Bridge Construction

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.

Bridge Construction

1. INTRODUCTION

Importance of bridges.

Objective:
Review

latest bridge construction systems.

Scope:
Highway

bridges (90%).
Prestressed concrete (most recent developments).
Superstructures.

Bridge Construction

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.

Bridge Construction

Classification of Prestressed Concrete Bridges:

Category
Pre-tensioned Girder
Bridges
(I- or T- Beam)

Method of Construction
Erected with Cranes

Erected with Launching

Girders

Cast in-situ:

Post-tensioned Bridges

On Falsework

Cantilever Segmental

Span by Span

Precast:
Incremental Launching

Cantilever Segmental

Span by Span

Cable-Stayed Bridges
Suspension Bridges

Incremental Launching

Free Cantilever

Balanced Cantilever

Latest Bridge Construction Systems:

Bridge Construction

System
Code

Description

Precast, Prestressed Concrete Girders

B
C
D
E
F
G

Incremental Launching Construction

(Deck Pushing System)
Cast-in-place,
Balanced Cantilever Construction
Precast Segmental,
Balanced Cantilever Construction
Flying Shuttering System
Cable-Stayed Bridges
Suspension Bridges
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Bridge Construction

Suitability of Bridge Construction Systems:

Sys.

Site
Cond.

Structure Span Lengths Structure

Depth
Level

Other Aspects

Inaccess.

High

Short
(40 - 80 m)

Variable

Sharp curvatures &

superelevations.

Inaccess.

High

Short
(40 - 80 m)

Constant

Straight or slightly-curved
superstructures.

Inaccess.

High

Long
(up to 250 m)

Variable

Crossing navigable
waterways.

Inaccess.

High

Long
(up to 200 m)

Variable

Crossing navigable
waterways.

Inaccess.

High

Short
(40 70 m)

Variable

Long viaducts with short

spans.

Inaccess.

Very High

Long
(200 to 1,000 m)

Variable

Crossing deep rivers, deep

valleys, and mountains.

Inaccess.

Very High

Very Long
(500 to 2,000 m)

Variable

Crossing deep rivers, deep

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.

Bridge Construction

(A) Precast, Prestressed Concrete Girders

Launching Truss Schematic Diagram

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Bridge Construction

(A) Precast, Prestressed Concrete Girders

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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Bridge Construction

(A) Precast, Prestressed Concrete Girders

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

(A) Precast, Prestressed Concrete Girders

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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(A) Precast, Prestressed Concrete Girders

Post-Tensioning of Girders

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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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(B) Incremental Launching (Deck Pushing)

Incremental Launching Construction Schematic

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Bridge Construction

(B) Incremental Launching (Deck Pushing)

Main System Components:

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).

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Bridge Construction

(B) Incremental Launching (Deck Pushing)

Temporary Bearing Blocks

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Bridge Construction

(B) Incremental Launching (Deck Pushing)

Construction Sequence:

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

(B) Incremental Launching (Deck Pushing)

Advantages:
Inaccessible sites.
Riding learning curve (Repetitive operations).
No interference with traffic.

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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(B) Incremental Launching (Deck Pushing)

Construction Sequence

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Bridge Construction

(B) Incremental Launching (Deck Pushing)

Inc. Launching Construction

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(C) Cast-in-Place, Balanced Cantilever

(Cantilever Carriage System)

Bridge Construction

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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(C) Cast-in-Place, Balanced Cantilever

Bridge Construction

Main System Components:

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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(C) Cast-in-Place, Balanced Cantilever

Form Travelers - Schematic Diagram

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(C) Cast-in-Place, Balanced Cantilever

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Construction Sequence:

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(C) Cast-in-Place, Balanced Cantilever

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Construction Sequence (Contd.):

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(C) Cast-in-Place, Balanced Cantilever

Cantilever Carriage System Closure Pour

Bridge Construction

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(C) Cast-in-Place, Balanced Cantilever

Bridge Construction

Advantages:
Inaccessible sites.
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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(C) Cast-in-Place, Balanced Cantilever

Construction Sequence

Bridge Construction

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(C) Cast-in-Place, Balanced Cantilever

Cantilever Carriage Construction

Bridge Construction

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Bridge Construction

(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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Bridge Construction

(D) Precast Segmental, Balanced Cantilever

Erection
Procedure
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Bridge Construction

(D) Precast Segmental, Balanced Cantilever

Erection
Procedure
(Contd.)

