Bridge Erection Techniques and their Influence on the Permanent Designs Er. V. G.

Abhyankar

Bridge Erection Techniques and their influence on Permanent Designs

Paper by Er. Vivek G. Abhyankar C.Eng.

Mumbai

Abstract : Bridge engineering has significantly grown-up in past 50 years because of the increasing infrastructure demands and the developments in other peripheral branches of engineering. Many new complex bridges are coming up in reality, now. But this has resulted into a few problem areas also. Unlike in past, the development that is taking place today, in the design of bridges, is not going hand-in-hand with the Construction (Execution) technology (especially in developing countries like India). In fact, in most of the modern bridges it is observed that unless the Construction methods are excelled, there is no point in adopting any modern theory / software in the bridge design. The increasing infrastructure demands necessitate faster, safer, economical, yet superior quality of erection of bridge superstructure. In certain cases, the modern bridge erection technology imposes significantly larger loads than the design loads. On the other hand, the construction methodology has to confirm the design requirements. In the present paper the author has attempted to present the linkage between the Bridge erection technology and the Permanent design of bridges with certain live case studies.

Key Words :
Enabling works, Permanent Works, Bridge Super structure, Arch Bridge, Segmental Construction, Launching Girder, Floating Crane, Cantilever form traveller (CFT), Moving scaffolding system (MSS), Construction stage analysis, Construction loading, stability, Curved Girders, HSE, Santiago Calatrava, Firth of Forth Bridge, Steel Arch, Cantilever Bridge, Secondary Stresses, Cable Crane (Cable way), JV

Introduction : Bridges are the backbones of any Transpiration / Infrastructure Project (Railway / Road). Bridge Engineering has a history of thousands of years, and finds its origin in Indian Mythology and spiritual scripts like Ramayana / Mahabharata. In those days bridges made of hip of stone blocks / bunds / timber logs were the only options possible. The old bridges were expected to merely act as a beam spanning across the gaps along the road / railway alignments. But as the growth of civilisation (society / cultural development) started taking place, the demand on all the branches of engineering (industry) increased by exponentially. The increased demand called for more and more research that started taking place. From study of engineering growth in last hundred years, we may observe that the development of Civil / Structural engineering is closely associated with the developments that took place in the peripheral branches like Material Science, Mathematics, Communication, Electronics, Computing technology (computer science), IT, and the Newly emerging branches of engineering. As all the branches of engineering started growing, it was observed that the growth was rapid, but not parallel! This fact resulted into a serious problem or a gap between imagination (Conceptual
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Bridge Erection Techniques and their Influence on the Permanent Designs Er. V. G. Abhyankar

planning / Design) and the ground-reality (i.e. actual bridge erected at sites). The end results of this gap (rather a knowledge gap) and the solution to bridge this gap is discussed in the further sections. Bridge Projects in Olden days : In olden days the computing technology / simulation software etc. were not available. Engineers had to struggle hard to prove the adequacy of the concept, before starting the design and construction. Fig.1 shows, photograph of Firth of Forth Bridge, Scotland, which is a steel cantilever bridge. It was built in the 1880s by Allan Stewart and Sir Benjamin Baker. But both of them had to struggle hard to demonstrate by a Conceptual Model (as shown in Fig.1 below) to the sceptical Victorians that a cantilever bridge would be safe. Fig. 1 also shows the actual bridge after construction.

Fig.1 Firth of Forth Bridge, Scotland (A Cantilever Bridge) Designed by Allen Stewart and Sir Baker

Similar to above bridge Fig.2 shows another interesting configuration of a Suspension cable bridge done out of India. In this structure the main pylons look like a posture of a standing person, reclining back slightly, with both the arms folded, kept on waist.

Fig.2 Another innovative bridge which had abutments like a racking human body

Introduction to New Types of Bridges : A Challenges for Designers : Unlike 50 / 60 years back, the computing technology, materials sciences have lead to converting even the complex shaped bridges in the reality. Fig.3 shows two a beautiful String Cable stayed bridge designed by Famous Architect and Structural Engineer Santiago Calatrava. During conceptual planning and the design of such modern bridges, often various challenges are faced. A few of these challenges are as listed ahead.

