BRIDGE ENGINEERING: LAUNCHING TECHNIQUES

Trends and Recent Advancements in Bridge

Launching Techniques

Vivek Abhyankar
Senior Manager (Design)
AFCONS Infrastructure Limited, India

Abstract: In complex Bridge construction projects, selection of As all the branches of engineering started growing, it was
correct method of construction / launching of superstructure observed that the growth was rapid, but not parallel! As far as
plays a vital role, towards overall success of the project. The bridge engineering is concerned this fact resulted into a wide
construction / launching method has a direct impact on cost, gap between imagination (i.e. conceptual planning and design)
time and safety of the project. Inexperienced clients often deploy vs. the ground-reality (i.e. actual bridge erected at sites). The
two separate agencies for (a) design of bridge structure and (b) end results of this gap (rather a knowledge gap) and the solu-
for detailing a launching scheme. As a result the coordination tion to ‘bridge’ this gap is discussed in the further sections.
between actual structure and construction is lost, resulting de-
lays and cost overruns. Launching scheme and actual design Bridge Projects in Olden Days
(supers/sub structure) has a strong linkage with each other; in In olden days computing technology / simulation software
complex bridge projects, the scope of design and construction etc. were not available. Engineers had to struggle hard to prove
method can’t be segregated. the adequacy of the concept, before starting the design and
The recent advancements in bridge launching technology construction.
demand changes in the main design itself. In the present paper
the author has described different method of launching (old and
new), along with various Indian and International cases studies,
and their prerequisites. The methods covered in this paper are :-
- In Situ Bridge Construction :- using Formwork-Staging;
Moving scaffolding system
- Precast, Pre Stressed Bridge Launching :- using Cranes,
Floating crafts, Push Launching, Launching Trusses (Un-
der slung / Over slung type), Launching using Ground sup-
ported staging system, Cable cranes.
Paper covers interrelation between permanent, temporary
structures with hints for engineers. (a) Bridge at Conceptual Design Stage

Introduction

Bridges are the backbones of any Transpiration / Infra-

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structure Project like Railway, Metro or a Road. Bridge Engi-

neering has a history of thousands of years, and finds it’s origin
in Indian Mythology and old spiritual scripts like Ramayana /
Mahabharata etc. In those days bridges were made from hip
of stones / soil bunds / timber logs etc. Olden bridges were
expected to merely act as a beam spanning across a gaps
along river or a road; but as the growth of civilisation started (b) Bridge after completion
taking place, the demand on all the branches of engineering in- Fig. 1: Firth of Forth Bridge, Scotland (A Cantilever Bridge)
creased, rapidly. For Civil Engineering, such increased demand Designed by Allen Stewart and Sir Baker
called for more and more research about structural configu-
ration and materials to be used for construction. From study Fig.1 shows, photograph of ‘Firth of Forth Bridge, Scotland’,
of grow of engineering industry in past hundred years, we may which is a steel cantilever type bridge. It was built in the 1880s
observe that the development of Civil / Structural engineering designed by Allan Stewart and Sir Benjamin Baker. But both
is closely associated with the development of other branches of them had to struggle hard to demonstrate by a Conceptual
of science / engineering like – Material Science, Mathematics, Model (as shown in Fig.1 (a) to the sceptical Victorians that a
Communication, Electronics, Computing technology (computer cantilever bridge would be safe. Fig. 1 (b) shows, bridge after
science), IT etc. actual successful construction.
90

