Construction and Maintenance

Content
• Erection of bridge super structure,
• Maintenance,
• Rating and Strengthening of existing
bridges
 Erection of bridge super structure
The development in the erection methodology of bridge
super structure revolutionize the process of bridge
construction. The various method used for the erection of
bridge superstructure are;
• Cantilever Construction (Segmental method)

1. Cast in-situ Construction

2. Construction using Precast Segments

• The staging Method
 Erection of bridge super structure

• Progressive Placement Construction Method

• Incremental Launching or Push out Technique
 Cantilever Construction
• Used in long span bridge construction

• Generally starts from a pier, extending on both sides.

• Eliminates the use of expensive form work and

scaffolding especially for bridges in deep valleys and
rivers with large depth of water resulting in faster
rate of work progress coupled with overall economy.
 Cast in-situ Construction
• Pier of the bridge is first constructed and the bridge
deck is cast in-situ units of 2.5 to 3 m length
cantilevering symmetrically on either side of the
pier.
• Form work is supported by steel frame work
attached to the complete part of the bridge deck
and the form work is moved progressively from one
completed section to the next part.
• In-situ construction is done by pair of travelling
gantries, each weighing about 40 t for casting 2.5 to
3 m segments of a two lane bridge deck.
 Cast in-situ Construction
• Gantry system also supports a suspended scaffolding for
constructional convenience and workers safety.
Total time duration to complete one cycle
• Shifting of travelling gantry system - 1 Days
• Completion of entire shuttering, - 3 Days
placing of reinforcement and prestressing
cables for the segment
• Casting concrete in the segment - 1 Day
• Curing the segment - 4 days
• Prestressing operations and Miscellaneous works - 1 day
• Total cycle time for completion to segmental unit - 10 days
Cast in-situ Construction

https://youtu.be/RFMazS96wXY
 Construction using Precast Segments
• Single cell or multi cell box girder (segment) are cast
near to the bridge site and cure for required day to
obtain the excellent quality.

• Segment are placed in position by means of mobile

launching girder.

• Segments are lifted by cranes to join them to the

previously erected units by using temporary stressing
cable. The rate of progress achieved in this method
is faster compared to the cast in-situ method.
Construction using Precast Segments
 The Staging Method
• Applicable for long viaduct structures with relatively
shorter spans.
• Superstructure is executed in one direction span be
span by means of a supporting traveller.
Progressive Placement Construction Method
• Precast element placed from one end of the bridge
• No need to switch side as in case of Cantilever
construction.
• Good access to the placement location is possible
• Progress is slower than the balanced cantilever
Incremental Launching or Push Out Technique

• https://youtu.be/S3Kf9e6JgF4
Bridge Constructed in India using Segmental
Construction
Bridge Constructed in India using Segmental
Construction
Bridge Constructed in India using Segmental
Construction
Bridge Constructed in India using Segmental
Construction
 Maintenance of Bridges
Maintenance is essential to ensure long term conservation
of bridge deck to serve its intended purpose.
• Maintenance involve

• periodic inspection,

• repair and

• Rehabilitation

Effective maintenance ensure the various limit states of

strength and serviceability.
 Type of Upgradations

Maintenance and Repair of Concrete Structures, SWAYAM

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 Maintenance of Bridges

• Good Maintenance practice requires;

1. Periodical Surveillance

2. Identification of local damage

3. Deterioration and loss of durability of the deck

due to environmental and other load effects.
 Maintenance of Bridges
Some time, cost of dismantling the damage bridge is much
more than its periodical maintenance and or
rehabilitation.

 Hence it is more prudent to inspect the bridge at regular

intervals for detection of any signs of deterioration and
initiate rehabilitation measure to restore the bridge
structure to a state of full serviceability.
 Maintenance of Bridges
• The primary objective of bridge maintenance is to ensure
the integrity of the structure during its intended life span so
that it functions without any disruption.
• Rehabilitation may become essential due to design and or
constructional deficiency, environmental effects,
overloading of the bridge deck either due to unanticipated
loading or due to accidents and user made changes in the
structure during its service life.
 Categories of Bridge Inspection
1. Identify minor deficiencies which
may lead to accidents or
maintenance problems at a
Routine Inspection future date
Type of Bridge Inspection