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Bridge Erection Techniques and their Influence on the Permanent Designs Er. V. G. Abhyankar

The various challenges that are faced are as listed below :

Complex Loading temperature, wind, erection, blast etc. and their combinations Complex Structural Geometry difficult load transfer mechanism Refined understanding about the Structural Behaviour failure theories, overall performance based design, reliability analysis as compared to Limit state vs. Working stresses Changing Codes / Standards requirements QAQC, Crack width, exposure, non-linearity etc. Advances in associated fields like : Material Science (Concrete-steel-etc.) Electronic devices (Strain Gauges), monitoring Surveying Instruments Increasing Project demands (Time, Cost, Safety, Quality, Aesthetics) New research towards Bridge execution / Testing HSE (health safety and environment) Requirements Construction Stage Analysis Structural Health monitoring systems Life expectancy . . . etc.

Fig.3 Two beautiful String Cable stayed bridge

The Architect / Structural Designer / Planner or Execution engineer can not overcome all these problems by working in isolation. A complete Team Work is essential to solve these problems and to converge to an effective solution. But, from the failures of many ambitious bridge projects, it can be observed the there is clear absence of the team work (except a few cases). Typical failure of bridge may happen in case the designer dont know how the contractor is going to construct that structure, and on the other hand, even if the contractor do not know how that bridge is designed (boundary conditions, assumptions, standard design practices etc.). The typical reasons of failures are (a) Insufficient Formwork, (b) Inadequate Launching Girder, (c) Improper execution, (d) Unexpected forces (wind / Blast) (e) misunderstanding between Designer-planner and the site personnel etc. Fig.11.a shows a typical failure of Bridge staging at Vietnam during construction stage itself. In certain cases, wrong sequence of pre-stressing exerts a huge / concentrated or even eccentric force for the supporting formwork / staging (for which usually the formwork may not have been designed), leading to collapse. In such cases after the collapse of structure occurs no one can exactly trace out where the things went wrong, i.e. whether the structure was designed wrongly or executed wrongly. Unless thorough investigations are made, one can not conclude in such cases. This explains that the work of designer, planner and the execution (site) engineer shall be complementary to each

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Bridge Erection Techniques and their Influence on the Permanent Designs Er. V. G. Abhyankar

other and not the contradictory. Thus each one of them must know the works of others (their counter-parts) to a sufficient extent. Introduction to various Bridge Erection Techniques : A Challenges for Execution From the above discussion it is clear that the complexity in Bridge Engineering is increasing, which can not be handled alone by the bridge designer or site engineer. The Designer must know the proposed method, which the contractor wants to employ for the construction site of the said bridge; and on the other hand the execution person and planner must know briefly, how the designer has designed the structure, with its Limiting conditions / Boundary Conditions / Assumptions. In certain cases, the execution of design, as it is, become difficult due to site specific conditions (probably, which could not have been addressed by the Structural Engineer at design stage). In such cases the modification in design becomes necessary. If the contactor knows the design basis, he can develop a better proposal indicating desired changes in design at a particular spot in the project. (On the other hand even, if the designer knows the constraints at site, in which the site engineer is supposed to work, he can develop better design, right from construction stage). A few of the popular methods adopted for construction of bridge super structure are as listed ahead : Erection using Traditional Methods Using Formwork With land based hydraulic cranes (single / double cranes for (i) span-by-span construction or even (ii) random span construction Erection using Modern Methods Floating Cranes / Barges / Jack-up platforms Using Bridge Launching Girders Cable Cranes CFT (Cantilever Form Traveler) / MSS (Moving Scaffolding System) Tower Carnes