Similar to above bridge, Fig.2 shows another interesting
configuration of a Suspension cable bridge done out of India. In
this structure the main pylons looks like a posture of a standing
person, reclining backward, with both the arms folded, kept on
waist. This bridge and many other similar bridges explain how
human is getting inspired by ‘nature’ and ‘natural behaviour’.
But definitely such bridges are the challenges for the Design
and Construction.
(a) Bridge Pier - Conceptual Racking human
(b) Bridge during construction
Fig. 2: Another innovative bridge which had abutments like a racking
human body
Introduction to New Types of Bridges : A Challenges for De-
signers:
Unlike 50 / 60 years back, the computing technology, mate-
rials sciences have lead to converting even the complex shaped
bridges in the reality. Fig.3 shows a beautiful String Cable
stayed bridge designed by Famous Architect and Structural
Engineer Santiago Calatrava with the inspiration behind this
unique shape of bridge. During conceptual planning and the
design of such modern bridges, often various challenges are
faced. A few of these challenges are as listed ahead.
The various challenges that are faced are as below:-
- Complex Loading :– temperature, wind, erection, blast etc.
and their combinations. Often the design codes and con-
tract specifications are silent about the construction stage
loadings.
- Complex Structural Geometry :– this includes a difficult /
sensitive load transfer mechanism,
- Refined understanding about the Structural behavior – fail-
ure theories, overall performance based design, reliability
analysis as compared to Limit state vs. Working stresses
BRIDGE ENGINEERING: LAUNCHING TECHNIQUES
- Changing ‘Codes / Standards’ requirements – QAQC, Crack-
width, exposure, non-linearity
Advances in associated fields like :-
– Material Science (Concrete-steel-etc.)
– Electronic devices (strain gauges and other monitoring de-
vices
– Surveying Instruments
- Increasing Project demands :- Time, Cost, Safety, Quality,
Aesthetics
- New research towards :– Bridge execution / Testing
- HSE (health safety and environment) Requirements
- Construction Stage Analysis
- Structural Health monitoring systems
- Life expectancy . . . etc.
(a) Alamillo bridge, Seville Spain (b) Ancient musical
Instrument Harp
Fig. 3: Alamillo bridge, Seville Spain
The Architect / Structural Designer / Planner or Execution
engineer cannot overcome all these problems by working in
isolation. A complete ‘Team Work’ is essential to solve these
problems and to converge to effective solution. But, from the
failures of many ambitious bridge projects, it can be observed
that there was a clear absence of the team work (except a few
cases). Typical failure of bridge may happen in case the de-
signer don’t know how the contractor is going to construct that
structure; on the other hand, even when the contractor does
not know how that bridge is designed (boundary conditions, as-
sumptions, standard design practices, loads etc.). The typical
reasons of failures during construction of a bridge could be :–
(a) Incapable Formwork, (b) Inadequate strength gain for con-
crete, (c) Lack of Synchronization between Hydraulic Jacks, (d)
Inadequate bearings / temporary bracings, (e) Unexpected forc-
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es (wind / Blast) (f) misunderstanding between Designer-plan-
ner and the site personnel etc.
Fig.17 (a) shows a typical failure of Bridge staging at Viet-
nam during construction stage itself. In certain cases, wrong
sequence of pre-stressing exerts a huge / concentrated or
even eccentric force for which often the supporting formwork
/ staging is not designed, leading to collapse. After the col-
lapse of structure occurs, no one can trace out exact reasons,
i.e. whether the structure was designed wrongly or executed
wrongly. Unless thorough investigations are made, one cannot
conclude in such cases. Fig. 17 (b) shows a typical collapse of
segmental bridge, which was getting launched in place using a
Launching Girder. All such failure cases explain that the work
of a designer, planner and the execution (site) engineer shall be
complementing to each other and not the contradicting. Thus
each one of them must know the works of others (their count-
er-parts) to a sufficient extent.
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 BRIDGE ENGINEERING: LAUNCHING TECHNIQUES
Introduction to Various Bridge Erection Techniques : A
Challenges for Execution
From the discussion till now it is clear that the complexity
in Bridge Engineering is increasing, which cannot be handled
alone by the bridge designer or a site engineer. The Design-
er must know the proposed method of construction, which
the contractor wants to use for his construction site; and on
the other hand the execution person and planner must know
briefly, how the designer has designed the structure, with its
Limiting conditions / Boundary Conditions / Assumptions. In
certain cases, the original designs /drawings are found to be
un-executable due to actual site constraints (probably, which
the Structural Engineer missed at design stage). In such cases
the modification in design becomes necessary. If the contactor
knows the design basis, then he can develop a executable pro-
posal indicating desired changes in the design at a particular
spot in the project, on the basis of which Designer can visit the
site, review exact situation and revise the design suitably. On the
other hand even, if the designer knows the constraints at site,
in which the site engineer is supposed to work, he can develop
better scheme, right from construction stage.
A few of the popular methods adopted for construction of
bridge super structure are as listed ahead:-
Erection using Traditional Methods
– Using Formwork / Staging
– With land based hydraulic crawler mounted cranes (single
/ double cranes – for (i) span-by-span construction or even
(ii) random span construction
Erection using Modern Methods
– Floating Cranes / Barges / Jack-up platforms
– Using Bridge Launching Girders, and push / incremental
launching
– Cable Cranes
– CFT (Cantilever Form Traveler) / MSS (Moving Scaffolding
System)
– Tower Carnes
– Ground Supported Staging (GSS)
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Bridge Erection using Traditional Methods
Mostly the traditional methods viz. use of Formwork / Stag-
ing or use of direct cranes is suitable for simple bridges. Simply
supported spans are mostly constructed using these methods.
Use of Formwork / Staging consumes lot of construction time
for erection of formwork, placement of reinforcements, casting.
curing and strength gain and removal of formwork / scaffolds.
Hence in modern bridge construction projects it not a preferred
option.
Bridge erection using direct cranes is suitable for pre-
cast-components only, heavy cranes are required to lift precast
girders / segments (ref. Fig.5). Even large space is required to
position the crane. Access roads right upto the erection loca-
tion is another requirement in this scheme. This option is rarely
used, for one or two locations in the project. In bridge construct-
ed in busy metro cities often this option is found to be unsuitable
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due congested busy roads. Open drains, cable trenches on the
side of road, and other utilities may not always permit access of
cranes to each span. Detailed explanation of these two methods
(i.e. bridge construction using Formwork and Crane launching)
are kept out of scope of present paper. But just a brief mention
is made in present para for completeness of the matter.
Fig. 4: Showing A typical floating Bridge erection Crane
Bridge Erection using a Floating Crane:
In case of long span bridges, Launching Girder (LG) is
becoming more popular option by the contractors (ref. Fig.6
and Fig.7, which shows a typical Truss type Bridge Erection
Launcher, used at Bang-Na-Trade Highway Project, Bangkok).
But if the bridge is passing over a large water bodies like rivers,
creeks then it is convenient to use floating cranes kept on the
Barges / vessels / jack-up platforms. Fig.4 shows such typical
floating crane. To use this methodology effective, points to pon-
der are as listed ahead.
Points to Ponder to use floating cranes for bridge launching:-
1) Duration of Project
2) Capacity of Floating Cart; weights of segments to be lifted
3) Availability and characteristics of water way (depth, width,
tide levels, waves / currents)
4) Facts of actual Site :
- Location / distance of Casting Yard
- Wind Speed
- Tidal variations
5) Cost / Budget
6) Cooperation from Designers / Design capacity
Bridge Erection using a Launching Girder:
From Fig.7, which is showing Bridge Erection Launcher,
used in Bangkok, it may be seen that the Permanent structure
has good Aesthetic look, which is correctly utilized by the De-
signer of LG system to place the LG; it can be also seen that due
to placement of LG inside the pier notch there is impact on the
design and reinforcement detailing of such pier, to cater for LG
loads. Also, from Fig.8, one may observe the necessity of sta-
bility of erection system during girder erection. Faulty system
may lead to incorrect bridge geometry or even accumulation
of secondary stresses in the girder body /distortion. Apart from
these, there could be accidents leading to damage to structure
or human life (as shown in Fig. 11, 17).
Apart from the regular bridge erection techniques like
 BRIDGE ENGINEERING: LAUNCHING TECHNIQUES

