aims

The challenge of Tres Unidos

What is Tres Unidos und why we decided in favour of it?
Coincidentally we came across the American charity Bridges to Prosperity. In a
technical magazine for bridge design and engineering we read about the donation of a
competitions award to this organisation.
The organisation helped us to identify Tres Unidos, a Peruvian village which has about
2.000 inhabitants, as a community urgently in need of a bridge. Tres Unidos lies deep in
the Amazon region. A river divides the village from its farmlands and makes it difficult for
the people to reach their fields.
To ease the hard life of the village people and to ensure the children, working on the
fields, can daily reach their school in time, we decided to help them building a simple but
durable suspension bridge.
Furthermore we wanted to see the money and our engagement going directly to the
villagers and not into bureaucracy of institutions.

aims

philosophy
Our visions und dreams
The vision was to build a bridge by sharing our knowledge with the Peruvians. We
wanted to teach the villagers on how to erect a bridge by just using local tools and
materials. They should make use of simple solutions, do almost without bolts and use
alternative ways of connecting elements instead.
Based on these facts the residents should understand the bridge as their own.
With our assistance from time to time they should erect the bridge themselves.
A big challenge!
Also, we wanted to hold the costs on a low level. All in all we faced the challenge to
create a footbridge that can be rebuilt elsewhere basic in design, out of local
resources, cheap to erect but nonetheless durable and safe.

schedule

time schedule

We had an ambitious time schedule, already taking into account, that two very different
mentalities will collide.

Jan. 06

1 engineer, 1 week

on place for evaluation

May 06

1 engineer, 1 week

purchasing material, teaching residents

May Sep. 06

people of Tres Unidos

excavation, concrete

Sep. 06

1 engineer, 1 week

foundations, teaching, material

Sep. Jan. 07

people of Tres Unidos

preparation wood and site

Jan. 07

4 - 6 colleagues, 2 weeks

erection with help of 50 villagers

highlights

highlights of the bridge

self-made nonelectrical winch

our Swiss example to reach the

needed preload-forces

special hangers

no bolts, no tools and

efficient functionality,
easy replacement

an old bottle

a bottle with an important

function in connection with
stability of the bridge

highlights

highlights of the bridge

shoe

support and hinge, it was a

significant detail to create
a bridge protected
against rotting

saddle

an easy solution to transmit

movements and forces
into the pylons, acting as
pendulum support

anchor rods

simple reinforcement bars

act as an undergroundconnection between
foundation and cables

local

materials and tools

directly from
Tres Unidos

from the vicinity

of Tres Unidos
(Tarapoto)

from the
capital Lima

- sand
- water
- welder
- bending tool
- blades for saw
- paint for anchor rods
- wood for pylons and
bridge deck

- reinforcement steel
25, 16, 10, 6 mm
- cement
- tools, welding equipment
- ropes
- plates and bars for fixation
of the pylons

- cable 460m, 19mm AA

(2 x 110m, 2 x 120m),
- 56 clamps

We tried to support the locals by buying as much material as possible in Tres Unidos.
The resources which we could not get in Tres Unidos were found in the surrounding
villages. Equipment we could not get in the vicinity of the village we bought in Lima.

design

bridge construction
pylons

foundation

bridge deck

72,3

4,2

Sout h

3,0

North

13,6

1:18 4m sag

4,3

12,1

15,2

16,3

1,5

9,1

16,2

1,1

5,5

3,0

3,0

10,0

3,5

10,3

design

bridge types we talked about

After certain evaluation we decided for the bridge with a sag, because of different reasons:
The valley is flat, the water level will not reach more than 3m. Nevertheless it is possible that extremely
rarely floating trees touch the deck.
We had to go for design details which allow an optimal combination of locally available conditions,
durability to resist collisions, safety and the ability for repair works by the residents. Therefore we
chose a heavy bridge deck, four instead of only two load bearing cables and tension/pressure
pendulum pylons.
Further, a slim construction now avoids the use of motocarros and the crossing of
too many people at once.

design

Bridges with two counteracting

cables are more stable and
resistant to wind.
However in our point of view this
did not countervail the
disadvantages of the erection with
two abutments on each side,
higher pylons and pre-stressed
cables.
Moreover the building site in Tres
Unidos is not so exposed to
strong wind loads anyway.

wood

wood Ana Caspi

One of our first decisions was the type
of the wood we wanted to use for our
project.
According to our philosophy we had to
get informed about the typical wood
types available in this area and find out
which one was the best for us.
Finally we opted for Ana Caspi
because of its long fibres, high
bending resistance and high density
(0.9).
The decision was based on the
recommendations of the residents:
a good co-operation!

foundation

anchorblock
We needed two kinds of foundations: one for the anchorblock and two for the pylons on
each side.
We found out CAD drawings are completely useless since the unskilled residents did not
understand these very technical information.
After many explanations, convincing and with help of the wonderful sketches of Roland
Weber, one of our supporters, the villagers did the whole excavation themselves.

foundation

The problem was not to calculate the excavation but to find a way to handle these
dimensions by manpower. We developed the cavity step by step and safely for the
people who did the digging.
Smart details like long bended ends of the anchor rods ensured that the villagers cast
the cage with the right amount of concrete. We told them to pour concrete in until the
ends are covered. A concrete cover of 20cm (!) excuses even the biggest casting
mistake!

long end of the anchor rod

foundation

checklist

Our Peruvian friend Damaso from Tarapoto who

spoke perfectly English used checklists we
prepared for the execution of all works. This way
we did not need to be on place all the time.
We bought a digital camera for him and he made
images which he sent us from time to time.
This way we were updated frequently.

foundation

placeholders
Another example for the simplicity we introduced:

The water filled bottles inside the reinforcement cage

made it easy to assemble and adjust the shoes for the
pylons.
After the concrete dried out our Peruvian friends removed
the bottles and we could assemble and adjust the shoes
together within a week. To do this, an engineer from
our side was on place.

first sample shown by one

of our colleagues

pylons

During the run-up of the construction phase we

discussed all possible conditions the bridge
could be exposed to.
It was a prerequisite to use wood and as less
bolts as possible.
Due to the slim bridge design and the vicinity to
the water we designed tension/pressure
pendulum pylons. Easy to build and durable.

