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Short Span Segmental

Bridges in Czechoslovakia
Jiri Strasky
Chief Design Engineer
Dopravni Stavby
Design and Construction Engineers
Brno, Czechoslovakia

Miroslav Korenek
Structural Engineer
Dopravni Stavby
Design and Construction Engineers
Brno, Czechoslovakia

R ecently, two distinct types of precast


prestressed segmental bridge design
have been developed in Czechoslovakia.
vation. The segments of the box cross si
tions were cast in forms similar to the
developed by Campenon and Bernard. " 2 T
These designs are suitable for both urban double-tee members were cast in forms i
and highway bridges with spans 'ranging up ing a new concept. The segments are c.
to 150 ft (45 m). The first design (Fig. 1) in one-day production cycles and the curi
consists of box segments transversely con- of the concrete was accelerated by steami
nected by the top flange while the second the freshly cast components.
alternative (Fig. 2) utilizes segments of open, 2. To control temperature and humid
double-tee cross sections. variations, deicing salts, and different ere
The development of these bridges was and shrinkage ratios of the segment sly
preceded by the successful construction of and webs, the joints between segments we
several segmental overpasses (Fig. 3). Al- covered with epoxy resin during assemb
though these bridges were built under dif- Also, the faces of the segments were pi
ferent social and economic conditions, some vided with multiple keys and erected
of their structural features and construction cantilever. This made it easier for the pi
methods have interest and applicability to cast segments to adjust to their proper 1
projects in other parts of the world. sition after temporary post-tensioning.
The following features are common to all 3. The erection process was designed
the bridge structures described herein: such a way that the structural configurati
1. The superstructure consists of precast of the bridge would not be affected by t
match-cast segments with a specified cube redistribution of creep caused by volume
strength of about 7000 psi (50 MPa). Short- stress changes.
line horizontal casting was used to produce 4. During the course of erection, the
all constant-depth segments while adjusta- perstructure was gradually post-tension
ble forms allowed for both horizontal and by two systems of tendons: straight tend(
vertical curves and variations in superele- placed in the deck and draped tendons plac

106
Presents an overview of the design features and
construction techniques used in some recent pre-
cast prestressed short span segmental bridges in
Czechoslovakia.

in the webs. Because of the relatively low tressing steel can act similar to mild steel
segment depth, no work in the low cells of reinforcement, thus limiting the width of
the box girders was possible. Therefore, all cracks in the joints. Note that the Czecho-
tendons were anchored in the upper part of slovakian Building Code prohibits the use
the section. The tendons were formed by of unbonded tendons.
six, 7-wire strands 0.612 in. (15.5 mm) in
diameter anchored by their own anchorage
OVERPASSES
system. The tendons are situated along the
entire length of the bridge in both the up- Overpass bridges for field and forest roads
per and lower faces of the superstructure. represent a specialized group of bridges.
Since the stresses in the tendons after losses They are characterized by the fact that the
are lower than permissible stress levels, in right angle of crossing and the width be-
cases of unexpected overloading, the pres- tween railings are always constant and their

Fig. 1. Bridges (DS-W type) in Prague.

PCI JOURNALJJanuary-February 1986 107


Fig. 2. Bridge (DS-T type) across the Rokytka River in Prague.

spans vary only slightly. This makes it pos- diate supports. The weight of typical seg-
sible to standardize them as whole bridges ments is 17 tons. Fig. 7 shows a continuous
of variable spans. box girder bridge.
The bridges were first designed as con- The bridge deck is supported by precast
tinuous beams or slant-leg portal frames (see columns. Since the intermediate supports
Fig. 4) with classical abutments. After ob- are very slender, the stability of the bridge
taining additional design experience, the is secured in the transverse direction with
abutments were replaced with precast end two tie rods supporting the end cross beam
beams and prestressed tie rods. This new (see Fig. 9).
design then served as a model for designing The arrangement of the prestressing steel
a standardized bridge. Varying the spans of resulted from the designed method of as-
the bridge was made possible by either sembly. During erection of the central span,
shortening or omitting central or end seg- the draped tendons placed in the webs were
ments (see Fig. 5). gradually tensioned. Next, the side spans
The superstructure is assembled with were erected and the straight tendons placed
segments of double cell, trapezoidal box cross in the deck segments were tensioned. These
sections (Fig. 6) and end cross beams. The tendons were then secured with continuous
segments, with widths of 21 ft (6.5 m), are tendons after erection was completed (see
cast simultaneously with fascia, and end cross Fig. 10a).
beams with short wings. Diaphragms are Construction of both continuous beam or
designed in segments above the interme- slant-leg portal frame bridges is generally