Fig.8: Bridge Segment Launching in Progress

Fig. 5: Bridge erection with single Land based Crane

Formwork / Staging, Launching Girders and advanced tech-

nique of Floating Cranes, A suspended erection crane / ca-
bleway is also used now days as shown in Fig. 10, for a steel
Arch Segmental Bridge in China. In such cases the Permanent
structure has to be designed keeping in mind the construc-
tion / erection and dismantling methodology. The construction
scheme / methodology imposes large loads on the permanent
structure, which are often greater than the Design loads even Fig.9 – Bridge Launching in River / Water
(i.e. critical combination of self wt, Live load, wind / earthquake
etc.). one abutment to another abutment. No external LT is used, ex-
Push / incremental launching is another interesting meth- cept a nosing. In such method the super structure experiencing
od, in which the entire precast bridge structure is pushed from ‘cycles of stress reversal’, this has to be catered for in advance.

Bridge Erection using a Suspended Cable Crane (Cableway):

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This is a unique and challenging technique of bridge con-

Fig. 6: Showing Schematic Diagram of Bridge launcher
struction. Fig.10 shows a photograph of steel segmental arch
bridge construction, in China, using cable crane (or alternatively
called as a cable way). In India, for erection of Chenab Railway
bridge over Chenab river, M/s Afcons is planning use similar
technique. Cableway is also- being used on the Concrete Arch
Bridge at world famous Hoover dam. In this case the design and

Fig.7 – Bridge Erection Launcher, used at Bang-Na-Trade Highway

Project, Bangkok (LG placed inside piers) Fig.10: Steel Arch Bridge Erection Using a Cable Crane
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 BRIDGE ENGINEERING: LAUNCHING TECHNIQUES

