Nota BHG 4 - Supervision of Bridge Construction

Bahagian 4
Pengurusan Pembinaan Jambatan
oleh
Ir. Abd Rahman Salleh
Bahagian Jambatan,
Cawangan Kejuruteraan Awam, Struktur & Jambatan
INTRODUCTION TO
BRIDGE
CONSTRUCTION
Supervision of Bridge Construction 2
 Bridgemay categorize into :-

1. Construction Materials,
2. Structural System or
3. Deck Types
1. Construction Materials
i) Concrete
ii) Steel
iii) Masonry
iv) Timber
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Why Bridges Need to be Built ?
 Bridges need to be provided to carry right of way
across a natural or artificial obstacle such as a river,
canal, water course, ravines or another road or
another railway or connecting an island.
Relationship Between Bridge Design & Construction

 The bridge design is dependent upon the construction
method as it is required to take into account the
construction stages such as sequence of installing
tendons, maturity of concrete at loading & load
effects from erection equipment.
 The design & construction method to be used depends

on several factors that include its functionality,
horizontal & vertical clearances, alignment,
geometry, hydrological requirement, geotechnical
capacity, construction schedule, site constraints,
environmental requirements & aesthetics.
 The options to use cast-in-situ or precast elements for
the various methods of construction will depend
primarily on the project size, construction schedule,
span length & access to the site.
2. Structural System
i Simply Supported
ii Continuous
iii Cantilever
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iv. Arch
v. Truss
vii. Frame
vii Cable Stayed
viii Suspension
ix Culvert
3. Deck Types
i. Reinforced concrete beam-

slab
ii. Prestressed concrete beam-

r.c slab.
iii. Concrete Box Girder (beam

bridge)
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Bridge Terminology
 The first step in understanding the principles &
processes of bridge construction is to know the basic
bridge terminology.
 According to Departmental Standard BD 37/01”Loads
for Highway Bridges”, components of a bridge is
categorized into :-
i. Superstructure - in a bridge, that part of the structure
which is supported by the piers & abutments.
ii. Substructure - in a bridge, the wing walls & the piers,
towers & abutments that support the superstructure.
iii. Foundation - that part of substructure in direct contact
with, & transmitting load to, the ground.
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Abutment
 Abutments are part of the substructure that form the
terminal ends of the bridge & support the end spans.
 Typical types of abutments are full heights, stub or
semi stub.
 Full height abutment - cantilever abutment that
extends from the underpass grade line to the grade
line of the overpass roadway
 Stub abutment - short abutments at the top of an
embankment or slope.
 Semi-stub abutment - size between full height & stub
abutment
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Retaining Wall
Bank Seat
Pile Bents
Approach Slab
 A reinforced concrete slab used at the approaches of
a bridge to prevent settlement of the approach
pavement.
Pier
 A vertical structure that supports bridge
superstructure. Piers transfer forces from the
superstructure to the foundations.
 Piers allow the total length of the bridge to be
divided into viable span lengths
 Selection of piers dependent upon flow of water &
bearing capacity of soil.
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 Those commonly found are :-
i. Wall type
ii. Multiple column on

pile foundation
iii. Pile bents
Foundation
 Deep foundation is commonly used such as :
- prestressed spun piles
- bored piles
- micro piles
- H- steel piles
- steel pipe piles
 A bridge can also be founded on shallow foundation
provided that the underlying soil strata near ground
surface is a sound bed rock layer i.e spread
foundation, caisson.
 Precast r.c piles may be used for pedestrian bridges
Beams and Girders

 Beams & girders are the main load-carrying elements
of bridge superstructure.
 Beams are generally either of concrete or steel.
 Concrete beams can be cast-in-situ, precast, post-
tensioned prestressed or pretensioned prestressed.
 They can take various shapes, such as rectangular
beam, Inverted T - Beam, I - Beam, M - Beam or U -
Beam.
 Steel beams can be in the form of rolled I - Beam,
riveted I - Beam or welded plate girder.
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Type of Beams & girder
Bulb-T- Beam
Y-Beam
Prestressing
 Application of tensile forces to the steel tendons
after the segments are in place. These forces allow
the span to carry the desired loads.
Tendon
 Steel strands used for post tensioning.
Falsework
 Structural system to support the vertical and horizontal
loads from forms, reinforcing steel, concrete, structural
steel, loads from placement operations & other related
loads.
Deck
 The load bearing floor of a bridge which carries &
spreads the vehicular traffic to the main beams.
 Usually bridge deck is constructed by cast-in-situ
reinforced concrete.
 The deck must be constructed according to grade so
that surface water run-off efficiently drains through
water down pipe.
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Diaphragm
 Diaphragms are used as cross-braces between the
main structural members and are also part of the
superstructure.
Bearings
 These are supports on a bridge pier, which carry the
weight of the bridge & control the movements at the
bridge supports, including the temperature expansion
& contraction.
 They may be metal rockers, rollers or slides or merely
rubber or laminated rubber (Rubber with steel plates
glued into it).
 The following are some common types of rubber

bearing:
1. Bearing pad, which is a single unreinforced rubber
slab.
2. Bearing strip, which is a continuous bearing pad.
3. Laminated bearing, which consists of one or more
slab bonded to metal plates so as to form a sandwich.
Dowel Bar
 Dowel bars are provided as a function of pinned
joints to the bridge superstructure.
 Normally they are located underneath the diaphragm
beams at the shear keys.
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Pad bearing
Bearing strip
Laminated
bearing
Expansion Joints
 These are provided to accommodate the translations
due to possible shrinkage & expansions due to
temperature changes.
 Expansion joints are installed at deck slab in between
its span.
 Type of expansion joints :
i. Asphaltic plug joint
ii. Compression seal joint
iii. Nosing
iv. Mechanical finger/comb joint
Mechanical type
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Spans & Span Length
 Spans are the main terms when referring to bridge
design & construction.
 A bridge is made up one or more spans. A span is a
segment of a bridge that crosses from one
substructure unit to the next, from abutment to
abutment, from abutment to pier, from pier to pier,
or from pier to abutment.
 Span length refers to either the length of any
individual span within the structure or to the total
bridge length. Span lengths are considered as the
distance between centerlines of bearing from one
substructure unit to the next.
Mainspan
 The center or primary span of the bridge over the
river, typically the longest span of the bridge.
Simple & Continuous

Spans
Simple & Continuous Spans

 Bridge also may classify as simple span, continuous
span or combination of simple & continuous span.
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High Performance Concrete
 Concrete meeting special combinations of
performance & uniformity requirements that cannot
always be achieved using conventional constituents &
normal mixing, placing & curing practices resulting in
longer structural life.
Deck Surfacing
 Normally top of the deck is overlaid by a layer of 50-
60mm thick wearing course to give a comfort riding
quality & as water proving to the deck surface.
 The construction of bridge is similar to other type of

structure construction such as buildings, dams,
retaining structure etc..
 It follows sequential process of physical work from
ground to the top.
 Supervision of bridge construction involves :-
i. Understanding bridge components & their function
& knowledge on theory of structures.
ii. Ability to understand & interpret details drawings,
description of works in B.Q & specification.
iii. Ability to transfer the intention of designer from
drawings into products.
iv. Quality of works.

v. Competency of designer, project manager, site
supervisors & good contractor.
 Understanding of bridge components is very
important so that the works are carried according to
their sequence.
 Construction drawings must be easily understandable
such as general arrangement, setting-out,
reinforcement detailings, details of prestressing &
the design criteria.
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 Method of construction must be fully understand to
avoid errors that may happen during construction &
may lead to serious consequences.
 Quality control must be in-place efficiently in order
to produce high quality of bridges & lead to low cost
of maintenance.
General Arrangement of Bridge
Supervision of
Bridge Construction
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 Scope of works for the construction of bridge :-
a) Site clearance
b) Setting out
c) Temporary works
d) Excavation & earthworks
e) Bridge construction
- foundation
- sub-structures
- super-structures
f) Approach road construction

g) Installation of bridge accessories
h) Installation of road lighting if required
i) Surfacing work & road marking
j) Installation of road signages
Bridge Construction Sequence
Schematic diagram of
construction sequence
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 Prior construction of bridge the following relevant
matters should be taken :-
- Approval of temporary bridge, temporary crossing &
staging, coffer dam, formwork, beams erection
system.
- Calculation, shop drawings & method statements of
the above must be endorsed by the Professional
Engineer.
- Inspection of casting yard.
-Inspection of casting factory.
-Inspection of concrete batching plant.
-Site/accredited laboratory.
- Raw materials quality tests.