Bridge erection using a Floating Crane : In case of long span bridges, Launching Girder (LG) is commonly used by the contractors (ref. Fig.6 and Fig.7, which shows a typical Truss type Bridge Erection Launcher, used at Bang-NaTrade Highway Project, Bangkok). But if the bridge is passing over a large water body it is convenient to use floating cranes kept on the Barges / vessels / jack-up platforms. Fig.4 shows such typical floating crane (and Fig.5 shows bridge erection using a single land based crane in segmental bridge). But during use of such methodology there are points to ponder as listed ahead.
Fig.4 Showing A typical floating Bridge erection Crane

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Bridge Erection Techniques and their Influence on the Permanent Designs Er. V. G. Abhyankar

Points to Ponder : Duration of Project Capacity of Floating Cart Availability and Characteristics of water way Facts of actual Site : Casting Yard location Wind Speed Tidal variations 5) Cost / Budget 6) Cooperation from Designers / Design capacity Bridge erection using a Launching Girder : From Fig.7, which is showing Bridge Erection Launcher, used in Bangkok, it may be seen that the Permanent structure has good Aesthetic look, which is not only utilized by the execution engineer to place the LG, but also the impact of Fig.5 Bridge erection with single LG on the permanent structure. Also, from Fig.8, one may Land based Crane observe the necessity of stability of erection system during girder erection. Faulty system may lead to incorrect bridge geometry or even accumulation of secondary stresses in the girder body /distortion. Apart from these, there could be accidents leading to damage to structure or human life (as shown in Fig. 10, 11). 1) 2) 3) 4)

Fig.6 Showing Schematic Diagram of Bridge launcher

Apart from the regular bridge erection techniques like Formwork / Staging, Launching Girders and advanced technique of Floating Cranes, A suspended erection crane / cableway is also used now days as shown in Fig. 9, for a steel Arch Segmental Bridge in China. In such cases the Permanent structure has to be designed keeping in mind the construction / erection and dismantling methodology. The construction scheme / methodology imposes large loads on the permanent structure, which are often greater than the Design loads even (i.e. critical combination of self wt, Live load, wind / earthquake etc.). Bridge erection using a suspended Cable Crane (cableway) : This is unique and challenging technique of bridge construction. Fig.9 a photograph of steel segmental arch bridge construction, in China, using cable crane (or alternatively called as a cable way). In Indian on Chenab river bridge project similar technique is planned to be used. Cableway is also- being used on the Concrete Arch Bridge at world famous Hoover dam. In this case the design and construction must go hand-in-hand to reach to successful conclusion. Issues like tension in the
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Bridge Erection Techniques and their Influence on the Permanent Designs Er. V. G. Abhyankar

cable, wind velocity for the stability of ropes under self wt and lifted wt condition (i.e. operating and idling conditions), safety from falling objects at night, anything being hit to the cable etc. are the critical issues in such method. These issues must be addressed prior to the start of design (at conceptual stage itself).

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

Fig.8 Bridge Erection Launcher, used at Bang-Na-Trade Highway Project, Bangkok

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Bridge Erection Techniques and their Influence on the Permanent Designs Er. V. G. Abhyankar

Fig.9 Steel Arch Bridge Erection Using a Cable Crane

Fig.10 Collapse of a Construction Worker During Bridge Erection Due to Sudden Cutting of a Wire Rope

(a) Bridge Formwork Failure

(b) Launching Girder Failure

Fig.11 Photographs of Bridge Failures during erection stage

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Bridge Erection Techniques and their Influence on the Permanent Designs Er. V. G. Abhyankar

As mentioned earlier there are many innovative methods like CFT / MSS / erection using tower crane. They can be used only if there is close interaction between the designs detailer contractor is established. Conclusions From the discussion till now it may be clear that the permanent design and erection method (enabling works) have very close relation to each other. Following are some of the projects where the permanents designs and enabling works have affected each other :