108
Fig. 3. Overpass bridge across the Highway Prague-Brno.

Fig. 4. Erection of side spans of overpass bridge.

the same. Fig. 10 shows the erection se- end cross beams are temporarily pre-
quence of the latter bridge type. The cen- stressed and the continuous tendons are
tral part of the superstructure is erected tensioned. After tensioning, the erected su-
symmetrically from the middle of the bridge perstructure is dropped onto the interme-
on staging. Erection then begins with the diate supports so that the static arrangement
placement of the central segment onto the of the structure corresponds to the three-
top of four jacks. Next, the second and third span continuous beam. The precast sup-
segments are temporarily prestressed to the ports are adjusted to the deck (Fig. 10d),
first segment, supported by jacks, and post- the pockets in the foundations are cast, and
tensioned by the draped tendons. Finally, temporary towers are removed.
the jacks supporting the first segment are The continuous beam is also erected in a
removed and the procedure is repeated (see similar way; however, the intermediate
Fig. 10b) until the segments reach the tem- towers are not necessary since they are
porary towers situated near the slant legs. formed by the piers. The erection of the
The segments of the side spans are then bridge structure itself is carried out within
erected, forming cantilevers on each side of 2 weeks.
the temporary towers (see Figs. 4 and 10c). Since 1974, more than 40 overpasses of
Each segment is first temporarily pre- this type have been built and construction
stressed to the already assembled structure of other structures is in progress. To date,
and the straight tendons are positioned. the structural performance of all such bridges
When the last segments are supported, the has been excellent.

PCI JOURNAL/January-February 1986 109


0

5300 6200
ED 650
x ° I I I I x o0 250 500 75
T T T t f i _^^
150;0) ( 500) (150;O)

2700=3000 L 1100-1400 I 800


f_Ii0O_l400
Fig. 5. Overpass bridges: (a) elevation of slant leg portal frame; (b) elevation of a continuous beam; (c) cross section.
Note: 1 cm = 0.3937 in.
C

1^ -t

1__
140 13U+
T-
143 ^2
X60
143
'

Fig. 6. Cross section of segment. Note: 1 cm = 0.3937 in.


160

Fig. 7. Continuous box girder bridge.

PCI JOURNAL/January-February 1986 111


Fig. 8. Slant leg portal frame.

Fig. 9. Slant leg portal frame — End cross beam and tie rods.

112
a2'

(b
1

(d

Fig. 10. System of prestressing tendons and erection sequence: (a) draped and
straight tendons; (b) continuous tendons; (c) erection of central span; (d) erection of
side spans; (e) adjustment of precast supports.

FOOTBRIDGE OVER THE side supports were formed by precast col-


umns. The columns of the lower end of the
TRAMLINE IN BRNO
bridge are fixed while the columns of the
In planning the overpass crossing over the upper end are hinged. The intermediate
high speed tramline in the city of Brno, it support is formed by a very slender octag-
was necessary to design a footbridge with a onal precast column (see Fig .15) which is
very small horizontal curvature radius of 148 situated eccentrically to the logitudinal axis
ft (45 m) and variable elevation (see Fig. 11). of the bridge with respect to the redistri-
Despite the complexity of the bridge's ge- bution of torsional moment.
ometry, it was possible to build the struc- The requirement to use existing manu-
ture using segmental construction. facturing equipment affected the arrange-
The two-span footbridge was designed ment of tendons and the erection process.
using segments and end cross beams which For this reason, the deck was post-ten-
were manufactured in the same forms as the sioned using continuous tendons that were
above mentioned overpass structures. The tensioned after the superstructure was

