Services

Bridge bearing test rig 100000 kN

In-house test rig

mageba has one of the biggest bearing test rigs in the
world for loads of up to 100000kN. The gigantic press was
built especially for testing of bridge bearings and has been
used successfully since 1981.
During these more than 20 years, numerous bearings tests
have been carried out on bearings, e.g. those for the
resund Bridge in Denmark. During these tests loads of
up to 90,000kN were applied per test.

Pot bearing in test rig

Description
The hydraulic cylinder is pulled out of the workshop into
the opening of the test frame using a PTFE-sliding layer
on a slide way.
In addition to the vertical load of up to 100000kN, the
testing object can be exposed to horizontal forces of up
to 10000kN, as well as movements of +/- 200mm from
the middle position. The required force for these
movements is 4500kN in each direction.

resund Bridge with tested pot bearing

A modern electronic measuring and data processing

system records the forces and deformations during the
test. It can calculate, process, and record up to 14
different measuring values.

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2 Description
Typical tests
Extreme load combinations, special design, and especially large bearing
dimensions often require testing of bearings. The aim of the tests is to verify
the results of the structural bearing calculation and the theoretically
expectable behaviour of bearings under actual loads.
mageba is able to carry out all the necessary load tests individually,
according to the customers requirements. Typical tests are vertical load
and/or horizontal load tests.
Additionally, mageba offers a special sliding/friction test for moving bearings,
in order to test the sliding behaviour of PTFE/chrome steel of bearings. In
combination with these tests, we also test the tilting ability of bearings, if
required by the customer.

Bearing fixed in test rig

Tests
In order to achieve the greatest possible flexibly in the processing of data, we
determine the test program in close collaboration with the client or design a
testing programme by ourselves. We are therefore able to carry out
complicated or non standard tests, according to the clients needs.

Testing apparatus on test rig

For example, we have carried out preliminary tests to determine not only the
best possible bearing type for the Klnbrein-dam in Austria, but also to verify
the theoretical design of bearings. These tests were conducted in close
collaboration with the client, who chose mageba due to the unique capabilities
of the test rig with regard to applicable loads and bearings sizes.

Analysis
After the test and following the unloading of the bearing, it is removed from the
test rig and demounted. Bearing components are visually checked and their
actual condition is evaluated.

Exact levelling of the bearing

We mark the existing defects, take photos, and document them. Then we
evaluate the results. The comparison of test diagrams, the performance trend,
and the photos of possible defects make it possible to determine their causes.
Finally, we prepare suggestions for improvements and optimization of
performance and durability of bearings.

Test report

Analysis of the bearing components

after execution of the test

The test report and the photos describe the test procedure, the test process,
the results, as well as their analysis. This report is submitted to the customer
as an official confirmation of the bearings performance.

Bearing tests: advantages

Bearing tests help to investigate the behaviour of bearings under extreme load
conditions. In this way, theoretical presumptions can be verified using actual
loads.
Bearing tests also make it possible to determine the loading limits of bearings,
as well as the failure type. This way, weak points can be exactly located. Then,
they can be improved, and so the safety factor can be increased, for example,
in the event of an earthquake.

Tested pot bearing ready for dispatch

3 Test Rig
Structure of the testing frame
The testing frame consists of two major components:
- a hydraulic cylinder with a piston diameter of more than 2m
- a frame of prestressed concrete with outer dimensions of about
9x9x3.5m
The inner width of the opening for bearing, which is to be tested is 3.0m, the
height 2.6m, and the depth 3.5m.

Load and movement possibilities

The bearing is fixed in the opening. After that, it can be exposed to both
vertical and horizontal loads.
The governing relations in the real structure are simulated as exactly as
possible. For this purpose, the movement, of the top of the bearing opposite
the bearing bottom can be generated, in addition to the horizontal and vertical
load.

Flexible concept
The device is designed for a multitude of various applications. The lining
plates of the test room, are equipped with anchoring possibilities in a close
raster so that additional equipment and/or stabilizing elements can be located
as freely as possible.

Lifting Devices
Two bridge cranes with 50kN lifting capacity each are available in the work
yard for the assembly of the bearings which are to be tested. The space
directly before and behind the frame is served by a 60-kN crane.

The hydraulic device

The hydraulic device of the testing frame consists of three press groups:
- hydraulic press for vertical loads
- piston diameter
2040 mm
- stroke
40 mm
- max. oil pressure
320 bar
- max. pressure
100000 kN
- hydraulic press for lateral load (3 pieces)
- piston diameter
200 mm
- stroke
40 mm
- max. oil pressure
720 bar
- max. pressure
3500 kN
- hydraulic press for longitudinal movement (3 pieces for each direction)
- piston diameter
150 mm
- stroke
250 mm
- max. oil pressure
700 bar
- max. pressure
1500 kN

Processing measured values

1 analog-digital converter for 16 channels
1 digital voltmeter
1 X Y analog writer
1 computer and monitor

4 References

resund Bridge, Denmark

References (Extract)
- Hong Kong Convention and Exhibition Centre (Hong Kong, 2007):
- 1 bearing, vertical and horizontal load test (V=77200kN; H=900kN)
- 1 bearing, vertical and horizontal load test (V=77200kN bei =2%)
- Wickers Viadukt (GB, 2005):
- 3 bearings, vertical and horizontal load test (V=2800kN; H=2950kN)
- resund Bridge (Denmark, 1996):
- 6 bearings, vertical and horizontal load test (V=69200kN; H=4300kN)
- 6 bearings, sliding-friction test (V=69200kN at +21C / -35C)
- PTFE durability test (5000m at =30N/mm2 and +21C / -35C)
- Deeside Road Link (GB, 1995):
- 2 bearings, vertical and horizontal load test (V=76000kN; H=6350kN)
- Kimpo Bridge (Korea, 1994):
- 1 bearing, vertical and horizontal load test (V=40000kN; H=2710kN)
- 1 bearing, sliding-friction test (V=46000kN; H=1850kN; e=+/-250mm)
- Schwbische Httenwerke GmbH (Aalen, 1986):
- 1 bearing, vertical test with tilting (V=66000kN at =1%)
- Lan Kam Brcke (Hong Kong, 1986):
- 1 bearing, vertical and horizontal load test (V=24000kN; H=2200kN)
- 1 bearing, sliding-friction test (V=8500kN; e=+/-70mm)
- Cordeaux River Rail Bridge (Sydney, 1984):
- 4 bearings, vertical and horizontal load test (V=30000kN; H=1345kN)
- Orwell Bridge (GB, 1981):
- 4 Roller bearings (V=55000kN; H=1200kN)
- 16 Spherical bearings (V=28000kN)

Storeblt West Bridge, Denmark

Hong Kong Convention Centre

mageba Product Range

Bridge Bearings

Expansion Joints

Shock absorbers

- Pot bearings
- Elastomeric sliding
bearings
- Spherical bearings
- ILM- bearings
- Special bearings

- Single gap joints

- Hydraulic buffers
- Modular expansion
- Spring dampers
joints
- Sliding finger joints
- Cantilever finger
joints
- Railway joints
- Architectural joints
More information on mageba and its products can be found on www.magebausa.com.
mageba USA LLC
magebausa.com

New York, NY
Tel. 212-653-8813
Fax 646-495-3005
San Jose, CA
Tel.: 408-281-9700
Fax: 408-281-9701

bridges linking people

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Version 2008.02

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