July / 2022 〜 January / 2023

Extradosed Bridge Superstructure

Construction Works
§1 GENERAL VIEW OF EXTRADOSED BRIDGE

• ① Overall of Extradosed Bridge

§2 WHAT IS THE CANTILEVER WORKS?

• ① Overall of CanƟlever ConstrucƟon
• ② Pier Table Works
• ③ Form Traveller

§3. TECHNICAL FEATURE OF GYAING KAWKAREIK BRIDGE

• ① Corrugated Steel Plate Web (CSPW)
• ② Strut Structure
• ③ PT Works and CalculaƟon
• ④ Closure Works
• ⑤ Pylon and Stay Cable

§4 Japanese Technologies for Superstructure

• ① Bearing
• ② Expansion Joint
• ③ Hand Rail
 §２ WHAT IS THE CANTILEVER
WORKS?

Overall of Cantilever Construction

①. OVERALL OF CANTILEVER CONSTRUCTION
(1). GENERAL

It is an erection method in which the bridge body is extended from the piers to the left and right. Blocks of 3 to
4 meters are assumed to be one block, and this is extended in a cycle of about 10 days.

This is the most common construction method used for bridges with a span of 60m or more.

Since there are few restrictions on the space under the girder, it can be applied in mountainous areas, over
rivers, and viaducts in cities.
 ①. OVERALL OF CANTILEVER CONSTRUCTION
(1). GENERAL CONSTRUCTION PROCEDURE
(1). CONSTRUCTION Applying Pre-Stress
Stressing!
BLOCK BY BLOCK

Construction
Block

(2). REPEATING Applying Pre-Stress

Keep Balance! Stressing!

Construction
Block

(3). COMPLETION Applying Pre-Stress Completion after Closing!

(1). DESIGN OF CANTILEVER GIRDER
(1). DESIGN METHOD
 (1). DESIGN OF CANTILEVER GIRDER

(1). DESIGN METHOD

The main design features of structures using the Cantilever Construction method are as follows.

1. Determine the block size of the main girder for Cantilever Works, and arrange the necessary prestressing steel
materials according to the block size.

2. Depending on the construction conditions, the use of “the temporary pillars”, “the Pirone method”, etc. may be
considered auxiliary construction methods. On the spot, set the PC steel material layout according to the
erection situation, including the temporary PC steel material to be removed after construction.

3. Structural analysis will be carried out at each construction stage with changes in the structural system, and a
design for erection will be made.
• Unlike the total shoring construction where the entire structure is erected at once, the sectional force at
the time of completion of the structural system is the total sectional force generated in the structural
system at each construction stage.
• This cross-section force changes to approach the cross-section force at the time of full support
construction under the influence of creep. Sectional force is generated due to creep, drying shrinkage, and
temperature change from the stage when the structural system becomes statically unstable even during
erection.

4. Care must be taken when there is a long construction or rest period due to river conditions. Investigate the
erection structure system including substructures during normal operation and during an earthquake.
(1). DESIGN OF CANTILEVER GIRDER

(2). DESIGN CALCULATION PROCEDURE

START

Linear Calculation Design Condition Settings

Setting of the Girder Height and

Cross-Sectional Shape of the main girder (pier)

Trial Calculation
Setting member dimensions

Design Calculation of Main Girder

Design Condition, Analysys model settings

・Erection Method
・Block arrangement, Parts Dimension, Part Dimension Changing
Trial Calculation
・Construction Procedure
Design Calculation ・Side Span・Center Span Closure Method
of Slab ・Side Span・Center Span Closing Procedure
・Construction Duration of each Blocks
・Design method for effects of Creep and Drying Shrinkage
・Seismic design conditions
・Calculation of section constants
 (1). DESIGN OF CANTILEVER GIRDER

(2). DESIGN CALCULATION PROCEDURE

・Load calculation (including Form Traveller and Hanging Formwork Support)

Trial Calculation
・PC Cable Arrangement setting, Pre-Stress Calculation

Consideration at the time of Completion and Construction

Design Calculation ・Necessity study of auxiliary construction method
of Cross Beam ・Consideration for bending moment
Trial Calculation
・Consideration for shear force (torsion moment)
・Earthquake resistance study (including substructure)

・Aggregation of reaction force

・Aggregation of deflection

Examination of structural details

Design of ・Examination of Anchorage part
・Bearing ・Fusing part cover thickness, distance
・Expansion Joint ・Relationship of Bearing, expanson joint
・Drainage ・Examination of Outer cable deviation section
 (1). DESIGN OF CANTILEVER GIRDER

(3). STRUCTURAL FORM

(a) Continues Girder Bridge

A continuous girder bridge has bearings installed on the abutments and each pier, and the main girders of multiple
spans are continuous. Since expansion joints are reduced, running performance is good, and deflection at the
center of the span due to concrete creep after completion is small.

Recently, rubber bearings have generally been used, and efforts have been made to increase the number of spans
by adding horizontal force distribution and seismic isolation functions to rubber bearings to improve earthquake
resistance performance, and by performing “Post-Slide Processing” on rubber bearings.

