BRIDGE CONSTRUCTION INCLUDING SEGMENTAL & INCREMENTAL

CONSTRUCTION

1. Introduction

Bridges have been constructed using the incremental launching method (ILM) for many years. In this method of
construction, the bridge superstructure is assembled on one side of the obstacle to be crossed and then pushed
longitudinally (or “launched”) into its final position. The launching is typically performed in a series of increments so
that additional sections can be added to the rear of the superstructure unit prior to subsequent launches.
When used for the appropriate project, the ILM offers a number of significant advantages to both the owner and the
contractor, including the following:
Minimal disturbance to surroundings including environmentally sensitive areas
Smaller, but more concentrated area required for superstructure assembly
Increased worker safety since all erection work is performed at a lower Elevation.
The ILM can be used to construct a bridge over a wide range of challenging sites which feature limited or restricted
access, including those with the following characteristics:
Deep valleys
Deep water crossings
Steep slopes or poor soil conditions making equipment access difficult
Environmentally protected species or cultural resources beneath the bridge.

2. Where it is used…?

The incremental launching method can be used for straight bridges, or where the superstructure has a spatial
curve of constant radius throughout the length. This means that it is even possible to construct bridges which are
curved both horizontally and vertically, provided that the radii are constant. The superstructure should consist of a
beam of constant section, for which the slenderness ratio, that is the span-to-depth ratio, is not more than 17 when
completed. Normally, the ratio lies between 12 and 15, the first value applying to larger, the second to smaller spans.
It is of advantage, with regard to design and detailing, if all the spans, except the end ones are equal or almost equal
in length; the length of the end spans should not exceed 75 % of that of the standard spans. The most suitable cross-
sections are the single-cell box section or the double T-beam; double-cell box sections have also been used, but their
construction is somewhat more complicated in respect of shuttering and supports. It is evident that a sufficient area
of suitable loadbearing ground must be available behind one abutment for the construction yard. If the bridge has a
longitudinal gradient, it is preferable for the construction yard to be behind the lower abutment, so that no braking
equipment is necessary during launching. If some of the preconditions for the use of the incremental launching
method do not already exist, the modifications required are frequently quite small. It is however to be hoped that in
the future increased attention will be paid at the design stage to the possible use of the incremental launching method.

3. CONSTRUCTION SUGGESTIONS

3.1 General

When the incremental launching method is used, the advantages of in-situ and precast concrete construction
are combined. The fabrication area is stationary and often covered to make it independent of the weather, and the
transport distances are very short. This concentration of equipment permits almost factory conditions of construction
and correspondingly high quality.
The fabrication area includes the formwork, concrete mixing plant, a rail-mounted tower crane, storage areas for
reinforcing and prestressing steel and the jacking equipment. If the prestressing tendons are made up on site, space
for tendon assembly is also required.
The jacking equipment at the abutment and the temporary bearings on the piers and in the fabrication area must be
accessible for the forward jacking operations.

3.2 Formwork

For a box-section structure, construction is usually carried out in two phases: in the rear part of the fabrication
area, the bottom slab is cast, while the webs and deck slab are cast in the forward part. Consequently, there are two
formwork units. The rear formwork, where accuracy is of especial importance so that the sliding surface shall be clean
and the launching direction accurately maintained, consists of the bottom formwork and of side forms each about 0.5
m high. The internal formwork is collapsible and movable, enabling it to be reinstalled with minimum expenditure
after each cycle. The two external forms in the second region are in a fixed position and can be hydraulically lowered.
The construction of a superstructure having a double T-beam section naturally requires only one formwork unit, in
which both the external and internal formwork are in fixed positions and can be hydraulically lowered outwards and
inwards respectively.
All formwork is of steel, provided the number of cycles is sufficiently high (in excess of about 25), otherwise it may,
for instance, be of plastic-coated timber.

4. Working Principles of the Launching Equipment

The launching process of the long-span arch bridge is very complicated with sensitive and frequent changing
structure loading performance. Therefore, a set of tracked incremental launching system is specially developed with
highly modularized equipment and automatic control. The set of incremental launching system has adjusting capacity
in vertical, longitudinal and transverse direction, powered by hydraulic jack and automatically controlled by
monitoring computer. The basic working principle is to use the vertical jack to lift the structure simultaneously in
multiple points, and the horizontal jack to push the structure forward to achieve the launching purpose, then vertical
jack is released and entire structure laid down on temporary pad beam to complete a launching process.

