Steel and composite bridges

in Germany
State of the Art
Univ.-Prof. Dr.-Ing. G. Hanswille
Institute for Steel and Composite Structures
University of Wuppertal
Germany

Univ.-Prof. em. Dr.-Ing. Dr. h.c. G. Sedlacek

Institute for Steel and Lightweight Structures
RWTH Aachen
Germany
1

Contents

Introduction
Typical composite road bridges with open sections and
box girders
Composite box girders with wide cantilevering concrete
decks
Composite bowstring arches
Composite trusses
Composite bridges for small and medium spans
Cable stayed bridges
Canal bridges

Advantages of composite bridges

Very slender and aesthetic bridges due to the optimal combination .

of high tensile strength of structural steel and the high compressive
strength of concrete
High durability of normal reinforced concrete decks due to restrictive
crack width limitation.
In comparison with steel bridges composite bridges have a better
behaviour with regard to freezing in winter.

Because the low dead weight of the composite bridges deck is, composite
bridges have advantages with regard to the foundation and
settlements of supports.

Due to innovative erection methods composite bridges are often used for
bridges over passing existent railways or highways without any
restrictions for the traffic. Where existing freeways with two lanes are
widened the short erection time of composite bridges avoids longer
restrictions for traffic.

Composite Bridges with open and

closed cross-sections

Werra-Bridge Einhausen
4

Typical cross-sections for composite bridges

plate girder bridge with three
rolled or welded main girders
16,75m
2,00

2,00

12,75m

25cm

2,5%

cross-section with two

separated box girders

45 cm
35 cm
2,575

5,80

45cm

2,575

5,80

35cm
2,5%

25cm

box girder
55cm

3,00

40 cm

1,80
airtight welded box
girders

25cm

6,80m
8,15m

4,30

3,00

7,15
1,80

2,5%

4,30

Bridge Schleusetal

view

55

72,5

80,0

80,0

80,0

75,0

72,5

67,0 58,0 40,0

680,0

5,00

cross-section at midspan
2875

1300

5700 mm

1300

2475

460
290

3,25
11,00

11,00

7000 mm

25,25 m
6

Bridge Schleusetal

Bridge Schleusetal
transportation of steel girders
on site

erection of
steel girders by
cranes

casting of the concrete deck by

moveable formwork
8

Examples for formwork systems

formwork tables on
temporary consoles
retractable
console

rollers
wedges

scaffold beam

formwork
tables

Bridge across the river Ruhr near

Hagen-Freeway A1

1,96

1,50 1,50

14,50

1,25

3%

2,50

3,52

3,46

3,20

4,76

4,50

6,00

1,96

14,50

3%

3,01 2,50

concrete end
cross girder

cross-section
at midspan

cross-section
at supports

2,50

3,52

6,00

2,50 3,01

35,06m

2,70

1,30

4,00m

view

73,48m

95,77m

71,83m
10

Bridge across the river Ruhr near

Hagen-Freeway A1

11

Bridge Neutting -Double composite box girder

2.00

30.00

cross-section at
support
11.50

3.00

11.50
0,34

0,52

2.00
3.75

concrete C35/45

6.92

3.75

cross-section at
midspan

4.01

6.99

0,35

4.00
concrete C 50/60

95.00

3.30

3.30

7.00

3.30

7.00

3.30

HHW 366.00

4.36

3.30

6.23

4.39

362.00

154.00

68.00

58.00

470.00
0

12

Double composite bridge Neutting

box girder with double
composite action at internal
supports

composite bottom flange

13

Box girders with corrugated webs

Bridge
Altwipfergrund

14

Bridge Langerfeld Freeway A1

view

30,5

40,0

42,0

42,0

42,0

42,0

42,0

36,0

316,5
36,75
2,25

14,50

2,25

14,50
1,75 1,50

cross-section
0,00

35

6%

40

4%

7,75

7,75
4%

15%

0,00

4%

6%

1,60

-2,95

3,35

5,90

5,90
18,50

3,35

3,35

5,65

5,65

3,60

18,25

15

Langerfelder Bridge Highway A1

16

Langerfelder Bridge Highway A1

Detailing at internal supports
support stiffener

transverse stiffener for

hydraulic press

elastomer
bearings

plate for jacking

supports by
hydraulic press in
case of exchanging
bearings

wedge
shaped
bearing plate
17

Composite box girders with wide cantilevering

concrete decks

Bridge Albrechtsgraben

18

Composite box girders with wide concrete decks

Bridge Reichenbachtal

Bridge Elben

Bridge Schwarza

Bridge Oehde

19

Bridge Wilde Gera

28,00m
2,00

1,50 1,50

10,00
5,50

10,00

2,00

5,50

longitudinal beams
transverse tension member
35

35
5,00

1,20

3,80

1,20

3,80

5,00

1,80

3,15

Schweinfurt

3,30

Erfurt

3,15

DB

14,50
Wilde Gera

30

36

42

42

42

42

42