There is “Temporary Fixing” of the bridge piers and main girders is necessary for stability during Cantilever
Construction Works.
 (1). DESIGN OF CANTILEVER GIRDER

(3). STRUCTURAL FORM

(b) Continues Rahmen Structure ( Gyaing Kawkareik Bridge Structure Type)

Compared to continuous girder bridges, continuous rigid frame bridges are superior in terms of economic
efficiency, seismic resistance, and maintenance since they require fewer bearings.
However, compared to continuous girder bridges, large indeterminate static forces are generated due to main
girder expansion and contraction caused by drying shrinkage and temperature changes.

For this reason, it is relatively suitable for high pier conditions.

This indeterminate force and horizontal seismic inertia force can be changed by adjusting the rigidity ratio of each
rigid-frame pier.
(1). DESIGN OF CANTILEVER GIRDER

(3). STRUCTURAL FORM

(c) Reference Technologies
“Post-Slide Processing” ・・・ Not applied for Gyaing Kawkareik Bridge
(Due to the Preliminary shear amount applied before setting it. = Pre-Slide method)

[Post-slide method] is a method in which the pre-calculated amount

of creep and drying shrinkage is given as a preliminary shear amount
after constructing a bridge girder that constrains the top and bottom
of the bearing.

In this method, a base plate fixed to the pier with anchor bolts is
installed under the lower shoe plate, and the lower shoe plate is
forcibly slid with a jack and then fixed.
 (1). DESIGN OF CANTILEVER GIRDER

(3). STRUCTURAL FORM

(c) Reference Technologies
“Temporary Fixing Method” ” ・・・ Not applied for Gyaing Kawkareik Bridge
(Due to Gyaing Kawkareik Bridge is Continues Rahmen Structure)

[Temporary Fixing Method] In the case of the continuous girder type, PC steel materials for temporary fixing,
temporary bearings, and temporary steel materials such as shaped steel are used to counter the unbalanced
moment during cantilever erection and horizontal force during earthquakes.
It is necessary to temporarily fix the part (pier).These temporary fixing works release and remove the PC steel
material for temporary fixing after the bridge body is connected. In addition, since PC steel materials for temporary
fixing are placed on the head of the leg, concrete with a strength of 30N/mm2 or more is generally used.
(1). DESIGN OF CANTILEVER GIRDER

(4). PC CABLE ARRANGEMENT

PC Cable Type Application Example in Gyanig Kawkareik Bridge

PC Cable for Cantilever Construction ---------------- Construction Cable (SWPR7BL 12S15.2)
PC Cable for Continuous Structure ------------------- Inner Cable for Center Span (SWPR7BL 15S15.2)
Inner Cable for Side Span (SWPR7BL 12S15.2)
PC Cable for Structure Connection ------------------- Not applied for Gyaing Kawkareik Bridge
(1). DESIGN OF CANTILEVER GIRDER

(3). GYAING KAWKAREIK BRDIGE DESIGN CONDITION

(1). DESIGN OF CANTILEVER GIRDER

(3). GYAING KAWKAREIK BRDIGE DESIGN CONDITION

 (2). CONSTRUCTION SCHEDULE

Erected Stay Cable Stay Cable

N-2 Block
Stay cable Anchored Block N-1 Block
Stay cable Erection, stressing
N Block
Rebar, F/w, PT Works

In the tensioning of Extradosed bridges, it is necessary to tension the Construction cables and Stay Cables against
the dead weight of the main girder and the working load of the mobile work vehicle in sequence as the tensioning
work progresses.

In the tensioning cycle of this bridge, the tensioning of the cable-stayed cables and shoring members is performed
at the difference between the overhanging block and two blocks, as shown in the figure, based on the stress
verification during erection.

This construction cycle separated the workspace for the main girder construction and the construction of the
diagonals, allowing them to progress simultaneously without difficulty, and also made it possible to create a
construction cycle in which the erection of the diagonals was not critical to the process.

The actual working days of the overhang construction cycle for this bridge was 24 days.
 (2). CONSTRUCTION SCHEDULE
Construction Cycle
Day 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
Form Traveller Launching

Stay Cable Erection

Formwork Assembly

Rebar Assembly

Bottom CSPW Installation

Slab Strut Installation

PC Duct Installation

Concrete Casting

Formwork Assembly

Rebar Assembly

Top Recess Pipe Installation

Slab PC Duct Installation

Concrete Casting

PC Cable Stressing
(3). PRE-CAMBER(GEOMETRY) CONTROL

(1). MANAGEMENT METHOD

For PC bridges constructed using the Cantilever Construction method, it is an important construction
control item to manage deflection so that the bridge face is at the specified planned height when the
concrete has finished creeping and drying shrinking. The PC bridge is to be constructed in accordance with
the PC Bridge Construction Method.

