction methods can also be used [e.g,
Incremental Launching (Deck Pushing) and Free Cantilever
Construction].
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 Stay Technology: Cables
(a) (b)
(c) (d)
Types of Stay Cables: (a) Parallel-Bar; (b) Parallel-Wire;

(c) Stranded; (d) Locked-Coil 51
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 Stay Technology: Anchorages
Anchorage System for Parallel-Wire Cables 52

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 Stay Technology:
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Advantages:
 High clearance for traffic or navigation.
 Suitability for long spans.
 Less material quantities (smaller depths).
Disadvantages:
 High risks involved in bridge construction.
 High tech. required (very long span lengths).
 High degree of control required on quality, time and budget.
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Construction Systems:
• Balanced Cantilever.
• Free Cantilever. Free Cantilever
• Deck pushing.
Balanced Cantilever
(Cast-in-Place) 55
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(G) Suspension Bridges
 System Concept:
 The superstructure is supported by steel suspenders (vertical
hangers) attached to main cables that are stung over the
support towers in the form of a catenary.
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Bridge Construction
 Construction Methods:
 Most construction methods for cable-stayed bridges are still
applicable for suspension bridges.
 However, the suspension cable technology is different from the
stay cable technology, particularly the anchorage of main
cables, and the connections of vertical hangers to the main
cables.
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1. Construction of towers and precasting of superstructure
segments.
2. Erection of main cables. Strands are pulled by winches and
erected individually using specialized equipment.
3. Installation of cable clamps and hanger rods using cranes.
4. Transporting superstructure segments below their final
position on barges.
5. Erection of segments using erection equipment (erection
girders, for example).
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Bridge Construction
 Construction Sequence: (Contd.)
6. Jacking-up of each segment prior to erection of hanger
bars.
7. Erection of hanger bars and their adjustment to
predetermined lengths to bring the segments into alignment.
8. Interconnection of superstructure segments.
9. Cambering the superstructure upwards by controlled
adjustment of hangers before casting the deck.
10. Bringing the deck to its final level through a final set of
hanger adjustments.
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Bridge Construction
Advantages:
 High clearance for traffic or navigation.
 Suitability for very long spans.
 Less material quantities (smaller depths).
Disadvantages:
 High risks involved in bridge construction.
 High tech. required (very long span lengths).
 High degree of control required on quality, time and budget.
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Bridge Construction
3. BRIDGE CONSTRUCTION IN EGYPT
 Major Bridge Projects in Egypt
Sys. Major Applications Span Lengths Comp.
(m) Date
A  6th of October Bridge (Ramsis/Ghamra). 33 – 40 1988
 Ring Road 9-D Bridge. 40 1998
B  Zamalek Elevated Road. 31@25, 2@23.5 1986
 Dessouk Overhead Bridge. 34.2, 7@40.7, 5@40, 34 1987
C  Al-Giza New Bridge. 104, 2@69 1969
 6th of October Bridge. 110, 2@100, 2@70 1976
 Abou El-Ela Bridge. 115, 2@69 1986
 Rod El-Farag Bridge. 130, 2@75 1990
 New Benha Bridge. 120, 2@69 1990
 Al-Warrak Bridge 120, 2@60 2000
D Has Not Been Applied
E  6th of October Br. (Ghamra/ Autostrad). 42 1998
 Suez Canal Bridge, Approach Spans. 40 2001
F  6th of October Br.(Ghamra/Autostrad). 133 (66.5 in each side) 1998
 Suez Canal Bridge, Main Spans. 404, 2@163 2001
G Has Not Been Applied
61
 Bridge Construction Systems Applicable forBridge Construction
Different Site Conditions in Egypt
System
# Site Conditions System Description
Code
A Precast concrete girders.
Under Running
I B Incremental launching.
Traffic
E Flying shuttering.
C Cantilever carriage.
Across Navigable
II D Precast segmental construction.
Waterways
F Cable-stayed bridges.
Deep Waterways and F Cable-stayed br. (up to 1000 m).
III
Mountains G Suspension bridges (> 1,000 m).
A* Precast concrete girders.
IV At Accessible Sites* B* Incremental launching.
E* Flying shuttering.
* May be feasible for accessible sites, particularly for very high
superstructures (high approach spans and viaducts). 62
Bridge Construction
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‫بسم هللا الرحمن الرحيم‬

2. BRIDGE CONSTRUCTION SYSTEMS

2. BRIDGE CONSTRUCTION SYSTEMS

A Inaccess. High Short Variable Sharp curvatures &

Launching Truss – Schematic Diagram 10

Incremental Launching Construction – Schematic 16

Temporary Bearing Blocks

Inc. Launching Construction 22

Form Travelers - Schematic Diagram 25

Cantilever Carriage System – Closure Pour 28

Cantilever Carriage Construction 31

Precast Segmental Construction 40

Stepping Shuttering Construction – Schematic Diagram 42

Flying Shuttering Details 47

Types of Stay Cables: (a) Parallel-Bar; (b) Parallel-Wire;

Anchorage System for Parallel-Wire Cables 52

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