- Concrete trial & design mix.
- Proper storing & staking of materials i.e piles,
beams, reinforcement, tendons, etc.
- Acceptance criteria for materials delivered to site.
- Approval of Jabatan Pengairan dan Saliran (JPS) if
involve temporary works in the river.
- Approval of Jabatan Laut if works involve
navigational way.
- Approval of Keretapi Tanah Melayu Berhad (KTMB)
if works crossing railway.
- Land acquisition.
Bridge Setting Out
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 After the contract is awarded, the first job is to
prepare the land for road / bridge construction
(ground clearing, setting out…).
 The plots are then marked out with the layout of the
R.O.W. This is known as setting out which is an
essential step before proceeding to the next phase.
 The setting out is a contractor's responsibility but
errors can result to serious problems in
constructing the bridge.
 It is therefore important for the site supervision to

ensure that the contractor's setting out is correct &
accurate.
 The setting out of bridge alignment must be carried
out by a License Land Surveyor with calibrated
survey equipment.
What happen if the bridge is out of alignment?
i. The cast prestressed beam cannot be placed in

between abutments or piers if the position of
abutments/piers are deviated from actual
coordinates.
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 HODT/Designer must be consulted for further advise
on the following :
- redesign of affected beams if its need to be
changed
- position of bearings
- capacity of piles
- dimension of end diaphragm
- gap between end of beam & ballast wall
ii. The vertical alignment of bridge structure &

approach road may be affected.
 HODT/Designer must be consulted for further advise

on the following:
- sight distance
- stopping sight distance if close to junction
- minimum vertical curve requirement
iii. Increase of height will increase the quantity of

embankment fill for approach road.
 HODT/Designer must be consulted for further advise:

- slope stability
- requirement of ground treatment
- requirement of retaining wall
- increase of abutment wall height
- design of abutment and pile capacity
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iv. Possibility of inadequate free board height
v. The horizontal alignment of bridge structure &
approach road may be affected.
- possibility of encroaching private lot & requires
additional land acquisition
vi. Horizontal & vertical alignment may not matching
the road alignments.
 Other than bridge alignment, survey need to be

carried out to determine:-
i. R.O.W
ii. Location of bridge
iii. Point of piles
iv. Position of bridge configuration
v. Dimension of bridge components
vi. Bridge levels
Little tolerances are permitted during bridge construction
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Temporary Works
Temporary Crossing
 Detailed drawings of the temporary crossing as
specified in the Scope of Work required for the
execution & maintenance of the work need to be
submitted by the contractor for the approval.
 The drawings must be submitted with the calculation
& description as necessary.
 A competent & experienced professional engineer
must sign all submissions.
 If the project involves upgrading or replacing the
existing bridge, the first stage is to divert the
affected road comprises of temporary bridge.
 Depending on the width of river, temporary bridge can

be of precast culverts or steel bridge.
 Although the diversion is only a temporary facility, the
works such as approach road to the temporary bridge
& pavement should be carried out according to the
specifications & should meet the same standard as the
existing road.
 Temporary road must always be maintained at all
times to ensure road safety & avoid inconvenient to
public during construction stage.
 Ensure sufficient warning signs, temporary road signs,
barriers, warning lights & flood lights are properly in-
place & functioning.
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 Works involve on water requires temporary crossing as
an access for the construction works.
 Contractor should get the approval from JPS before
constructing temporary crossing, staging & cofferdam
 Where bridge is located at wider river mouth or water
course, barges or pontoons are used for transporting
resources & may serve as working platform.
 Temporary staging is also constructed to provide a
working platform for piling & piers works. This
temporary staging will extend from the temporary
crossing to around foundation location or cofferdam.
Temporary crossing
Penggunaan Barge &Tug Boat Bagi Kerja-kerja

Substruktur Di kawasan Perairan
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Temporary Works
61
Typical plan of temporary

Typical cross section of
staging finger
temporary staging
Supervision of Bridge Construction
Temporary Works
temporary
crossing
staging
62 Supervision of Bridge Construction
Temporary Works
Piling machine
rests on
staging
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Cofferdam
 On completion of staging, temporary cofferdam will
be constructed in the location of each proposed
bridge pier.
 Cofferdams constructed to allow dry foundation
installation.
 The dimensions of the cofferdam will be slightly
larger than the dimensions of the pile cap to allow
the pile cap to be constructed within.
 Cofferdam should be safety designed & constructed &
be made as water tight as it is necessary for the
proper performance of the work which must be done
inside.
 Normally coffer dam will be constructed from steel

sheet piles & steel waler beams.
 Within the cofferdam, dewatering by pumping is
required in order excavation & concreting works for a
pilecap can be done on dry platform.
Temporary Works
Installing Wale and Strut for sheet

pile cofferdam framework
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Temporary Works
Paras air
Kerangka Sangga
Cerucuk keping
Pengedap konkrit
Pumping
of water
Pumping water out from coffer dam
Piling Works
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 Matters that required attention during piling works:-
- Setting up of piling rigs, other machineries &
equipment.
- correct lifting of pile at the designed lifting points.
- pile position, cut-off level & as-built position.
pile jointing.
- pitching & driving of pile, it’s verticality/rake.
- driven length & set.
- cutting of pile heads, reinforcement anchorage
length/plug length.
- load tests on preliminary piles/working piles.
- pile integrity tests.
- usage of permanent casing, temporary casing,
bentonite.
- piling records.
Correct lifting of pile
Pile verticality control
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Control of rake pile inclination
 Maximum permitted deviation of the pile centre from

the centre points must not exceed 75 mm in any
direction.
 Maximum permitted deviation of the finished pile
from the vertical is 1 in 75.
 Before piling works commence, a detailed method
statement for the installation of piles must contains:-
i) Shop drawings showing details of all special
requirements for the construction activities such
as hoisting of piles, reinforcement cages, cast in
fixing etc.
ii) Design calculation of key temporary works
endorsed by his Professional Engineer.
iii) Material, plant & labour requirement at each

construction stage.
iv) Rate of production output based on resources
allocated.
v) Other information relevant to the piling works.
 During storage, piles must be placed on adequate
supports located under the lifting points of the piles.
 Piles must be stored & stacked on firm ground not
liable to settlement under the weight of piles.
 When stacking, the pile supports must be vertically
above one another.
 All piles within a stack must be in groups of the same
length.
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 Support packing of uniform thicknesses must be
provided between piles at the lifting points when
staking.
 When lifting the pile, only the designed lifting &
support points must be used.
 During driving & until the pile has set or been driven
to the required length, all exposed piles must be
supported & restrained to maintain position &
alignment & to prevent buckling & damage to the
piles.
 When an acceptable resistance or set appears to

have been reached, the driving of pile must be
suspended for an interval sufficient to permit the soil
to recover from the disturbance of pile driving &
then resumed to determine whether there is any
increase or decrease in resistance.
 The final set of a pile other than as friction pile,
must be recorded as the penetration in mm per 10
blows.
 The following requirements must be met when a set

is being measured, :-
i. The pile in good condition, without damage or
distortion.
ii. The hammer blow in line with the axis of the pile &
the impact surface is flat & perpendicular to the
hammer axis.
iii.The hammer in good condition, delivering the
required energy per blow & operating correctly.

