B2P - Volume 3 - 2013

BRIDGE BUILDER MANUAL
THIRD EDITION
2013
VOLUME 3
B2P_manual_05.indd 4
8/16/13 2:51 PM
THIRD EDITION
2013
VOLUME 3.1
PART ONE : Bridge Design
8/16/13 2:51 PM
SUSPENDED PEDESTRIAN BRIDGE MANUAL

Introduction
The designs included in the
Volume 3 Suspended Pedestrian
Bridge Manual originated with the
Helvetas Nepal Short Span Train
Bridge Technical Handbook that
was created with over 30 years
of experience in the mountainous
regions of Nepal that have resulted
in over 3400 bridges to date.
In 2003, Bridges to Prosperity
(B2P) staff traveled to Nepal to
train with the Swiss organization
Helvetas to learn about their cablesuspended bridge technology. In
addition to learning about design
and construction of the suspended
bridge, Helvetas also taught B2P
their approach to participatory
bridge building at the community
level. B2P has introduced this
B2P has encountered new technical and cultural challenges as we have taken the technology from Asia to Africa, then to Latin
bridge remains a locally sustainable option for communities in varying topographic and geographic regions of the world.
There are four sections in Volume 3: Suspended Pedestrian Bridge Manual, structured as follows:
Part 1: Design and Analysis
Part 2: Technical Drawings
Part 3: Construction Guide
Part 4: Operations & Maintenance
As with any modulated design, usage assumptions must be made by the bridge designer. The following manual will attempt
to provide both modulated drawings and design guides for those interested in bridge uses not covered within these manuals.
For further design and loading assumptions, please reference the Helvetas Nepal Short Span Train Bridge Technical Handbook
(available on the B2P website on the Technical Resources page), internationally accepted design standards as well as locally
pertinent design codes and standards.
Terms of Use and Disclaimer
No representations or warranties are implied or expressed herein. In consideration of this manual being provided gratis to others,
all users agree to allow a listing and brief description of footbridges built with this manual on the B2P website, so that others in the
same geographic region can visit such bridges for observation and training. Furthermore, all users agree to hold B2P, its employees,
partners, sponsors, contractors and agents harmless from any and all liability arising from the use or application of the information
provided herein.
Volume 3: Suspended Bridge
Part 1 Design & Analysis
VOLUME 3 SUSPENDED PEDESTRIAN BRIDGE

Part 1: Design and Analysis
Table of Contents
Section 1: Suspended Bridge: Design Background
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
Design Criteria and Material Properties

Cable Analysis
Anchor Analysis
Foundation Analysis
Suspender (Hanger) Analysis
Timber Decking & Crossbeam Analysis
Factors of Safety
Manual Limitations
Section 2: Suspended Design Procedure

2.1
2.2
Overview
Abney & Auto Level Survey
2.4
2.5
2.6
2.7
2.8
2.9
Calculate Required Number of Tiers

Finalize Position of Foundations
Select Tier & Anchors Designs
Select Cable Sizes: Cable Lookup Tool
Select Construction Drawings
Compile Final Drawings
Section 3: Material Estimate

3.1
3.2
3.3
3.4
3.5
Cable & Clamps

Steel Reinforcement Bar
Concrete
Decking
Other Materials
SECTION 1: SUSPENDED BRIDGE: DESIGN BACKGROUND

The following section details basic design criteria and assumptions used by Bridges to Prosperity when modifying
PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT
need not be referenced for non-engineer designers, as all modular designs have already considered the following
codes and assumptions. For typical bridge project use, skip to Section 2: Bridge Design Process.
1.1
Design Criteria & Material Properties

Bridge Layout
Minimum Freeboard
= 3.0 m (gorges)
Minimum Setback
= 3.0 m or 35 degrees from bank (for soil)

= 1.5 m or 60 degrees from bank (for rock)
Maximum Span
= 120 m
Design Sag
The Design Sag, B d , is assumed 5% throughout this manual. B d is a percentage value that must be
h sag , discussed later in this section.
Design Sag, B d is used in the Distance to the Lowest Point of Cable (f) calculation, which in turn is
considered to ensure proper freeboard above the High Water Level.
Note: while preparing for construction, the Hoisting Sag B h is used when calculating the Distance to the
Lowest Point of Cable (f). This allows for cable hoisting at a higher elevation than expected due to the
elastic stretch of the cable. No structural cable stretch is assumed, as cable is assumed repurposed.
= Span
25
2
= Q4B - H V measured from low side
16B d
d
Deck Width
= 1.0 m
Walkway Width
= 1.5 m
(measured at height of 1m above deck)
Design Loads
Assumed Material Unit Weights

Steel
Concrete
Gabions
Timber
General Soil (sand)
= 7850 kg/m3
= 2400 kg/m3
= 1900 kg/m3
= 900 kg/m3
= 1800 kg/m3
= 490 lb/cf
= 150 lb/cf
= 120 lb/cf
= 60 lb/cf
= 110 lb/cf
Dead Load
Actual Dead Load of the bridge to be based on material takeoff. For both the B2P Suspension and
Suspended bridges,100 kg/m (for 1m wide deck) is a reasonable assumption.
DL = 100 kg / m
Live Loads
Note: newer versions increase the design live load to 90 psf, a measure not adopted by B2P.
Distributed Live Loads:
Assuming 1.0 meter deck:
LL = 415 $ T 0.25 +
4.57
Y
L
> 320 kg / m (65 psf)

< 415 kg / m (85 psf)
Point Live Loads:

LL = 226 kg (500 lb)
The deck system shall support a point load anywhere between suspenders.
Base Wind Load
WL = 1.7 kN/m2 (100 mph wind)
To account for the reduced effective area the wind acts, ie. non-solid surface area of the deck
side elevation, safety fence and cables, the wind load used is as follows;
Effective Wind Load
w = 30 kg/m
Reference Helvetas Short Span Trail Bridge Manual (2003), SSTB-D type.
Load Combinations
DL + LL
DL + LL + WL
DL + WL
(applicable for most components)

(applicable for loaded windguy design)
(applicable for unloaded windguy design)
Steel Pipe:
f 'c = 15 MPa
f 'c = 10.3 MPa
fy = 240 MPa
= 2200 psi (mixed by drum mixer, or other)

=1500 psi (mixed by hand)
= 35 ksi
Steel Reinforcing:
fy = 275 MPa
= 40 ksi
Timber:
fb = 3.96 MPa
= 575 psi
Material Properties
Concrete:
fv = 1.44 MPa
= 210 psi
= 3,000 psf
= 112 pcf
q allowable = 143 kPa

Y = 1.8T/m3
Soil:
= 33 degrees
Cable / Wire Rope
attained through load testing the cable at its section showing greatest wear.
1.2
Cable Analysis
Overview
in the main-span and backstays at full load. The increased sag at full load, decreases the overall tension in
the cables, thus decreasing the demand on the cables. Reference: Hanes Supply Catalog; Modulus of Elasticity for 6x19
IWRC, or other appropriate cable section.
Geometry and Forces
The geometry of the cable between the two towers on a suspended bridge is that of a catenary cable. For
simplicity, the geometry can be assumed as a parabolic curve. The following equations and diagrams describe the
theory governing the geometry of the main span cables and the resulting forces.
Horizontal Tension:
Where:
Ph =
W c $ L2
(equal throughout cable)
8 $ h sag
Wc
= total distributed load
h sag = B d $ 100 = sag height (distance unit)
L
= span
Ph
cos (i)
Total Tension (Main Span):
Ptm =
Vertical Tension (Main Span):
Pvm = Ptm $ sin (i)

4 $ h sag + DH X
i low = tan -1 $ S
L
$
4
h
sag - DH
-1
X
i low = tan $ S
L
Angle to Horizontal (Main Span, Low Side):

Angle to Horizontal (Main Span, High Side):
Ph
cos (})
Total Tension (Backstay):
Ptb =
Vertical Tension (Backstay):
Pvb = Ph $ tan (})
Angle to Horizontal (Backstay):
} low,high = depends on anchor geometry
Total Vertical Reaction (at Tower)
Pv = Pvm + Pvb
Cable Design
To determine the required number of cables, take the maximum tension in the cable per the above outlined
process, multiply by the factor of safety (minimum 3.0) and divide by the breaking strength of the cables available.
B2P provides a spreadsheet to assist in the determination of main cables. This topic is covered in greater detail in
Section 2.7 of this Volume.
Total Number of Cables Required:
= Maximum Calculated Tension x FS
Resultant Force & Eccentricity
The geometry of the layout is also critical for the tower, tier and foundation design, and should be considered
bearing capacity kairn of the foundation as the resultant force (R) must not exceed maximum allowable eccentricity.
Eccentricity is measured from the center of the tower. Equations dictating allowable eccentricity are as follows:
Tower Width > E tower

Maximum Eccentricity (at Tower): E max - tower =
3
Maximum Eccentricity (at Foundation): E max - found. =
Found.Width > E foundation

2
(from CL Tower): b = (90 - ( (90 - }) + (90 - i) 2 + i))

Eccentricity (at Tower): E tower = H tower $ tan (b)
Eccentricity (at Foundation): E foundation = H found. $ tan (b)
1.3
Anchor Analysis
Overview
This section describes the details of the deadman anchor design and associated assumptions. Rock anchor
design discussion is beyond the scope of this manual. Refer to licensed Professional Engineer for rock anchor
analysis support.
The anchorages secure the ends of the main cables and transfer the force into the ground. The direction of the
horizontal forces, which often results in large anchorage structures ideally, the design should utilize the ground
as much as practically possible i.e. be buried below ground, and a large mass of in-situ earth in front, to utilize the
passive resistance of the earth and thus increase the horizontal resistance.
Some of the general assumptions used throughout the design process that may be of interest to the Professional
Engineer verifying or otherwise modifying B2P modular designs:
Soil wall friction ( d
Friction on the base of the foundation and approach walls is considered ONLY when a compression
n = 0.30,
between the earth and these components is recommended
Soil is conservatively assumed to be sand and therefore assumed cohesionless (i.e. c = 0).
No consideration of earthquake design has been taken into account.
applied to the deadman.

Design has been completed assuming deadman anchors are in non-saturated conditions. Where a high
water table is a concern, assume saturated condition is possible and deduct the buoyant force of the
anchor beam and soil.
There are no surcharge loads acting on the anchor.
Anchor: Design Calculations

throughout this section. The principle modes of failure of the deadman anchor are sliding, uplift and overturning,
although the latter of the three is typically judged an unrealistic mode of failure. Sliding and uplift are both checked
herein, while overturning is deemed adequate via engineering judgement.
The forces acting on the anchor cause an active lateral pressure to develop behind the deadman (i.e. the earth
exerts a force on the anchor an additional force to the pull from the cable), and a passive pressure to develop
in front of the deadman (i.e. the anchor exerts a force on the earth the earth creates a resisting force to the pull
from the cables). Since soils have a greater passive resistance, the earth pressures are not the same for active
and passive conditions.
For a cohesion-less soil, the earth pressure theory of Rankine provides expressions for the active and passive
the lateral earth pressure to the vertical earth pressure or unit weight of the soil.
1 - sin (z)
K a = 1 + sin
1 + sin (z)
11 +
sin (z)
+ sin
Kp =
1 - sin (z)
(unitless)
(unitless)
where z is the internal angle of friction, assumed 30 .

The lateral earth pressures acting on the anchor are equal to the area of the trapezium along the height H 4 :
Active Earth Pressure: Pa =
1
Ka
2
H 12 [ kN
m ]
Passive Earth Pressure: Pp =
1
Kp
2
H 12 [ kN
m ]
The resultant forces on the anchor due to the pressures act at 1 the height from the base of the anchor, and are
3
given as:
Force due to Pa : F Q K aV = Pa $ L !kN $
Force due to Pp : F Q K pV = Pp $ L !kN $

where L is the length of the anchor.
10
Anchor: Check Against Sliding

A check of the deadman anchor for safety against sliding is calculated by resolving the forces acting on the anchor
and ensuring that the horizontal resisting forces are at least 1.5 times greater than the horizontal driving forces
(i.e. a factor of safety of 1.5).
If the anchor is connected to the foundation by means of a compression strut (included in B2P Modular designs
via the approach ramp walls), the friction force between the base of the foundation and the soil may be considered
a horizontal resisting force in determining the factor of safety against sliding. This force can be determined by
n =0.3 multiplied by the total vertical load from the foundation, tiers, towers, and the
maximum vertical component of tension in the cable due to dead and live loads. Else, assume friction at base of
anchor = 0.
Total Vertical Load:
W total = W foundation + W tiers + W towers + VPB v
Resisting Force Due to Friction:
F Q Ff V = W total $n
Factor of Safety (Sliding):
F (K p )
F Q K aV + Ph
1.5
If the water-table rises above the base of the deadman anchor, the unit weights of the soil and concrete must be
taken as buoyant unit weights i.e. the saturated unit weights of the soil/concrete minus the unit weight of water.
Depending on the duration of the submerged case, the factor of safety may be reduced. For a Temporary Case
(referring to a single event in a season), FS = 1.0. For a Long Term Case (referring to the entire rainy season), FS
must remain = 1.5. Seek support from a Professional Engineer for all saturated cases.
Anchor: Check Against Uplift
A check of the deadman anchor for safety against uplift is calculated by resolving the forces acting on the anchor
and ensuring that the vertical resisting forces are at least 1.5 times greater than the vertical driving forces (i.e. a
factor of safety of 1.5).
Factor of Safety (Uplift):
QW soil + W conc.V
Pv
1.5
If the water-table rises above the base of the deadman anchor, the unit weights of the soil and concrete must be
taken as buoyant unit weights i.e. the saturated unit weights of the soil/concrete minus the unit weight of water.
Depending on the duration of the Submerged Case, the factor of safety may be reduced. For a Temporary Case
(referring to a single event in a season, FS = 1.0). For a Long Term Case (referring to the entire rainy season, FS
must remain = 1.5).
1.4
Foundation Analysis
Overview
All of the vertical forces generated in the cables are transferred through the towers and tiers into the foundation,
in addition to the extra loading generated from the self-weight of the towers. To perform satisfactorily, the total
distributed load generated must not exceed the bearing capacity of the soil, also known as shear failure. The load
11
per unit area of the foundation at which shear failure in soil occurs is called the ultimate bearing
capacity ( q u ).
Some of the general assumptions used throughout the design process that may be of interest to the Professional
Engineer verifying or otherwise modifying B2P modular designs:
No consideration of earthquake design has been taken into account.
Design has been completed assuming foundations constructed on level ground.
Design has been completed assuming foundations are in non-saturated conditions. Where saturated
conditions are of concern, deduct the buoyant force of the soil.
Design Calculations
The allowable soil bearing capacity q allow is the maximum bearing stress that can be applied to the foundation
your soil. The designs in this manual assumes allowable soil bearing, q allow = 3,000 psf.
The maximum bearing stress ( q max ) is calculated by summing the total vertical load on the foundation (total
vertical tension at the towers plus the self weight of the foundation, tiers, and towers) and dividing by the area of
the foundation.
Maximum Bearing Stress: q = W foundation + W tiers + W towers + Vc
max
Total bearing area of Foundation
The allowable bearing capacity is calculated from the ultimate bearing capacity, using a factor of safety
of 2.0.
Factor of Safety (Shear):
1.5
q allowable
q max
2.0
Suspender (Hanger) Analysis

Overview
In order to design the suspenders, a factor of safety of 5.0 should be used. The increased factor of safety is to
account for the likelihood of multiple bendings, and thus, multiple yieldings of the steel during installation. The in
creased factor of safety is also to help account for the likelihood of corrosion of the steel over time. Based on
the loads and yield strength assumed, B2P recommends no less than a 9 mm ribbed reinforcing bar for
suspenders or #3 bar. Smooth rebar often is of inferior quality and strength, and thus should be avoided.
This provides more than adequate factor of safety and has proved to withstand corrosion over the design life of
the bridge. Furthermore, a single suspender (hanger) failure will result in increasing the tributary load on
neighboring suspenders, thereby inducing progressive failure.
1.6
Timber Decking & Crossbeam Analysis

Overview
The B2P Modular designed cross beams and decking have been designed according to NDS 2005. NDS designs
using Allow Strength Design. The basic principle of the design methodology is to ensure that the wooden planks
have the capacity to carry the vertical shear and bending moments applied to them from the loading.
Design Calculations
For the calculation of member capacity the following equations have been used:
12
Maximum Shear Due to Distributed Load:
Vdistributed = W c L
2
Maximum Shear Due to Point Load:
P
V po int = 2
W c L2
Maximum Moment Due to Distributed Load: M distributed = 8
Maximum Moment Due to Point Load:
PL
M po int = 4
All assume the structure is simply supported, 1m lenghts which is a conservative assumption.
Check against Bending Moment
To design both the crossbeams and the decking, the actual stress in the member due to bending must be less
than or equal to the allowable stress of the given material. Timber material properties for the actual types of
timber should be referenced from local suppliers. B2P assumes Fb = 3.96 MPa for allowable stress in bending.
Stress due to bending: fb
F b'
CfC
F bl = Fb C d C m C t C L C F C v C
ui C irC
CrcC
CcfC f
fu
Fb = allowable stress in bending
C d = load duration factor (assume 1.25)
C f = shape factor (assume 1.2)
Cm C
CL
= tmoisture
factor (assume 0.97 for moisture >19%)
=c other factors (assume 1.0)
Cffuu C i C r C
Cm Ct CL C F Cv C
fb = actual stress in bending
M
fb = Smax (where greater of M dist. or M po int is used)
2
S = Section Modulus = bd
6
Where:
Check against Shear

To design both the crossbeams and the decking, the actual stress in the member due to shear must be less
than or equal to the allowable stress of the given material. Timber material properties for the actual types of
timber should be referenced from local suppliers. B2P assumes Fv = 1.44 MPa for allowable stress in shear.
Stress due to shear:
Where:
fv
F v'
F vl = Fv C d C m C t C i
Fv = allowable stress in shear
C d = load duration factor (assume 1.25)
Cm C
CL
= tmoisture
factor (assume 0.97 for moisture >19%)
C m C t C i = other factors (assume 1.0)
fv = actual stress in shear
fv = V $ 3 (where greater of Vdist or V po int is used for rectangular
2bd
members)
13
1.7
Factors of Safety
Overview
For the design of the main cables:

FS = 3.0
For the design of bridge suspenders:
FS = 5.0
For design of deadman anchors, use conventional passive/active soil resistance methods. Where saturated conditions
are of concern, deduct the buoyant force of the anchor beam and soil above it. Note, a long term saturated condition refers
Anchor Sliding: FS = 1.5 (Unsaturated)
FS = 1.5 (Saturated, long term)
FS = 1.0 (Saturated, temporary)
Anchor Uplift: FS = 1.5 (Unsaturated)
FS = 1.5 (Saturated, long term)
FS = 1.0 (Saturated, temporary)
For the design of bearing capacity of the foundation:
FS = 2.0
Design of all other structural elements shall be per recognized design codes using Safety Factors consistent with
Allowable Stress Design methodology.
Referenced design codes include;
Building Code Requirements for Structural Concrete (ACI 318-11) and Commentary.
AISC (American Institute of Steel Construction) Steel Construction Manual, 13th Edition.
1.8
Manual Limitations
The suspended bridge is intended for pedestrians, livestock and narrow transportation aids (bicycles,
wheelbarrows) capable of crossing on the 1.0 meter wide deck. Widening the deck up to 1.5 meters is possible
with further engineering of the anchor, tower and decking plans, but any additional width in excess of 1.50m risks
the inadvisable use by small cars. It is recommended that any bicycles, animals or motorbikes be walked across,
but all are considered acceptable for crossing.
Wood decking changes the deadload depending on the weight of the wood being used. If a steel deck is chosen,
the corresponding deadload also changes. Note that the original Helvetas Nepal design included the steel deck
Although the lateral wind loadings proportionally increase with increased span, there is a design limit of 120
meters without additional wind guy structures. The longitudinal rigidity of the bridge is compromised beyond 120
as two (2) additional cables and four (4) additional anchors are required. Contact Bridges to Prosperity for
Wind-guy Design guides and tools.
14
SECTION 2: DRAWING SELECTION PROCEDURE

This section outlines the steps in order to select appropriate drawings from B2Ps standard suspended bridge
design drawings, found in Volume 3.2. This process does not require a technical background or any design
calculations to be performed. All pertinent design assumptions and bridge geometries have been taken into
account in the standard B2P suspended bridge drawings. For background information and design assumptions,
refer to Section 1.1 in this Volume.
2.1
Overview
Designing the suspended cable bridge requires minimal technical background. The following section will provide
a step by step guide to designing a bridge following the completion of the site survey as outlined in Volume 2
Feasibility & Topographic Survey.
2.2
2.2
Abney or Automatic Level Survey
2.4
2.5
2.6
2.7
2.8
2.9
2.10

Select Tier & Anchors Designs
Select Cable Sizes: Cable Look-up Tool
Compile into Final Drawings
Design Example
Abney Level or Automatic Level Survey

Reference Volume 2 Feasibility & Topographic Survey for complete details.
2.3
Bridge Profile & Fix Foundation Locations

preliminary location of the towers for the left and right side respectively.
water to ones back.
Note soil or rock type on either side
See sample sketch on next page.
15
16
2.4

A minimum clearance is required between the lowest point in the cable and the highest point that the water has
ever reached (HWL). Furthermore, the maximum height difference between the two towers must be no more
than the span (L) divided by 25, or four percent of the span. If DH
and to equalize differences in elevation between two sides, one must calculate the required number of tiers; each
tier is 1.0 meter tall as the elevation of the bridge towers dictate the elevation of the cables. In order to calculate
the required height, the following information must be known;
Span (L) in meters (must be less than 120 meters)
an additional 1.40 meters on either side to include walkway saddle to walkway saddle span. Once drawings
Height difference ( DH ) = Elevation L Elevation R
elevation assumptions and nomenclature as used in the survey: low side foundation elevation = 100.00.
( DH ) is not greater than the 4% of span length, or L/25.
Cable Design Sag ( B d ) and Hoisting sag ( B h )
The Design Sag, B d , is assumed 5% throughout this manual. Design Sag, B d is used in
the Distance to the Lowest Point of Cable (f) calculation, which in turn is considered to ensure proper freeboard
above the High Water Level. While preparing for construction, the Hoisting Sag B h is used when calculating
the Distance to the Lowest Point of Cable (f). This allows for cable hoisting at a higher elevation than expected
due to the elastic stretch of the cable. No structural cable stretch is assumed, as cable is assumed repurposed.
Re-purposed Cable (includes cable donated from B2P program)
Percent of Span
5.00%
Design sag ( B d )
Hoisting sag ( B h )
4.60%
Distance to Low point f
If both sides are equal height ( DH = 0), then the low point is directly in the middle. If not, calculate the actual
distance to low point, f, using the following equation or use the low point matrix on the following page.
2
f = ( 4B d - DH)
16B d
17
Distance to Low Point f

Relative to low side abutment
35
0.0
0.25
0.50
0.75
1.00
1.25
1.50
1.75
2.00
2.25
2.50
2.75
3.00
3.25
3.50
3.75
4.00
4.25
4.50
40
45
50
55
Span (m)
60
65
70
75
80
85
90
95
100 105 110 115
1.75 2.00 2.25 2.50 2.75 3.00 3.25 3.50 3.75 4.00 4.05 4.09 4.32 4.55 4.77 5.00 5.23
1.63 1.88 2.13 2.38 2.63 2.88 3.13 3.38 3.63 3.88 3.93 3.97 4.19 4.42 4.65 4.88 5.10
1.51 1.76 2.10 2.26 2.51 2.76 3.00 3.25 3.50 3.75 3.80 3.84 4.07 4.30 4.53 4.75 4.98
1.40 1.64 1.89 2.14 2.39 2.64 2.89 3.14 3.38 3.63 3.68 3.72 3.95 4.18 4.41 4.63 4.86
1.29 1.53 1.78 2.03 2.27 2.52 2.77 3.02 3.27 3.52 3.57 3.61 3.83 4.06 4.29 4.51 4.74
1.18 1.42 1.67 1.91 2.16 2.41 2.66 2.90 3.15 3.40 3.45 3.49 3.72 3.94 4.17 4.39 4.62
1.08 1.32 1.56 1.81 2.05 2.30 2.54 2.79 3.04 3.29 3.34 3.38 3.60 3.83 4.05 4.28 4.50
0.98 1.22 1.46 1.70 1.94 2.19 2.43 2.68 2.93 3.17 3.22 3.26 3.49 3.71 3.94 4.16 4.39
1.36 1.60 1.84 2.08 2.33 2.57 2.82 3.06 3.11 3.15 3.38 3.60 3.83 4.05 4.28
1.50 1.74 1.98 2.22 2.47 2.71 2.95 3.00 3.04 3.27 3.49 3.71 3.94 4.16
1.64 1.88 2.12 2.36 2.60 2.85 2.90 2.94 3.16 3.38 3.60 3.83 4.05
2.02 2.26 2.50 2.74 2.79 2.83 3.05 3.27 3.50 3.72 3.94
2.16 2.40 2.64 2.69 2.73 2.95 3.17 3.39 3.61 3.83
2.30 2.54 2.59 2.63 2.85 3.07 3.29 3.51 3.73
2.44 2.49 2.53 2.75 2.96 3.18 3.40 3.62
2.43 2.65 2.86 3.08 3.30 3.52
2.55 2.77 2.98 3.20 3.42
2.88 3.10 3.32
3.00 3.22
Verify adequate Freeboard (Fb)

Freeboard is the clearance required between the lowest point in the cable and the highest point of the water. An
engineer may reduce or increase the suggested freeboard values in accordance with site topographic and
hydrological conditions, but for general purposes, minimum freeboard clearance required is as follows;
- Flood Plains: 2.0 meters
- Gorges: 3.0 meters
elevation of the High Water Level. If the value of Freeboard is less than required, the designer must increase the
number of tiers on either one or both foundations.
Fb = Low Ele. - f - HWL

2.5

After selecting the number of tiers required to achieve freeboard, the size of the foundation footprint is known per
Verify adequate slope angle or distance from slope (Volume 2 Topographic Survey)
18
Maximum 35 degree slope in soil

or minimum 3.0 meters from edge
Maximum 60 degree slope in rock

or minimum 1.5 meters from edge
updated Freeboard value. If the Freeboard ( Fb ) exceeds minimum, move forward with design.
(HWL) at elevation 96.5 meters from the survey;

Low side elevation = 101.40 meters
Fb = Low Ele. - f - HWL

= 101.40 - 2.08 - 96.5 = 2.82 > 2.0
OKAY
19
2.6
Select Tier & Anchor Designs

There are two types of anchor designs; Gravity Anchors and Drum Anchors. Gravity Anchors may be
As such, the excavation required is considerable.
Drum Anchors require rock conditions as they rely on friction between the rock face and the poured
concrete drum. As such, only hard or fractured rock conditions are acceptable. See Volume 2: Feasibility
& Topographic Survey for more information.
Gravity Anchor plans are split into two main subcategories; 0 - 60 meter spans, and 61 - 120 meter
Anchor Plans found in Volume 3 Part 2: Suspended Bridge Drawings are as follows:
0 - 60 m 1
0 - 60 m 2
0 - 60 m 3
61 - 120 m
61 - 120 m
61 - 120 m
Tier Gravity Anchor

Tier Gravity Anchor
Tier Gravity Anchor
1 Tier Gravity Anchor
1G60
2G60
3G60
1G120
2G120
3G120
anchors do not lend themselves to more than one tier. This is due to the short distance between the
anchor and the saddles, required due to sloped rock conditions. There are two sizes of drum anchors;
small and medium. Small (0 - 40 meters) and Medium (41 - 60 meters) anchors are included in 1D60.
Note: 60-120 meter projects in rock require design support from a Professional Engineer. A summary of
Drum Anchor Plans found in Volume 3 Part 2: Suspended Bridge Drawings are as follows:
0 - 60 m
2.7
1 Tier Drum Anchor in Rock
1D60
Select Cable Sizes: Cable Look-up Tool

Bridges to Prosperity created a Microsoft Excel Cable Look-up Tool, available at the website at
www.bridgestoprosperity.org/resources.
The Cable Look-up Tool requires the user to input the breaking strength (often referred to as breaking force) of
available cable (in pounds), and based on any number of cable combinations, outputs the maximum span
allowable for a given deck width. Before using the tool, research available steel cable and request a Proforma
Invoice stating breaking strengths for available cables, and if using B2P repurposed cable, request breaking
The Cable Look-up Tool assumes that the cable has a liveload elongation of 0.325% and is intended for use with
repurposed cable (this includes cable sourced as part of B2Ps recycled cable donation program).
Step 1
Research available cable breaking strengths. If reported in metric tons or kilonewtons (kN), convert into pounds
using the following relationships:
Metric Tons # 2204.62 pounds Metric Ton = pounds

kN # 224.81 pounds kN = pounds
20
Step 2
Input Breaking Strength values (in pounds) and desired number of cables (red text), as shown in the
following diagram.
Step 3
Modify combinations until desired deck width has value at least as long as bridge span (yellow).
Example
handrail cables. The span highlighted in yellow, beneath the 100cm deck width results in a span
less than our 60 meter span. Try again with 4 walkway cables and 2 handrail cables. The allowable
span shown is 64m, longer than our actual span, so this is acceptable.
crossbeam.
Step 4
Calculate quantity of cable. Refer to Section 3.1 Material Quantities, Cable & Clamps.
21
2.8
For a given span, geologic conditions and number of tiers, two (2) Abutment Tier & Anchor drawings must be
selected, one for each side of the river. The Tower drawing details the 1.0 meter deck width tower and is required.
Three (3) Decking drawings must be selected for either 3 or 5 walkway cables, with alternatives between
crossbeam nailers or no nailers respectively.
Abutment Tier & Anchor (Right and Left side required)
Gravity Anchors
0 - 60 m
1 Tier
0 - 60 m
2 Tier
0 - 60 m
3 Tier
61 - 120 m
1 Tier
61 - 120 m
2 Tier
61 - 120 m
3 Tier
Rock Drum Anchors
0 - 60 m
1 Tier
1G60
2G60
3G60
1G120
2G120
3G120
Tower
1.0 m deck width
T1
3 walkway cables
5 walkway cables
W3.1
W5.1
Decking Section 3 walkway cables

5 walkway cables
W3.2
W5.2
1D60
Decking
Decking Plan
Decking Detail
With Nailer
3 walkway cables
5 walkway cables with Nailer
No Nailer
3 walkway cables No Nailer
5 walkway cables No Nailer
W3.3
W5.3
W3.4
W5.4
22
2.9
Compile Final Drawings

drawings for the other details, as included below.
Include the following critical dimensions and select the following drawings;
Critical Dimensions
Span
Depth to anchor
Distance to back of anchor
Deck width
Free board from HWL
Sag (design and hoisting)
Height differential between abutments
2.10
Drawings
Right Side Anchor
Left Side Anchor
Tower
Decking Plan
Decking Section
Decking Detail
(G series)
(G series)
(T series)
(D series part 1)
(D series part 2)
(D series part 3)
Design Example
Point L Elevation (low side) = 100.0 meters
Point R Elevation (high side) = 102.0 meters
HWL = 96.5 meters
for a valley. Start by assuming one tier (1.0 meter tier height plus 0.4 meter saddle height above tier).
Span (L) = 60 meters
Elevation low side walkway saddle = 100m + 1.40m = 101.4m
Elevation high side walkway saddle = 102m + 1.40m = 103.4m
103.4m - 101.4m = 2.0m

Verify:
L
60
DH < 25 = 25 = 2.4 > 2.0
Distance to Low point f =

Cable Design Sag (Bd) = 5% of span = 60 $ 0.05 = 3.0m
2
Low Point f = (4B d - DH) = 2.083
16B d
23
Or, cross reference span and
35
0.0
0.25
0.50
0.75
1.00
1.25
1.50
1.75
2.00
2.25
2.50
2.75
3.00
3.25
3.50
3.75
4.00
4.25
4.50
40
45
50
55
60
65
70
75
80
85
90
95
100 105 110 115
1.75 2.00 2.25 2.50 2.75 3.00 3.25 3.50 3.75 4.00 4.05 4.09 4.32 4.55 4.77 5.00 5.23
1.63 1.88 2.13 2.38 2.63 2.88 3.13 3.38 3.63 3.88 3.93 3.97 4.19 4.42 4.65 4.88 5.10
1.51 1.76 2.10 2.26 2.51 2.76 3.00 3.25 3.50 3.75 3.80 3.84 4.07 4.30 4.53 4.75 4.98
1.40 1.64 1.89 2.14 2.39 2.64 2.89 3.14 3.38 3.63 3.68 3.72 3.95 4.18 4.41 4.63 4.86
1.29 1.53 1.78 2.03 2.27 2.52 2.77 3.02 3.27 3.52 3.57 3.61 3.83 4.06 4.29 4.51 4.74
1.18 1.42 1.67 1.91 2.16 2.41 2.66 2.90 3.15 3.40 3.45 3.49 3.72 3.94 4.17 4.39 4.62
1.08 1.32 1.56 1.81 2.05 2.30 2.54 2.79 3.04 3.29 3.34 3.38 3.60 3.83 4.05 4.28 4.50
0.98 1.22 1.46 1.70 1.94 2.19 2.43 2.68 2.93 3.17 3.22 3.26 3.49 3.71 3.94 4.16 4.39
1.36 1.60 1.84 2.08 2.33 2.57 2.82 3.06 3.11 3.15 3.38 3.60 3.83 4.05 4.28
1.50 1.74 1.98 2.22 2.47 2.71 2.95 3.00 3.04 3.27 3.49 3.71 3.94 4.16
1.64 1.88 2.12 2.36 2.60 2.85 2.90 2.94 3.16 3.38 3.60 3.83 4.05
2.02 2.26 2.50 2.74 2.79 2.83 3.05 3.27 3.50 3.72 3.94
2.16 2.40 2.64 2.69 2.73 2.95 3.17 3.39 3.61 3.83
2.30 2.54 2.59 2.63 2.85 3.07 3.29 3.51 3.73
2.44 2.49 2.53 2.75 2.96 3.18 3.40 3.62
2.43 2.65 2.86 3.08 3.30 3.52
2.55 2.77 2.98 3.20 3.42
2.88 3.10 3.32
3.00 3.22
Fb = Low Ele. - f - HWL = 2.82 > 2.0
60
60
1
13
23
33
24
SECTION 3:
MATERIAL ESTIMATE
The following section details material quantity take-offs. This section is intended for use only with B2P suspended
3.1
Cable & Clamps

Select steel cable based on cable breaking strengths and the Cable Look-up Tool, available on
www.bridgestoprosperity.org/resources, as outlined in Section 2. After initially selecting the optimum combination
of cables for the given span, calculate the total quantity to order by multiplying the number of cables by the length
of each cable, L cable .
L cable = 1.04 (L + 14 + d left + d right)

length that is helpful while laying out cables (particularly in long-spans) and provides length to account for cable
sag and wrap-back around the anchors. The distance between anchors and towers d left and d right can be found
using B2P Construction Drawings and site topography.
Consider the costs of several combinations of cable before moving on. Often cable is sold by the reel of 500
meters, so if one combination requires slightly more than 500 meters, it may be worth the additional cost to
increase the size of the cable to reduce the number of cables and thus the total required length.
The quantity of clamps per cable is dependant on the size of the cable and the type of clamp selected. The table
below is the Bridges to Prosperity standard for torque requirements for drop-forged cable clamps at given cable
only as a guideline.
Cable Diameter
(inch)
(mm)
5/8
16
3/4
19
7/8
22
1
25
1 1/8
29
1 1/4
32
1 3/8
35
1 1/2
38
3.2
Spacing
(mm)
102
114
121
132
144
160
160
171
Drop-Forge clamps
# of clamps
Torque (foot-lbs)
3
95
4
130
4
225
5
225
6
225
7
360
7
360
8
360
STEEL REINFORCEMENT BAR

Towers
- 4 pieces steel rebar, 20 mm z (or #6) x 4.50 meters in length
- 3 angle iron x 67cm in length
- Rebar guides for walkway cables: (optional)
# of walkway cables + 1, 16 mm x 20 cm each
- 4 x cut tire rims (2 complete tire rims)
25
Suspenders (hangers)
- 2 x (Span + 1), minimum 10 mm ribbed rebar (#3), cut to 1.80 m length
Anchors: Gravity (Deadman) Beams

Rebar size
Small/Medium anchor
(up to 60m span)
Large Anchor
(up to 120m span)
20mm z x 2.9 m
10mm z x 2.2 m
11
bent into square 0.5m per side
N/A
10mm z x 3.4 m
N/A
20mm z x 3 m
11
3
bent into U-shape for erection
hooks
3
hooks
Anchors: Rock Drum (Drilled Pier)