252m

42

42

42

42

42

36

30
20

10

Bridge Wilde Gera

21

Bridge Wilde Gera Highway A71

transverse steel
tension members

transverse frames
22

11

Bridge Wilde Gera Highway A71

cantilever
erection of the
arch
23

Bridge Wilde Gera Highway A71

Bridge girder during

launching
24

12

Bridge Albrechtsgraben - Highway A71

140

150

130

120

110

100

90

80

70

60

50

40

30

20

10

770
45

55

60

70

70

70

45

40

40

45

70

60

50

45

29,00
25,00

2,00

2,00

6,00

1,50

4,15

4,15

1,50

6,00
25

Bridge Albrechtsgraben - Highway A71

26

13

Different detailing of transverse tension members

27

Joints between the longitudinal girders/box girders

and the transverse tension members

Bridge
Albrechtsgraben

Bridge Schwarza

28

14

Detailing of the transverse tension members

Dc
A

Zs
Za

Zs,q
outside longitudinal girder

Zs

section A-A

pulling down joint

horizontal loops

vertical
stirrupps

tension member
29

Acessment of different solutions for

transverse tension members
geometry of the
concrete slab

internal forces in the

tension member

connections

a constant depth of the slab

over the total width of the
bridge deck is required, uniaxial load transfer in
transverse direction

high stresses due to local

concentrated wheel loads
(Fatigue resistance)

economical simple
connections with the top
flanges of the box girder
and the secondary
longitudinal girders

haunched concrete slab,

expensive formwork, bi-axial
load transfer in transverse
and longitudinal direction

higher stresses due to

local loads. Resistance of
the tension member to
normal forces, bending
moments and vertical
shear should be
considered

slabs with constant depth

and haunches in longitudinal
direction are possible, uniaxial load transfer in
transverse direction

no significant stresses in
the steel tension member
due to local loads

complicate connection
caused by the eccentricity
between the tension
member and the top
flanges of the box girder

30

15

Sequense of casting of concrete

1

Method I : continuous in one direction

Method II: continuous in one direction but
regions at internal supports are casted in a
second step after the concrete in mid-span
regions is effective

45 55

7,5

7,5

70

70

70

70

70

70

55 45

690
10

Method III: span-wise in reverse direction

70,0

70

20

30

40

50

cross-section

60

70

80

90

100 110 120

28,50

70,0
17,5 7,5

3 x 15,0

3 x 15,0

17,5 7,5

3 x 15,0

3,80

Method I

10 11

12

12

10

11

12

11 10

Method II

Method III

31

bending moments acting on the composite section

due to dead weight of concrete
My= -103,2

My= -107,5

My= -105,3

Method I
-

My= -31,9

My= -43,7

My= -31,9

My= -45,4
+

+
My= 27,2

+
My= 28,1

My= -32,5

My= 26,5

My= 25,6

My= -33,5

Method III

Method II

+
My= 27,3

+
My= 25,4

[My in MNm]
32

16

Formwork carriage running on the top of the deck

formwork carriage for cantilevers

formwork tables on temporary consoles

33

Formwork carriage running on the top of the deck

Bridge Wilde Gera

34

17

Formwork underneath the concrete deck

formwork carriage for outer cantilevers

formwork tables on temporary consoles

Bridge Albrechtsgraben
35

Formwork underneath the concrete deck

(system Kirchner)

Bridge Schwarza
36

18

Exchange of concrete decks

Normally it is a general requirement in Germany to

have separate bridges for each traffic direction in
order to be able to divert the full traffic on the
remaining bridge in case of major maintenance
work on the other. The concrete deck is the most
vulnerable part of a bridge section. With regard to
the expected intensive increase of road traffic and
local wheel loads in future, the concrete deck must
be regarded as a wearing part in contrast to the
steel structure with implication of different lifetimes
of the concrete deck and the steel structure.
In case of one main composite box girder for both
traffic directions the flow of traffic has to be
maintained in both directions just on one half of the
bridge during a future replacement of the bridge
deck. For this procedure the bridge deck will be
partially cut out with high-pressure water method
and will be replaced by a new bridge deck. During
this procedure significant additional stresses result
in the superstructure, which have to be considered
during design and construction.