78
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 When pile has been driven to the required set or
depth, the head of the pile must be cut off to the
level shown on the drawings.
 Cutting must be done carefully to avoid shattering or
damaging the rest of the pile.
 Any cracked or defective concrete must be cut away
& made good with new concrete properly bonded to
the old.
 The length of reinforcing bars projecting above cut
off level must be as shown on the drawings.
 After construction, actual pile locations must be
certified by a Licensed Surveyor employed by the
Contractor.
 Supervision of Bridge Construction 79
Bored Piles
 Permanent casings which form part of the designed
pile must be as specified on the Drawings.
 Support fluid material i.e bentonite/polymer must
comply with the manufacturer’s certificate & mix
proportion.
 A certificate must be obtained from the
manufacturer of the bentonite powder, showing the
properties of each consignment delivered to the site.
 Bentonite must be mixed thoroughly with water to
make a suspension which will maintain the stability
of the pile excavation for the period necessary to
place concrete & complete construction.
 Bentonite test must be carried out at regular interval

to ensure consistency of the batching process.
 For maintaining the stability of boring, level of
support fluid or a column of water in the excavation
must be maintained such that the fluid pressure
always exceeds the pressure exerted by the soil &
external ground water.
 Adequate temporary casing must be used to ensure
the stability of the strata near ground level until
concrete has been placed.
 The fluid water level must be maintained at a level
not less than 1 metre above the level of the external
ground water.
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 In the event of a rapid loss of bentonite suspension,
polymeric fluids or water from the piling excavation,
the excavation must be backfilled with lean concrete
or well compacted sand without delay.
 A pile constructed in stable soil, without the use of
temporary casings or other support must be bored &
concreted without delay to ensure that the soil
characteristics are not significantly altered.
 Sandy clays or clayey silts may soften significantly in
less than 12 hours.
 The time interval between completion of boring &
placing of concrete is preferably within 6 hours.
 Where prolonged delay in construction arises, the

bore may have to be backfilled with lean concrete or
well compacted sand to minimise deterioration of the
shaft.
 If the pile excavation is carried out using permanent
or temporary casing, the time period between
completion of pile excavation & completion of
concreting is recommended not to exceed 24 hours.
 Adequate spacer blocks must be provided so as to
maintain the reinforcing steel in the positions.
 If temporary casing is employed, the longitudinal

reinforcement must extend at least 1.0 metre below
bottom of the casing so that movement of the
reinforcement during extraction of the casing is
minimised.
 For vertical piles, concrete is poured through a funnel
with a length of tube so that the flow is directed &
does not hit reinforcement bars or the side of the
hole.
 For raking piles, an enriched mix of 20% more cement
should be used in the first few batches of concrete to
minimise segregation.
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 When concrete is placing under water, 20% more
cement content mix should be used.
 Concrete to be placed under water or support fluid
must be placed by tremie & should not be discharged
freely into the water or support fluid.
 The tremie pipe must at all times penetrate the
concrete which has previously been placed & should
not withdraw from the concrete until the completion
of concreting.
Piling Works
Typical Conditions of Use Slump Range
(mm)
Placed into water-free unlined bore. Widely spaced
reinforcement leaving room for free movement 75 to 125
between bars.
Where reinforcement is not spaced widely enough to

give free movement between bars.
100 to 175
Where casting level of concrete is within the casing.
Where pile diameter is less than 600 mm.
Where concrete is to be placed by tremie under water

150 to collapse
or drilling fluid.
The top of the pile must be brought at least 300 mm

or more as specified in the drawings above the cut-off
level of the pile to permit all laitance & weak
concrete to be removed & to ensure that it can be
properly keyed into the pile cap.
Only hand held cutting equipment or hydraulic
splitters should be used.
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Construction of Pile Caps
 Before commencing to construct a pile cap, make

sure the eccentricities & the cut-off levels of all piles
on the ground are checked & verified by the
supervision team.
 The length of pile shaft embedded or keyed into the
pile cap above its soffit level must be referred to the
details shown on the drawing.
 Lean concrete acts as blinding layer of grade 15 or
otherwise specified must be placed at the bottom of
excavation.
 Normally 50 mm thick is placed to form flat
horizontal plane before receiving reinforcement bars.
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Bridge Construction
Pile Head Cut Off
Removal of unwanted concrete to

cut off level

pile keyed or embedded into pile cap
Formworks
 Formworks must be provided similar to other buried
structural components as in the Specification.
 Formwork must be rigid & tight to prevent leaking of
mortar from the concrete which may cause
honeycombing.
 No concrete should be placed until the formwork has
been inspected & approved by the supervision team.
 The main reinforcement is basically bi-directional.
Makes sure that the correct bar sizes & placements as
well as the lapping or staggered lapping to be
exercised on site.
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 At the soffit, minimum concrete cover under
reinforcement bars are 75 mm & 50 mm to all sides
unless otherwise stated.
 The concrete spacers must be of at least the same
strength as the concrete to be poured. Spacer blocks
must be as small as possible with 10mm nominal size
of aggregates.
 Pile cap should be continuously cast.
 To avoid segregation of the concrete & the
displacement of the reinforcement, the long troughs,
chutes, or pipes for conveying the concrete from the
hopper or bucket should be used for placing
concrete. 94
Bridge Construction
Pile Caps
Concreting using sheet pile cutes Concreting from day time through
the night
 Some pile caps are large in dimensions & involved

massive pours of concrete. Large concrete pours
require special consideration by the supervision team.
 Concreting must be well-planned accounted for
controlling the temperature gradients, heat of
hydration, setting time & proper curing.
 Such control must be done to avoid unacceptable
surface cracks or internal damage to concrete in the
pile cap.
 Normally high performance concrete type is adopted
if the bridge is exposed to marine environment. The
supervision team must take note on this requirement
as specified in the Specification & Drawings.
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Backfill
 Pile cap must be backfill with suitable material &
properly compacted as per Specification by hand held
compactor.
 Where pile cap is located below the river bed, well
compaction may slow down the degradation process
or scouring effect. Scouring of foundation may cause
lost of piles capacities.
 Where below carriageway, well compaction may
prevent differential settlement between the top or
edge of pile cap & roadway.
 Where behind the abutment, well compaction may

prevent differential settlement between the
abutment & approach road.
 Occurrence of unacceptable differential settlement
may lower the riding comfort or even road safety
aspect.
Construction of
Abutments
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Dimensional Control
 If dimensional control is not emphasized, the
following may happen :
i. abutment wall will be affected in appearance.
ii. precast beams unable to fit the deviated span
between abutments or pier.
iii. adjustment of design or details i.e beams, width
of abutment, position of bearings, expansion
joints, etc.
iv. beam centerline & pile group capacity need to be
checked.
 Where works involve high abutment to the roadway

finish grade, attention to the accuracy of dimensions
especially the verticality is very important.
 If the wall is not poured vertical, along the correct
skew, or if the form is allowed to bulge, then the
bridge will not have the proper clearance needed for
expansion & so the expansion joint will be difficult to
fix.
 Particular attention should be given on the cross fall
grade of the abutment top. Normally gradient of 2.5%
from the centre of abutment or one sided.
Bituminous Coating
 The external wall surfaces of abutment in contact
with soil must be applied with waterproofing layer in
three (3) coats of bitumen solution as according to
the specification.
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104 Kerja Pemasangan