Anchor rods, 16 pieces, 25 mm z , cut at 1.50 meters
Inner drum: 8 pieces, 10 mm z , cut at 3.40 meters, bent into 0.85 m
diameter circle
Outer drum: 8 pieces, 10 mm z , cut at 5.25 meters, bent into 1.45 m
diameter circle
Anchor rods, 20 pieces, 25 mm z ,, cut at 1.50 meters

Inner drum: 8 pieces, 10 mm z ,, cut at 4.15 meters, bent into 1.10 meter
diameter circle
Outer drum: 7 pieces, 10 mm z ,, cut at 5.90 meters, bent into 1.65 meter
diameter circle
3.3
CONCRETE
This is to be used to calculate all concrete materials - cement, sand and aggregate
Masonry:
The numbers below are given to the 3G series and should be adjusted based on the drawing used. They also include the
2 bags poured in each tier and the capping of that tier.
Foundation
Tier 3
Tier 2
Tier 1
18 bags
16 bags
14 bags
12 bags
Towers (masonry)
Approach walls
Approach cap
8 bags
16 bags (for 2m height)
16 Bags
26
Poured concrete:
sand: aggregate) and should be revised when needed based on the materials available. The sum
voids between the coarse aggregate. The materials normally have 30 to 50% greater volume than
the concrete mix.
If accelerant is to be used to expedite the curing time, take care to note the affective 28 day strength
minimum time. It is recommended to error on the side of additional time for anchor pours. The
3.4
DECKING
Bridges to Prosperity is using wood decking when a sustainable source of wood is a viable option.
If you choose to use metal or plastic decking please research and design according to the material
you use.
width as the decking panels, and is attached to the top of a narrower cross-beam to increase the
and allows for a smaller crossbeam size while increases the total length of decking panels required.
Decking panels are cut to 3.0 meters for any span over 60 meters and preferably all spans. If the
bridge is shorter than 60 meter span, 2.0 meter decking panels are allowable. The total number of
decking panels is equal to [span divided by length of each board (either 2.0 or 3.0)] multiplied by
additional (Span plus one) meters of decking panels will be required, cut at 1.0 meters.
Quantities
Crossbeams: (Span + 1)
Decking: (Span / length of each board (either 2.0 or 3.0) x 5)
Nailers (optional): (Span + 1)
27
3.5
OTHER MATERIALS
Flexible plastic tubing: 3 diameter*
Flexible plastic tubing: 3 diameter*
Tie- wire
Galvanized tie-wire
U-nails
Screws: 5/16 x 10 cm (4)
Anti-corrosive paint
Fencing: 1.20 m high
Handrail saddles or tier rims
67cm 3 angle iron / walkway saddles
Sand / gravel
Masonry block / Bricks
4 meter per cable (around adjustable anchor)

1 meter per cable (threaded over tower)
10 kg
5 kg
1 kg per 10 linear meters
5-6 per deck panel+ 4 per cross beam if using Nailer
1 gallon (3.8 L) per 50 linear meters
Bridge span x 2
1 gallons
4 pieces
2/4
varies based on design
varies based on design
* The best product for this purpose is reinforced tube, often found at plumbing stores.
28
3.6
MATERIAL QUANTITIES EXAMPLE
Unit
Units required
m
piece
391.04
64.00
bags of 40kg
unit
(9m)
(9m)
(9m)
unit
unit
kg
mts
gal
173.66
180.00
6.00
11.00
4.00
4.00
4.00
10.00
20.00
8.00
piece
piece
unit
kg
(9m)
gal
mts
kg
kg
62.00
155.00
62.00
26.00
32.00
1.00
76.00
6.00
20.00
m
m
m
m
40.00
10.00
80.00
40.00
Transportation of materials
per trip
6.00
Mason
Supervision
Logistical Support
daily
daily
per visit
180.00
90.00
12.00
Cable 26mm
Clamps 26mm
Concrete Blocks = 40 x 20 x 15 (cm)

Rebar 10mm (3/8")
Rebar 16mm (5/8")
Rebar 20mm (3/4")
Handrail saddles
Walkway saddles - 2 cable
Tying wire
Plastic suction tube 3"
Roofing Tar
Wood crossbeams - (10cm x 20cm) x 140cm

Wood platform - (5cm x 20cm) x 200cm
Screw - 8mm x 10cm(nailing panel to crossbeam connection)
Nails - 15cm
Smooth iron bar 10mm (3/8") (suspenders)
Anti-rust paint (suspenders)
Safety fencing = 1.5m in height
U-Nails
Tying wire
Sand
Gravel
River rock
Dressed Stone
Note: For pricing estimate, local material and labor costs must be considered.
29
THIRD EDITION
2013
VOLUME 3. 2
PART TWO: Bridge Drawings
8/16/13 2:51 PM
THIRD EDITION
2013
VOLUME 3. 3
PART THREE: Bridge Construction
8/16/13 2:51 PM
Volume 3: Suspended
Part 3 - Construction Guide
We build to INNOVATE by developing and sharing engineering solutions that are safe, replicable,
and locally viable. We build to EDUCATE by providing educational programs that teach footbridge
construction to reach the greatest number of people in need. We build to INSPIRE by providing opportunities for leadership development and personal growth through international collaboration.
Bridges to Prosperity (B2P) provides isolated communities with access to essential health care, education and economic opportunities by building footbridges over impassable rivers. We envision a world
where poverty caused by rural isolation no longer exists.
Welcome to Volume 3: Suspended Bridge Manual, Part 3 Construction. This

volume includes Safety, Quality Control, Design, Construction and Maintenance guide for our cablesuspended bridges. Refer to Volume 1: Community Development, Volume 2: Feasibility and Topographic
Survey and Volume 4: Suspension bridge Manual, as necessary.
INTRODUCTION
Travel member responsibilities

B2P Health and Safety
Safety in Project Planning
On-Site Safety
2.4.1 Safety System
2.4.2 Safety Culture
2.4.3 Near Hits
2.4.4 Personal Protective Equipment
2.4.5 Hand and Power Tool Safety
2.4.6 Fall Protection
2.4.7 Trenching and Excavation Safety
Quality Control Overview

Quality Control Requirements
3.2.1 Photo Inventory
3.2.2 Quality Control Forms
3.2.3 As-Built Reports
Construction Material Quality Control
3.3.1 Concrete
3.3.2 Stone Masonry
3.3.3 CMU Masonry
3.3.4 Main Cable Inspection and Care
3.3.5 Clamping and Cable Crush
Volume 3: Suspended
3.3
3.1
3.2
Section 3: Quality Control
2.1
2.2
2.3
2.4
Section 2: Safety
Section 1: Construction Overview
VOLUME 3 SUSPENDED PEDESTRIAN BRIDGE

PART 3: CONSTRUCTION GUIDE & QUALITY CONTROL
Table of Contents
Required Materials
4.1.1 Local Materials
4.1.2 Delivered Materials
4.1.3 Materials List
4.1.4 Recommended Tool List
Excavation Layout
Excavation in Soil
Excavation in Rock
Bridge Terminology Guide

Foundation Tier Construction
Tower Construction
Anchor Construction & Cable Installation
Cable Sag Setting
Cable Clamp Installation
Cable Care
Bridge Approach Construction
Wood Deck Installation
Connecting Deck to Approach
Fencing Installation
Section 7: Bridge Completion
6.1
6.2
6.3
6.4
6.5
6.6
6.7
6.8
6.9
6.10
6.11
Section 6: Construction
5.1
5.2
5.3
Section 5: Site Preparation
4.1
Section 4: Material Preparation
Volume 3: Suspended
Responsibilities
Community
Labor
Implementing Agency
Supervision - 5 days
Masons
> Foundation Tiers - 2 to 4 weeks
Responsibilities
Community
Labor
River rock
Implementing Agency
Sand, gravel and blocks
Construction materials
Cement, rebar and misc. items
> Material Collection and Excavation
Construction
Total time required: variable, 2 to 4 months
Total time required: variable, 2 weeks to several months
Preparation
SECTION 1:
CONSTRUCTION OVERVIEW
Volume 3: Suspended
Responsibilities
Community
Labor
Implementing Agency
Masons
> Cable Sag Set - 2 days
Responsibilities
Community
Labor
Implementing Agency
Masons
> Anchors and Cable Installation - 3 to 5 days

(plus 4 weeks for curing concrete)
Responsibilities
Community
Labor
Implementing Agency
Masons
> Tower Construction and Saddle Installation - 5 days
Volume 3: Suspended
Responsibilities
Community
Coordination
Implementing Agency
Attendance
> Bridge Opening Ceremony - 1 day
Responsibilities
Community
Labor
Implementing Agency
> Deck and Fencing Installation - 3 to 5 days
Responsibilities
Community
Labor
Implementing Agency
> Approach Construction - 1 to 4 weeks
SAFETY IN PROJECT PLANNING
2.3
Volume 3: Suspended
Individual task level

This type of planning should be done on a constant basis by each worker, considering how they are going to do each task in a safe manner and how that task relates
to the Daily Work Plan that was devised at the beginning of the day.
nize the potential hazards and determine what safety measures need to be taken.
Daily work level
Whole project level - What actions contribute to a culture of safety over the duration of the entire project?
Planning for project safety should take place before the ground breaking of a project and should encompass a broad perspective of a culture of safety. Considerations may include: the location of water, latrines and other sanitation needs for workers, the location of the nearest emergency medical attention, relations with the
local community especially regarding safety concerns, resources that may be available for safety training for workers, etc.
Bridges to Prosperity has developed the B2P Health and Safety Program with the aim to develop the same culture of safety that is paramount to success in the
construction industry. Daily actions, like the use of personal protective equipment or fall protection, are critical to safety on any work site, however developing a
Safety must be considered at multiple
levels:
In conjunction with our partners and industry experts, Bridges to Prosperity developed the B2P Health and Safety Plan to address the hazards that may be encountered on a bridge site. In many of the countries where B2P operates, safety standards that are commonplace in many western countries are largely absent or, at
best, lackadasically enforced. National organizations focused on safety in those countries, like OSHA in the United States, are generally too weak to be effective, or
may not exist at all. B2P values the health and wellbeing of all personnel on bridges sites, both local community members and visiting volunteers, and expects the
Health and Safety Plan to be applied comprehensively on site. This often means that foreign volunteers have the opportunity to share their experiences in work site
safety with local laborers to ensure a safer workplace for all. This exchange of ideas in safety culture awareness is a keystone in the Build to Educate component of
B2Ps mission. Please reference the B2P Health and Safety booklet for more detailed information on the topics listed.
B2P HEALTH AND SAFETY PLAN
2.2
All team members and community members working on site must abide by the B2P Health and Safety Plan, and actively engage with the Safety Manager, aligning
with all safety plans and protocols.
TRAVEL MEMBER RESPONSIBILITIES
2.1
SECTION 2: SAFETY
communicated in the local language to any community members involved in that task.
The Safety Manager is responsible for ensuring a translator conveys the necessary
information and answers any questions that come up. Note: A language barrier should
never be grounds for exclusion of community members in a construction task. Ultimately, it
is their bridge and they should be able to help in any task. The Project Manager and Safety
Manager must coordinate a translator as necessary.
Communication
Communication and working safely go hand in hand; workers that are uninformed have the
highest potential for injury. The Safety Manager on site needs to ensure that everyone on
site knows and accepts the expectations. This includes both local community members
Commitment
Safety is a function of leadership. As a result, safety must start from the top of an organization
and be consistent throughout. Expectations need to be set and met by all people on the
team without exception.
Each of these will be further explained in the following sections. Refer to the B2P Safety
Training PowerPoint presentation for additional information before completing the B2P Safety
Training Quiz, found at Bridgestoprosperity.org/Resourses..
This safety system was developed to better understand the aspects of safety. There are 6
different elements to this Safety System .
1. Commitment
2. Communication
3. Planning
4. Education
5. Evaluate/Modify
6. Reinforcement
Safety System
ON-SITE SAFETY
Volume 3: Suspended
2.4
REQUIRED ON SITE
REQUIRED SUBMISSION TO B2P
Daily
Daily
Daily (when applicable)
Daily (when applicable)
Daily
Daily
Daily
FREQUENCY
Volume 3: Suspended
No workers health and safety is ever more valuable than another workers. Safety standards are to be applied equally to all personnel working on site. It
is possible that language barriers and cultural differences will require more time is spent on training.
Education
On most projects, each person brings a different level of safety training and experience. It is essential that everyone on the work site can effectively identify
hazards and knows the best measures to protect themselves. A bridge project is an opportunity for better safety-educated workers to teach those who
have less knowledge and experience. This includes both local community members and visiting volunteers. Safety managers should organize all training
sessions necessary to ensure that all personnel thoroughly understand the hazards associate with all tasks, and how those hazards can be mitigated.
Daily Work Plan

Yes
Yes
Daily Site Inspection
Yes
Not Required
Excavation Inspection
Yes
Not Required
Fall Protection Inspection
Yes
Yes
Work Area Hazards
Yes
Not Required
End of Day Review
Yes
Not Required
Incident Report
Yes
Yes
*(when applicable) meaning when that type of work is included in the Daily Work Plan.
FORM NAME
Project Planning forms

All of the following forms can be found under the Resources section of the website
(http://bridgestoprosperity.org/resources/technical-resources/
has used industry standard material and the assistance of safety professionals to ensure our Safety Program achieves the same culture of safety that is
a keystone to success in the construction industry.
Planning
Thorough planning is critical to achieving two goals of a robust safety plan: 1) eliminating incidents and problems that can create disruptions in work, and
Volume 3: Suspended
be injured unnecessarily.
10
The information gathered from those Near Hits can be used to modify bridge building procedures in order to avoid similar dangerous situations in the
A near hit is an event that did not result in injury, illness or damage but had the potential to. Near hits are important because they can teach a great deal
without injury, illness or damage occurring. Many people do not report there Near Hits for a fear of punishment or lack of understanding of their importance.
Near Hits
Bridges to Prosperitys goal is to develop a safety culture as strong as the safety culture of our partners on their projects in developed countries. A strong
safety culture is a product of shared safety values, attitudes, goals and practices, where commitment, communication, and planning occurs on a daily
basis. It is important that all personnel on B2P bridge sites support one another in safe work practices. Furthermore, the Safety Manager on site must
share any feedback regarding the safety on site and ways that the safety culture can be improved.
Safety Culture
seen, it is important that everyone stops and discusses them as a team.

Reinforcement
Individuals frequently choose safe behavior as a result of either positive activators or consequences. It is important that all workers receive proper
feedback from both peers and the Safety Manager.
Evaluate and Modify

It is important to continually evaluate both conditions and actions on a work site since they are both always changing. It is important that everyone on site
Corrosive gases, vapors, and liquids

Molten metal that may splash
Intense light from welding and lasers
Volume 3: Suspended
face shield does not provide much protection from impacts though. It is to be worn with safety
glasses underneath. Face shields must be worn when cutting rebar ,cables or during other
activities involving the grinder.
Face Shield
The face shield provides more complete protection of the face than safety glasses. It is to be
Safety Glasses
Safety glasses are required when any of the following are present;
Hard Hats
Hard hats are most important when there is a possibility of hitting your head on low hanging
objects or when there is the possibility of falling objects. Even if these hazards are not present, it is still a good idea to wear a hard hat when possible.
The goal of a safety program is to eliminate many of the hazards through engineering and
work practices. However, not all hazards can be eliminated so personal protective equipment
is still necessary. Personal protective equipment or PPE is worn to act as the last line of defense against injury or illness. There are many different kinds of PPE depending on the work
and the equipment involved.
Personal Protective Equipment (PPE)
11
Volume 3: Suspended
General Hand Tool Safety

Basic hand tools are used on a daily basis on all work sites. When working side by side
with local community members, a vast array of tools in various states of repair are likely
to surface. It is imperative to site safety that tools being used by both visiting volunteers
and local community members are inspected to ensure they are in proper working condition and will not create unnecessary hazards.
Tools are essential for all Bridges to Prosperity Projects. While tools are very helpful
and in some cases essential, they can also be very dangerous. This section will discuss
the hazards associated with tools and ways to prevent possible hazards.
Hand and Power Tool Safety
Hand Protection
Hand protection, typically gloves, can protect hands from cuts, crushing, abrasions, heat
and cold and chemicals. There are different types of gloves depending on the application
they are needed for. Leather, fabric, coated fabric and rubber are some of the more common ones. Leather gloves are best for protecting against cuts, burns and heat. The fabric
and the coated fabric gloves are best for protecting against dirt and abrasion. Rubber
gloves are best at protecting against chemical burns
Work Boots
Work boots should be worn at all times while on bridge sites but are most important when
heavy falling objects, sharp objects, hot surfaces and/or wet surfaces are present. Work
boots are typically made of leather and provide ankle support. Some work boots have a
steel reinforced toe as well but this is not a requirement of B2P.
Hearing Protection
There are many different types of hearing protection. These include ear plugs, canal caps
and ear muffs. The rule of thumb is that if you have to speak loudly with a colleague, from
two feet away, you need to wear hearing protection.
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SAFETY DURING CABLE

TENSIONING
Some General Rules for Using a Come Along:

ALWAYS double-check the calculations for the calculated load that is being pulled
ALWAYS double-check the calculations for the calculated load that is being pulled
Ensure that ALL devices being used are capable of carrying the load force, including the anchor
points, and any other straps or fastening devices that may be used to carry the load.
ALWAYS make sure the device is well maintained and the safety latch is working properly.
ALWAYS check the cable and chain for damage(i.e. corrosion, failed links, etc.).
ALWAYS use appropriate end clamps and connections.
ALWAYS use the proper Personal Protective equipment when operating it
DO NOT use if parts are damaged.
DO NOT exceed the rated capacity of the come along
DO NOT use a cheater bar.
NEVER straddle the tool and keep your body out of harms way.
Come Along Safety

Come alongs, also known as hand winches, cable pullers, or cable hoists, are used for
cable placement and sag setting on all Bridges to Prosperity projects. This is one of the
most critical steps in the construction process and potentially one of the more dangerous.
Special care needs to be taken in the selection and use of a come along. Any failure can
lead to a cable slip which is extremely dangerous. A loose cable can whip out of control
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Best Practices:
Operate within design limits
Use gloves, safety glasses and safety shoes
Store in a dry place
Dont use in wet locations unless approved for that
Keep work areas well lit
Ensure cords dont present a tripping hazard
Regarding corded power tools:

Keep cords and hoses away from heat, oil, and sharp edges
When possible, use tools that are properly grounded and that are double insulated.
DO NOT carry portable tools by the cord
DO NOT use hoist or lower power tools by their electrical cords.
DO NOT yank a cord or hose to disconnect it.
Make sure the cord is not in the way of the work
General rules for Power tool safety:

Disconnect tools when not in use, before servicing, cleaning and changing accessories.
Try to secure work with clamps or vices to free both hands to operate the tool
Always keep tools sharp and clean
Consider what you are wearing when operating power tools; loose clothing and jewelry can get
caught in moving parts
Remove a damaged electric tools and mark them DO NOT USE and communicate the meaning of
this to all workers. Also a good idea to keep the tool separate from the operational tools.
DO NOT hold the switch button while carrying a plugged in power tool.
they are eager to help and learn new construction methods, but they may be unfamiliar with the hazards
of such tools. If community members will be using power tools, then patient, clear instruction and close
supervision are absolutely required.
Power Tools
As the size and complexity of B2Ps bridges grow, the use of power tools on site is becoming more
prevalent. This necessitates that extra care is taken in not only using those power tools, but in making
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be labeled as such and taken out of service immediately.
Harnesses must be inspected before each use. Bridges to Prosperity has an inspection
Chest strap should be across the breast bone

Have someone else check the harness for twists in the straps
General Fitting Rules:

Be able to touch your D-ring with your thumb
Harnesses
Harnesses are devices that are worn over your clothes and they are designed to catch and
support you when you fall. There is a main ring or the D-ringon the harness that when
worn properly, is located on your back between your shoulder blades. This ring is where
you connect your lanyard or retractable meaning this is what catches you if you fall.
Types of fall protection

Fall protection is necessary for anyone that is working 6 feet (~2m) above the ground or
higher. There are different types of fall protection that can be used when working on a
surface that meets this criteria.
Best way to control fall exposures:

Always try to eliminate the hazard
Select appropriate fall protection system
Properly construct and install the systems
Train workers in the proper selection, use and maintenance of fall protection systems
Supervise everyone on site wearing fall protection
Overview
It takes a person approximately 1/3 of a second to become aware that they are falling. It
takes an additional 1/3 of a second for the body to react. In that 2/3 of a second, the human
body can fall up to 7 feet!
Fall prevention is a series of reasonable steps taken to eliminate or control the potential effects of an unintentional fall while accessing or working at heights. This is applicable when
constructing the deck and when working on the towers for a suspension project.
Fall Protection
D-Ring
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Rescue Plan
With fall protection, it is important to not only protect against falling but to also to have a
plan of how to safely rescue the individual from their position after the fall. It is likely that an
individual that just fell will not be able to pull himself or herself up. Also, when the individual
is suspended in the harness, it does not take long before the straps will start cutting off the
circulation to legs. Some harnesses have straps that the individual can put their feet into to
Anchorage Points
Equally as important as the harness and the connection is the anchorage point or the point
that you are tying off to. Keep in mind that an anchorage point must be able to support
5,000 lb (2300 kg) per person or twice the intended load when using a horizontal lifeline. If
a retractable is being used, the bearing capacity of the anchorage point can be reduced to
3,000 lb (1400 kg) per person. It is always best to tie off to a point that is at or above D-ring
height. Also, make sure that the anchorage point is convenient for the individual. In the
picture to the right, note that the workers are tied off to a cable that is set higher than the
main cables to serve only as a tie off point.
a seat belt. If you pull slowly, it will release slack but if you pull quick, it locks up minimizing free-fall distance to a couple of feet. These work best in vertical applications. It is not
okay to connect two retractables in a series. They are not designed for this application
and therefore may not function properly. Also, if used in more of a horizontal application,
although the retractable will lock up, it is likely that the individual will swing. This is called
a Swing fall and it could be dangerous depending on what the individual might swing into.
Self-Retracting Lifeline
A Self-Retracting Lifeline (also known as Retractable or Yo-yo) is also used to connect a
Lanyards
The simplest of connections from a harness to an anchorage point, lanyards come in many
different styles and lengths. It is important that the lanyard being used will in fact provide
the desired protection. For example, if an individual is working 6 feet above the ground
and they are using a 6 ft (~2m) lanyard, they will likely hit the ground before the lanyard is
engaged. With a 6 ft lanyard, a minimum of 18.5 ft (5.6m) of clearance is needed between
the individual and the ground.
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Type B Soil
square foot or greater. Examples a cohesive soil are clay, silty clay, sandy clay and clay
Type A Soil
with vertical sides and remain intact while exposed. While this does produce the most
stable type of excavation and is best for foundations, it is not very common for B2P sites.
Stable Rock
as stable rock. The type of soil is what dictates the allowable slopes of the excavation
(see the following diagram).
Rock and Soil Properties

When making an excavation or trench, it is important to know the soil properties to ensure
tion that is narrow in relation to its length below the surface of the ground. In general,
the depth is greater than the width, but the overall width of a trench is not greater than 15
ft (4.6 m).
Background
An excavation is any man made cut, cavity, trench, or depression in an earth surface,
Trenching and Excavation Safety

Excavations and trenches pose another major safety concern on bridge sites. It is essential to know the in-situ soil and rock conditions when considering excavation and trenching
activities planning.
help take pressure off the leg straps. If a plan is not made ahead of time, there may not be
enough time to rescue the person before they go into shock. Also it may take more than
one person to lift the fallen individual so plan accordingly.
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a generic procedure for most penetrometers. First, a sample of undisturbed soil must be collected. The
easiest way to get this is to dig a hole and use the penetrometer on the shear face of the small excavation.
Next, on the penetrometer, move the ring to the lowest reading on the scale which should correspond to
the lower edge of the instrument handle. Slowly push the piston into the soil up to the groove that should
be located 1/4 away from the end of the instrument. Once the end has penetrated the soil up to that
point, pull the instrument away from the soil and read the value marked by the location of the ring. This
value will give you the compressive strength of you soil in ton per square foot (tsf) or kg per square centimeter (kg/cm^2).
Pocket penetrometer
A handheld device that is used to measure the bearing capacity of the soil at a given location. It is best
The Thumb Test: (ASTM test designation D 2488)

For this test, one must retrieve a large clump of undisturbed soil. Next the individual must attempt to penetrate the
soil with the tip of their thumb. A type A soil can only be penetrated with a great force. Alternatively, a class B
soil will penetrate to the full length of the thumb nail and a class C can be penetrated several inches with ease.
Again, given the obscurity of the test, it is best to classify conservatively.
Plasticity Test
For this test, collect a small sample of soil and add water until it is moist. Roll the soil into a ball and next into a
1/8 diameter thread. If this can be done, hold the sample by an end. If it remains suspended without tearing, the
soil is cohesive.
Type C Soil
Class C soil consists of soil that has a compressive strength of 0.5 ton per square foot or less. It
stable.
and 1.5 ton per square foot. They can also be granular, non-cohesive soils such as angular gravel
(crushed rock), silt, silty loam and sandy loam. Previously disturbed soils can also qualify as well
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Class B Soil
Allowable excavations per OSHA

Class A Soil
Allowable Excavation for Class A and B Soils
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1. Photo Inventory and Submission

2. Quality Control forms
3. As-Built Reports
Requirements
If working completely independent of B2P, the following items are still highly recommended.
QUALITY CONTROL REQUIREMENTS
world countries. This section will assist in making sure that all construction methods are done properly.
This section is not meant to be a hindrance but rather an aid for individuals that lack experience working
in these types of remote areas.
As with any construction project, there must be an aspect of quality control. It is imperative that these
QUALITY CONTROL OVERVIEW
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3.2
3.1
SECTION 3: QUALITY CONTROL
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A. Site
D. Towers
Left side
A2- Location of foundations with marked center line D1- Rebar installation in Tower
D2- Complete Tower
B. Excavations
D3- Saddle alignment
Left side D4- Walkway hump
B1- Complete excavations
Right side
B2- Distance from back anchor to front tower
D5- Rebar installation in Tower
B3- Anchor depth
D6- Complete Tower
B4- Foundation depth
Right side D8- Walkway hump
B5- Complete excavations
E. Anchors
B7- Anchor depth
Left side
E1- Completed rebar cage
E2- Cross-section of cable (for size)
C. Foundation and Tiers
E3- Cable position in excavation
Left side
E4- Completed anchor
C1- Completed foundation
Right side

C3 - Complete second tier
C4 - Complete third tier
Right side

G6- Completed approach
I. Completed Bridge
H. Suspenders, Decking and Fencing

H1- Decking installation
H2- Deck Installed
H3- Suspender connection to crossbeam
H4- Suspended connection to handrail
H5- Fence installed

Right side
G4- Thickness of approach walls
Left side
G. Approaches
F. Sag Setting
F1- Handrail cables aligned
F2- Walkway cables aligned
F3- Clamp spacing
F4- Torque technic used
F5- Representative photo of clamped cable
F7- Tar on cables
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The following is a list of photos that MUST be taken during construction. These photos are to ensure that each step of the process was properly executed. Upload to the bridge
appropriate Flickr folder, named: QC_[Name of bridge].
Photo Inventory and Submission
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AS-Built reports are markups done to the construction drawings that better represent how something was actually built. During construction the construction of a bridge, there
3.2.3 AS-BUILT Report Requirements
The included forms are designed to help ensure quality control standards are met.
3.2.2 Quality Control Forms
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Also, note that there are different types of cement and varying levels of quality.
Ensure that the cement being used if of good quality and it is the desired type.
Materials
Check the availability and quality of required materials. Locate the source for cement, sand, gravel and water on the job site or elsewhere if necessary.
Ensure the following;
Cement should be fresh (no older than 60 days) and from a reliable source
Sand and gravel should be clean and free of debris (sticks, leaves, trash, etc.)
Sand should be course, not round or shiny
Sand should not contain silt or clay particles
Water should be clean and transparent
Gravel should be no larger than 5 cm
Gravel should be relatively round yet jagged (note: round refers to the overall shape and not the surface)
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that if for some reason, this person cannot be present throughout the duration of the project, the head mason for the project, in most cases a local, should be trained
and held responsible for concrete mixed on site without the QC person.
Quality Control Person

Assign one person to oversee concrete proportioning and mixing operations. They will be considered the Quality Control (QC) person for concrete operations. This
quality of concrete on the job and must be submitted upon project completion
The intention of this section is to serve as a guideline for standard and replicable concrete mixing techniques for use on all projects. It is to be used as an outline and
Concrete
The quality of bridge projects is completely dependent on the materials used. During the project, it is important to use the best materials available. This section can
be used as an aid in sourcing materials for construction. If the materials used are in question, it is best to consult experienced personnel before using them.
MATERIAL QUALITY CONTROL
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3.3
Sand ( m 3 )
0.5
Gravel ( m 3 )
0.75
Yield ( m 3 )
1.0*
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*Design and Control of Concrete Mixes,14th edition
The water amount will likely vary from site to site based on the characteristics of the aggregates. As a starting
value for the volume of water, it is recommended that the water necessary for a minimum slump is added and
then water is added in small amounts until the desired consistency is reached. For a 1 - 2 in (2.5 - 5 cm) slump
with 5 cm gravel, the recommended water is 0.15 cubic meters per cubic meter of concrete*. This means that for
the diagram below, it is recommend to start with about one half of a bucket of water and continue to add water
until the desired consistency is met. A slump test is very useful for this application and is covered in a following
section.
*Note that it is assumed that there is a 33% reduction from the summation of the volumes of the components to
the volume of concrete produced.
Cement ( m 3 )
0.25 (8 x 42 kg bags)
Materials Needed for 1 Cubic Meter of Concrete Using a 1:2:3 Mix Design
For all B2P projects, a 1:2:3 volumetric mix ratio is recommended. This means that one bucket of cement is
mixed with two buckets of sand and 3 of gravel. Note the size of the bucket does not matter as long as it is
consistent. Below is a table representing the amount of cement, sand and gravel needed for 1 cubic meter of
concrete. Note that the below table is more useful in estimating total materials needed rather than for use when
mixing concrete.
Mix Ratio
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Gloves
Cement
Gravel
Water
Safety Glasses
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Placing Concrete
Concrete should always be placed within 1 hour of mixing. If this time limit is exceeded, the concrete
should be discarded.
details on how to preform the slump test are included later in this section but a slump of 3-4 inches
(7.5-10 cm) is recommended. .
The method of sifting water is superior to the Volcano Method or cone method that is commonly used.
The puddle of water in the middle of the cone shape does not produce an even and consistent product
as when water is mixed slowly and evenly into the mixture.
that is well mixed, add the cement and gently mix the pile so no cement is lost (cement is very light).
Using shovels, mix the dry components thoroughly. Do so by shoveling into a single pile, then moving
the pile twice (back and forth). After the dry materials are well mixed, add water using the same
method stated above. During this process, continue moving the pile to ensure uniformity.
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required. When the use of a portable mixer is not feasible, a manual method of concrete mixing is required. In order to ensure material strength properties assumed in
the design, it is important to use only clean and fresh materials and mix them using the sifting method. Before starting, pour a thin concrete pad where the concrete
mixing will take place. This will limit the amount of unwanted constituents in the mix (i.e. soil, grass, sticks,etc.) and will allow less water to escape the mix.
(i.e. 0.6 buckets of water for 1 bucket of cement). Following that, all dry materials should be added. Let materials become well mixed and slowly add water until the
Recommended Materials
Shovels
Buckets
Sand
Flat clean working area
recommended since it usually produces much stronger concrete in comparison to hand mixing.
Concrete Mixing Methods
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If 3 cubic meters of concrete is needed for the anchor and the anchor needs to be loaded as soon a
possible, how much sika accelerant is needed?
1. Identify how many kilograms of cement is needed for the 3 cubic meters of concrete. In this case,
8-42 kg bags per cubic meter so 8*42*3=1008 kg
2. Look at the manufacturers recommendation for milliliters needed per kg of cement. In this case it
is 520-1950 mL per 100 kg of cement Lets say 1000 mL per 100 kg
3. Take 1,008kgs of cement *(1,000 mL /100 kg cement). The result is 5,242 mL min. and 19,660
mL max. Note this is for 8 bags and a more useful number would be per bag of cement. Take
these values divided by 24 bags to get 220mL min. and 820 mL max.
4. Lets say 500 mL per 42 kg bag of cement and we will need 12 liters totoal. For this, cut the top
off of a 1 liter bottle of water and mark the 500mL line. Use for adding to the mixes.
accelerant or on the manufacturers website.
Example:
29
Also note that many accelerants contain Calcium Chloride. There is a lot of data and experience that states that these types of accelerants increase drying shrinkage, increase potential for reinforcement corrosion and increase potential for scaling. If the accelerant available contains calcium chloride, it is recommend that a
professional engineer be consulted to determine how to proceed. The following example uses Sika Rapid-1, a non-chloride containing accelerant.
for the application and dosage required. If accelerant is used, remember;

Read all available manufacturer literature and ensure proper dosage.
Reduce the initial amount of water added to the mix per the manufacturers instructions (approximately 25% is typical)
The accelerant will act as a plasticizer so it will reduce the amount of water needed to reach the desired consistency
Admixtures - Accelerators
Curing
Fresh concrete will crack when it is allowed to dry rapidly, thus curing the concrete is essential. After the concrete is placed, covering the concrete will help reduce the
amount of moisture lost due to evaporation and to help ensure consistent hydration. Wet burlap sacks or plastic sheeting works best, but anything that helps reduce
water loss is acceptable. Moistening the empty cement bags and covering the fresh concrete with them is another good option for curing. Whichever is used, add water
each day to the surface of the concrete to better hydrate the concrete.
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Also, the use of concrete admixtures, such as liquid accelerants, can affect the slump of the concrete.
If an admixture is used refer to the manufacturers data to verify if and how the slump will be affected.
The slump for any batch of concrete (excluding grout mixes) should be from 3-4 in (7.5-10 cm) should
be no more than 11 cm (5). If a batch of concrete exceeds this amount either discard the batch or use
on a non-critical part of the bridge (listed on the QC checklist).
Concrete Scoop
Tamping Rod - (~1.58 cm dia (5/8) x 40-50 cm (16-18) long, smooth steel rod)
Tape Measure
Tools Required
Slump Cone - (20 cm (8) base dia. x 10 cm (4) top dia. x 30 cm (12) tall)
Slump Test
If there is a standard slump cone available on site, take one slump test per batch of concrete made. A
slump test is used to help verify the workability and mix proportioning of a single batch of concrete. It
is also useful to determine consistency between multiple batches of the same mix of concrete. In order
to perform the test you will need some basic tools listed below. The slump cone needs to be exactly as
30
Grout and Mortar Mixes