2. Conduct monthly or bimonthly

intervals
1. GI Planned annually
2. Inspection Cover all the structural
Detailed Inspection components of the bridge
3. Visual Inspection , Standard
(a) General Inspection Instrumental aids
4. MI planned 2-3 years, smaller
(b) Major Inspection interval for aggressive environmental
conditions
5. Detailed written report

1. Planned during Earthquake, high

Special Inspection intensity/abnormal loading, flood
2. Structural Testing (internal micro
crack, excessive deflections using dial
gauges
3. Test results analyse in the presence
of expert engineer
 Sunshine Skyway Bridge, Florida
In 1980 this bridge was hit by a cargo ship and a 1200 ft
section of bridge fell into the Tampa Bay.
Replaced with a segmental, post-tensioned (PT) bridge in
1987
Only 13 years later - PT tendon of the new bridge failed
If two tendons fail - PT bridge can collapse (Pillai 2009)
Golden Gate Bridge, San Francisco, CA
Chloride Induce corrosion map of India
Carbonation is also a major issue
Typical Location where chloride induced
corrosion can occur
Core-Crete – Strength and Cover-crete -
Durability
External Sulphate Attack on bridges
Cyclic Freeze-thaw exposure can lead to popping
out of aggregates and paste
Cyclic Freeze-thaw exposure can lead to D-
Cracking of concrete
Pattern of cracking due to ASR(alkali-silica
reaction)

Thomas E. Stanton
Plastic Shrinkage Crack
Uneven Thermal Loads-bridges
Uneven thermal loads-cracking
Creep and Deformation
Creep and Deformation
Fire/elevated temperature damage of bridge
Crazing and Spalling of concrete elements due to
fire attack

Crazing – Network of fine crack on the surface crazing. A network pattern of fine cracks that do
not penetrate much below the surface, is caused by minor surface shrinkage. Crazing cracks are
very fine and barely visible except when the concrete is drying after the surface has been wet
Shear Crack in prestressed girder
 Reference Code for the Identification of crack
• ACI 201.1R-08 Guide for Conducting a Visual
Inspection of Concrete in Service
 Passive and Active Strengthening
• When do the loads act on the additional components?
• Passive Strengthening
• Repair do NOT participate in stress sharing until
additional loads (live or dead) are applied and/or until
acceptable levels of additional deformation occurs
• Active Strengthening
• Repairs do immediately participate in stress sharing
and additional deformation is unacceptable.

Peter. H. Emmons (1993)

43
 Passive Strengthening

Peter. H. Emmons (1993)

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 Active Strengthening

Peter. H. Emmons (1993)

45
 Flexural Strengthening Methods

Peter. H. Emmons (1993)

46
 Section Enlargement

Maintenance and Repair of Concrete Structures, SWAYAM

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 Beam Overlay and Tendons

Maintenance and Repair of Concrete Structures, SWAYAM

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 Externally Bonded Steel Plate

Maintenance and Repair of Concrete Structures, SWAYAM

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 Externally Bonded CFRP Plates

Maintenance and Repair of Concrete Structures, SWAYAM

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 Externally Bonded Pre-stressed CFRP Plates

Maintenance and Repair of Concrete Structures, SWAYAM

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 External Post Tensioning

Peter. H. Emmons (1993)

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 External Post Tensioning –Bents, Pier Caps

Peter. H. Emmons (1993)

53
Bearings and Joints
 Bridge Bearings

Bearings are structural contraptions provided at the top of piers and

abutments to support the girders of the super structure.

Main function of the bearing is to accommodate the movement of the

super structure.
 Movement are induced due to the following reasons
Translational movement of the super structure like expansion and
contraction due to the variations in the temperature at the bridge site.
Rotational movements due to the vertical deflections of the super
structure arising out of highway loads.
Vertical movement due to the sinking of supports

Movement due to the sinking of the super structure

Movement due to pre-stressing or creep

 Thermal movement and Rotation of Bridge deck/Girder
Thermal movement of bridge deck depend upon the coefficient of
linear expansion and temperature range at bridge site
If L = 30m, coefficient of linear expansion = 6.5 × 10-6 per Degree
Centigrade. The temperature at the site changes from a minimum of 10
Degrees to a maximum of 40 degrees Centigrade,

The change in length ‘δL’ of the bridge deck is computed as

δL = (α × L × t) = 6.5 × 10-6 × 30 × 103 × 30 = 5.85 mm

Therefore, suitable provision for the movement of the deck should be
made by providing bearings at the supports.
 Thermal movement and Rotation of Bridge deck/Girder
In addition to the horizontal movement, the bridge girders rotate near
the supports.