PCI JOURNAUJanuary-February 1986 113


R= 300
226% t=6.5m
ALAoti t 3,81m

n= =s^oo ^
^-tt-t-

3200 _ _ _ 1 19-^
U__-moo

N S

±HFH
Fig. 11. Footbridge over tramline in Brno: (a) elevation; (b) plan; (c) cross section over upper side support;
(d) cross section over intermediate support. Note: 1 cm = 0.3937 in.
erected. The segments were placed contin- ments were gradually prestressed using 2
uously from the lower end of the structure x 2 continuously coupled cables placed in
to its upper end in successive cantilever. the top flange. Since the hydraulic jacks only
The static effects were controlled by tem- supported the erected segment during its
porary towers that supported each succes- erection (inducing a very small force), the
sive segment. superstructure was stressed by only nega-
Erection began with placement of the first tive moment load which was later balanced
two segments on jacks situated on a short during post-tensioning. After erecting all the
staging (see Fig. 12a). After post-tensioning segments and the end cross beam (see Fig.
(Fig. 13), the inside jacks were removed and 12e), the pockets in the foundations were
the end cross beam was prestressed to them. cast. Then, the superstructure was post-
The remaining segments were then erected tensioned by the continuous tendons and
using the cantilever method of progressive the temporary towers were removed. The
placement (see Figs. 12b through 12d). entire erection sequence can be seen in Fig.
During the erection process, the seg- 12.

b 1

o1

Fig. 12. Erection sequence.

PCI JOURNAL/January-February 1986 115


Fig. 13. Post-tensioning of the first two segments.

Fig. 14. Erection of the end cross beam.

116
Fig. 15. Finished structure.

The footbridge was erected precisely in direction of the bridge makes rotation of the
the designed shape without any shims or superstructure possible, and rotation in the
concrete joints. These excellent results en- transverse direction ensures stability (see Fig.
abled progressive placement technology to 18).
be used for other types of bridges. Diaphragms are designed only in pier
segments. The typical segment weight is 20
tons while the weight of the pier segments
DS-W BRIDGES is 25 tons.
The DS-W bridges are designed with box Originally, the first bridge structures were
girders transversely connected by the top transversely connected only by post-ten-
flange (see Fig. 16). The shape of the struc- sioning recognizing the pressure reserve in
ture was designed on the basis of detailed the joints. Because of the relatively high live
structural analysis' which showed the suit- to dead load ratio, the amount of prestress-
ability of this type of structure for bridges ing was quite large.
of various widths, skew crossings, and cur- For this reason, full-scale tests were car-
vatures. This type of construction is also ried out on the connection between two
being used to design bridges with complex segments. The test segments were sup-
geometry conditions. ported under their webs and then the 3.3
The box beams consist of segments with ft (1 m) wide joint between flanges was rein-
the dimensions shown in Fig. 17. The ends forced with mild reinforcing steel and cast.
of the bridges are always perpendicular while The segments were loaded not only by a
the intermediate supports may be skew. concentrated force placed on the deck, but
These supports are formed by slender pre- also by different positions of the supports
cast columns connected to the deck by con- corresponding to the rotations and deflec-
crete hinges. The hinge in the longitudinal tions of the bridge girders.

PCI JOURNAL/January-February 1986 117


O O

Fig
-D
0
C-
0
C
z
D
C-
C-

CD0
m

CD
w
ED
1 166 1 Q-- - - ^37LL - '65 _
ED
CO
m
)
0

mox 40 t4 t ^44 1 m 40 3 7 7

Fig. 17. Segment of DS-W type bridge: (a) cross section; (b) longitudinal section. Note: 1 cm = 0.3937 in.

CD
Fig. 18. Construction of DS-W type bridge in Brno-Reckovice, Czechoslovakia.