Grout and mortar mixes are required at various location on the bridges. Mortar is used as part of masonry walls and grout is used in the tubes at the anchor locations.
Mortar is often made from cement and sand (roughly 1 : 4, with water added until workable) and does not contain large aggregates. Grout mixes are typically from a
bag and do not contain any aggregate.
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Step 5: Compare results to typical values
Step 4
Slowly pull the cone upwards (should take about 5 seconds to completely remove the cone). Then, turn
the cone over (small side down) and measure the distance between the top of the cone, and the center
of the top of the slumped concrete. This measurement is your slump.
the remainder of the way, and repeat tamping 25 times, just barely penetrating the second layer. Use the
rod to smooth off and remove any excess concrete from the top of the cone.
Step 3
Fill the cone a third of the way with concrete (to a height of 2-5/8). Then, use the tamping rod to
consolidate the concrete in the cone by use of an up and down motion, 25 times. Fill the cone another
Step 2
Place the slump cone (large side down) on the slump board and secure it in place by standing on the
Step 1
Moisten the slump cone, tamp rod, scoop and slump board so that they are wet to the touch.
Slump Test - Procedure
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Concrete Scoop
Tamping Rod - (~1.58 cm dia (5/8) x 40-50 cm (16-18) long, smooth steel rod with rounded end)
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Step 4
Because little information of strength of concrete mixed in these areas is available, testing results from
all groups is appreciated. Break test cylinders after 28 days and send results to Bridges to Prosperity
at info@bridgestoprosperity.org.
lb (4 kg) each. Plan accordingly to transport cylinders to testing facilities.
Step 3
layer 25 times with the tamping rod (When rodding the second and thrid layers, the rod should just
nate voids in the mold. Strike off the top of the cylinder using any straight edge you have and put the
cap on.
Step 2
Step 1
Procedure for Casting and Storing Concrete Cylinders
Tools Required
Plastic cylinder molds - (10 cm (4) dia. x 20 cm (8) talll)
32
Compressive Test
It is encouraged to make concrete cylinders that can be used for strength testing. The results will be useful in developing future mix proportioning guidelines and in
bridge evaluations. Note that grout mixes use a different testing method that is not outlined here.
Is it transparent?
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NOTES:
If produced onsite, is it clean and free of debris?
Was the gravel produced onsite or delivered?
If produced onsite, is it clean and free of silt and clay?
If produced onsite, is it clean and free of debris?
Was the sand produced onsite or delivered?
Source of water?
Concrete Competent Person:
Country:
Bridge Name:
Concrete Quality Control Form
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Location on
Bridge
Accelerator
used? If yes,
how much?
Mix Proportion
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Date
Concrete Quality Control Form
Measured
Slump
Were
cylinders
taken?
34
Competent
person
Approval
Chisel
Trowel
Level
Hammer
Plumb Bob
String
Square
gaps.
Always stagger each layer of masonry as shown below.
Try to place large stones so that their large face is facing down.
without assistance.
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thick with the grading on the outside of the wall..
Unreinforced, stone masonry walls should not exceed 2 meters in height. If walls larger than this are
Good masonry uses 5cm or less of mortar between joints. Staggering the layers (alternating joints) so
that joints are not above each other is also key to strong masonry structures.
There are some important factors that contribute to a masonry structure being strong and long lasting.
Use as many stones as possible and as little mortar.
Tools Required
Stone/Rubble masonry
35
Trowel
Level
Plumb Bob
String
Wood formwork
Square
Nails
Hammer
Always stagger each layer of masonry as shown below
gaps
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Also, be aware of the quality of the CMUs that are available locally. The quality and therefore strength of
these can vary greatly from site to site. In most cases, these blocks are used as formwork so as long as
they can withstand the lateral pressures from the wet concrete.
Note the size of locally available block, and plan wall dimensions accordingly. It is ideal to use whole
In some instances, masonry walls will need to be reinforced for additional stability. In the case of most
suspension bridges, this is not needed. If additional reinforcement is deemed necessary i.e. working
There are some important factors that contribute to a masonry structure being strong and long lasting.
Make sure blocks are wet before applying (in order for mortar to bond)
Mix as little mortar as possible at a time to ensure freshness
Mortar between blocks should not be thicker than 1-2cm
Tools Required
C.M.U Masonry
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*Consult the Wire rope users manual for more information on how to take care of and inspect wire rope.
Take care when unwinding the cable from the spool. Kinks in the cable are detrimental to the material
strength and are a point of weakness. Furthermore, take care not to lay the cable in sandy areas. Sand
may get in between the cable strands and cause damage. Use heavy tie wire to wrap around the loose
ends of the cable to stop unraveling if any cuts in the cable are made (note that the wire should be placed
on both sides of the cut).
Unwrapping Cable
Individual Wire Breaks

TA careful inspection of the rope should be done to identify any broken wires.
Important items to check the cable for

Welded joints
Kinks
Individual wire breaks
Cable Inspection
It is imperative that the cable that is to be used is thoroughly checked. This can be more of an issue
when using donated cable. Note that if cable from B2P is being used, it is recycled cable.
If using repurposed wire rope, all cables must be inspected before they are considered adequate for use
on a B2P bridge project.
Main Cable Inspection and Care
37
Red is Dead
Never
Saddle a Dead
Horse
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38
(Malleable clamps are inferior and are not suggested for any bridge use. If no drop-forged clamps are available, no clamp size greater than 1 1/8 is recommended.
Note that the required torque for malleable clamps is far less than drop-forged and over tightening malleable clamps will lead to clamp failure. The use of malleable
clamps requires re-tightening and additional clamps. As such, when using malleable clamps, leave at least half of the clamps permanently above ground.)
DROP-FORGED CLAMPS ARE OF SUPERIOR QUALITY AND MUST BE USED ON ALL B2P PROJECTS!.
There are two types of clamps that are readily available for cable terminations; Forged and malleable
clamps. Note the these clamps can be referred to as clips, U-bolts, bulldog clamps, etc. Forged
clamps are made from a solid piece of steel that is heated up until the metal is soft and then bent
to shape. With malleable clamps, the metal is heated until it is liquid and then poured into a form.
In this process, there are chances of voids being created or imperfections existing in the clamps
that cannot be easily detected. For this reason, malleable clamps are not allowed for use on the
main cables and are not permitted on B2P projects for use on the main cables. Note that Crosby
clamps are forged clamps and are used on all B2P projects. Also note that drop-forged is a type of
forging process.
Clamp Material Properties
Clamping and Cable Crush
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Since the torque required for the clamps will reduce the cross-sectional area of the wire rope, it is important
that the clamps are properly oriented. Clamps must be placed such that the saddle is around the live or loadbearing cable and the pinched side is the loose or dead cable as shown in the diagram below. The common
expression for remembering this is Never saddle a dead horse.
is not available, tighten until the cross-sectional area of the dead cable is reduced approximately 25%. This
reduction in area is what makes this type of connection work.
If a torque wrench is available, read the amount of torque applied by tightening the nuts similar to a typical
The table to the right is from the Crosby Group and is intended to be used in conjunction with Crosby clamps.
It is always recommended that manufacturers guidelines be followed for the clamps that will be used on any
given project. Even if Crosby Clamps are used, information from the manufacturer should be used when
determining proper torque and spacing.
could cause failure as a result The required torque varies depending on the quality of the clamp (drop-forged
Ensuring that the cable clamps are properly tightened is the single most important quality control issue for
Clamp Torque & Spacing
39
Volume 3: Suspended
Delivered Construction Materials

All construction materials that cannot be found on site should be purchased and delivered to site before
starting or during construction. These materials also need to be included in the construction sequence and
project management plan. Contingency for materials acquisition should be accounted for in the schedule,
in particular with critical path elements. Consult the material quantity estimate in Volume 4.1 Suspension
Design, Section 4: Material Quantities to ensure quantities are correct.
Local Construction Materials

All local construction materials should be prepared on site before starting construction. A construction
sequence and project management plan should be created and shared with all project stake holders.
Contingency for materials acquisition should be accounted for in the schedule, in particular with critical path
elements. Consult the material quantity estimate in Volume 4.1 Suspension Design, Section 4: Material
Quantities to ensure quantities are correct.
On most suspension projects, the materials needed for construction will be divided into two groups;
materials that are readily available on or near site and materials that will require transportation to site.
4.1 REQUIRED MATERIALS
SECTION 4: MATERIAL PREPARATION
40
Grain sacks
Chisels
Volume 3: Suspended
as formwork, the inside dimensions of the walls must be kept the same as well as the height to ensure the
same amount of concrete is poured.
Consult the drawings in Volume 4.2 to determine how many of each dressed stone type will be needed to
Face Stones :
The face of one side (of a generally four sided stone)
needs to be cleanly chiseled
straight and square as it will be placed facing out from the masonry work. Stones should be
approximately 20 cm x 28 cm.
Corner Stones:
Two adjacent sides of a stone need to be cleanly chiseled and square for use at the corners
of the towers. Stones should be approximately 20 cm x 28 cm.
Dressed Stone
In some areas, dressed stones are widely used in construction. If this is the case, dressed stones can be
used in place of cinder blocks. The decision to use these should be based solely on the area where the
bridge will be and the local construction techniques. Dressed stone is dressed to be square with hammers
and chisels. There are two types of dressed stones:
the stone is required.
Broken Stone
Local Materials
Hammers
Buckets
Local Materials
41
The water used for concrete is often times not potable water. This being said, it is important that the
water is relatively clean. Many times, the only water available in the quantities needed is river water.
In this case, make sure that the water has a low turbidity and is transparent. If the water has a higher
turbidity (cloudy), it should not be used directly. One way to deal with turbid water is to have a holding
container for the river water on both sides. While the water is in the container, some of the impurities
will settle to the bottom, making the water on top clearer. There are many other ways to deal with
high turbidity so do what makes sense for a given site.
earthen smell of organic soils. Silt must be avoided in sand mixtures.
thoroughly mixed with coarser sand from another location. Sand can be collected from river deposits
or from a quarry. The quality of the sand should be assessed before collection. Check the content of
impurities such as mud, clay, debris, silt, sand, etcetera and avoid sand with a high content of these
materials to reduce the need for washing. Sand with silt must be washed out in grain sacks at river
before use.
The sand will be used for the concrete mixture and the sand sizes should be well graded. The best
design has 50% medium size particles (~2mm) with decreasing amounts of very large and very small
The coarse aggregate (gravel) will be used in the concrete mixture and should be rough and clean
with broken faces; rounded particles will not adhere well in the mixture and should be avoided
if possible. Dirt and organics in the mixture will also decrease mix strength, and any aggregate
containing soils must be washed until clean. Riverside gravel should be broken with a hammer to
form rougher surfaces. Maximum gravel size is always 5 cm, but is usually smaller and dependent on
the formwork and dimensions of the rebar. Aggregates larger than 7 cm will usually reduce concrete
strength. Gravel can be collected from river deposits or by breaking boulders into the necessary size.
Volume 3: Suspended
Water
Sand
Gravel
42
The cable (wire rope) must be sourced in-county from either B2P, a local supplier or a local importation
company. Once in country , the cable must be delivered to site. Develop of rough estimate of how much the
cable will weigh before arranging transportation , as the size of the truck size will be dependant on the total
weight of volume.
When silt-free sand cannot be found on site, sand will have to be purchased. This is necessary only if there is
Volume 3: Suspended
ONLY drop forged clamps are permitted for use on B2P projects. Drop forged clamps are usually not available
locally and should be brought from the United States or Europe.`
Cable Clamps
Cable
Gravel
effect the strength of the cement.
It is important to buy cement from a trusted store in the area. It is more likely that the cement is stored properly
and is not stored for very long. If cement is not properly stored, there can be sizable decreases in the strength.
Even when properly stored, the cement can lose up to 50% of its strength in 18 months of storage! Check
for hard spots in the cement bag. This is an indication that the cement has been exposed to moisture. If hard
Cement
4.1.2 delivered Materials
43
The recommended crossbeams are two 1.75 steel angle pieces that have been welded or bolted together. These
must be fabricated in a shop and delivered to site. It is recommended that the crossbeams are painted in some type of
anticorrosive paint after they are fabricated.
delays in getting the timber are not uncommon, it is best to plan accordingly.
Timber will be needed for both the decking and the nailers. B2P standard decking boards for these bridges are not
Volume 3: Suspended
C.M.U Blocks are typically used for the pedestals and approach ramp. Take note of the their dimensions as they may
but rebar from bigger cities tends to be of better quality. Also take note of maximum lengths of rebar available.
Reinforcement steel
Timber
44
Local Materials
Volume 3: Suspended
4.1.3 Materials List:
Cement bags for Anchor

Cement bags for Tower
Cement bags for Approach
Masonry blocks for Tower
Steel reinforcement bar 10 mm (6m pieces)
Handrail Cable, width __________
Walkway cable, width __________
Clamps, drop-forged
Sand
Stones
Gravel (crushed stone)
Material item
site
Date of
Notes
45
Diamond shape trowel
2
1
Wrench; minimum 3 foot, socket size same as

cable or socket wrench with breaker bar
Hand drill and bits; reference decking
drawings to locate sizes.
Masonry string
10 meter rope
Spray paint
Pipe to bend suspenders
Volume 3: Suspended
Pliers
Abney Level
1
1
2 kg sledgehammer
4 kg sledgehammer (if stone work)
1
1
1
1
1
1
1
Flagging stakes
Vice grips
1
2
Wheelbarrow
20 liter (5 gallon) buckets
Machete
Measuring tape, 5 meters
Masonry tools (if not provided by mason)
Woodsaw and blades
Hacksaw and extra blades
Rice sacks
4 screws or lag bolts
Suspender rebar
Rebar
Calculator with Sine & Cosine
Rock chisel
1
2
6
1
2
Material item
Hammers
100 meter tape
Quantity
4
2
Shovel
Pick
Material item
4.1.4 Recommended Tool List:
20
2
1
4
5
1
46
Tools Required
Spray Paint
String & Picks
Wood saw
EXCAVATION LAYOUT
Shovels
Stakes
Hammer
Automatic level and tripod (if available)

Plumb bob
Nails
Volume 3: Suspended
47
Find the distance between the front of the foundation to the back of the anchor in your plans and place another stake at that point. Finally, go back a 2.00 m further and place
Step 2
Using the markers R and L on the right and left side of the river respectively, as marked in the survey, measure the distance from R (or L ) to the front of the tower, according
to your design. If an automatic level is available, use it to establish the bridge centerline from side to side, then set all subsequent points off of the established center line. Place
a stake at the point of front of Foundation, named FOF(R) - Front of Foundation Right.
Step 1
5.1
SECTION 5:
SITE PREPARATION
Volume 3: Suspended
Extend string around these four stakes at each of the towers and anchors. These are your excavation areas.
Step 6
The four corners of the foundation and anchor blocks respectively are found from the centerline Using a 12 meter
string, connect at FOF(R), and have one person hold the 4.0 meter mark of the string along the centerline. The second
person holds the string at 9.0 meters, repositioning until the remaining 3.0 meters can reach back to the start point,
creating a 3-4-5 triangle. The relative dimensions of the triangle create a right angle along the 3m leg. Stake this point,
1. Repeat for all corner points for both foundation and anchor.
Step 5: the 3-4-5 method
Measure the distance from front of foundation (FOF) to front of anchor (FOA) and mark FOA(R).
Step 4
Repeat the process on the other side of the river. If an automatic level is available, verify both sides are square to each
other. Run a string between the permanent center line stakes.
Step 3
48
EXCAVATION IN SOIL
Volume 3: Suspended
Dig out the access trenches to the anchor.

*Note, anchors are often excavated after the towers have been completed.
Step 3
Dig the anchor trench according to the measurements given in the plans.
Step 2
Excavate the area indicated in the foundation layout level.
Step 1
5.2
49
EXCAVATION IN ROCK
Volume 3: Suspended
Soft rock anchors require excavation to one meter (1m) depth, but do not need to be at the same level as the
tower excavation. Excavate a soft rock anchor according to the dimensions in your design. Since stakes are
hard to use, use spray paint to mark the excavation area.
Foundation placed on solid rock bed do not require excavation to one meter (1m) depth. Ensure the rock
The method of marking fron of foundation (FOF(R)) and front of anchor (FOA(R)) is the same as described in
section 5.2 - Excavation in Soil
5.3
50
Volume 3: Suspended
Excavation
Layout
If water in excavation, have drainage systems been constructed?
No water allowed to enter excavation?
Excavation depth consistent with plans?

Excavation width consistent with plans?
Permanent control stakes placed along centerline?

Excavation layout indicated with stakes and string, or spray paint for rock?
Centerline established using automatic level (if available) and marked with stringline?
QUALITY CONTROL CHECKLIST: SITE PREPARATION

X
51
BRIDGE TERMINOLOGY GUIDE
Volume 3: Suspended
6.1
SECTION 6:
CONSTRUCTION
52
Sand
Materials Required
Cement
Tools Required
String
Shovels
Square
Plumb bob
Buckets
Hammer dressed stone or CMUs
Water level
Masonry tools
FOUNDATION & TIER CONSTRUCTION
Volume 3: Suspended
Pour a foundation layer (25 mm) of concrete onto the soil at the base of the foundation.
In the case of hard rock, pour a thick mortar mixture to roughened rock area.
Step 2
Ensure that the foundation excavation is level from front to back, side to side. Ensure that the foundations on
either side of the river are square to one another. Always use the centerline for positioning.
Step 1
6.2
53
Volume 3: Suspended
Continue with the masonry layers until the tier has reached 1.00m in height.
Step 5
Fill the layer of masonry stones between the corner stones, around the perimeter of the foundation tier,
placing stones as closely together as possible. The wall should be 30 cm thick.
Step 4
plans). Ensure the stones are placed square using a plumb bob and level using a water level.
Step 3
54
Volume 3: Suspended
* reinforcing with wire mesh can be added to distribute the load of the above tier or tower
the edges as a base for the next course of stone masonry to sit on.
Make a watery grout of concrete/sand mix in 1:2 proportion out of 2 cement bags and pure over the
Step 8
Step 7
gaps with smaller stone, then another layer of bigger stones and so on.
Step 6
55
Volume 3: Suspended
drawings. Each tier reduces in width from the one below it, per
the following dimensions.
56
AS YOU BUILD UP THE TIERS, RECONFIRM THAT EACH TIER IS TRUE TO THE CENTER LINE BEFORE CONSTRUCTION BY MARKING THE CENTER LINE ON THE
FOUNDATION OR TIER BELOW.
Step 10
* If river stones are not available tiers may be built of CMUs. In the case
of block masonry a reinforced concrete wall will be constructed on the
inside of the masonry wall. Place vertical bars (12mm) the full height of
the foundation/tier wall (1.00m) at each corner and every 50cm along
the inside of the wall. Wrap and tie (to the vertical bars) horizontal bars
(12mm) around the inside wall at 20cm, 50cm, and 80cm. With wood,
Repeat 3-8 for to build all needed tiers. Verify each tier is correctly
sized and straight.
Step 9
Volume 3: Suspended
Tier/s
Foundation
All concrete used within 60 minutes of mixing?
Each tier dimensioned in decreasing size with height, per plans?
Each tier corners are set true to the centerline?
No water allowed to enter excavation upon completion?
Foundation minimum depth 1.0 meter?
Foundation corners square to centerline?
QUALITY CONTROL CHECKLIST: FOUNDATION & TIER CONSTRUCTION