Supervision Besi
of Bridge Construction Tetulang Sebelum Kerja Konkrit Dijalankan
Bridge Construction
BRIDGE SUPERSTRUCTURE DESIGN
Abutment
Corbel
Bituminous
coating
Abutment
Wall
35
Construction of Abutment
Ballast Wall
Plinth for
pad bearing
Abutment
Wall
Shear Key
Curtain wall
Shear keys
Pier cross head
Pile Bent
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Cast-in-situ parapet
Wing
wall
Ballast wall
Approach slab resting Road

on corbel structure Embankment
Construction of Piers
Dimensional control
 Emphasized on the dimensional control is similar the
construction of abutment.
 Special attention should be given to the construction
of pile bent pier type.
 Any deviation of the pier either its location point or
its verticality may not matching the dimensions at
the soffit of cross head.
 This will impair the aesthetic in view of piers
linearity in row or the symmetric of cross head.
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Bridge Construction
Piers
Construction of Pier Column / Wall

Formworks
 The forms are typically constructed to cast or build
segments of the pier vertically & moving the forms
upward as the pier construction takes place.
 For long pier, metal forms are normally utilized
because wood forms have a tendency to bulge when
high lifts are poured.
 Common type of forms used are Slip Form or Jump
Form depending on the shape of piers & the speed of
construction.
 Falsework is required to be provided if involved

cantilevered pier head or so called “hammer-head”.
 The contractor has to submit working drawings &
calculations for the approval of the S.O.
 Where existing road is underneath of cantilever part,
ensure the required vertical clearance of 5.4m below
soffit of falsework is complied.
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Bridge Construction
Piers
Falseworks for constructing cantilevered pier head
Bridge Construction
Piers
Pile-Bent System
Bridge Construction
Piers
39
BEARING
INSTALLATION
 Bridge bearings were provided at positions where the

beams & girders sit on their support at the piers or
abutments.
 Bearing can either be fixed or free.
 Fixed bearing permits no movement other than
angular rotations.
 While free bearing allows rotational movement as
well as displacement in either longitudinal or
transverse direction or both.
Bearing bedding
 The beddings / plinths on top of abutment must be
constructed before placing the bearings for adjusting
the grade of beams & so the deck slab to be
constructed later.
 The beddings must be made of epoxy mortar
material.
 Ensure bedding level plane surface will touch the
entire plane surface of bearing.
 No epoxy mortar bedding be loaded until its control
cube has attained the specified compressive strength.
40
 The concrete surface on which the epoxy mortar
bedding are to be placed & the bearing surfaces on
the prestressed concrete beams must be kept free of
oil, grease, dirt, laitance & other foreign materials.
 Immediately prior to placing the epoxy mortar the
concrete surface which is to receive the epoxy
mortar be primed with a 0.8mm thick cast of the
epoxy resin binder used in the mortar.
 Bearings must be located so that their centre lines
are within ± 3mm of their correct position.
 The level of a single bearing or the mean levels of

more than one bearing at any support must be within
a tolerance of ± 0.0001 times the sum of the adjacent
spans of a continuous girder but not exceeding ±
5mm.
 Bearings must be set to their correct inclination
within a tolerance of 1 in 200 in any direction.
 Epoxy mortar bedding which does not meet these

tolerances may be repaired by either grinding the
surfaces which will be in contact with the bearings to
achieve the desired tolerances, or by roughening
theses surface & casting a layer of approved epoxy
material over the complete surface to a minimum
thickness of 3mm.
Verify the required 5 mm cover of elastomer for top &
bottom steel reinforcing plates.
 Check for cracks in the elastomer & for irregular or
excessive bulging or splitting under vertical loads.
41
Elastomeric Bearing
 Ensure elastomeric bearings have been tested in
accordance with the specifications.
 No bearings is allowed to be installed until they have
been accepted in writing by the S.O.
 Check for imprint of mark number, date of
manufacture & name of manufacturer on face of
bearings.
When installing bearing, ensure it’s entire bottom &
top faces touch the surface of plinth & soffit of beam
respectively.
This to avoid the occurrence of “walking bearing”.
 Inspection should be made on the bearing longitudinal

movement indicator.
 Should the bearing move by more than the design
capacity, the structural engineer & bearing specialist
should be informed so that the remedial works can be
carried immediately.
Bridge Construction
Bearings Installation
Elastomeric Bearing
42
walking bearing
Dowel Bars
 Dowel bars are provided to fix the superstructure
(pin-joint).
 Normally dowel bars are installed at shear keys
constructed on top of abutment or pier surface.
 Dowel bars must be of galvanized as shown on the
Drawings.
 Dowel bars must be accurately installed in position &
direction.
43
Dowel Bars have been

fixed
Shear keys with pair of

dowel bars
44
PRESTRESSED CONCRETE
USED FOR BRIDGE
CONSTRUCTION
133
Bridge Construction
Methods of Prestressing
 Pre-tensioning
A method of prestressing in which the tendons
are tensioned before the concrete is placed, &
the prestressing is transferred to the concrete
when concrete attains an acceptable specified
strength.
 This technique is used principally for the
construction of relatively short span bridge decks
using standard JKR beams.
Bridge Construction
Methods of Prestressing
 Post-tensioning
A method of prestressing in which the tendon is
tensioned after the concrete has reached an
acceptable specified strength. The tendons are
anchored against the hardened concrete
immediately after prestressing.
45
Difference between Pre-tensioned and Post-
tensioned concrete
Pre-tensioned Post-tensioned
 Prestressing force applied before  Prestressing force applied after
concrete cured concrete cured
 Usually strands arranged in  Usually strands arranged strands
straight profile in parabolic profile
 For shorter span construction 10m
to 24m  For wider range of construction
from span 10m to 300 m
 Req. stressing bed/platform  No stressing bed/platform req.
 Preferable for casting in

 Preferable for casting on site
factory/casting yard
No stressing anchor req. at
concrete end  Req. stressing anchor at live end.
136
Pre-tensioning Method
Stage 1 Stage 2 Stage 3 Stage 4

Tendons and Tendons are Concrete is cast When the concrete
reinforcement are stressed to about into the beam has cured, the
positioned in the 70% of their mould and stressing force is
beam mould. ultimate tensile allowed to cure to released and the
strength. the required initial tendons anchored
strength. them selves in the
concrete.
137
Pre-tensioning
Prestressing Bed
46
Pre-tensioning Process
Monostrand jack
Prestressing Strand
Post-tensioning Method
Stage 1 Stage 2 Stage 3 Stage 4

Cable ducts and Concrete is cast Tendons are Wedges are inserted
reinforcement are into the beam threaded through the into the end
positioned in the beam mould and allowed cable ducts and anchorages and the
mould. The ducts are to cure to the tensioned to about tensioning force on
usually raised towards required initial 70% of their the tendons is
the neutral axis at the strength. ultimate tensile released. Grout is
ends to reduce the strength. then pumped into
eccentricity of the the ducts to protect
stressing force. the tendons.
140
Typical Post-Tensioned Beam Details