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Bridge Construction

(D) Precast Segmental, Balanced Cantilever

Main System Components:

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

(D) Precast Segmental, Balanced Cantilever

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

(D) Precast Segmental, Balanced Cantilever

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 posttensioning 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.
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Bridge Construction

(D) Precast Segmental, Balanced Cantilever

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

(D) Precast Segmental, Balanced Cantilever

Construction Sequence

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Bridge Construction

(D) Precast Segmental, Balanced Cantilever

Precast Segmental Construction

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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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(E) Flying Shuttering System

Bridge Construction

Stepping Shuttering Construction Schematic Diagram

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(E) Flying Shuttering System

Bridge Construction

Main System Components:

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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(E) Flying Shuttering System

Bridge Construction

Construction Sequence:

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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(E) Flying Shuttering System

Bridge Construction

Advantages:
Long viaducts with short spans.
No interference with traffic.
High construction progress rate.

Disadvantages:
Special equipment.
Unsuitability for long spans.

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(E) Flying Shuttering System

Construction Sequence:
Concreting Phase and Advancing Phase

Bridge Construction

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(E) Flying Shuttering System

Flying Shuttering Details

Bridge Construction

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(F) Cable-Stayed Bridges

Bridge Construction

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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(F) Cable-Stayed Bridges

Bridge Construction

Cable Arrangements:

Transverse:
(a)
(b)
(c)
(d)

Single Plane Vertical

Single Plane - Vertical/Lateral
Double Plane Vertical
Double Plane - Sloping

Longitudinal:
(a)
(b)
(c)
(d)

Radiating
Harp
Fan
Star

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(F) Cable-Stayed Bridges

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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(F) Cable-Stayed Bridges

Bridge Construction

Stay Technology: Cables

(a)

(c)

(b)

(d)

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

(c) Stranded; (d) Locked-Coil

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(F) Cable-Stayed Bridges

Bridge Construction

Stay Technology: Anchorages

Anchorage System for Parallel-Wire Cables

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(F) Cable-Stayed Bridges

Bridge Construction

Stay Technology:

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(F) Cable-Stayed Bridges

Bridge Construction

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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(F) Cable-Stayed Bridges

Bridge Construction

Construction Systems:

Balanced Cantilever.
Free Cantilever.
Deck pushing.

Balanced Cantilever
(Cast-in-Place)

Free Cantilever

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(G) Suspension Bridges

Bridge Construction

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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(G) Suspension Bridges

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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(G) Suspension Bridges

Bridge Construction

Construction Sequence:

1.
2.
3.
4.
5.

Construction of towers and precasting of superstructure

segments.
Erection of main cables. Strands are pulled by winches and
erected individually using specialized equipment.
Installation of cable clamps and hanger rods using cranes.
Transporting superstructure segments below their final
position on barges.
Erection of segments using erection equipment (erection
girders, for example).

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(G) Suspension Bridges

Bridge Construction

Construction Sequence: (Contd.)

6.
7.
8.
9.
10.

Jacking-up of each segment prior to erection of hanger

bars.
Erection of hanger bars and their adjustment to
predetermined lengths to bring the segments into alignment.
Interconnection of superstructure segments.
Cambering the superstructure upwards by controlled
adjustment of hangers before casting the deck.
Bringing the deck to its final level through a final set of
hanger adjustments.

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(G) Suspension Bridges

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
(m)

Comp.
Date

6th of October Bridge (Ramsis/Ghamra).

Ring Road 9-D Bridge.

Zamalek Elevated Road.

Dessouk Overhead Bridge.

Al-Giza New Bridge.

6th of October Bridge.
Abou El-Ela Bridge.
Rod El-Farag Bridge.
New Benha Bridge.
Al-Warrak Bridge

33 40
40
31@25, 2@23.5
34.2, 7@40.7, 5@40, 34
104, 2@69
110, 2@100, 2@70
115, 2@69
130, 2@75
120, 2@69
120, 2@60

1988
1998
1986
1987
1969
1976
1986
1990
1990
2000

D
E

Has Not Been Applied

6th of October Br. (Ghamra/ Autostrad).
Suez Canal Bridge, Approach Spans.
6th of October Br.(Ghamra/Autostrad).
Suez Canal Bridge, Main Spans.
Has Not Been Applied

42
40
133 (66.5 in each side)
404, 2@163

1998
2001
1998
2001

F
G

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Bridge Construction Systems Applicable forBridge Construction

Different Site Conditions in Egypt

System
Code
A
Under Running
I
B
Traffic
E
C
Across Navigable
II
D
Waterways
F
Deep Waterways and
F
III
Mountains
G
A*
IV At Accessible Sites*
B*
E*
#

Site Conditions

System Description
Precast concrete girders.
Incremental launching.
Flying shuttering.
Cantilever carriage.
Precast segmental construction.
Cable-stayed bridges.
Cable-stayed br. (up to 1000 m).
Suspension bridges (> 1,000 m).
Precast concrete girders.
Incremental launching.
Flying shuttering.

* May be feasible for accessible sites, particularly for very high

superstructures (high approach spans and viaducts).

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Bridge Construction

Thank you for listening

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