X
57
Steel hacksaw
Masonry tools
Level
Materials Required
Cement
Sand
Gravel
Hammer dressed stone
Tubing
Tying Wire
4 x 13 half-tire rims for handrail saddles.
4 pieces of steel rebar, 20 mm (#6) x 4.50 meters
67cm long, 7.5cm (3) angle iron
rebar guides for walkway cables: (optional)
# of walkway cables + 1, 16 mm x 20 cm each
Tools Required
String
Plumb bob
Shovels
Buckets
Square
Wire cutters
TOWER CONSTRUCTION
Volume 3: Suspended
6.3
58
Volume 3: Suspended
Place the four outside corner-blocks ensuring they are level and square relative to the centerline. Create
a second tower centerline to work from, and verify correctness of dimensions from centerline are level and
square.
Step 2
Set Corners
The base of the two symmetrical towers is dimensioned 1.00 meter long x 2.80 meters wide.
The alignment of the towers, perpendicular to the bridge centerline, is extremely important, as the cable
running over the saddles must not impose a side or lateral force on the towers. Even if the tiers are skewed,
it is crucial the towers will be parallel to one another and perpendicular to the centerline. For that, all
measurements should be based on the centerline.
Step 1
Align Towers
59
Volume 3: Suspended
For each side, 2 pieces of 20 mm rebar should be bent in U shape per diagram below.
Place the two rebar into the cavity formed from Step 3 and cover with concrete .
Step 4
Insert Steel Rebar
of a tower (2.80 x 1.00). When using CMUs 20cm is the height of one block.
Step 3
Build Tower Base
60
Volume 3: Suspended
as a frictionless surface for the walkway cables, as the elastic cable is expected to stretch under loading
conditions.
of tower). Insert the 67cm long x 7.5cm (3) angle iron at the top of the hump. Make sure the placement is
Step 6
Complete the Walkway Hump and Install Angle Iron
(use of fabricated saddles, go to step 7)
section 2 - Quality Control.
the needed height. Fill to 10cm below the top of the towers. The rebar should be slightly extending from
tower.
side.
Step 5
Complete Tower Construction and Fill
61
Volume 3: Suspended
accordingly.
Cut a used tier-rim in half. Install the tire rims (or prefabricated handrail saddles) so that the cable will
cross at 25 cm from the inside of the tower and 40 cm from the front of the tower on the anchor side. Build
up to the hump with concrete 1:2:3. Make sure handrail saddles are level side to side. Make sure the inside
Step 8
Form Tire Rim (Handrail saddle)
cm from either side of center point (center between the 2 towers) and
place the fabricated saddle, this is the inner-most dimension for the
saddle. From the center line the guides should be placed at 58cm,
63cm, and 68cm respectively. This steel surface of the saddle will act
as a frictionless surface for the walkway cables, as the elastic cable is
expected to stretch under loading conditions.
Step 7
Complete the Walkway Hump and Install
Fabricated Walkway Saddle (optional)
62
Volume 3: Suspended
Construction
Pre-Construction
Handrail saddles aligned with centerline and level?
Angle iron or fabricated walkway saddles aligned with centerline and level?
Height difference on R side between walkway and handrail saddles equal to 1.10 meters
Height difference on L side between walkway and handrail saddles equal to 1.10 meters
Centerline alignment used to lay out both towers?
QUALITY CONTROL CHECKLIST: TOWER CONSTRUCTION

X
63
ANCHOR CONSTRUCTION & CABLE INSTALLATION
Sand
Plastic tubing
Plumb bob
Gravel
Water level
3
hooks
20mm x 3 meter
11
bent into 0.8m per side
3
hooks
Volume 3: Suspended
*Designating Anchor with Erection Hook

If a bridge has one rock drum anchor and one soil beam anchor on the other side, the beam anchor is the adjustable anchor. As such, ensure the erection hook
is attached to the beam anchor.
If a bridge has two of the same type of anchor (beam or drum), the lower elevation anchor is the adjustable anchor. As such, ensure the erection hook is attached
to the lower elevation anchor.
N/A
10mm x 3.4 meter
N/A
Large Anchor (up to 120m span)

8
Wrench or breaker bar with cheater bar (1 meter +)
Drop forged cable clamps (for cable clamps size and quality see design guide)
Steel rebar:
Rebar size (dim x length) Small anchor (up to 60m span)
20mm x 2.9 meter
4
11
10mm x 2.2 meter
Materials Required
Cement
Tie wire
Tools Required
String
All Soil and Soft Rock Conditions for spans up to 120 meters
Small Anchor = Spans up to 60 meters
Large Anchor = Spans from 61 to 120 meters
6.4.1 BEAM ANCHOR
64
There are two anchor types discussed herein; beam and drum. The latter is only used for soft-rock conditions with spans less than 60 meters. All other bridge scenarios require
a beam type anchor.
6.4
Volume 3: Suspended
65
Tie 3 erection hooks ONLY to the anchor that will be adjustable. Again, if two similar anchor types are used
(drum or beam), the lower elevation is adjustable. If one drum and one beam anchor is used, the beam is the
adjustable side. Attach the bent rebar erection hooks 0.80 meters from either end of the rebar cages. A cable
winch will attach to the hooks while setting cable sag, so ensure the hooks are well secured.
* As 3 deck cables are used its advisable to add the third Erection Hook in the middle of the rebar cage.
Step 2
Add Erection Hooks
8 straight bars, 20mm , 2.90m in length;

11 square rings, 10mm , cut to 3.4m each, bend into
squares 0.80 m per side
Large beams: Spans greater than 61 meters to 120m
4 straight bars, 20mm , 2.90m in length;

11 square rings, 10mm , cut to 2.20m each, bend into
squares 0.50 m per side
Small beams: Spans less than 60 meters
Tie together the straight steel rebar with square ties per the following quantities and dimensions:
Step 1
Build Beams
Volume 3: Suspended
66
Each cable needs to wrap around the anchor and extend back towards the tower with the loose end sitting in
the approach area. Care needs to be taken to ensure the location of each cable is aligned with its respective
saddle and where it will stay when the bridge is done. A pre-measured alignment board may be helpful. Once
secured, the cable must come off either the walkway or handrail saddle and follow a straight path to the anchor.
Step 5
Pull Cable Over Anchor
Set the anchor beams in the excavation on top of the cables. The anchor should sit at an angle of approximately
45 degrees so the front face with the erection hooks is perpendicular to where the cable will come off the
towers. It is helpful to prop the beam with rocks to allow the anchor to sit at the angle.
Step 4
Place Anchor Beams
tubing in pit. The non-adjustable side does not require tubbing.
Lay out the cable to either side of the river. Drop the cables into the excavation pit, in line with crossing points
at tower.
Step 3
Lay out Cable & Add Tubing
Volume 3: Suspended
Remember - Cables should not to be under tension when pouring the

anchors.
On the adjustable side put minimum of 2 clamps per cable and hand-tight fully.
67
Immediately fully torque the non-adjustable anchor side (the side without erection hooks) using a wrench or
breaker bar with a minimum 1 meter extension (cheater bar) until the dead end of the cable has a reduced
cross-sectional area of at least 25% as shown bottom left.
Red is Dead
Never
Saddle a Dead
Horse
ad
Red
is d
e
THIS IS THE MOST CRITICAL STEP OF CONSTRUCTION. DO NOT PROCEED

WITHOUT PROPER DROP-FORGED CLAMPS, SOCKETS AND WRENCH
WITH CHEATER BAR.
Readjust the alignment of the cables relative to the saddles.
a
ddle
a
s
er
se
Nev ad hor
de
Ensure that the clamp saddle lies

against the live-end of the cable.
For information on the number of clamps to use and the spacing between clamps see volume 3.3 section
6.6 CABLE CLAMPS INSTALLATION
WIth the dead end of the cable (cut end) sitting on top of the live end (extending to tower and across bridge)
Step 6
Cable Clamps
Volume 3: Suspended
(Cables must be completely free
NOTE: If the excavation is too big, use formwork on the rear side of the anchor.
concrete gets into the tubes and that the tube ends remain exposed.
1:2:3, verify with the concrete mixing guideline in volume 3.3 section 2 - Quality Control.
Step 7
Pure Anchor
deck is on and the bridge is

complete
(In case adjustments need to
be made)
68
- Spans greater than 40 meters and up to 60 meters

- Anchor rods, 20 pieces, 25 mm , cut at 1.50 meters
- Inner drum: 8 pieces, 10 mm , cut at 4.15 meters, bent into circle 1.15 meter diameter
- Outer drum: 8 pieces, 10 mm , cut at 5.90 meters, bent into circle 1.70 meter diameter
- Spans 40 meters or less

- Anchor rods, 16 pieces, 25 mm , cut at 1.50 meters
- Inner drum: 8 pieces, 10 mm , cut at 3.40 meters, bent into circle 0.90 meter diameter
- Outer drum: 8 pieces, 10 mm , cut at 5.25 meters, bent into circle 1.50 meter diameter
Gravel
Water level
Wire cutters
Volume 3: Suspended
69
When using a drum anchor on spans greater than 40 meters but less than the maximum 60 meters, the cable is cut into two pieces. As such the cable sag setting procedure
is different for the two types.
NOTE:
Sand
Plastic tubing
Materials Required
Cement
Tie wire
Steel rebar:
Plumb bob
Buckets
Tools Required
String
Shovels
6.4.2 DRUM ANCHOR (ROCK CONDITIONS)
than 40 meters).
165
145
125
100
Dia. Rod Dia. Drum
110
85
Dia. Rod
Inner Drum
5.18
6.25
Total
Volume
(m3)
Volume 3: Suspended
**If large anchors are need, seek additional design guidance from an engineer
180
160
Dia. Drum
Outer Drum
Required Diameters
20
16
Total #
Rods
(25mm)
70
Medium Drums: Span 41 - 60 meters

Anchor rods, 20 pieces, 25 mm , cut at 1.50 meters
Inner drum: 13 pieces, 10 mm , cut at 4.15 meters, bent into circle 1.10 meter
diameter
Outer drum: 7 pieces, 10 mm , cut at 5.90 meters, bent into circle 1.65 meter
diameter
Small Drums: Span 0 - 40 meters

Anchor rods, 16 pieces, 25 mm , cut at 1.50 meters
Inner drum: 8 pieces, 10 mm , cut at 3.40 meters, bent into circle 0.85 meter
diameter
Outer drum: 8 pieces, 10 mm , cut at 5.25 meters, bent into circle 1.45 meter
diameter
Place the vertical anchor rods as shown in to the diagram below. First tie together the outer rebar cage with 10 mm rebar
Step 2
Build Cages
critical to leave the edge closest to the towers as clean and sharp as possible. The depth of excavation
is also critical to the design.
Step 1
Excavation
Small
0-40 m
Medium
41-60 m
Volume 3: Suspended
Lay out the cable to either side of the river. Thread 4.0 meters of plastic tubing on each of the cables on
the adjustable side. The non-adjustable side does not need tubing. For spans less than 40 meters, both
loose ends must lie on the adjustable end.
Lay out Cable
from the tower. The outer cage diameter allows the handrail cables to come off the tower and connect to
the anchor at a straight line. The inner drum diameter allows the walkway cables to come off the saddles
and connect to the anchor in a straight line. Frame and pour the inner drum with concrete mix proportion
1:2:4
top of the rebar cage approximately 0.50 meters above ground (on adjustable side, the erection hook must
face towards tower). Place the outer cage around the inner cage, attaching vertical rebar to the backside of
Step 4
Place Rebar Cages and Pour Inner Drum
Step 5
Tie two erection hooks to the anchor that will be adjustable. Attach the bent rebar erection hooks 0.50
meters from the top of the outer cage. A cable winch will attach to the hook while setting cable sag so
ensure the hooks are well secured.
Step 3
Add Erection Hooks
For less than 40 meter span (continuous cable)
71
Volume 3: Suspended
cable is continuous. Rather, wrap the cable fully around the respective drum and return to adjustable side.
forged, clamp failure will occur if taken to an equivalent torque. For spans less than 40 meters, there are no clamps on the
Tie the walkway cables onto the opposing walkway cable after wrapping behind the anchor. Hand-tighten the cable clamps
so the saddle touches the live-end of the cable (do not saddle a dead horse!). Hand tighten the adjustable side. Tighten
Step 7
Clamp Walkway Cables
Red is Dead
Never
Saddle a Dead
Horse
When using 3 walkway cables the middle one will be wrapped around the anchor drum and tied to itself.
Each walkway cable needs to wrap around the inner anchor and the loose end should be placed into the approach area after
180 degree turn. Once secured, the cable must come off the walkway saddle and follow a straight path to the anchor. The
cable should wrap around the drum below ground level, at least 75 cm from the top of the drum.
Pull Walkway Cable around Anchor
Step 6
72
Volume 3: Suspended
Tie the handrail cable onto the opposing handrail cable after wrapping behind the anchor. Hand-tighten the cable
clamps immediately. Torque until the dead end of the cable has a reduced cross-sectional area of at least 25%.
If clamps are malleable rather than drop forged, clamp failure will occur if taken to full torque but cross-sectional
reduction is critical. See Suspended Volume 1: Design & Analysis for additional information.
Step 10
Clamp Handrail Cables
Each handrail must wrap around the outer anchor (both cages should be incased in concrete) and the loose end
should be placed into approach area. Once secured, the cable must come off either the walkway or handrail saddle
and follow a straight path to the anchor. The cable should wrap around the drum at ground level, ensuring there is
50 cm depth from the top of the drum.
Step 9
Pull Handrail Cable around Anchor
no voids form. Repeat for the adjustable side, ensuring no concrete gets into the tubes and that the tube ends
remain exposed. Let both sides cure a minimum 7 days unless concrete curing accelerator is added.
Fill the excavation pit with concrete aggregate, ensuring the entire rebar cage is covered in at least 10 cm of
Step 8
Pour the Anchor
Never
Saddle a Dead
Horse
73
Red is Dead
Cable wrapped 75 cm below top of drum?
0.5 meters of drum formed above ground?
Front edge of excavation has sharp edge ?
Cable wrapped full turn around drum (540 degree)?
Cable clamps dropped-forged?
Cable clamp saddles on live end of cable (the cable in tension from the bridge).
Cable clamps reduce cable cross-section by 25% for every clamp?
No form-work used below ground level on the front side?
Cable clamps torqued on non-adjustable anchor with minimum 1-meter pipe wrench?
Volume 3: Suspended
Drum anchor:
Construction
QUALITY CONTROL CHECKLIST: ANCHOR CONSTRUCTION & CABLE INSTALLATION
74
Volume 3: Suspended
Re-purposed Cable (includes cable donated from B2P program)

Percent of Span
Design sag ( B d )
5.00%
Hoisting sag ( B h )
4.60%
75
The cable sag is the vertical drop that the cable will dip below a line drawn between each towers, measured as the chord at center span. The cable is hoisted to
a lesser sag than is designated due to the elasticity of the cable, as once the cable is set, the self-weight of the bridge will slightly stretch and the bridge will lower
Bh .
Bd
The Design Sag, B d , is calculated as 5% of span. This value is used in the Distance to Low Point of Cable (f) calculation, which in turn is considered to ensure
proper freeboard above the High Water Level.
CABLE SAG SETTING
6.5
invite accidents.
Never allow participants or spectators to stand in front of the anchor when cable or cable
winch are under tension.
Never use a cable clamp at the saddle to hold live cable under tension.
Volume 3: Suspended
CABLE CAN SLIP - MAKE SURE IT IS SECURED WITH FULLY TORQUED CLAMPS
NEVER leave a cable not secured! When you are working on a cable to set its sag, and so releasing its
clamps, make sure the tail of this cable is secured to another cable.
Cable Safety:
Additional Safety Concerns:

ONLY active participants in the cable sag setting should be present at site. Spectators only
Cable Winch Attachment:

The cable winch should always attached at or behind the anchor and never in front of the tower.
The cable winch should always be attached so that the cable is being pulled in a straight line between tower saddle and anchor.
Cable Winch Components

Hook: to attach to the erection hooks
Large chain with hook: to attache to the live cable with either chain or clamp
Hoist chain: to pul through cable winch while hoisting
Never
Saddle a Dead
Horse
76
Red is Dead
Inspection should include: An examination of the chain for wear, twists, excessive dirt, broken links, and proper lubrication; Hooks should be inspected for deformations, cracks,
damage, and properly operating latches.
A thorough inspection of the cable winch intended for use in cable sag setting is mandatory prior to use. A failed winch can seriously injure or even kill a person. Never use a
winch you do not trust or that has been provided by an unknown source, or one that shows excessive rusting or is broken.
Cable Winch Safety:
6.5.1 IMPORTANT SAFETY NOTICES
Volume 3: Suspended
77
Before tensioning cables and putting any load on the winches, determine Danger Zones which are unsafe and should not be occupied during sag setting. Also determine areas
which are safe Escape Routes that should be used in case of emergency. See the diagram on the next page. Converse those to all workers on the site!
Safe Zones:
Safety Zone during cable tensioning
6.5.2 SAFE ZONES
45
50
55
60
65
70
75
80
85
Volume 3: Suspended
90
95
100 105 110 115
3.00 3.22
2.88 3.10 3.32
2.55 2.77 2.98 3.20 3.42
2.43 2.65 2.86 3.08 3.30 3.52
2.44 2.49 2.53 2.75 2.96 3.18 3.40 3.62
2.30 2.54 2.59 2.63 2.85 3.07 3.29 3.51 3.73
2.16 2.40 2.64 2.69 2.73 2.95 3.17 3.39 3.61 3.83
2.02 2.26 2.50 2.74 2.79 2.83 3.05 3.27 3.50 3.72 3.94
1.64 1.88 2.12 2.36 2.60 2.85 2.90 2.94 3.16 3.38 3.60 3.83 4.05
1.50 1.74 1.98 2.22 2.47 2.71 2.95 3.00 3.04 3.27 3.49 3.71 3.94 4.16
1.36 1.60 1.84 2.08 2.33 2.57 2.82 3.06 3.11 3.15 3.38 3.60 3.83 4.05 4.28
0.98 1.22 1.46 1.70 1.94 2.19 2.43 2.68 2.93 3.17 3.22 3.26 3.49 3.71 3.94 4.16 4.39
1.08 1.32 1.56 1.81 2.05 2.30 2.54 2.79 3.04 3.29 3.34 3.38 3.60 3.83 4.05 4.28 4.50
1.18 1.42 1.67 1.91 2.16 2.41 2.66 2.90 3.15 3.40 3.45 3.49 3.72 3.94 4.17 4.39 4.62
1.29 1.53 1.78 2.03 2.27 2.52 2.77 3.02 3.27 3.52 3.57 3.61 3.83 4.06 4.29 4.51 4.74
1.40 1.64 1.89 2.14 2.39 2.64 2.89 3.14 3.38 3.63 3.68 3.72 3.95 4.18 4.41 4.63 4.86
1.51 1.76 2.10 2.26 2.51 2.76 3.00 3.25 3.50 3.75 3.80 3.84 4.07 4.30 4.53 4.75 4.98
1.63 1.88 2.13 2.38 2.63 2.88 3.13 3.38 3.63 3.88 3.93 3.97 4.19 4.42 4.65 4.88 5.10
1.75 2.00 2.25 2.50 2.75 3.00 3.25 3.50 3.75 4.00 4.05 4.09 4.32 4.55 4.77 5.00 5.23
40
Height differential not to exceed 4% of span (L/25)