The loading was repeated in several cycles Also during erection, the draped tendons
and finally the ultimate strength of the con- (Cables A) are gradually tensioned from the
nection was determined. The cracks which face of the segments which are being assem-
developed under service load were smaller bled.
than 0.08 in. (0.2 mm) and they closed im- The segments are manufactured in forms
mediately after unloading. Also, sufficient described in Ref. 3. Segment geometry was
ultimate strength was found to exist over determined by a computer program and
the entire connection area. manufactured according to the design level
For this reason, girders with an axial dis- line and real measured values of segments
tance of less than 21 ft (6.5 m) are connected which had previously been cast.
only with mild reinforcing steel. Segments The superstructure itself is erected in
with larger axial distances are connected with cantilever from one end of the bridge to the
mild reinforcing steel and post-tensioning to other. The segments are placed in position
reduce the secondary effects due to creep either by a mobile crane which moves on
and shrinkage of the concrete. land or by a portal crane moving on a track
During erection, the box girders are con- situated along both sides of the erected
tinuously post-tensioned using two systems bridge portion (see Fig. 21). Stresses in the
of tendons which distribute loading during assembled cantilever are reduced by using
both erection and service life of the bridge one or two temporary towers to distribute
(see Fig. 19). Straight tendons are placed in loads.
the deck slab and are uniformly distributed The erection sequence is illustrated in Fig.
along the deck width and anchored at the 20 and shows the assembly of the end and
slab stiffening near the joints. first intermediate spans. Span length is 82
One group of tendons (Cables B) is situ- and 98 ft (25 and 30 m), respectively.
ated only near the supports, while the sec- The end span is erected in three stages:
ond group (Cables C) is gradually tensioned 1. The first segment is placed on the
and coupled along the entire length of the abutment and temporary tower. After an-
bridge. The function of these tendons dur- choring to the abutment, the second and
ing erection is to balance the negative mo- third segments are erected and prestressed
ment in the cantilever and, during placement with Cables C (Fig. 20a). Then, the third
of additional segments, produce uniform segment is supported and Cables A are ten-
compression of the intermediate spans. sioned.

120
construction drection
As —^
At A3 A< As^A3' ( Aa A2 , -A

zx

pL Wi ris C

Fig. 19. System of prestressing tendons.

N
n

ED________

ED
JL J H1HHIN.LiL
_

ED ____

Fig. 20. Erection sequence.

sioned, the temporary support under the


2. This stage includes the erection of an
additional three segments in cantilever (Fig. sixth segment is removed, the first span is
20b), the supporting of the sixth segment rectified in elevation, and the concrete hinge
and removing the support from the third is cast (Fig. 20d).
The erection of the intermediate spans is
segment.
also carried out in three stages:
3. During the final stage, the last three
segments of the end span are erected in 1. The first four segments are erected (Fig.
cantilever after the rectification of align- 20a). After supporting the fourth segment,
ment is done on the temporary supports (Fig. Cables A are tensioned and the reaction of
20c). After supporting the cantilever with required intensity is induced.
the rectification support, Cables A are ten- 2. Erection of an additional three seg-

122
Fig. 21. Erection of DS-W segment by a portal crane.

ments is carried out (Fig. 20f), the support effects and monitors the structure during
tower under the fourth segment is removed erection.
and the reaction of required intensity is in- The DS-W bridges were successfully de-
duced. signed for two overpasses with very small
3. Finally, the last three segments are horizontal curves of 230 and 427 ft (70 and
erected (Fig. 20g), the cantilever is sup- 120 m), respectively, and for four urban
ported by a rectification support, Cables A viaducts in Brno. All the structures are per-
are tensioned, the temporary support under forming superbly and the correctness of the
the seventh segment is removed and the structural and construction details has been
reaction corresponding to the given stage of verified.
erection is induced and the concrete hinges
are cast (Fig. 20h).
DS-T BRIDGES
The magnitude of the forces of the tem-
porary support is determined so that the The DS-T bridges represent the latest type
moment above the support may constantly of construction developed and combine the
have the same value as the moment which advantages of both simple manufacture and
appears after erecting the first four seg- erection with low concrete and steel con-
ments. A computer then determines static sumption. These bridges are comprised of

PCI JOURNAL/January-February 1986 123


I.
A

0 O Rte. I

U^

Fig. 22. Arrangement of DS-T type bridges: (a) elevation; (b) plan; (c) cross section. Note: 1 cm = 0.3937 in.
O 3Q 5 95 , q 95 5 J

^2 •

O
{ 1950
340

1800 —
-1630
lion

59Q5 4
475 800 5 g0 ^5

Fig. 23. Segment of a DS-T type bridge: (a) cross section; (b) longitudinal section.
Note: 1 cm = 0.3937 in.