47
Bridge Construction
Post-tensioned Prestressing Equipments
METHOD EQUIPMENT
Fixed mould, concreting 20 tonnes crane
Concreting Poker vibrator and engine

Uncoil prestressing strands Bripad / Strand dispenser
Cutting prestressing strands Disc cutter
Stressing cables Stressing jack

Operation jack Hydraulic stressing pump
Mixing cement grout and grouting Grout mixer cum pump
Making grouting test cubes 100mm Test cube moulds
Cutting of reinforcement Cutting machine
Bending of reinforcement Bending machine
Make onion – end for dead end Dead end machine
For poker and clean mould Air compressor
Supply electricity for machine Gen-Set 37 kva
Prestressing Materials
Tendon Ducts
 Ducts/sheaths are made of
galvanised corrugated steel, in
helical form.
 Used to protect tendons in concrete.
 Number of joints must be kept to a
practicable minimum & each joint
adequately sealed against the
ingress of any material.
Corrugated Galvanised Steel
 Joints in adjacent sheaths must be Sheaths
staggered by at least 300mm.
 Sheaths must be kept free from any
materials which is detrimental to
bond between sheath & concrete.
48
Tendon Ducts
 The ends of ducts/sheaths must be always sealed
until the insertion works of tendon commence.
 Cement grout will be pumped into the ducts to
protect prestressing strands from corrosion.
Tendon Ducts
Corrugated metal sheath
49
50
Prestressing Strand
 Commonly Low Relaxation

high tensile steel is used.
 Tensile strength varies
between 1570N/mm2 to
1860N/mm2 Prestresing strand coils
 Commonly 7 wires or 19
wires.
 Nominal dia. 12.7mm or
15.2mm
Strand coils dispenser / bripad

51
Post-tensioned anchorage system
Sheath/Duct
Anchor block
Prestressing
Strand
Wedges Bearing plate

Source : Freyssinet PSC Malaysia
LIVE END ANCHORAGE
52
Post-tensioned anchorage system
 Wedges  Anchor/End Block
 Threaded finish for providing sufficient

159 friction/grip to strand
53
Concrete Strength
 The prestressing force has to be produced by a

high tensile steel & therefore it is necessary to use
high quality concrete to resist the higher
compressive stresses that are developed.
 For prestressed concrete, the minimum concrete
strength for JKR practice is Grade 50.
 The minimum concrete strength at transfer is
30 N/mm2 . Normally designer will specify 40
N/mm2 .
Prestressing Strand Handling
 Strands must not be:-

i. Cut using oxy-acetylene torch.
ii. Welded for any purpose of lapping
iii. Kinked or twisted
 Strands can only be cut using high speed abrasive
cutting blade.
 Strands must be always clean & free from rust,
grease or wax.
54
Prestressing Equipment
Prestressing Strand Handling
 Stressing Jack
- Commonly hydraulically operated
- Pulling strand up to specific length (stroke)
Mono strand jack Multi strand Jack

Source : VSL International
Stressing Sequence
Step 3; Secure/lock strand to

Step 1; Placing of anchor stressing jack. Jack to
block and wedges req. force/elongation
Step 2; Inserting prestressing

strand through the jack Step 4; Releasing stressing jack
55
Stressing Sequence
 Where two or more wires or strands are stressed

simultaneously, they should be approximately of
equal length between anchorage points.
 The tensioning apparatus must be a controlled
system in order that total force can be imposed
gradually to ensure no secondary stresses are
induced in the tendons, anchorage or concrete.
 The force in the tendons during tensioning should
be measured by direct-reading load cells or
obtained indirectly from gauges fitted in the
hydraulic system to determine the pressure in the
jacks.
equal length between anchorage points
gauges fitted in the hydraulic system
56
Stressing Sequence
 Facilities must be provided for the measurement of

the extension of the tendon.
 The load-measuring device must be calibrated to
an accuracy within 2%.
 The tensioning equipment must be calibrated
before the tensioning operation.
Stressing Force
 As specified on the drawing

 Max. jacking force – (Cl. 6.7.1 BS 5400 Part 4)
-Pre-tensioned : Max. 75% Ultimate Tensile
Strength
-Post-tensioned: Max. 70% Ultimate Tensile
Strength
Max. force allowed during stressing must not
exceed 80% of Ultimate Tensile Strength
Stressing Force
Where Pavg=Average Pressing force
Ls =Effective free strand length
Es = strand Young Modulus
Basic formula, Extension  cal = Pavg .Ls
As.Es
Jacking Force at stressing end = Pj
Jacking Force at Dead End /non-stressing end = KPj
Where K =Losses of prestressing due to :
i. Elastic deformation of concrete
ii. Anchorage draw-in
iii. Friction losses
Pavg = (Pj +KPj)/2
Extension cal = (Pj +KPj)/2.Ls

As.Es
57
Stressing Force
Tendons extension by site measurement
 Slack due to draw-in at anchorage & stressing device could be unknown
during stressing
 However the actual total extension measured at site, Mea could be
calculated by simple linear interpolation method
Jacking
Force ( kN)
i = Pi . (F/(PF - Pi)
PF Mea = F + i
Mea = F + Pi . (F/(PF - Pi)
= F [1+ (Pi/(PF - Pi)]
= F [(PF - Pi+ Pi)/(PF - Pi)]
Mea =  F [(PF)/(PF - Pi)]
Pi Where
Pi = initial jacking force
PF = final jacking force
i = extension due to initial jacking force
i F  (mm)
F = extension due to initial jacking force
 Mea Supervision of Bridge Construction
172 Slack Mea = actual total extension measured at site
Stressing Force
Percentage of difference in extension

= mea -cal x100 %
cal
BS recommended a difference of  6% between

calculated & measured values.
BS 5400: Part 8: 1978 Cl. 5.7.5.4 & BS 8110: Part 1:
1985 Cl. 8.7.5.4 stated ;
“…if the difference is greater than 6%, corrective
action should be taken…”
Sample of Stressing
Record
174
58
Stressing Force
Possible Causes
 Difference of prestressing strand sectional area or
E value which have been used for computation
extension.
 High deviation in cable profile from specified in
drawing (due to wrong installation, displaced prior
or during concreting).
 Blockage of duct during concreting.
 Pressure gauge not in good working condition/not
calibrated.
Post-tensioning Works Flow
CARRY OUT Perform Perform

PRESTRESS storage area casting yard Unload mobilized Unload mobilized
POREPARATION preparation preparation prestress equipment prestress material
WORK work work
CARRY OUT Perform

Confirm Perform
DUCTING ducting Perform tendon Fix cable
tendon ducting
INSTALLATION arrangement profile marking support bar
position placing work
WORK work
Perform
Perform Perform tendon
Perform grout Check grout ducting
coupling profile
vent fixing vent position cleaning
ducting work inspection
work
CARRY OUT Carry Out

Check Strand
STRAND Unloading Check Strand Strand Coil Check Strand
Stressing
THREADING Strand Coil Coil Dispenser Numbers
Length
WORK Fixing
Perform Perform
Strand Strand
Cutting Threading
Carry Out Perform Live Perform Live Perform Dead

Seal Dead
Anchorage Fabricate Dead End & Dead End End End
End
Installation End Anchorage Anchorage Anchorages Anchorages
Anchorage
Work Marking Fixing Fixing
Check Dead Check Dead