5. TYPES

5.1 Balanced cantilever (cast-in-situ and precast)

The proven and safe balanced cantilever method, as used by the BBR Network, is often appropriate and cost-
effective for the construction of long span concrete bridges including various landmark structures where height,
topography or geotechnical conditions render the use of conventional formwork uneconomical.
The economical range of span lengths for cast-in-situ cantilever construction begins at roughly 70m and extends to
beyond 250m.

5.2 Incremental launching

Incremental launching of bridges can save time, money, space and disruption while easing access and
delivering a high quality finish.
The incremental launching method is particularly suited to the construction of continuous post-tensioned multi-
span bridges. It involves casting 15-30m long sections. The sections are cast contiguously and then stressed
together. The superstructure is launched over temporary sliding bearings on the piers.
5.3 Precast span-by-span

The precast span-by-span bridge construction method offers a very high speed of construction. Used in
conjunction with an erection truss under the bridge segments. The method has been used most often for spans
ranging from 25m to 45m.
As spans increase, there is a significant increase in the cost of the erection girder. Erection girder can support the
segment from below, or above – underslung and overhead launching gantries. This method allows a fast rate of
erection.

5.4 Progressive placement

The method is based on a very simple idea. It consists of placing the precast segments of a deck continuously
from the first abutment to the other one. The stability of the deck is maintained with a set of stays.
Transported over the finished portion of the deck to the end of the cantilever span under construction, each new
segment is placed in its final Position with the lifting device. The new segment is held by exterior temporary ties.
The lifting device is moved to the end of the deck.The corresponding pair of stays is added and tensioned.

6. CONSTRUCTION OF SEGMENTAL BRIDGES

6.1 Casting of segments

6.1.1 Short Line Method

In the short-line method, each segment is cast next to the previous segment in a special adjustable casting machine.
This ensures that the interface between the two segments matches exactly when erected. Each successive segment is
then cast next to the previous one. In this rate of segment production is slow. Three or four segments cast at a time.

6.1.2 Long Line Method

In the long-line method, formwork matching the shape of the soffit is erected on the ground. A traveling form for the
webs and deck is moved along the soffit form for the casting of each segment. In this rate of segment production is
fast. Segments equal to one span cast at a time. After casting, the segments are stored at staking yard and curing of
segments is done. After curing the segments are transferred at erection site with the help of traveler or crane.

6.2 Erection of segments

Erection of segments is done by following methods:

6.2.1 Balanced Cantilever erection

6.2.2 Progressive Placement erection

6.2.3 Span by Span erection

6.2.4 Incremental Launching erection

6.3 Epoxy Gluing

In between the two segments epoxy Gluing is used to prevent the leakage of grout during grouting.
6.4 External prestressing
Used for giving the final strength to bridge.

6.4.1 Pre-tension method

6.4.2 Post tension method

6.5 Grouting
The main purpose of grouting is to protect the strands against corrosion and develop the bond between prestressing
steel and surrounding concrete.

7. Conclusions
This method is ideal for bridge construction
bridge give Aesthetical view or good quality.
Longer span bridge now possible.
Longer bridge over water now possible.
Construction of long bridges now easy.
Construction time is less.
Environment friendly construction.
Construction line is highly mechanized by this method.

References:
Bishara, A. G. (1984). Prestressed and precast concrete. Dept. of Civ. Engrg., Ohio State Univ., Columbus, Ohio.

Bishara, A. G., and Jang, S. Z. (1980). "Settlement induced forces in concrete bridges." J. Struct. Engrg. Div., ASCE,
106, 1423-1436.

Branson, D. E., Keeton, J. R., and Roll, F. (1970). "Prediction of creep, shrinkage, and temperature effects in
concrete structures." ACI Publications, SP-27, American Concrete Institute, Detroit, Mich.

Ketchum, M. A. (1986). Redistribution of stresses in segmentally erected prestressed concrete bridges. Dept. of
Civ. Engrg., Univ. of California, Berkeley, Calif.

Muller, J. (1979). "Long-span precast prestressed concrete bridges built in cantilever." ACI Publication SP23-40,
American Concrete Institute, Detroit, Mich.

Papakonstantinou, N. G. (1987). "Analysis of cast-in-situ segmental prestressed cantilever bridges," thesis

presented to Ohio State University, at Columbus, Ohio, in partial fulfillment of the requirements for the degree
of Master of Science.

Podolny, W., and Muller, J. (1982). Construction and design of prestressed concrete segmental bridges. John
Wiley and Sons, New York, N.Y.