Each H-shaped pylon is clamped by two

additional wooden inclined logs on each side
which were connected to the foundation too.

pylons

foundation for the pylons

The pylons foundations are simple reinforced concrete blocks

of 1.5 x 1.0 x 0,8 metres.

pylons

shoes
The so-called "shoe" is the
connective part between concrete
foundation and wooden pylon. On a
horizontal plate which acts as a
bearing, four reinforcements rods
were welded inclined. These are
cast into the concrete foundation.
On the upper side a vertical plate
protrudes into the notch of the
pylon and is connected to it with
the another reinforcement rod.
A distance of 15 cm to the soil
provides a good protection
otherwise sooner or later even Ana
Caspi would start rotting.

pylons

saddles
The saddles form the upper end of the pylons. Here, a bent steel sheet was welded on a
flat steel plate. All cables are guided over them, but they are not supposed to move.
We designed a commuting pylon to avoid tension forces in the wood.

cables and winch

anchor rods
To connect the anchor block and the cables under ground we used reinforcement bars,
25mm.
In Picota, the neighbouring village about an hour away, a blacksmith could handle the
rods. He bended the ends on one side and forged eyes at the other.
Finally they were welded in Tres Unidos and painted five times to avoid corrosion.

eyes

cables and winch

winch
As aforementioned we deprecated the use of winches, heavy tools etc.
A simple bar with a fork at one end inserted into the eyes was used to coil a rope to
tighten the main cables.
Not only there but also for erecting the pylons we used this technology.

textile rope
steel cable
anchor rod with an eye
winch with a fork

cables and winch

Swiss style

vs.

Peruvian style

corrosion protection

One of our most challenging

problems was the surface coating
of the anchor rods.
We did not expect that painting in
the understanding of the
residents has only a visual
meaning. We could not explain
them, that the main reason is
corrosion protection.
So, only under strict and
permanent supervision they
carried it out in an acceptable
way.
Amazing - here we reached a
limit!

bridge deck

requirements for the bridge deck

- little lateral buckling
- simple installation
- easy production
- high durability
- no bolts
- exchangeability
- slip-proof surface
- heavy weight (approx. 8t)

bridge deck

The bridge deck was the last constructive element we had to plan for.
It was the most difficult design part since we wanted to work with as less connecting
elements as possible, still providing a stable construction but flexible in terms of motion.
The bridge deck foremost had to be a safe path to cross the river even when it rains. Since
the bridge is long (free span altogether 74 meters) its deck had to be heavy (mass inertia)
and non-slippery.
It's trapezoidal shape provides
additional resistance to movement.

bridge deck

boards
All boards are notched for a safe fit on the lower cable.
We did not use any other connectors than the hangers, all floorboards are pressed
together by their own weight.
The thickness of every second board differs by one centimetre from its neighbour
to ensure a non-slippery surface.

bridge deck

hangers
The solution for connecting the upper and lower main cable
was discussed intensively. We performed tension tests in
Germany and came to the conclusion to be seen here.
The hangers are made of 6mm reinforcement.
This will not get a design award but it is the cheapest
alternative with material easy to get and very easy to
replace.
In distances of about 1m, they are twisted around the upper
and lower cable and around an extra 10mm reinforcement
rod laying on top of the boards to avoid their lift-off . The
space between is secured with fibre ropes.

hangers 6mm
10mm rod

Puente Machingero

Puente Machingero

conclusion

transfer of knowledge and know-how

It was very important for us see that the resident of Tres Unidos understood the design
and methods in order to reconstruct this type of bridge on a other place.
We tried to explain and show that just by using simple tools also for surveying, men can
build things like a suspension bridge.
This is not a privilege of the first world!

laying out excavation

demonstration

facts Puente Machingero

facts

wood
cables, galvanized
total length
free span
sag
max. pylons height
total weight
width boardwalk
boards, 130 x15 x 7/8cm
pylons, 20 x 20cm
concrete
reinforcement
material costs/labour
travel costs
erection time
people involved in Tres Unidos
people involved in Germany

Ana Caspi
19mm AA 460m
110m
73m
4,50m
5,20m
10t
90cm
660 pcs.
13 pcs.
16m
500kg
9.800 EUR
12.200 EUR
1 year
approx. 120
17 (incl. donors)

tools: shovels, two hammers and chisels, one pincer, one wrench,
a hand-driven drilling machine, a welding machine, chain saw, metal saw, truck, two
pieces of a metal pipe, 8 bolts 60cm M12 and - not to forget - few meters of textile rope
from the local market

facts

Most important was to have a village and its residents who really wanted to build a
bridge without getting paid for it.
Same important was our Englishspoken contact person Damaso Martinez.
Without him the project would be unimaginable too!

Thanks to all who worked with us and provided a huge support base!

Alpin Technik und Ingenieurservice GmbH

Plautstrasse 80
D-04179 Leipzig

www.alpintechnik.de
info@alpintechnik.de