End Bonding End
Length Anchorage
59
Procure Procure
ORGANIZE Set up Install
Stressing Jack Pressure Gauge Perform Jack
STRESSING Stressing Stressing
Calibration Calibration Positioning
EQUIPMENT Equipment Gauge
Certificate Certificate
Install Perform
Prepare
Stressing Prepare Jack Hydraulic
Stressing
Hydraulic Hoisting Facility System Trial
Platform
System Run
ORGANIZE Procure
Procure Procure Cable
STRESSING Tendon
Stressing Force Extension
PREPARATION Stressing
Calculation Calculation
WORK Sequence
CARRY OUT
Prepare Perform Perform Perform
ANCHORAGE Prepare
Anchorage Anchorages Anchor Head Wedges
COMPONENTS Anchor Heads
Recesses Cleaning Installation Fixing
INSTALLATION
Check Bearing
Surface
Condition
Arrange
CARRY OUT Verify Concrete Check Strand Barricade Arrange
Prestressing
STRESSING Transfer Stressing Working Prestressing
Jack
WORK Strength Length Area Tools
Accessories
Perform Perform Tendon Measure & Record Calculate

Strand Stressing Corresponding Total Tendon
Marking Incrementally Tendon Elongation Elongation
Organize Perform Perform Grouting Execute

Perform
Grouting Stressing Equipment Setup; Grouting
Tendon
Preparation Anchor pump, pressure gauge, Equipment
Cutting
Work Patch-Up grouting hose Testing
Organize Perform Perform Perform

Grouting Water Material Grouting
Material Measurement Measurement Mixture
Perform Grout Perform Perform

Carry out
Pump Though Grout Vent Grout Vents
Grouting Work
Anchorage Flow Grout Closing
60
Strand preparation / cutting
182 Completed
Supervision of Bridge Construction reinforcement cage
61
Anchorage bearing plate installed

185
Awaiting
Supervision of Bridge anchor
block & wedges to be installed
Construction
62
Stressing Works
187 Mono strand jack; Hydraulic jack for tensioning cables
Multi strand jack; Hydraulic

jack for tensioning cables
Marking by painting before Extension after initial stressing,  i

stressing
189
Measurement of extension after final Pressure indicated on the reading
stressing,  F unit
63
Launching Girder
Camber
Stressing Works
Safety
 The prestressing operation can be a potentially
dangerous one due to the tremendous forces
involved.
 If a failure occurs, there is a good possibility that
high velocity projectiles will be produced.
 The field engineer should always stay alert & be
aware of the prestressing operation as follows:-
 Stay clear of the area when the contractor is
unpacking the strands. Securing bands may spring in
any direction when released, causing injury.
 Before the contractor begins the stressing operation,
check all of the high-pressure hoses for leaks and/or
poor condition. Worn or damaged hoses are to be
replaced only with hoses that can withstand the high
pressures involved.
Stressing Works
Safety
 Never stand behind, along side, or directly above

the prestressing jack during the stressing operation.
 Never stand behind the “dead end” of the tendon
during the stressing/ de-stressing operation. Use
“caution” around tendons until after they are
grouted.
64
Grouting
 Grout is needed to transfer loads & to protect

tendon from corrosion.
 Mixing equipment shall produce a grout of
homogeneous consistency & shall be capable of
providing a continuous supply to the injection
equipment.
 Grout material should consist only of Ordinary
Portland Cement & water.
 Water shall be added to the mixer first with the
cement. Admixture shall be added later. The grout
shall be mixed for a minimum of 2 minutes.
Grouting
 Admixtures containing chlorides or nitrates shall

not be used.
 Mixing shall not be done by hand.
 Grouting must be done immediately after
tensioning.
 Maximum permitted grout pressure must not
exceed 1 N/mm2 .
POST-TENSION GROUTING WORKS
65
{
VSL PLASTICIZER - MY
66
Grouting Process
Grouting tube
Grouting vent
Bridge Construction
Beams
Typical section of PRT1

pre-tensioned beam
Rebars ;Continuity End Diaphragm
Bridge Construction
Prestressed beams
 Bulb T-beams are normally designed as a post-
tensioned member with 2 stage post-tensioning.
 The first stage post-tensioning is carried out to
resist bending due to self weight of beam & dead
weight of deck slab.
 The stresses due to these forces & bending is
within the allowable limits specified in the code.
 The second stage prestressing is carried out to
provide full prestressing. From the above
sequence of stressing, the losses due to
prestressing will be reduced.
67
Bridge Construction
Prestressed beams
Typical section of post-

202 Supervision of Bridge Construction tensioned Bulb-T beam
Bridge Construction
Prestressed beams
 As the piling works is in progress, the pre-

tensioned beams are independently cast &
prestressed.
 In order to minimize the effects of creep &
shrinkage it is advisable to cast the beams as early
as possible.
 According to BS 5400: Part 4
(Clauses6.7.2.4&6.7.2.5) it can be assumed that
half (1/2) the total creep & shrinkage takes place
in the first month after transfer.
Bridge Construction
Prestressed beams
 Three-quarters of the total creep & shrinkage is

assumed to take place in the first 6 months after
transfer.
 The age of the precast beam should be 180 days
or more at the time of casting of the abutments or
pier cross heads.
 This would minimize the intensity of the restraint
moment at the supports caused by creep due to
prestressing & dead load.
 All beams are to be handled & transported only
after transfer of the prestressing force.
68
Bridge Construction
Prestressed beams
 Beams should be transported in the upright

position with points of support & directions of
reactions, with respect to the member,
approximately the same as in its final position.
 Pick up points should generally be located a
maximum distance of 1 m from the beam end.
 Beams should not be erected until the concrete
has reached the minimum strength specified on
the Drawing at the time of erection.
Launching of Precast
Elements
Bridge Construction
Launching of Precast Elements
 The Contractor should inform the S.O. at least 1

month in advance of each launching operation &
submit the following for acceptance:
i. Method statement including launching systems
& transportation,
ii. Proposal for traffic diversion, as appropriate,
iii.Detailed program of each launching operation.
69
Bridge Construction
 The Contractor must obtain the necessary

clearances for the transportation of the pre-cast
elements & movement of the lifting equipment to
the launching site.
 Contractor‟s method of transportation should
demonstrate that the elements being transported
would not be damaged.
 A certificate of test of lifting equipment must be
submitted to the S.O., together with particulars of
the experiences of the operator.
Bridge Construction
 Prior & during erection works of pretensioned

beams, the following attention need to be taken:
-Ensure records are verified such as beam
reference number or identification marking, date of
casting, dimensions, date of prestressed, strength
of concrete at transfer, required concrete strength
is achieved before launching.
-Ensure the delivered beams on site is free from
any damage.
Bridge Construction
-Ensure crane or beam launcher has the capacity,
stability & safety („fail-save‟ method) to avoid
fatality.
-Beam must be handled slowly & carefully without
sudden shock or impact avoiding any effect on the
integrity of prestressed tendons.
-Ensure the beam is lifted at the designated points
as indicated on the drawing.
70
Bridge Construction
-Immediately report to the S.O if any damage on

beam is found due to improper erection or
launching.
-Ensure the bearings & dowel bars are not
damaged due to launching of beams.
-Ensure the position of beam is correctly placed on
the centre point of bearing and the surface of beam
soffit is completely touched the top surface of
bearing.
Bridge Construction
 Precautions must be taken to eliminate any danger

to the workers & general public while launching
precast elements.
 All lifting equipment must be designed, such that if
the primary lifting mechanism fails, a secondary
mechanism will ensure that the pre-cast element
does not fall.
 Upon erection, a “fail-safe” method must be used
to temporarily secure the precast unit until the
permanent fixing arrangements are implemented.
Bridge Construction
 The securing systems, should include:

i. providing chains between beams & supports;
ii. connecting adjacent beams by welding protruding
bars of the beams; or temporary bracings between
the beams;
iii. providing wedges or brackets to the beams.
71
Bridge Construction
 Products must be adequately braced during all

stages of erection to resist wind forces, weight of
forms & other temporary construction loads,
especially those eccentric to the vertical axis of the
products.
 The horizontal alignment of prestressed concrete
beams should not be allowed to deviate from the
design alignment prior to placement of the
diaphragms & deck.
Bridge Construction
 Diaphragm may be poured & allowed to set prior

to the deck concrete being poured as indicated on
the Drawing.
Bridge Construction
Placing of Beams
Bracing of beam
using steel bars
72
Bridge Construction
Placing of Beams
Bridge Construction
Beams diaphragms
Intermediate
Diaphragm
Precast I-Beam as the superstructure
Construction of Deck Slab
73
Bridge Construction
Deck Slab
 Normally bridge decks are constructed as cast-in-

situ reinforced concrete slabs.
 Bridge decks are required to conform to the grade
of the approach roadway so that there is no bump
or dip as vehicles cross onto or off the bridge.
 Improper deck construction will probably only
initially be present in the appearance & riding
surface of the bridge.
 Particular attention to be given where the
horizontal alignment of the roadway on the
deck is a curvature with super elevation. 220
Bridge Construction
Deck Slab
 The fundamentals of deck slab construction are as
follows:-
i. Accuracy in the setting forms.
ii. Properly proportioned mix and consistency in
concrete.
iii. Proper handling and placing of the concrete
mix.
iv. Uniform "strike-off" or screeding.
v. Straight edging by experienced pavement finishers.
Bridge Construction
Deck Slab
vi. Uniform texturing.

vii. Proper finishing at gutter areas for drainage.
viii. Proper curing.
 Quality of curing greatly affects the properties of
concrete & therefore has an impact on durability
of the deck.
 Placement of fresh concrete is preferred at late
evening or early night.
74
Bridge Construction
Deck Slab
 If placement at the time is imperative, chilled
water may be used for mixing concrete, forms &
bars cooled before placement to avoid significant
increase in concrete temperature; & wind speed
lowered by shielding.
 The appropriate deck construction sequence
should be observed:
i) place complete deck at one time whenever
feasible.
ii) If multiple placements must be made on
simple spans, place each span in one
placement.
Bridge Construction
Deck Slab
iii) If the bridge is simple spans, but cannot be
placed in a single placement, then divide the
deck longitudinally & make 2 placements.
iv) If bridge is simple spans & single placements
cannot be made over the full span length, then
place the center of span segment first & this
placement as large as possible.
v) If multiple placements must be made & the
bridge is continuous spans, then place
concrete in the center of the sagging moment
regions first, & observe a 72 hour delay between
placements.
Bridge Construction
Deck Slab
 Wet curing should be implemented immediately

at areas where concrete has set to reduce the
temperature of the concrete surface.
 Curing shall be by continuously damped double
layer of gunny bags with excess water for not
less than 7 days.
75
Bridge Construction
Deck Slab
Deck width is subjected to the standard geometric road design and

road classes under local authorities.
Bridge Construction
Deck Slab
Typical Dual Carriageway Structure
76
INSTALLATION OF
EXPANSION JOINTS
Bridge Construction
Expansion Joints
Multiflex expansion joint Compression seal
Bridge Construction
Expansion Joints
 Expansion joints are provided at joints between
span members to accommodate various
movements at the joints & at the same time permit
traffic to be carried across the gap between the two
independent members or bridge segments.
 Shop drawings indicating the details types,
materials, dimensions & installation etc. which are
not shown on the construction drawings must be
obtained from the contractor.
77
Bridge Construction
Expansion Joints
 The position of all bolts cast into concrete & holes

drilled in plates must be accurately determined
from templates.
 Ensure that any surface designed to be filled with
a compressible materials or void, is kept clean of
any materials likely to impair the efficiency of the
joint.
Bridge Construction
Expansion Joints
 When one half of the joint is being set, the other
half must be completely free from longitudinal
strain. In particular where strong backs or
templates are used to locate the two sides of a
joint, they must not be fixed simultaneously to both
sides.
 Screw thread must be kept clean & free from rust.
Ramps must be provided & maintained to protect
all expansion joints from vehicular loading.
Bridge Construction
Expansion Joints
 A poured sealant, must be placed when the mean
bridge temperature is between 21°C 38°C.
 Proprietary expansion joints must be installed by
specialist workmen who have been trained &
approved by the joint's manufacturer.
 Surfacing must be carried across the joint & then
cut back to accommodate the nosing. The cutting
must be done with a diamond saw to give a clean
edge throughout the depth of the material provided
to be removed.
78
Bridge Construction
Expansion Joints
 Masking materials provided to prevent surfacing
materials adhering to concrete surface at the joint
must be properly located to prevent displacement
by the paving machine.
Reinforced elastomeric
expansion joint
Buried Joint
Asphaltic Plug Joint
79
Nosing Joint
Reinforced Elastomeric
Cantilever comb or tooth joint
CONSTRUCTION OF
INTEGRAL ELEMENT
80
Bridge Construction
Fully Integral Bridge
 Rigid connection between superstructure &
substructure at abutment & piers are transferred by
way :-
i) the beams or girders are cast into a concrete end
diaphragm
ii) which is connected to a concrete pile
cap/abutment
iii) and generally supported by a single row of
piles.
 The critical detail that makes a bridge an integral
bridge is the connection of the superstructure to the
abutment &Supervision
pier. of Bridge Construction 241
Bridge Construction
Bridge deck Approach

road
Elimination of expansion
joints offer better riding Continuous pavement surface
confort between bridge deck and
242 Supervision of Bridge Construction approach embankment
Single Span of Fully Integral Bridge
81
Typical Girder-Abutment-Pile Joint For Fully Integral Bridge
Hinged
Approach Slab
Precast Girder
Abutment Wall
Single Row of Pile

Bridge Construction
Precast beam
End Diaphragm
Full rigid connection

Rubber bearing
Abutment wall
Bridge Construction
Rigid connection between precast beam

diaphragm and abutment
82
Bridge Construction
Full Continuity at
abutments and piers
Flexible piers
Multi-span Fully Integral Bridge

Bridge Construction
Continuous deck slab over pier
Bottom reinforcement
is provided to resist
tensile stress due to
creep and shrinkage
effect
Typical continuity between superstructure

& substructure for multi-span fully integral bridge
Bridge Construction
Monolithic Connection
Prestressed JKR
Standard T-beam
Pier Cross Head/Diaphragm
83
Bridge Construction
Semi Integral Bridge
 A semi-integral bridge structure is where the

superstructure is not rigidly connected to the
substructure.
 Absence of a bridge deck joint.
 Superstructure & substructure are integrated by
means of mechanical/rubber bearings.
Semi Integral Abutment

No expansion joint
Rubber shear strip to

accommodate deck slab Gap to allow for
movement expansion & contraction
Precast beam
Rubber Bearing
Abutment
Continuous Deck Slab Over Pier For Multi spans