The magnitude of rotation at support depends upon the magnitude of

deflection at centre of span and the span length.
Θ = rotation of the girder at the supports, L = Span length (30m), e =
Maximum deflection at centre of span (60 mm)
Assuming the deflected profile of the beam to be parabolic, the rotation
at the supports of the girder is

Θ = (4e/L) = (4 x 60)/(30 x 106) = 8 x 10-3 radians or 0.46 Degrees

 Types of Bearings

Fixed Bearings

It permit rotations while, preventing expansion.

Expansion Bearing
Expansion bearings accommodate both horizontal movements and rotations.
 Types of Bearings
The type of bearing to be selected depends upon the type of super structure, type
of supports and also the span length.

A simply supported span is generally provided with a fixed bearing at one end
and an expansion bearing at the other support.

For a two span continuous girder, a fixed bearing is provided at the central support
and expansion bearing at the end supports.

In case of major bridges the cost of bearings are in the range of 10 to 15 % of the
total cost of the bridge.
For culverts with reinforced concrete slab of small spans, no special bearings are
required. However a thick layer of kraft paper is provided between the slab and
the bed block.
 Types of Bearings

Expansion Type Bearings

Simplest form of expansion bearing used for girder

bridges of span up to 20m.

When the contact surface are flat, Teflon coating

should be used to prevent the development of
frictional resistance and to facilitate smooth
movement due to expansion.

The current practice is to provide a curved shape to

the top plate to reduce the contact area and frictional
resistance.
 Types of Bearings
Sliding cum Rocker
Bearings

In the case of bridges with curved alignment, the

bearings provided should permit sliding movement
and also rotation in different directions.
Essentially the bearings comprises a sliding and
tilting plate with a pressure pad and base plate. The
matting surface should be coated with Teflon to
reduce the fictional resistance.
 Types of Bearings

Steel Rocker Cum Roller Bearing

Roller cum roller bearings permit longitudinal

movement by rollers and rotational movements by
the rocker.
For long span bearings cast steel roller bearings are
generally used. Rollers of diameter 100 – 150 mm are
generally preferred.
Single or two large diameter rollers are preferred to
a nest of small rollers.
The Indian road congress code IRC: 83-1999(Part-1)
provides some guide lines for the selection of the
diameter of rollers.
 Types of Bearings
R.C. Rocket Cum Roller Bearing

These bearings are designed as compression members with

sufficient reinforcements to support the axial loads from
bridge deck according to the specifications of the Indian
Standard code IS 456-2000.
A typical R.C. rocker cum roller bearing comprises a rigid
reinforced concrete block with lead sheets provided at the
top and bottom of the pedestal.
The length of the lead sheet coincides with that of the girder
width while its breadth should be sufficient to limit the
stresses on the sheet within permissible limits.
The R.C. pedestal is designed as a short column to support
the reaction from the girder. Mild steel dowel rods are used
to resist the shear due to longitudinal forces. The lead sheet
permit the girder to rotate.
 Types of Bearings
Elastomeric Bearings

Elastomeric bearings are easy to maintain and

also to replace when damaged. Chloroprene
rubber termed as neoprene is the most commonly
used type of elastomer in bridge bearings. The
specification for design of elastomeric bearing is
provided in IRC 83-1987 (Part-II).
 Types of Bearings
Elastomeric Bearings
 Types of Bearings
Steel Rocker Fixed Bearing

Steel Rocker bearings are generally used for longer span exceeding 15 m. A typical steel rocker
bearing comprises a top portion with a curved contact surface rocking over the bottom plate
which has flat contact surface.
The rocker pin is designed to resist the horizontal shear.
 Types of Bearings
R.C Rocker Bearing

Concrete rocker fixed bearings are also referred to as linear concert hinges and these are
simple and cheap to produce bit require proper detailing and care during construction. This
type of bearings permits large rotations if constructed properly and accurately with correct
design dimensions.
A narrow throat and a very low height of the hinge (generally about 2 cm) with circular
curved faces all-round is provided to ensure a three dimensional confinement of concrete. This
region of confined concrete in the throat can resist compressive stresses nearly 7 times that of
the standard 28 day strength of concrete since the concrete in the throat is in a state of triaxle
compression. The reinforcement are provided above and below the throat in the form of hair
pin loops.