Sag elevations are for use with cables donated as part of B2Ps recycled cable program
NOTE:
0.0
0.25
0.50
0.75
1.00
1.25
1.50
1.75
2.00
2.25
2.50
2.75
3.00
3.25
3.50
3.75
4.00
4.25
4.50
35
6.5.3 Distance to Low Point HOIST ELEVATION,
78
Volume 3: Suspended
79
Measure the low point f (distance to lowest cable point) relative the low side tower For the handrail cables - measure f from the top of the towers
For the walkway cables - measure f from the top of the walkway hump
Mark clearly on the tower/tier with spray-paint. This is your reference point for visualizing when the cable
has reached the hoisting sag level
Step 2
Mark Low Point f (lowest cable point)
(if using Auto-level refer to volume 2: Feasibility and Topographic Survey)
rigidity and notch out 30 mm guides on either end of the horizontal stick to allow the T-level stick to slide to the middle of the span without slipping off
the cables. Place a plum bob at the center that hangs without touching the T-stick when the stick is completely vertical.
Sag set T-guide with
Note - when using 3 walkway cables remember to leave space for the middle cable
plum bob
suspended from
center
stick or a level can be used to insure cables alignment. If you choose to use T-level-stick fabricate one using a 1.5 meter minimum length stick as
Step 1
Decide on Sag Setting and Cable Alignment Methods
There are many different ways to set the sag. Below we will describe two of these. You can choose to use any different way as long as at the end of the process All walkway cables are aligned to one another
Both handrail cables are aligned to each other and are 1.1m higher than the walkway cables
The cable low point is at f - low point elevation
Tools Required
Cable hoist with cable winch
Abney Level
Two long straight sticks (#1a, #1b)
1- meter tall stick (#2)
T-level stick: see diagram
Spray paint
6.5.4 CABLE SAG SETTING
Volume 3: Suspended
ing cable and that all participants are standing above the towers, anchors and cable, NOT below towers or cable.
Important Safety Notice: Make sure that only those working on the cables are in the near vicinity when tighten-
Look through Abney level towards cable in center of span to verify its about the marked point.
Raise the cable with the cable winch until the cable is well above the low point (f) marked in Step 2 (lowest cable point).
Step 5
Raise Cable
Lock the knob at zero degrees.
Step 4
Zero Abney Level
Important Safety Notice: Ensure that the winch you are using is correctly rated and in good working condition,
and that the connection to the cable is secure.
Connect t
chain around the cable, or securing a piece of pipe with a clamp, to ensure no slippage.
Step 3
Attach Cable Winch
80
Volume 3: Suspended
than , tighten cable and re-do.
When lowering the cable with a winch and not in the method describe above, mark the cable on the saddle to
Step 10
(when using cable-winch to lower the cables) Mark Cable at Saddle
Repeat steps 6 to 8 for all cables
Step 9
Repeat for all cables
Loosen the clamps slowly a 1/4 turn. Using a large piece of wood, strike the cable just above the clamps. The
cable should slip and lower very slightly with each hit. If the cable does not move at all, loosen the clamps slowly
a 1/4 turn until the cable moves when hit.
Look through the Abney level or Auto-level from the lower sag point at the adjustable side toward the point marked
in Step 2 on the other side. Make sure the Abney level is level by viewing the level bubble or that the Auto level is
set correctly. Lower the cable in this manner until the Abney level sees the bottom point of the cable at the sag
point marked in Step 2. When done, hand-tighten fully minimum of two clamps to hold the cable in place.
Step 8
Hit Live Cable
Detach the cable winch and set to the side.
Step 7
Remove Cable Winch
Attach two (2) cable clamps to hold the cable and hand-tighten the clamps. Secure the tail of the cable to another cable to make sure it does not slip while working on it.
Step 6
Hand-Tighten 2 Clamps
81
Volume 3: Suspended
Add clamps to all cables and tighten them per the information in 6.6 CABLE CLAMP INSTALLATION.
Step 12
Add Clamps - Beam Anchor (for Drum Anchor please go to next page)
82
Red is Dead
Never
Saddle a Dead
Horse
With the T-level stick, or any other method you choose to use (in the picture using a level), make sure all walkway cables are aligned and level, and both handrail cables are
aligned and level. If not, modify the needed cables. (Easiest doing by adjusting the location of the clamp closest to the anchor).
Always slide the T- level stick or the Level to the middle of the bridge and visually verify that the vertical stick of the T is vertical or that the bubble on the level is in the
middle.
Step 11
Cable alignment
Volume 3: Suspended
NOTE: The same apply both to the walkway cables on the inner drum, and the handrail cables on the outer drum.
When using 3 walkway cables the middle cable stay attached to itself.
Remove th
Remove Temporary Cable
Cables attached to themselves temporarily
83
Remove the hand-tightened clamps from cable #1 and move the loose cable tail to the opposing cable (#2) and clamp in place. Do the same for cable #2 as shown in
Remove Temporary Clamps
Cut 5 meters of cable as temporary cable and place around the anchor. Attach the temporary cable to the live end of both cables (#1 and #2) to keep the tension as
Use minimum of two (2) clamps and hand-tighten fully.
Attach Temporary Cable Piece
Cable
clamps and hand-tighten fully.
Set Sag and temporarily clamp Cables to Themselves
Step 12
Add Clamps - Drum Anchor
(Rock conditions, for Beam Anchors see Previous Page)
CABLE CLAMP INSTALLATION
Spacing
(mm)
102
114
121
132
144
160
160
171
Drop-Forge clamps
# of clamps
Torque (foot-lbs)
3
95
4
130
4
225
5
225
6
225
7
360
7
360
8
360
Volume 3: Suspended
84
(Malleable clamps are inferior and are not suggested for any bridge use. If no drop-forged clamps are available, no clamp size greater than 1 1/8 is recommended. Note that
the required torque for malleable clamps is far less than drop-forged and over tightening malleable clamps will lead to clamp failure. The use of malleable clamps requires retightening and additional clamps. As such, when using malleable clamps, leave at least half of the clamps permanently above ground.)
Cable Diameter
(inch)
(mm)
5/8
16
3/4
19
7/8
22
1
25
1 1/8
29
1 1/4
32
1 3/8
35
1 1/2
38
The table below is the Bridges to Prosperity standard for torque requirements for drop-forged cable clamps at given cable and clamp diameters. Cable clamp manufacturers
the clamp size.
Proper cable c
DROP-FORGED CLAMPS ARE OF SUPERIOR QUALITY AND MUST BE USED ON ALL B2P PROJECTS!.
6.6.1 CLAMPS TYPE, QUANTITY, AND TORQUE
6.6
Volume 3: Suspended
Clamps must be placed such that the saddle is around the live or load-bearing cable and the pinched side is
the loose or dead cable as shown in the picture to the right. The cable clamps spacing (G) in the diagram
below is also important and is detailed in the chart on the previous page.
cross-sectional area of the dead cable is reduced approximately 25% as shown to the right.
If a torque wrench is available, read the amount of torque applied by tightening the nuts similar to a typical
The torque required for the drop-forged clamps will require a minimum 1 meter heavy open box wrench with
pipe extension or socket wrench. A typical man is able to reach 100 foot-pound torque, so with a 1-meter
extension he applies just over 300 foot-pounds of torque with his force applied at the very end of the wrench.
If a 1 meter wrench is not available use a breaker bar (cheater bar) with a socket wrench.
6.6.2 CLAMP TORQUE & SPACING
Never saddle
a dead horse
Red
is dead
85
potential for corrosion if water enters the underground tubes. A funnel created from a cut-off
soda bottle is ideal for directing the watery grout into the tubes.
After completing the decking and making sure the bridge is aligned and no farther
Fill Tubes with Grout
Take care when unwinding the cable from the spool. Kinks in the cable are detrimental to
the material strength and become points of weakness. Furthermore, take care not to lay the
cable in sandy areas. Sand may get in between the cable strands and cause damage. Use
electrical tape or duct tape and tie-wire to wrap around the loose ends of the cable to stop
unraveling at the ends of the cable.
Unwrapping Cable
CABLE CARE
Volume 3: Suspended
6.7
86
Volume 3: Suspended
87
To add redundancy in the case of potential cable clamp slippage, excess cable should be
wrapped back into the approach area and clamped back onto itself. Care should be taken
to clamp the dead end of the cable (not on the picture on the left clamps were installed
incorrectly).
Loop Back Excess Cable
corrosion and cable weathering.

Do this after completing the decking and making sure the bridge is aligned
and no farther adjustments is needed.
The cables which remain underground, and all the clamps, must be coated
Roofing Tar on Cables that Lay Underground
Volume 3: Suspended
Cable Care
Setting Sag
Excess cable has been attached back onto itself?
Care has been taken to insure no kinks or excessive broken threads on cable?
Verify number of clamps used per cable per side: ________ and spacing between clamps : ________
All cables are set level?
Distance to low point of cables set: f = ___________ (relative to low side) calculated using Bh
Hoisting sag (Bh) calculated as span (L) x 4.6% = __________
Design sag (Bd) was calculated as span (L) x 5% = __________
QUALITY CONTROL CHECKLIST: SETTING SAG AND CABLE CARE

X
88
Plumb bob
Buckets
Sand
Broken stone
Tools Required
String
Shovels
Materials Required
Cement
Tamper
BRIDGE APPROACH CONSTRUCTION
Gravel
Volume 3: Suspended
yer of the approach must be a layer of compacted gravel, 10cm thick. Take care to compact by using
either animals or people jumping on the area. Following compaction, cover the approach with a smooth concrete
slab, 10 cm thick.
Step 3
Concrete Slab
Fill the area with available stone, gravel and sand ensuring the stone is vibrated and tamped into place. Ensure
regular compaction with a tamper to reduce settlement. No soil or organics should be used as they will cause settlement.
Step 2
Backfill Area
CMUs should be used only if there is no other option and should be double layered and are not recommended for
over 2m high walls.
If the wall height exceeds 2 meter (for 3 tier structure) build the wall stepped on the outside. Build 70cm wide wall for
Set a plumb line between the edge of the top tier and the front of the anchor excavation. Dig a 25 cm deep and mini-
Step 1
Build Approach Walls
6.8
89
WOOD DECK INSTALLATION
Volume 3: Suspended
There are three types of crossbeam alternatives; 1) wooden crossbeam with a nailer, 2) wood crossbeam
without a nailer, and 3) steel crossbeam with a nailer. The nailer is the same width as the decking panels,
and is attached to the top of the narrower cross-beam to increase the amount of surface area available for
nailing the decking panels. The nailer improves constructability and allows for a smaller crossbeam size.
Crossbeams
Materials Required
Crossbeams
Deck panels
Nailer Panels*
Galvanized Screws: long enough to hold the wood-width used
Steel ribbed rebar,
- (2 x (Span + 1)) pieces, 10 mm (#3) ribbed, cut to 1.80 meters
Tools Required
Hammers
Wood saw
Wrenches
Hack saw and blades
2cm diameter pipe (for bending suspenders)
While placing the decking, everyone on the bridge should be wearing

fall protection!
6.9
90
Volume 3: Suspended
Construction Drawings and paint with anticorrosive paint.
91
Cut minimum 10mm (#3) diameter ribbed rebar into 1.8 meter long pieces. Using ribbed rebar is recommended
as smooth rebar tend to be of lower quality. The total number of suspenders required is equal to 2x(span + 1). For
example, a 30 meter bridge would require 62 suspenders.
Step 2
Suspender Preparation
wide. If nailers are used, an additional (span plus 1) meters of decking panels will be required, cut at 1.0 meters.
Deck preparation
Cut decking panels to 3.0 meters for any span over 60 meters and preferably all spans. If the bridge is shorter than 60
meter span, 2.0 meter decking panels are allowable. The total number of decking panels is equal to [span divided by
Crossbeam preparation
Cut (span plus 1) crossbeams to 136 cm minimum length and pre-drill for suspender connections. The hole spacing is
based on the number of walkway cables. See Volume 3, Part 2: Suspended Bridge Construction Drawings. The hole
size should be bigger than the suspender size (for example - if a 10mm bar is used, drill a 13mm hole).
Step 1
Decking Preparation
Volume 3: Suspended
Correct
92
Not Correct
meter further so each are at a 1.0 meter spacing on center. Begin with 3 full length deck panels and two (2)
partial decking panels. Start with a full length panel on one side, second panel a shorter piece, third or middle
panel full length, and so on.
Place all decking heart down to minimize cupping, shown below.
Cut one deck panel to allow for deck panel staggering. If using 2.0 meter panels, cut starter pieces into two
(2) 1.0 meter panels. If using 3.0 meter panels, cut into one (1) 1.0 meter panel and one (1) 2.0 meter panel.
Step 5
Start Decking
crossbeams are then attached to the walkway cable by inserting the suspenders through the bottom of the
crossbeam and around the walkway cable. The top of the suspender is bent over the handrail cable.
installation. Insert the suspender and wrap around the crossbeam and handrail cable. Use a temporary clamp
Step 4
Install Crossbeams
If using nailer panels, cut (bridge span plus 1) panels to 1.0 meter. Attach the nailer to the crossbeams with
a minimum four (4) galvanized screws, aligning from the center of each board. The crossbeam should exceed
the length of the nailer by least 36 cm.
Step 3
Attach Nailer Panels to Crossbeams (Nailer Recommended)
Volume 3: Suspended
Continue until the bridge is complete, adding only three (3) or four (4) crossbeams and suspenders at a time.
When all decking is done go back and wrap the suspenders around the handrail.
Step 7
Lay Decking and Wrap Suspenders
93
(or nailer) it lays on using 2 screws. Make sure there is enough room to connect the next deck panel. Place
another screw connecting the panel to the middle crossbeam. It may be necessary to pre-drill screw holes in the
decking. This can be decided onsite based on the quality of materials and tools available.
Step 6
Screw Deck Panels
1 bag cement
Volume 3: Suspended
At the insertion point where the cable enters the approach, a small formed lift will hinder
the ability for water to pool at the connection. A small wedge may be formed with
drawing to the right for details.
To ensure a smooth transition between the decking and the ramp approach, additional
formwork was required during tower construction. Each walkway cable was threaded
with tubing, and each cable is aligned between saddles. An additional layer of concrete
was formed over the tubes to an elevation equal to the total depth of the decking. This
The ends of the decking panels end at an elevation above the hump of the tower crest
as shown in the top right picture. There are several design alternatives to mitigate this
potential safety hazard.
Materials Required
Deck panels
Tools Required
Hammers
Wood saw
Wrenches
Hack saw and blades
2cm diameter pipe (for bending suspenders)
6.10 CONNECTING DECK TO APPROACH

WalkWay ToWer Tube deTail
94
Volume 3: Suspended
After the fence is placed throughout the span of the bridge, push the top of the fencing over the handrail
cables and tie tightly against itself with galvanized tie-wire. If the fence height exceeds 1.5m, the excess
fencing should wrap over the top cable or under the decking at the base.
Step 3
Attach to Handrail Cable
Lift the fence up. In small sections pull it tightly and connect the bottom of the fencing to the decking
panels near the walkway cables with U-nails or regular nails bent over the edge. Attach the fencing to
each suspender with galvanized tie-wire.
Step 2
Pull the Fence Tightly and Connect to Deck and Suspenders
Uncoil the fence onto the ground (or the bridge) and stretch the wire out as much as possible. Several
rolls may need to be used depending on the length of the bridge. Connecting one roll to the other is by
placing the 2 ends one by the other (making sure both ends facing the same direction) and weaving an
opposite direction wire in between. Same method is applied to cut the excess length.
Step 1
Unroll Fencing and Connect Rolls
Materials Required
Galvanized fencing mesh (recommended 1.2 meters high)
U-nails
Galvanized Tie wire
Tools Required
Wire Cutters
Pliers
6.11 FENCING INSTALLATION
95
Volume 3: Suspended
Decking
Approach
Fencing tied tightly and frequently to avoid gaps?
Suspenders wrapped tightly around handrail cables?
Was a termination between approach and deck created?
Decking in place and properly coated with water sealant if not pre-treated?
Was the excess cable stored inside approach unless malleable clamps?
QUALITY CONTROL CHECKLIST: BRIDGE COMPLETION

X
96
These forms can be found in Volume 2.
97
and following the completion. It is ideal to complete the survey several times throughout the lifespan of the bridge, as the impact of the bridge may not be immediately
Pedestrian bridges have varying impacts on differing communities. Most typically, economic stimulus is evident from the increased access and drastic improvements
in public health and education are seen as well. But bridges may also create problems, unforeseen during the initial bridge assessment (completed before the bridge
project was started--see Volume 2).
SOCIOECONOMIC IMPACT
The Bridge Registry must be completed following the completion of the bridge. The purpose of the registration is to create institutional memory surrounding a project.
This includes technical data such as the size of the cable and clamps, the span and assumptions used in the design. Furthermore, often engineers may opt to modify
the standard design or the construction supervisor may chose to alter materials based on availability. All of this information is critical to document to ensure future
parties involved in the maintenance and upkeep of the bridge are able to do so with a full understanding of the structure. The Registry also includes information
surrounding the personnel involved in the project and information about the geographic location of the bridge.
BRIDGE REGISTRY
Volume 3: Suspended
7.2
7.1
The Bridge Registration includes both a technical As-Built assessment of the bridge as well as a socioeconomic survey evaluating the impact of the bridge on the local
community. The agency responsible for the construction of a bridge needs to keep records of this information for all completed bridge projects. Bridges to Prosperity
also asks to receive a copy. By keeping record of completed projects, this ensures any follow-up quality control inspections and third party monitoring are able to
fully understand the structure as it was built before starting the assessment, and furthermore helps quantify the impact of the bridge on the community. As such, the
submittal of the Bridge Registry to B2P is required for all co-sponsored bridges, and appreciated for all others. Please contect B2P at info@BridgestoProsperity.org
SECTION 7:
BRIDGE COMPLETION
THIRD EDITION
2013
VOLUME 3. 4
PART FOUR: Maintenance & Evaluation
8/16/13 2:51 PM
Introduction
Maintenance is the essential to the safety of all bridge projects. Following the project completion, the community,
local government, and bridge owners are responsible for monitoring the bridge to ensure safety and for performing
basic maintenance.
Bridges to Prosperity keeps a database of completed bridge projects. This system ensures any follow-up quality
control teams are able to fully understand the as-built structure before starting the assessment. The system also
helps quantify the impact of the bridge on the community. As such, the submittal of the Bridge Registry to B2P is
required for all co-sponsored bridges, and appreciated for all others. Section 1 introduces the bridge registry. All
referenced forms are included in Section 5 of this manual.
Bridge maintenance includes both general annual bridge upkeep and scheduled quality control assessments. The
community is responsible for general bridge upkeep and the local sponsoring institution (typically the government
body) is responsible for returning to the site for thorough bridge inspections.. The Bridge Committee (reference
Volume 1) must designate a person or team of people to inspect the structure after every rainy season. Section 2
of this manual addresses what this team must check annually.
The bridge Construction Manager must specify the party or agency responsible for the quality control reviews
to 10 years after completion. If Bridges to Prosperity is directly involved in the construction of the bridge, B2P
will work with the agency to designate responsibility. Section 3 address the quality control requirements for the
full technical assessments, and Section 4 outlines required maintenance and may be used as a resource for
Bridges to Prosperity (contact at www.BridgestoProsperity.org) immediately, irrespective of our involvement.
Volume 3: Suspended
Part 4 Maintenance & Evaluation
Volume 3 Suspended Pedestrian Bridge