37

Different possibilities for the exchange

of the concrete slab
A

The width of the span is the

most important factor for
choosing the different methods.
Method A can only be used for
spans up to 50 m. Methods B or
exchange over a quarter of the bridge in two steps C are possible for the exchange
of the concrete deck of bridges
with larger spans of up to 100 m.
exchange of one half of the deck

B1

B2
C

exchange of one half of the deck with additional

horizontal bracing
Horizontal bracing

38

19

Bridge Oehde Freeway A1

00

10

20

30

40

50

60

70

3,8%

44,70

56,0

72,80

72,80

64,0

56,0

44,70

418,30 m

3800

5600

3800

2310

2,5%
3785

2310

3800

5600

3800

39

Bridge Oehde Freeway A1

transverse tension
member

40

20

Bridge Oehde Freeway A1

P1 P3

P2

P6

P4 P5 P9

P7 P8 P11

P10 P13

P12 P15

P14

concrete deck with

partially prefabricated
concrete elements

launching of the bridge with

partially prefabricated concrete
elements
41

Composite bowstring arches

Saalebridge Besedau
42

21

Composite bow string arches

Composite bow string

arches with concrete
decks are an often used
system where the
construction depth is
limited e.g. for bridges
over canals and
rivers.The reinforced
concrete deck is
connected with the steel
structure by horizontal
bracings at the end of
the bridge and is acting
as a tension member in
the main system.
43

Normal forces in the concrete tension member

For the normal forces in the concrete member

the effects of tension stiffening of concrete
between cracks should be considered.
The concrete member acts as a
tension member in the main system.

N= Ns+Na

s,2

Na,2

s,m

Na= Na,2-Nts

Na

Ns= Ns,2 + Nt,s

Nt,s

Na= Na,2-Nts

Ns,2

Ns
Ns,cr

Ns,crn
44

22

Bridge Ladbergen near Ladbergen Highway A1

3958
2000
19850 19850

plan

view

104270

cross-section

1500

end-bracing

2400

2400

15389

15389

800

800

1500

10100

9750

2000

9750

10100
45

Detailing of composite bowstring arches

46

23

Composite trusses

Bridge St. Kilian

47

Composite truss bridge with double composite

action Bridge Nantenbach across the river Main

208,00m

83,20m
7

12,5

83,20m
9

10

view

48

24

Composite truss bridge with double composite

action Bridge Nantenbach across the river Main

1,40 50
R=2650,00m

1,10-1,80

80
3,95

80

80
6,80

2,00 1,20

6,80

20

14,30

R=2650,00m

15,26

80
3,95

1,40 50

1,00

1,40 50

1,00

R=2650,00m

20

20

14,30

1,00

20

20

14,30

1,20

20

80 2,60
1,60

2,60 80

2,60

1,60

49

Composite truss bridge Kragenhofer

58,40

73,60
249,60

59,20

58,40

view

cross-section

4350

14300
4700

2200

2200

2600

400
R=
1552,35

5600

9000

700

280

2600

4350
50

25

Bridge St. Kilian

28,5 m

5,0 m
51

Bridge St. Kilian

steel trusses with hollow

sections and cast iron nodes

52

26

Composite bridges for small and medium spans

Bridge Oberhartmannsreuth
53

Composite bridges with rolled sections for

small an medium spans

Advantages

short construction time

simple erection method because of no steelwork on site.
steelwork only in the shop
small total depth of the composite section
concrete slab without any pre-stressing

54

27

Longitudinal reinforcement at internal supports

L+lb

bQRT

L+lb

concentrated shear
connectors at the end
of the girder

lb-anchorage length of
the reinforcement

bottom layer of
reinforcement
As,min = 16 a=10 cm

The longitudinal reinforcement at internal supports should be placed over a

length not smaller than L= 0,15 LSt where LSt is larger span length adjacent to
the support considered.
at the end of the steel girder the number of shear connectors should be
increased due to local introduction of the tensile force in the reinforcement in
the composite section.
In case of sagging bending moments at internal supports due to temperature
effects, traffic loads and settlements of supports for the tensile forces in the
bottom flange a connection by steel plates or studs in combination with
loops is required.

55

Detailing of transverse supporting beams in

concrete
bmin = 80cm (indirect support )

b>bmin

b>90 cm

bmin= 60 cm (direct support)

56

28

Detailing of partially prefabricated concrete

elements

mortar

Cnom
= 4,5cm

hc
4,0
2,5

1,0
21
shear reinforcement

the depth of the concrete above the

prefabricated elements hc should be
not less than 20 cm within the traffic
lanes. in other regions hc should not be
less than 15 cm.

