BRIDGE CONSTRUCTION

method of
construction

incremenatal
balanced
span by span launching
cantilever
method

one go segmental segmental with precast with cast in situ

construction construction construction elements elements

using launching with precast with precast with cast insitu

from ground
truss elements elements elements

using under
with launching using form
slung launching
truss traveller
truss

BALANCED CANTILEVER METHOD

• Cantilever construction is a method of construction of a cantilever in segments and

stitching them to the segments already completed by pre stressing.

• Balanced cantilever construction (BCC) is done to counterbalance each cantilever arm

with another cantilever arm projecting the opposite direction.
The construction is done in the following sequence:

How BCC done?

OPERATION SEQUENCE

1) SURVEY WORK: Center line marking for foundation of trestles will be done with the
help of theodolite/ total station.

2) CONSTRUCTION OF PIER HEAD:

• Cutting ,bending and reinforcement cage.

• Casting pier starter.

• Fixing shutters.

• Concreting of Pier.

• De-shuttering and dismantling staging.

• Curing.

3) CONSTRUCTION OF CANTILEVER
 FORM TRAVELER (FT)

• The FT is a large piece of equipment that, once assembled and attached to the
edge of the bridge deck, will allow the bridge deck to be built over the inlet.

• The FT gets locked to the completed deck area, a new deck area is concreted in
front of it and the traveler moves to that edge to begin the process again

• The system is lightweight, versatile, easy to assemble and operate, rolling

forward on rails, the system can be reset quickly and easily.
A typical segment cycle would consist of the following steps

1. The launching System is launched on rails in the new segment location.

2. The external formwork is aligned, leveled and fixed into place.

3. Reinforcing steel is placed in the bottom slab and web walls.

4. The interior formwork assembly is advanced, and the top deck slab soffit and wall forms are
leveled and fixed into place.

5. Reinforcing steel and post-tensioning tendons are placed in the deck slab.

6. Concrete is placed in the bottom slab, web walls, and deck slab.

7. The post-tensioning tendons are stressed.

8. The internal and external formwork is stripped from the cast and cure segment, and the
Form Traveler is launched to the next segment.
 4) CONSTRUCTION OF END SPAN.

Casting of end span is done after the cantilever construction. Activities involved remains
the same as explained for pier head construction.

5) CASTING OF STITCH SEGMENT

After casting of span, the remaining portion of length 2.50m segment is to be stitched.

ADVANTAGES OF CANTILEVER METHOD

• This type of bridge could be erected without any scaffoldings from the ground.

• Accordingly erection need not to be affected by the land condition (River, Sea,
Valley, and Ravine) and/or road, railway surrounding the erection spot.

• Could be erected SAFELY and be erected by a small number of workers, because

of the repetition works.

• Arrangement of the PC tendons and the bending moment distribution are

similar. Therefore, the rational design could be done.

• Can be applied for the certain curve alignment.

• Useful where span length is more but launching of girder is not possible.

• Useful for odd sizes, single span

DISADVANTAGES

• BCM has more expansion joints

• Require more number of bearing , anchorages

• Shear stress can be very high at hinges hence there are very congested with steel.

• Joints are generally not pleasing to eyes

• Vertical alignment during construction

Each load added or moved causes the deck to deflect. Creep and shrinkage increases the
deflection. The objective is to get the vertical alignment correct for some stage after
construction, usually when the bridge is opened to traffic or at some time after that.

• Stability of end cantilever:

Adequate ground area for laying the temporary pier support

 FT-S Series Form-Traveler (Over Head Model) Main Specification

Item Description Specification

1 Model FT-S

2 Capacity 100t ~ 480t

3 Segment Length 3.5m ~ 7.0m

4 Deck Width 5m ~ 35m

5 Bridge Curvature Radius 100m-unlimited

6 Bridge Type Balance Cantilever Box Girder or Cable Stay

7 Launching Mechanism Hydraulic

8 Formwork Material Metal Sheet or Plywood Sheet

9 Shape of Bridge Section Any shape

5 days – 7 days depend on site condition, concreting capacity,

10 Production Cycle time concrete design, pier height, reinforcement fabrication method
etc.

Longitudinal 7%
Max. Bridge
11
Slope
Transverse 5%

INCREMENTAL LAUNCHING METHOD

• The incremental launching method is one of the highly mechanized erection methods
used in bridge construction.

• The method consists of manufacturing the superstructure of a bridge by sections in a

prefabrication area behind one of the abutments
 • A set of tracked incremental launching system is specially developed with highly
modularized equipment and automatic control

• These can be adjusted in vertical, longitudinal and transverse direction.

• Segments of bridge can be casted behind abutment in 10 to 30m.

The basic working principle is

• The vertical jack to lift the structure simultaneously in multiple points,

• The horizontal jack to push the structure forward to achieve the launching purpose,

• Then vertical jack is released and entire structure laid down on temporary pad beam to
complete a launching process.