Part 4: Maintenance
Table of Contents
Section 1: As-Built Bridge Registration
1.1
1.2
5.1
5.2
Bridge Registry
Socioeconomic Implications
Bridge Registration Form
Socioeconomic Survey
Section 2: Committee Annual Inspection

2.1
Checklist of items to review
Section 3: Technical Inspection

3.1
3.2
Materials Required
Quality Control Overview
Refer to 5.3
Section 4: Maintenance
4.1
4.2
4.3
4.4
4.5
4.6
Volume 3: Suspended
Overall Site Condition

Foundation Tiers & Towers
Anchors
Cable & Clamps
Approach
Decking
SECTION 1:
AS-BUILT BRIDGE REGISTRATION
1.1
Bridge Registry
1.2
Socioeconomic Implications
Volume 3: Suspended
Volume 3: Suspended
Photo Inventory and Submission

The following is a list of photos that MUST be taken during construction. These photos are to ensure that each step of the
process was properly executed. Upload to the bridge appropriate Flickr folder, named: QC_[Name of bridge].
A. Site
A2- Location of foundations with marked center line

B. Excavations
Left side B1- Complete excavations

B3- Anchor depth
Right side B5- Complete excavations
B7- Anchor depth
C. Foundation and Tiers

Left side

Right side

D. Towers
Left side
D2- Complete Tower
D4- Walkway hump
Right side
D6- Complete Tower
D8- Walkway hump
E. Anchors
Left side
Right side
F. Sag Setting
F1- Handrail cables aligned
F2- Walkway cables aligned
F3- Clamp spacing
F4- Torque technic used
F5- Representative photo of clamped cable
F7- Tar on cables

G. Approaches
Left side

Right side
H. Suspenders, Decking and Fencing

H1- Decking installation
H2- Deck Installed
H3- Suspender connection to crossbeam
H4- Suspended connection to handrail
H5- Fence installed
I. Completed Bridge
Volume 3: Suspended
Volume 3: Suspended
Volume 3: Suspended
BRIDGE COMMITTEE ANNUAL INSPECTION FORM

In order to keep your bridge in the optimum condition, continual upkeep is required. An annual inspection is essential to
maintenance. Following the end of the rainy season, one or more representatives of the Bridge Committee must visit the
bridge site and go through the following checklist and complete corresponding maintenance.
Remove any excess mud and debris from the bridge deck.
Ensure weeds and plants growing beneath the bridge do not obstruct the bridge.
Ensure all bolts, screws and nails are in place and tightened.
Replace deteriorating wood deck panels.
Replace deteriorating crossbeams.
Ensure that fencing is secure. Should any wires be loose or fencing missing, repair or replace to original
condition.
Check for erosion. Should erosion or scour occur, causing the water to reroute toward the anchor or approach,
contact the local supporting agency and request assistance with a drainage structure.
Measure the distance between the paint on the cable and the saddle guides (inset bottom right). If more
than half meter, local supporting agency immediately and if possible, Bridges to Prosperity (contact at www.
BridgestoProsperity.org).
Additional Inspection Notes:
Volume 3: Suspended
SECTION 3:
QUALITY CONTROL INSPECTION
To ensure an adequate inspection has been completed for each bridge, a Quality Control Inspection & Picture Inventory
are required for all quality control inspections completed on behalf of Bridges to Prosperity. For those tracking bridges
be inspected without the design engineer on-site and furthermore, by someone without an engineering background.
manual.
To complete the quality control inspection, prepare yourself by reading the As-Built Bridge Registry and spend time
looking through pictures. Take special note of the size of the cables, for this will dictate the size of torque wrench
socket required. If a previous quality control review has been completed, also review the inspectors comments and
concerns. If not familiar with how to use and read a torque wrench, reference Volume 3, Part 3: Construction Manual.
3.1
Materials Required
3 meter measuring tape
Digital Camera
Torque Wrench
Socket (sized to correspond to cable diameter)
Pen & paper
Copy of Quality Control Inspection (Form)
Volume 3: Suspended
10
3.2
Technical Inspection
Following the completion of the bridge, a follow-up quality control inspection must be completed a minimum of
bridge must be reviewed by an engineer to ensure safety of cables, structure and decking.
The Quality Control Inspection Report in Section 5 includes the following items;
Overall Site Evaluation
Anchors
Cable Condition
Cable Clamps
Approach Walls & Ramp
Decking
For each sub-section, an adjoining chapter is included in Section 4: Maintenance; Section 4 must be referenced for
keep one copy of each report and send a copy to Bridges to Prosperity (contact at www.BridgestoProsperity.org).
Volume 3: Suspended
11
Site Evaluation
Inspect the area surrounding the bridge, on both abutments.
Take special note if erosion has occurred and what the drainage
path of run-off water appears to take. If the erosion has caused
scour, undercutting the anchor, approach or foundation structure,
reference the maintenance section.
For all following sections, reference Section 4: Maintenance to
address any possible concerns. If the manual does not address
www.BridgestoProsperity.org).
Include the following pictures on disk or in printed form and attach
to Quality Control Inspection report;
Left and Right abutment general picture
Pictures of bridge in use (people, livestock etc.)
Notes on site evaluation, include drainage concerns:

Inspect the foundation tiers and towers. Note the masonry condition of towers.
Is one able to pick out aggregate with hands?
On either side, verify the base foundation layer is level (see black line on
picture to right). Note if the foundation structure appears to be dipping (orange)
towards the water, or slipping (green arrow). If the structure has settled in either
manner creating change of elevation of line greater than 30 cm, contact agency
responsible for bridge.
Notes on foundation tiers & towers:
Include the following pictures with report:
Concerning masonry degradation, if any
Volume 3: Suspended
Pictures from both sides, either abutment
Picture of settlement, if any
12
Anchors
Inspect the area surrounding the anchors (far back side of
approach, on both abutments. Take special note if erosion has
occurred and what the drainage path of run-off water appears to
take. If the erosion has caused scour, undercutting the anchor,
reference the maintenance section.
Walk behind the approach, if possible. The view should be
similar to that in the picture to the right. For soil conditions,
the anchor is a large beam, as shown in the picture to the right.
Note if the cable is kinked at the saddles, implying the cable
is not wrapped directly behind the corresponding cable saddle
(handrail on outsides, walkway on inside, as shown to right).
For rock conditions, the anchor is a cylindrical drum. The cables also should come straight off the saddles, as shown in the
diagram to the bottom right. Note is the cable is kinked.
Picture from behind abutment & ramp, on either abutment
Left and Right abutment general picture
Picture/s of erosion or drainage concerns, if any
Notes on anchor, sketch area if drainage concerns:
Volume 3: Suspended
13
Cable Condition
Inspect the cable at all points of insertion into concrete, the approach or the
ground. Inspect general cable condition and note if loose strands occur
anywhere along the cable.
Note the slide of the cable. Reference the colored mark on the cable, which
originated between guides on saddles. If the amount of movement exceeds
1 % of length of cable (see Span on Quality Control Page 1), cable slip or
excessive cable stretch has occurred (assume 2% equally divided between
two sides as an upper limit of concern). Please contact B2P immediately
(contact information at www.BridgestoProsperity.org).
Cable insertion into approach, if any corrosion or rust appears
Pictures of all four (4) handrail saddle pictures: look for amount of
slide for mark on cable.
Cable fraying, if any
Figure above: Handrail saddle
Figure above: Cable at concrete

Cable Clamps
Inspect all clamps that are visible above ground. Using torque wrench,
document existing torque on each above-ground clamp. For torque
Bridge Register. Reference the corresponding minimum torque from the
torque requirements on the following page.
If the measured torque is less than 80% torque required, re-tighten all aboverequired torque, notify implementing agency immediately to discuss need to
rip out approach or return with additional clamps.
Figure above: cable clamps

Clamp condition (before re-torque, if required)
If re-torqued, torque technique used for each
Figure above: Re-torque clamps
Volume 3: Suspended
14
every above-ground clamp):
Table above: Clamp torque requirements

Inspect the condition of the approach walls and ramp. Evaluate and
document extent of cracking on concrete approach ramp. Typical source
of crack propagation is the insertion point of cable, or settlement within
the approach. Note opinion on source of cracks. If cracks between rock
walls exist, look into the approach to evaluate if excessive settlement has
occurred inside. Note if any usage issues occur. This may include water
pooling, excessive cracks or bumps in the approach or connection to
ground etc.
Cable insertion into approach if cracks
If separation between tower and approach, if more than 30 cm separation,
Figure above: Cracking ramp side-view
note if settlement occurred with tower or approach.
Notes on approach walls and ramp:
Figure above: Cracking
Volume 3: Suspended
15
Decking
Rate the condition of the deck panels. Note if any longitudinal deck
panels are missing. Note if rot has occurred and to what extent.
Document with pictures, quantity and extent of rot and opinion of current
usability.
Rate condition of cross beams (transverse beams, likely will need to go
below deck). Note if any cracking between suspender drill hole and end
of beam. Note any structural damage (split beams, missing sections of
beams etc.). Note if rot has occurred and to what extent. Document
with pictures, quantity and extent of rot and opinion of current usability.
General decking condition
General crossbeam condition
Decking/crossbeam pictures if rotting or other issues
Notes on approach walls and ramp:
Full-Bridge Photos
Volume 3: Suspended
16
Section 4:
Maintenance
This section includes mandatory upkeep items to be completed during every Quality Control Inspection, as well as solutions
to repair bridge components found to be substandard during inspections.
The Maintenance chapter includes the following sections:
4.1
4.2
4.3
4.4
4.5
4.6
4.1

Anchors
Cable & Clamps
Decking
If the Quality Control Inspection notes that erosion and scour are undermining the bridge structure, a drainage structure may
allow the water to reroute, thus saving the structure from further damage.
recommended to avoid sites where any instability is prevalent. If unavoidable, it is necessary to drain out the runoff and
seepage to ensure the stability of the slope and to avoid under-scour of structures. Water should be collected as closely
as possible to its origin and navigated away from the bridge structures. A surface catch drain on a slope may be required,
drainage around the structure or both.
Below right if an example subsurface drainage systems, and bottom right are example surface drainage systems. For further
details, reference Volume 2.
Subsurface Drainage
Surface Drainage
Volume 3: Suspended
17
4.2
severe degradation, consider replacing when possible.

If the structure is found to be slipping (either slipping downhill, or tipping forward), hire a local engineer to evaluate the stability
of the slope. If considered unsafe, close the bridge. It is possible to reconstruct the structure of the failing side using many
of the scrapped materials, but do not relocate at such a distance that the cables create a lateral load on the opposing side
towers.
4.3
Anchors
If the Quality Control Inspection notes that erosion and scour are undermining the anchor, a drainage structure may allow the
water to reroute, thus saving the structure from further damage. See section 4.3.1 and reference Volume 2 for further details
on drainage structures.
4.4
Cables & Clamps
If the cable is found to be corroding or fraying, estimate the percentage of the cable cross-section that has been damaged.
If greater than 10% of cable is fraying, evaluate the extent of the damage. If localized in one point, consider a splice.
Reference cable-manufacturing materials for details. If evaluated to have extensive damage, close the bridge until cable can
be replaced with new cables. If this occurs, contact Bridges to Prosperity to describe situation, providing pictures and details
when possible (contact at www.BridgestoProsperity.org).
If the clamps are found to have less than 80% of required torque,
each above-ground clamp must be re-tightened. The picture to the
top right depicts the cross-sectional reduction that is required when
the clamps are fully torqued (assuming drop-forged, not malleable.
For more information, see Volume 3, Part 3). Bottom right shows the
proper length of the breaker bar or torque wrench required to apply the
adequate amount of torque.
If the clamps are found to have less than 60% of the required torque,
additional clamps must be added. In severe cases the approach should
be removed to tighten clamps below ground.
4.5
structure is degrading, use a cement mortar to patch

the areas. If severe degradation, consider patching
with wedge stones.
If the approach ramp is separating from the tower
structure, a method to tie back the structures together
is required or the bridge must be closed. This method
is beyond the scope of this basic manual as it will
require engineering consultation.
If the ramp is cracking from settlement (not just
localized cracking around the insertion points of the
cable), rip out the 5 cm thick concrete ramp top,
aggregate and stone and recover with a fresh layer of concrete, 5 cm thick.
Volume 3: Suspended
18
4.6
Decking
If any decking panels are rotting through or missing entirely, they must be replaced. The standard thickness of a decking
drawings for complete details. Note that the pattern of laying the deck panels requires an alternation, as shown in the picture
to the right.
If any crossbeams are in need of replacement, either an additional board must be attached to the bottom as reinforcement
or the beam must be replaced.
If replacement is chosen, start by removing the deck panels directly above the crossbeam in question. Unwrap the fencing
in the direct location; cutting may be required. Secondly, unwrap the suspenders from the top of the cable, which likely will
Volume 3, Part 3 Construction for details. Complete the process by screwing and nailing the deck boards back into place.
Replace and repair any damaged fencing before leaving.
Volume 3: Suspended
19
Post Construction Inspection

1. Clamp torque inspections for those clamps exposed, right and left. Take related photos.
2. Uphill erosion analysis, right and left. Take related photos.
3. River bank erosion analysis, right and left. Take related photos.
4. Crack assessment (most critical, would be crack and differential settlement showing in the internal tower
structural concrete column; also any heaving would be critical if occurring between anchor and tiers........which
might indicate a slipping anchor) right and left. Take related photos.
5. Inspect for offset sag causing sloped deck. Measure the amount of deck out-of-level in cm per meter
(measurement taken in middle of bridge). Take related photos.
by span to get percentage. Any percentages over 5.0% should be put on watch list. If there is excessive sag,
taken that show side elevation of entire bridge.
7. Verify span with measurement.
8. Is there any indication that the anchor might be slipping? Example of such indications would be excessive
sag (sag over say 6%), or a slipping anchor or drum that would cause compression heaving in the approach
between the anchor and the tiers. Right and left. Take related photos.
9. Measuring the departure angles from the towers to the anchors and from the tower to the river to be sure
Photo of cable departure at towers.
10. Differential settlement: Is there any indication that the abutments (foundations/tiers/towers) are not level,
and that such out of level is caused by differential settlement of the foundations? right and left. Take related
photos.
11. Dig up a small section of handrail cable at the approach (dig out and expose one foot of cable), and see if
there is any signs of corrosion below ground. Take related photos.
12. Community Maintenance Responsibility Items: What kind of job was the community doing on maintenance
of the approach, deck, and fencing? What work was the community leaders told to perform (decking repairs,
fence repairs, etc.)? Take related photos.
Submit Technical Inspection and Socioeconomic Follow-up Survey information to info@bridgestoprosperity.org.
For staff, update information to Admin, Inspection.
Volume 3: Suspended
20

B2P - Volume 3 - 2013

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BRIDGE BUILDER MANUAL

BRIDGE BUILDER MANUAL

PART ONE : Bridge Design

SUSPENDED PEDESTRIAN BRIDGE MANUAL

Volume 3: Suspended Bridge

Part 1 Design & Analysis

VOLUME 3 SUSPENDED PEDESTRIAN BRIDGE

Design Criteria and Material Properties

Section 2: Suspended Design Procedure

Calculate Required Number of Tiers

Section 3: Material Estimate

Cable & Clamps

Volume 3: Suspended Bridge

Part 1 Design & Analysis

SECTION 1: SUSPENDED BRIDGE: DESIGN BACKGROUND

Design Criteria & Material Properties

PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT

PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT

= 3.0 m or 35 degrees from bank (for soil)

PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT

Volume 3: Suspended Bridge

(measured at height of 1m above deck)

Part 1 Design & Analysis

Assumed Material Unit Weights

> 320 kg / m (65 psf)

Point Live Loads:

(applicable for most components)

= 2200 psi (mixed by drum mixer, or other)

Volume 3: Suspended Bridge

Part 1 Design & Analysis

q allowable = 143 kPa

Geometry and Forces

Total Tension (Main Span):

Vertical Tension (Main Span):

Pvm = Ptm $ sin (i)

Angle to Horizontal (Main Span, Low Side):

Total Tension (Backstay):

Vertical Tension (Backstay):

Pvb = Ph $ tan (})

Volume 3: Suspended Bridge

Part 1 Design & Analysis

Angle to Horizontal (Backstay):

} low,high = depends on anchor geometry

Total Vertical Reaction (at Tower)

Resultant Force & Eccentricity

Tower Width > E tower

Found.Width > E foundation

(from CL Tower): b = (90 - ( (90 - }) + (90 - i) 2 + i))

Volume 3: Suspended Bridge

Part 1 Design & Analysis

applied to the deadman.

Anchor: Design Calculations

Volume 3: Suspended Bridge

Part 1 Design & Analysis

where z is the internal angle of friction, assumed 30 .

Passive Earth Pressure: Pp =

Force due to Pp : F Q K pV = Pp $ L !kN $

Volume 3: Suspended Bridge

Part 1 Design & Analysis

Anchor: Check Against Sliding

W total = W foundation + W tiers + W towers + VPB v

Resisting Force Due to Friction:

Factor of Safety (Sliding):