open cross section segments which are DS-W bridges (see Fig. 19). Furthermore,
formed by two girders: the deck slab and a finite element analysis shows that the ap-
fascia beams (see Figs. 23 and 24). Each proaching of tendons to girders does not af-
segment is reinforced by a cross beam at fect distribution of normal stress from the
midspan while the deck slab is strengthened straight tendons. Therefore, these tendons
near the faces. Segment depths are 5.2 and are uniformly distributed in the deck for
6.6 ft (1.60 and 2 m) and various segment simple manufacture.
widths are obtained by changing the pro- The draped tendons are placed in the gir-
jection of the cantilevers. ders and anchored in the top part of the
DS-T bridge construction was designed section. The segments are reinforced with
on the basis of a very detailed analysis by mild reinforcing steel in the transverse di-
both the grillage idealization and finite ele- rection of the bridge. Transverse prestress-
ment methods.' The analysis also showed ing was used in only one case, namely, the
that DS-T construction may be applied for bridge across the Rokytka River in Prague,
bridges with small horizontal curves, 820 ft where the segment widths of 64 ft (19.50 m)
(250 m), and for bridges with the interme- were extended by monolithic fascias.
diate supports skew. Fig. 22 illustrates a The segments weigh a maximum of 63
typical arrangement of a DS-T structure. The tons and are manufactured in a stationary
ends of this type of bridge are always per- precasting plant using a special method of
pendicular and the abutment segments are match casting. In contrast to the forms de-
reinforced with monolithic cross beams near signed by Freyssinet International which
expansion joints. On slender, intermediate provide a blank end and a soft mold bottom
monolithic supports, the superstructure is to enable the twisting of segments, the new
placed with the help of the pot bearings. method utilizes equipment formed by two
DS-T structures are gradually post-ten- mutually independent elements: a fixed form
sioned during erection by two systems of and a manipulator (see Figs. 25 and 26).
cables — straight and draped tendons — in After stripping, the segment cast is not
the same way as in the previously discussed shifted in the contact position on mold bot-

PCI JOURNAL/January-February 1986 125


Fig. 24. Segments of a DS-T type bridge.

tom, but is lifted, shifted, and placed on the squeeze-out roller heads in the form.
manipulator. The contact joint is always on The production equipment is further
the same level as the contact segment and supplemented with a device for guiding
is pressed to the rear, perpendicular edge the segment onto the manipulator, a walk-
of the form. Since the form bottom is al- way, and trucks equipped with a winch for
ways plane, twisting is obtained by turning pulling out the tubes forming the tendon
the contact segment along its longitudinal ducts.
axis. The basic operations involved are as fol-
The form itself consists of two fixed frames, lows:
outside and inside shutters, and a movable 1. Placing the reinforcing cage into the
front end. The frames are situated under open mold
the girders and contain two squeeze-out 2. Adjusting the contact segment on the
rollers which, after stripping, slightly lift the manipulator
segment before it is removed from the form. 3. Adjusting the movable front end
The required segment shape is formed by 4. Adjusting segment parameters
turning the movable front end (see Fig. 27). 5. Forming the tendon ducts
The manipulator makes it possible to adjust 6. Casting the segment
the contact segment into a position parallel 7. Taking out the tubes forming the ten-
with the rear edge of the form and to press don ducts
the segment to the form to stabilize that 8. Measuring the segment after casting
position in casting. 9. Form stripping
Note that the manipulator is formed by 10. Moving the contact segment into
two frames placed on top of each other so storage and placing the newly cast
that the lower frame enables the lifting of segment on the manipulator
the manipulator while the upper frame en- The reinforcing cage is assembled inside
ables the turning of the vertical axis. Turn- a wooden template where the tubes for the
ing the segment along its longitudinal axis tendon ducts and the inserts for forming
is achieved by using different heights of pockets for the tendon anchors are placed.
guiding inlays shaped identical to the Concrete is supplied to the mold via a con-

126
Fig. 25. Forms for DS-T type segments: (a) cross section of form; (b) cross section of
contact segment on manipulator; (c) longitudinal section; (1) movable front end; (2)
outside shutter; (3) inside shutter; (4) frame; (5) manipulator; (6) guiding device.