Fig.11: Collapse of a Construction Worker During Bridge Erection Due

to Sudden Cutting of a Wire Rope

– construction must go hand-in-hand to reach to successful

conclusion. Issues like maintaining tension in the cable, limiting
sag due to dead loads, wind velocity for the stability of ropes un-
der self wt and lifted weight condition (i.e. operating and idling
conditions), safety from falling objects at night, possibility of any
object getting hit to the cable etc. are the critical issues in such
method. All these issues must be addressed prior to the start of
design (at conceptual stage itself). Without coordination with the
contactor, it simply cannot be done !
As mentioned earlier there are many other innovative
methods like CFT / MSS / erection using tower crane. They can
be used only if there is close interaction between the designs
– detailer – contractor is established. The same are briefly ex-
plained ahead. Fig.13 – Use of a Precast Segment Erector for balance cantilever
(Ref- MIC / Earlington Heights Connector project at MIAMI, Florida)
Erection / Construction of Balance Cantilever Bridges using
- CFT (Cantilever Form Traveler) or Segemnt Erector or LG

A Cantilever Form Travel (CFT) is commonly used meth-

od for the construction of Balance cantilever bridges. This is
a method of ‘in-situ’ construction. In recent days to save time,
instead of in-situ construction the balance cantilevers are
even erected using a ‘Precast-Segment erectors’ Fig. 12 and
13 ahead show these two methods respectively. In both these Fig.14 – Schematic Sketch showing use of a Launching Girder for
methods the central fixed-pier and the post-tensioning cable erection of Balance Cantilever Bridge
configuration has to be designed to sustain the forces gener-
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ated during the erection stages. The balance cantilever bridge
gets ‘Tension’ at top during construction due to only self-weight.
But as soon as at the end of the construction the tip of balance
Fig.12: A typical bridge constructed using a CFT
cantilever rests on the far-end pier, the structure starts acting
like a ‘propped cantilever’ and the force pattern get completely
changed i.e. top tension in cantilever changes to bottom tension
in the propped cantilever due to self-weight. Thus the Designer
has to design the PT-cable configuration so as to take care of
tension occurring at top during construction and at bottom (at
mid span) in service stage.
Another innovative technique sometime used for the con-
struction of ‘long-span’ balance cantilever bridges is using a
Launching Girder (ref. Fig.14 below). In such erection method
there is no additional ‘bending moment’ generated in the bridge
due to weight of formwork like in case of CFT (or at least can
be minimized). But the contractor need to invest on additional
cost of LG and even the piers and segments shall be designed
/ detailed support the legs of LG. But the construction time can
be reduced. So while selecting any of the above three methods,
thorough comparison may be made.
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 BRIDGE ENGINEERING: LAUNCHING TECHNIQUES

Erection using Tower Crane

Yet one another method of bridge erection is using tower

cranes. Normally tower cranes are used for the construction
of pylons in cable stayed bridges due to the large heights. But
rarely tower cranes mounted on track are used for erection /
servicing of the bridge superstructure as well. But as often load
carrying capacity of tower cranes is very less as compared to
crawler cranes, they can be used for erecting light-weight units
only (like bearings, cables etc) instead of full superstructure.

Fig.15: A typical MSS for Bridge Construction

(a) Bridge Formwork Failure

(b) Launching Girder Failure (in Water)

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Fig.16 – GSS System Designed by author for Barapula, Delhi

MSS (Moving Scaffolding System)