3cm

seal
2,5 cm

Elastomeric support strips with

a thickness of 2 cm and a width
of 3 cm. The minimum value of
pressing should be 3-5 mm and
the maximum value should not
exceed 10 mm.
57

Casting of concrete

in case of smaller span length the transverse supporting

beams and the concrete slab should be casted in one
operation.
in case of larger span length or for bridges with a big total
length at first the midspan regions and subsequently the
internal supports and the transverse supporting beams
should be casted.
0,15 L

casting of midspan regions

casting of supporting
beams and the slab at
internal support

58

29

VFT-Bridges with welded or rolled I-sections

in situ concrete slab

precasted
concrete flange

steel girder

steel girder in the shop

transport on site

installation by crane

59

VFT-Filler beams

3200

rolled section
640

shear connection
60

30

VFT-Filler beams

61

Preflex - Beams

steel girder

prestressed
composite
bottom flange

The Preflex-Beam is a girder with a pre-stressed

composite bottom flange where the pre-stressing is
applied by elastic bending of the steel girder.
The pre-stress causes a higher bending resistance
and a high flexural stiffness. Therefore the
deflections under serviceability conditions very
small. This type of beam is often used for railway
and road bridges where the available construction
depth is highly restricted. Ratios of span to
structural depth up to 45 are possible for road
bridges.

62

31

Preflex Girders pre-stressing of the concrete

bottom flange

campered steel girder

Fv

Fv

pre-stressing forces Fv
applied to the steel
girder (elastic bending)

Fv

Fv

casting of the concrete

bottom flange

Fv

Fv

removing of the
prestressing force Fv
after hardening of
concrete causes
compressive stresses
in the concrete bottom
flange
casting of the concrete
top flange on site
63

Composite bridge with Preflex-Girders

Hermann-Lieberum Bridge in Leipzig

continuous beam, span 33 m and
construction depth 130 cm

64

32

Cable stayed bridges

65

cable stayed bridge Wesel across the river Rhein

10

20

30

40

53,24 64,554 64,554 64,554

60

50

64,554 64,554

396,132

80

70
334,82

90

61,76

376,412

66

33

Cable stayed bridge Wesel across the river Rhein

cross-section axes 10 - 70

4250

550

700

6150
550

4250
2800
550
700

6150

400

550
67

Cable stayed bridge Wesel across the river Rhein

cross-section axes 70 - 90
3500

8750

27500 mm
3000

8750

2,5%

7710

5900

3500

2,5%

2000

5900

7710

13800

68

34

Joint between the steel and the concrete section concrete

end cross girder

joint with overlapping steel

plates and headed studs

concrete end cross girder

69

concrete end cross girder

70

35

Pylon in high strength concrete

+145,30m

composite section
3000

1000

4000 1000

3000 2000

concrete section

400

4000

500

3295-3971
.+15,90
71

cables

Use of parallel strand

cables of galvanized
waxed and PE-coated
strands instead of
traditionally used fully
locked coil ropes.

72

36

erection stages
70
10

80 90

stages I and II

stage III

stages III to VIII

stage IX

73

Canal bridges

canal bridge Lippe

74

37

Canal bridge Magdeburg

view

57,10

106,20m

10x5,71

10x5,31

57,10

7,81

10x5,71

10x5,31

20

10

6,30

30

40

cross-section

3,98

34,04

3,98

42,00 m
75

Canal bridge Magdeburg

total length 228 m

span length 57,1 m 106,2 m 57,1 m
Structural steel 9.500 t
76

38

Canal bridge Magdeburg

1900

4819

1087.5

transverse frame

740

2440

740
77

Launching of the bridge

stage 2

stage 11

stage 17

stage 22

78

39

Canal-bridge Lippe

24,00m

24,80m

24,00m

B
28,00m

4,75

C
3,00

4,75

3,00

28,00m

+56,50 NW
7,84

+56,50 NW

2,21
2,21 2,16
LT7

10,82
LT6

LT5

10,82
LT4

LT3

2,16 2,21
LT2

4,33
LT7

4,33
LT6

4,33
4,33
30,40m
LT5

LT4

4,33

4,33
LT3

LT2

2,21
LT1

LT1

79

Canal-bridge Lippe

80

40

7th Japanese German

Bridge Colloquium Osaka 2007

Thank you very much for your attention

81

41