veyor belt. First, one girder is filled to the Segments of common spans are erected
lower edge of the slab, and then the other. by a special portal crane, KPJ-90, which
The slab with the cross beam is then cast, travels on the girders of the deck being as-
followed by the fascia. Next, the concrete is sembled. The storage of segments behind
compacted by means of internal and surface the abutment is operated by another portal
vibrators. Hardening of the concrete is ac- crane travelling on tracks situated along the
celerated by steaming. abutment wings where the first three
During the manufacturing process, much segments of the end span are also assem-
emphasis is placed on the precise adjust- bled.
ment of segment dimensions and on sub-
sequent segment measurements after casting.
The values of segment depths and lengths
which were adjusted and measured are
shown in Fig. 27. Length was measured us-
ing a slide measuring gage and theodolite;
depth values were determined by level-
ling. The adjusted values were set by a
computer program which determined the
dimensions of manufactured segments ac-
cording to the designed level line and real
measured values in segments which had al-
ready been cast.
The superstructure of a DS-T bridge is
assembled in cantilever from one end of the
bridge to the other (see Fig. 29) and re-
sulting stresses are controlled by using tem-
porary supports (see Fig. 30). The
arrangement of the basic assembly compo-
sition is illustrated in Fig. 28. Fig. 26. Forms for DS-T type segments.

PCI JOURNAUJanuary-February 1986 127


N

Fig. 27. Segment geometry.


Fig. 28. Erection sequence for DS-T type bridges: (a) cross section behind abutment; (b) cross section by deck; (c) view from face of
erected cantilever; (d) elevation; (1) portal crane; (2) portal KPJ-90 crane; (3) service walkway; (4) temporary support; (5) rectification
support.

N
(O
During erection of common spans, the pendent of the crane.
portal crane turns the segment and shifts it However, since the erection sequence
in front of the KPJ-90 crane which is trav- depends on finishing the earthwork behind
elling behind the abutment. The crane then the abutment and on transporting and as-
takes the segment and lifts it to the face of sembling the KPJ-90 crane, some bridges
the erected cantilever (Figs. 31 and 32). After must be erected using the portal crane only
the segment is prestressed with four tem- if the above conditions cannot be met.
porary tendons, the crane returns for the The erection process of individual seg-
next segment. The prestressing tendons are ments is the same as outlined for the DS-
tensioned from the service walkway, inde- W bridges and illustrated in Fig. 20. At

Fig. 29. DS-T type bridge at Valasske Mezirici during construction.

Fig. 30. Temporary support of DS-T type bridge at Valasske Mezirici.

130
present, four segmental bridges with a total CONCLUSION
length of approximately 0.6 mile (1 km) have
been constructed and bridges with a total Low concrete and steel consumption, easy
length of 1.3 miles (2 km) are currently un- manufacturing, speed of construction, and
der construction. In addition, the attention bridge aesthetics demonstrate the advan-
given to precise manufacture, careful as- tages of using segmental construction for both
sembly, and the effects of creep and shrink- long and short span bridges. In addition,
age has enabled bridges 1300 ft (400 m) in the positive economic benefits of precast
length to be assembled without steel shims segmental construction are making future
or concrete joints. technological developments successful.

Fig. 31. Portal crane KPJ-90 on deck of bridge across Rokytka River in Prague.

Fig. 32. Erection of bridge segments across the Rokytka River in Prague.

PCI JOURNAL/January-February 1986 131


This technology has been applied for the
REFERENCES
design of Czechoslovakia's first cable-stayed
bridge across the Elbe River, where con- 1. Muller, Jean, "Ten Years of Experience in
struction began early in 1985. It is our hope Precast Segmental Construction," PCI JOUR-
that others, too, will challenge current de- NAL, V. 20, No. 1, January-February 1975,
sign practices and further develop this ad- pp. 28-62.
2. Podolny, Walter, and Muller, Jean, Construc-
vanced technology.
tion and Design of Prestressed Concrete Seg-
mental Bridges, John Wiley & Sons, New York,
ACKNOWLEDGMENT N.Y., 1982.
3. Strasky, Jiri, "Segmental Bridges DS-W, DS-
The design systems of the bridges de- T — Static Analysis and Structural Design,"
scribed in this paper were developed by PhD Thesis, Technical University, Brno,
Enterprise Dopravni Stavby in Brno, Czechoslovakia.
Czechoslovakia.

132

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