Permanent Design affecting the Enabling Works

a) Allahabad-Nainy Cable Stayed bridge project : This project was done by Joint venture (JV) of HCC and Hyundai. In this project almost 20m wide bridge deck was supported with 1400mm wide and 3500mm deep two Pre-stressed rectangular girders (which were monolithically cast with the deck slab). Each span was 60m long. There were 4 modules to be cast. The longest module has nine continuous pres-stressed spans. Every 60m span was cast along with the 1/5th (i.e. 12m) of next span i.e. at theoretical point of contra flexure. During the application of pre-stress as the 60m portion of the girder used to get hoggedup, the remaining 12m portion used to get dipped-down, because of the continuity in the construction, This resulted into enormous increase in the load on the formwork / staging in the 12m portion (which was temporarily acting as cantilever, till the remaining 48m was cast in next pour). This effect was predetermined and the Formwork and Staging was designed accordingly. Also the pre-camber was pre-determined and set in the staging during erection work. b) Koaldam hydro electric project, (Himachal Pradesh) :In this project the De-silting chamber was to be construed. The RCC I Girders, were to be cast on the top of De-silting chamber at height of 50m above the ground (where wind speed is beyond imagination). Even the tower carne available was having a limited load lifting capacity (5Mt at 20m radius). Hence the centering steel trusses (to cast the girder) were spliced in three parts (to reduce self wt below 5Mt), and these Steel-centering-trusses were supported on the piers. While dismantling they were suspended from the set girder during lowering operation. The holes for suspension wire were left-out after discussion with the designer.

Enabling works affecting the Permanent Design

a) Longest Railway Bridge at Cochin for RVNL :In this project Rail Vikas Nigam Limited (RVNL) had initially proposed a 600Mt single box girder per span. But as the SBC of soil at casting yard was very less, the contractor proposed Two-Pre-stressed concrete I girders at each span. This Modification of Bridge Super Structure considering the Limitations of Soil Bearing Capacity in casting yard, Time Cycle and the possible erection methodology (NRS Launching girder) was readily approved by the client. The project was completed ahead of the schedule, within the budgeted cost. This
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Bridge Erection Techniques and their Influence on the Permanent Designs Er. V. G. Abhyankar

example describes how the enabling works forced to modify the permanent structure, yet leading to ultimate success of the project. b) DMRC project : In this project the LG threw more reaction (Shear force and bending moments, both) on the Girder, which was more than the Design value. This was pre-estimated at design stage itself by the close interaction between client, consultant and the contactor. Even at one place as the load on pier due to LG was more than the design load at later stage the design had to be modified. Lets hope that all these projects, and the discussion above is eye-openers to all the stakeholders (Client, Designer, PMC, Planner, QAQC, Site Engineer) involved in the execution of bridge superstructure. If practiced sincerely, this will be definitely lead to better infrastructure for our society. Acknowledgement & References : The author is thankful to the Afcons Infrastructure Limited and entire site team for making all the relevant data available for this paper. The thanks go to organiser of the National Workshop, COEP. Alumni, also for considering this paper in this bulletin. All the references mentioned here are purely from academic interest and there is no purpose to promote anything, directly or indirectly or to accuse anyone. In addition to the present Paper following papers may be referred for more information :a) Nad-al-Sheba Race Course Development Project : Construction of three Bridges author V. G. Abhyankar published as Cover Story in quarterly journal of Indian Society of Structural Engineers (ISSE), Mumbai, Vol-13/2, April-May-June2011 issue. b) Construction Longest Railway Bridge Project at Cochin author V. G. Abhyankar published as Cover Story in quarterly journal of Indian Society of Structural Engineers (ISSE), Mumbai, Volume 11-3, Jul-Aug-Sep c) Various posts / articles published by the Author on Structural Engineers Form (Sefi) and Linked-In. d) Other Various websites / projects, mentioned below the respective photo / locations. About Author: Er. Vivek G. Abhyankar C.Eng, Sr. Manger (Design), AFCONS Infrastructure limited, has more than thirteen years of experience in planning and design, detailing of various enabling and permanent works in Reinforced concrete and Steel. The Author himself was deputed at the Project site described in the present papers to handle all the technical matters. The author has written many papers on Civil / Structural engineering aspects and also has proof checked a book on earthquake engineering. (email abhy_vivek@hotmail.com)
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