Semi-Integral
Continuous deck slab
Precast Beam
Pier Crosshead
84
Multi-Spans Semi-Integral Bridge, Jambatan
Pinang Tunggal, Seberang Perai Utara
Bridge Construction
Construction Sequence of Integral Bridge
 The abutment piles are driven to their founding

level.
 The connection between the piles & the abutment
is then prepared, the abutment crosshead cast up
to the level of the underside or soffit of the beams.
 Meanwhile the central pier with its pile cap is also
constructed.
 Concrete pedestals or plinth is cast on top of the
abutment & pier, along with bearing pads to
provide proper beam seat elevations.
Bridge Construction
 Integral abutment details usually include a heavy

abutment diaphragm cast integrally against the
beam ends & connected to the abutment seat with
reinforcing bars.
 The beams are first set on bearing pads to span
from abutment to abutment or pier, simply
supported.
 Prestressed beams aged must be minimum 90
days prior to pouring continuity diaphragm.
 Then, the deck & diaphragms are poured
simultaneously.
85
Bridge Construction
 As deck concrete loads the beams during

construction, the beams rotate on their bearings as
simply supported. Once the diaphragm cures,
though, it provides a compressive base at the
bottom of the (already dead-load rotated) beams.
The cured deck & beam composite provides paths
for negative moment tension stress through deck
reinforcing bars & beam starter bars.
Bridge Construction
 When there is a large deck to pour, the pour

should be staged.
 In staged construction, the mid-span deck sections
are poured first so that the beam still rotates under
the dead load.
 The deck above the pier support & diaphragm for
that pier are then poured simultaneously.
 The continuity between the abutment &
superstructure is achieved by placing a cast-in-situ
closure segment joining the abutment & the deck
together.
Bridge Construction
Deck
Precast beam
Abutment
The continuity between the abutment & superstructure is achieved by

258
placing a
Supervision of cast-in-situ closure
segment joining the abutment & the
Bridge Construction
deck together.
86
JKR Standard T- Beams

Rebars ;Continuity End Diaphragm
Supervision of 259
Bridge Construction
Creep deformation in continuous composite jointless

construction due to prestressing force
Deformation in continuous composite jointless construction

due to differential shrinkage, sustained dead load of the
girder & deck slab Supervision of Bridge Construction 260
Bridge Construction
Construction Sequence of a Single Span Integral Bridge
Piling & Construction of Abutments
Embankment Fill behind abutments
Erection of Prestressed Beams
Deck Slab Rebars & Concreting at mid-span
87
Bridge Construction
Concreting of remaining ends Deck
Slab + top Abutment Walls + End
Diaphragms, Granular Fill below
Approach Slab
Rebars & Concreting of Approach Slabs
Parapet Installation, Approach Pavement + Surfacing
Bridge Construction
Integral Abutment Details
CONCRETE PARAPET
88
Bridge Construction
Parapet
 The parapet wall was actually made of independent

units of precast concrete block 950mm in length
fixed on top at the edge of the deck slab.
 They were hold in position individually by two (2)
number M24 holding down bolts which were cast
together with the deck slab.
 Precast concrete parapet must be formed with
finish surfaces of Class F3.
 The parapet must be set so that the front top arise
conforms to the line & grade required.
Bridge Construction
Parapet
 Parapet must be laid with joints as narrow as

possible & filled with mortar containing 1 part
Portland cement & 2 parts sand.
 Expansion joint must be formed at intervals as
shown on the Drawings. The expansion joint in the
parapet must be filled with an expansion joint filler.
 When parapets are erected, they must be securely
held in their correct position until all connections &
fastenings are complete & fixings have gained
sufficient strength to withstand the design holding-
down moment.
89
PROTECTIVE COATING
90
Protective coating
Protective coating mock up
Bridge Construction
Protective Coating
 The purposed of providing protective coating on

the surface of bridge is for the long life of concrete
against the effect of environment.
 It also gives value added to the aesthetic
appearance to the structures.
 Prior to application, all surfaces must be dry & free
from oil, grease, loose particles, decayed matter,
moss or algal growth.
 All such contamination & laitance must be
removed by the use of grit blasting, high pressure
water jetting or equivalent mechanical means
91
Bridge Construction
Protective Coating
 The application must be in accordance with the

manufacturer's recommendations, particularly with
respect to the maximum application thickness of 3
mm.
 Fresh concrete must be at least 28 days old before
receiving surface preparation.
Bridge Construction
Protective Coating
Coating to exposed surface of deck soffit,

diaphragms, beams, parapets, piers above water &
abutments above water
 The protective coating must consist of a dual
protective system formed by two coats of
silane-siloxane based primer & two coats of
solvent based methacrylate pigmented top
coat.
Bridge Construction
Protective Coating
Coating to exposed surface of piers & abutments

below water
 Two layers of epoxy coating inclusive of surface
preparation to all exposed underwater surfaces of
abutments and piers.
 The coating may be applied by spray, roller or
brush.
 Primer must be applied in at least 2 flood coats
using a low pressure knapsack sprayer.
 Application must be repeated until correct
coverage is achieved.
92
Bridge Construction
Protective Coating
 On very porous surfaces application must be
repeated until surface is completely saturated.
 All treated surfaces must be allowed to dry for at
least 2 hours.
 When the surface is visibly dry, the Topcoat then
applied.
 A two coat, pinhole free application of the Topcoat
is applied. Four hours drying between coats must
be allowed.
Bridge Construction
As-Built Drawings
 For record & reference purposes, as-built drawings

were prepared by the Main Contractor upon the
completion of the bridge project.
 At the end of the Contract, the as-built drawings
were submitted to relevant authority through the
Supervising Consultant/S.O.
KURSUS PRA-PTK
SESSI 2-20007
Sekian
Terima kasih di atas perhatian
anda..!
93

Nota BHG 4 - Supervision of Bridge Construction

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Bahagian 4

Pengurusan Pembinaan Jambatan

Supervision of Bridge Construction 2

 Bridgemay categorize into :-

Supervision of Bridge Construction 3

Relationship Between Bridge Design & Construction

 The design & construction method to be used depends

Supervision of Bridge Construction 5

Supervision of Bridge Construction 6

Supervision of Bridge Construction 7

vii Cable Stayed

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i. Reinforced concrete beam-

ii. Prestressed concrete beam-

iii. Concrete Box Girder (beam

Supervision of Bridge Construction 9

Supervision of Bridge Construction 11

Supervision of Bridge Construction 12

Supervision of Bridge Construction 14

Supervision of Bridge Construction 15

Supervision of Bridge Construction 16

Supervision of Bridge Construction 17

Supervision of Bridge Construction 18

ii. Multiple column on

iii. Pile bents

Supervision of Bridge Construction 19

Supervision of Bridge Construction 20

Beams and Girders

Supervision of Bridge Construction 21

Supervision of Bridge Construction 22

Supervision of Bridge Construction 23

Supervision of Bridge Construction 24

Supervision of Bridge Construction 26

 The following are some common types of rubber

Supervision of Bridge Construction 28

Supervision of Bridge Construction 29

Simple & Continuous

Simple & Continuous Spans

Supervision of Bridge Construction 33

Supervision of Bridge Construction 34

 The construction of bridge is similar to other type of

iv. Quality of works.

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Supervision of Bridge Construction 37

General Arrangement of Bridge

Supervision of Bridge Construction 40

f) Approach road construction

Supervision of Bridge Construction 41

Bridge Construction Sequence

Supervision of Bridge Construction 42

- Raw materials quality tests.

Bridge Setting Out

Supervision of Bridge Construction 46

 It is therefore important for the site supervision to

Supervision of Bridge Construction 47

What happen if the bridge is out of alignment?

i. The cast prestressed beam cannot be placed in

Supervision of Bridge Construction 48

Supervision of Bridge Construction 49

ii. The vertical alignment of bridge structure &

 HODT/Designer must be consulted for further advise

Supervision of Bridge Construction 50

iii. Increase of height will increase the quantity of