SLIDING BEARING

• The sliding bearings were installed on all permanent and temporary piers.
 • The sliding bearings consist of concrete blocks covered with stainless steel and Teflon-
coated reinforced elastomeric pads.

• Steel/neoprene/Teflon plates were placed between the leading box girder and these
bearings to keep the friction to a minimum.

• The friction recorded at each launching operation was approximately five percent,
which was close to the assumption made during the design.

• Low friction bearings must be provided.

Various sensors type:

• Pressure sensors to measure working pressure of lifting oil cylinder,

• Displacement sensors for launching oil cylinder travel distance measurement,

• Angle sensors to record the hybrid girder longitudinal slope

• All signals from sensors and measuring equipment are then transmitted to the main
control computer to go on data analysis and processing

• Any transverse discrepancy can be instantly monitored with automatic transverse

adjustment

Withdrawing Lifting

Launching Descending
LAUNCHING PROCESS
Step 1 lifting: the lifting oil cylinder is activated to uplift the entire girder structure from the pad
beam.
Step 2 launching: the launching oil cylinder is activated to move the girder structure and the
upper part of the launching system forward.
Step 3 descending: the lifting oil cylinder is released and descended, the girder structure is laid
down on temporary pad beam.
Step 4 withdrawing: the launching oil cylinder is released and the whole launching system back
to initial state, a launching cycle completed and prepare for next repetition.

FORMWORK
• Formwork used is stationary which is laid in the prefabricated area near the abutment.
• Steel forms are used when there are many repetition of work.
• Timber forms can also be used.
• I sections are used to support the formwork
• Double T beam can be used where only one formwork for both internal and external .
They are fixed together and can be hydraulically lowered outwards and inwards
respectively.

LAUNCHING NOSE

A stiffened steel plate girder is fixed to the tip of the bridge, its length being normally 60% of
the regular span length.

The nose usually consists of two braced main girders of steel. Its length is 60 to 65 % of the span
of the bridge.

Its weight ranges between 1 and 2 t/m, or more if the length is over 30 m.

ADVANTAGES

• It eliminates the traditional scaffolding required for supporting the formwork

• This is particularly valuable for projects with high piers, in urban areas, spanning over
deep water, over roads and over railways.

• Most of the construction operations take place in the same location, which may be
organized as a pre casting yard.

• The pre casting work is thus more easily supervised, giving a high quality of
workmanship.

• Minimal temporary works.

 • A moderate investment in specialized equipment.

• If over timing is done, one cycle can complete in 7 days.

• Reduction in construction joints and hence shortens construction duration.

DISADVANTAGE

• This form of construction can be used for bridges having constant cross sectional

shape throughout their length.

• The bridge should be straight or have constant horizontal and vertical curvatures.

• ILM is not economical upto 150 m span length

• After construction of one unit, hardening of concrete and subsequent launching require
one week

SPAN BY SPAN CONSTRUCTION

• Construction of bridge from one span to other starting at one end.

• Construction joints are usually placed at the counter flexure points.
• This method is for concrete and rarely for steel bridges.
• The form carrier may be supported on the pier from the edge of the previously
completed construction or from side of pier.
• Pre stressing tendon ensure the span assembly a good continuity with preceding span.
TYPES
• The formwork gantry can be either
• above-deck
• below-deck.
• The formwork is suspended from steel rods. After concreting and post-tensioning, the
forms are released and the gantry rolled forward by means of outriggers on both sides
gantry's superstructure
SEQUENCE:
• Bottom truss is laid
• Stressing the connection of truss
• Reinforcement vertical and horizontal(slab)
• Concreting the reinforcement
• Finishing the reinforcement
• Curing the concrete
• Stressing of tendon
• Grouting the deck of tendon
• Main jack lifts
• Outer form moves
 • Launching jack
ADVANTAGES
• Faster construction
• Lower operating cost
• Better quality
• Constant monitoring
• Simple connections
• Greater ease of transport
• Assembly on site is easy
• Reduction of construction site space
MSS-S Series Moveable Scaffolding System (Over Head MSS) Main Specification
Item Description Specification

1 Span 25m ~ 70m

2 Span weight Capacity 380t ~ 1600t

3 Self weight 300t ~ 950t

4 Bridge Curvature Radius 300m

5 Formwork Material Metal Sheet or Plywood Sheet

6 Launching Mechanism Hydraulic

Span by span construction, continuous

7 Type of Bridges
or simply supported

U-Shape, Double-T, Single Box,

8 Shape of Bridge Section Double Box, Box with Strut, Concrete-
Steel integrated bridge.

10 days – 14 days depend on site

condition, machinery capacity, pier
9 Production Cycle time height, reinforcement fabrication
method and internal forming system
used.

Max. Longitudinal 7%
10 Bridge
Slope Transverse 5%