Moving Scaffolding System (MSS) is another upcoming

method of bridge construction (Fig.15). It includes a bridge
formwork mounted on a moving girder at the construction site
itself. Thus the girder moves ahead to each span one by one and
keep casting the same at it’s desired place (in-situ construc-
tion). Basically this is a slow method, also imposes additional
loads on the Piers. The moving girder get’s locked with the piers
for the period, till concrete gains specified strength and the
post-tensioning is done. This is a cumbersome / bulky method
of construction; it is suitable only for fairly straight spans with
nominal gradient. While designing the bridge using MSS the (c) Launching Girder Failure (On Land) in Mumbai
designer must first consult the contractor and client. Fig.17 – Photographs of Bridge Failures during erection stage
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 BRIDGE ENGINEERING: LAUNCHING TECHNIQUES
Ground Supported Staging (GSS)
Sometimes the launching girder cannot be used for
launching bridge superstructure in cases like – sharp radi-
us of curvature in plan, large gradient (longitudinal slope) and
super-elevation, continuous spans etc. In such the segments
can be erected using Ground Supported Staging System (GSS).
GSS system can be used only if the ground below has sufficient
load bearing capacity and availability of separate crane / EOT
for placing the segments from trailer to the GSS. If these two
re-conditions are satisfied then GSS proves to be most com-
fortable and fast system of erection. Weight of GSS system is
significantly lesser than the LG. Ref Fig.16 for GSS.
Construction Failures During Bridge Laucnging / Construc-
tion
All Bridge erection methods explained till now have certain
advantages and limitations; to use any selected method effec-
tively one need to fulfill certain prerequisites (already discussed
in respective method above). But as explained at the beginning
of this papers, the consultant may not know (or wants to know)
the construction method, and on the other hand the contractor
/ bridge erection agency does not know the basis of the designs.
In such cases there is a likelihood of certain pre-requisites may
not get fulfilled, leading to catastrophes as shown in Fig. 17.
A Few Case Studies
From the discussion till now it may be clear that the per-
manent design and erection method (enabling works) have very
close relation to each other. Following are some of the proj-
ects where the permanents designs and enabling works have
affected each other. The author of this paper has experienced
many live case studies; amongst which two cases are present-
ed here as a sample:-
a) Allahabad-Nainy Cable Stayed bridge project (example
of a project where Permanent Design of Bridge affecting the
design of Formwork)
This project was done by Joint venture (JV) of HCC and
Hyundai in Uttar Pradesh India, in Yr. 2002-03. In this project a
20m wide bridge deck was supported with 1400mm wide and
3500mm deep two Pre-stressed rectangular girders (which
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were monolithically cast with the deck slab). Each span was
60m long. There were 4 modules to be cast. The longest mod-
ule had nine continuous pres-stressed spans. Every 60m span
was cast along with the 1/5th (i.e. 12m) of next span i.e. at theo-
retical point of contra flexure.
During the application of pre-stress as the 60m portion of
the girder used to get ‘hogged–up’, the remaining 12m portion
used to get dipped-down, because of the continuity in the con-
struction, This resulted into enormous increase in the load on
the formwork / staging in the 12m portion (which was tempo-
rarily acting as cantilever, till the remaining 48m was cast in
next pour). This effect was predetermined and the Formwork
and Staging was designed accordingly. Also the pre-camber
was pre-determined and set in the staging during erection
work.
98
b) Longest Railway Bridge at Cochin for RVNL
(example of a project where Erection Method influenced the
design of Bridge) :-
This bridge was constructed by Afcons Infrastructure Ltd.
for Rail Vikas Nigam Ltd. in Yr. 2007-08. In this project, Rail Vi-
kas Nigam Limited (RVNL) had initially proposed a 600Mt single
box girder per span. Launching such a heavy structure was not
possible inside the crek area. Also the SBC of soil at casting
yard was very less. Considering these limitations the contractor
proposed Two-Pre-stressed concrete I girders at each span.
This Modification was readily approved by the client considering
the practical limitations. NRS Asia ‘Over-head type’
Launching girder was used for erection. The entire proj-
ect was completed ahead of the schedule, within the budgeted
cost. This example describes how the enabling works forced to
modify the permanent structure, yet leading to ultimate suc-
cess of the project.
Conclusions
From the discussion till now, which has covered (a) the
olden method of construction of bridges, (b) the challenges in
new era (like complex loadings, geometry, codes, new mate-
rials etc), (c) upcoming methods of bridge construction / erec-
tion, and from various case studies the interrelation between
the Paramagnet design and the Erection Design of Bridge must
be clear. Many hints are embedded for the Designer as well
as contractor at each method of launching, one can use them
while working on live project.
At the end, the main fact to be remembered is ‘Bridge De-
sign and Construction’ is not a single agencies responsibility;
only ‘Team-work’ can lead to a overall successful project!
Acknowledgements
The author is thankful to the Afcons Infrastructure Limited
and entire site team for making all the relevant data available
for this paper. Author is thankful to authors of various books /
papers / techniques listed in the References below. Author also
wishes to express his thanks to the Organizers of Structural
Engineering World Conference 2015 for considering present
paper.
References
- Dhanajay Bhide, “Syzygy between Design and Construction of Bridges
(Part-I of II)” Indian Road Congress Journal, July’2015.
- Dhanajay Bhide, “Replcament of damaged Suspension Span of Verso-
va Bridge Across Vasai Creek on NH-8”, Indian Roads Congress, Jan-
March’15.
- Vivek G. Abhyankar, “Nad-al-Sheba Race Course Development Project
: Construction of three Bridges” Indian Society of Structural Engineers
(ISSE), Mumbai, Vol-13/2, April-May-June’2011 issue.
- Vivek G. Abhyankar, “Construction Longest Railway Bridge Project at
Cochin” Indian Society of Structural Engineers (ISSE), Mumbai, Volume
11-3, Jul-Aug-Sep
- M. K. Hurd, “Formwork for Concrete”, ACI, seventh edition.
- Marco Rosignoli, “Bridge Launching”, Thomas Telford Publishing (Jan-
uary 1, 2002) w