In order to control overtopping, dead loads at each stage of construction, loads during erection such as
moving work tables, and stresses due to cresting and creep, etc. must be taken into account. The amount
of deflection due to dead load, erection load (e.g., moving work table), cresting, creep, etc. at each
construction stage is calculated in advance. The height of the main girder overhang at each stage of
construction is calculated based on these values, and this overhang height is added to the planned height
when the formwork is set to determine the formwork set height. The height of the formwork set is
determined by adding this overtopping height to the planned height when the formwork is set.

There may be a situation in which the difference between the workmanship during construction and the
calculated overtopping height is expected to be a large error at the time of completion. Therefore, it is
necessary to compare and analyze the planned height at each construction stage and the measured
deflection during construction, and if the error is expected to increase in the future, it is necessary to
estimate the cause of the error, correct the planned value using an appropriate method, and adjust the
formwork set height to reduce the error at completion.
 (3). PRE-CAMBER(GEOMETRY) CONTROL

(1). MANAGEMENT METHOD

For PC bridges constructed using the
Cantilever Construction method, it is an
important construction control item to
manage deflection so that the bridge face
is at the specified planned height when
the concrete has finished creeping and
drying shrinking. The PC bridge is to be
constructed in accordance with the PC
Bridge Construction Method.

In order to control overtopping, the

amount of deflection due to dead load,
load during erection such as Form
Traveller, Pre-stress, creep, etc. at each
construction stage is calculated in
advance.

The height of the formwork set is

determined by adding this overtopping
height to the planned height when the
formwork is set.
 (3). PRE-CAMBER(GEOMETRY) CONTROL

(3). CONCEPT OF PRE-CAMBER CALCULATION

Focus section (i): Focus section (i):
The amount of deflection of the girder is calculated for Set position of formwork Set position of formwork

each block during and after the completion of ①. Deflection at the cross section (i) due to the load on the construction block (j)
construction, and the planned value is obtained from
the cumulative total and the formwork is set. block (j)

The amount of girder deflection is calculated so that the

girder will be at the specified planned height after the ②. Deflection at the cross section (i) due to the load on the construction block (j+1)

concrete has finished creeping and drying shrinkage, block (j+1)

taking into account changes in the structural system and
loading conditions.
③. Deflection at the cross section (i) due to the load on the construction block (j+2)
This planned value given at the time of formwork setting
block (j+2)
is called the overtopping amount, and the calculation of
girder deflection to obtain the overtopping amount is
called the overtopping calculation. ④. Cumulative deflection :δi at cross section (i)

The amount of overhang is obtained by accumulating

the amount of deflection of the girder caused by each
load that occurs at the position of interest after the
formwork is set.
⑤. Amount of pre-camber at cross section (i) of focus: -δi
The amount of overhang is obtained as the amount (-δi) in the
reverse direction of the accumulated deflection (δi).

block (j)

Focus section (i): Set position of formwork

(3). PRE-CAMBER(GEOMETRY) CONTROL
(4). LOADS TO BE CONSIDERED IN OVERHANG CALCULATIONS
The following loads are to be considered in the pre-camber calculations for PC girder bridges.

Loads to be considered
(1) Weight of the mobile work vehicle
(including all equipment such as scaffolding and formwork)
(2) Dead weight of concrete
(3) Pre-Stressed force
(4) Load of hanging supports
(5) Bridge surface load (Asphalt pavement, curb, barrier etc.)
(6) Effect of creep and drying shrinkage
(7) Other loads
(temporary fixing release, reaction force adjustment, effect of Pre-Stressing of temporary PC steel,
temporary supports, hinge shoes, counterweight, etc.)
(8) Other considerations
(a) Deformation and settlement of the support itself
(b) Deformation of the mobile work table itself
(c) Structural characteristics and aesthetics
(3). PRE-CAMBER(GEOMETRY) CONTROL
(5). ACTUAL PRE-CAMBER MANAGEMENT
(FORMWORK SETTING SHEET)
(3). PRE-CAMBER(GEOMETRY) CONTROL
(5). ACTUAL PRE-CAMBER MANAGEMENT
(PRE-CAMBER TOLERANCE CONTROL GRAPH)
②. PIER TABLE WORKS
(1). PIER TABLE CONSTRUCTION USING LARGE BRACKET SHORING
Pier Table Length:23.0m

Backing Concrete

The column head of P3 and P4 piers, which will be the starting point of the Cantilever Construction works, will be
constructed with a total length of 23.0m with an overhang length of 9.5m.
Therefore, the Pier Table was constructed using a large bracket shoring that supports the overhang length of 9.5m.
②. PIER TABLE WORKS
(1). PIER TABLE CONSTRUCTION USING LARGE BRACKET SHORING
STEP-3: Completion of Form Traveller
STEP-2: Assembly Form Traveller STEP-3: Launching Form Traveller
Assembly
STEP-1: Pier Table Completion

On the bracket shoring, it was difficult to secure the space for the work table and formwork equipment for the work
trolley after the shoring work for the overhang floor slab with a large overhang length and the pillar head BL
construction.
Therefore, the formwork equipment for the work trolley is pre-assembled on the bracket shoring in advance, and
after using it as a formwork when constructing the column head, the mobile work trolley is assembled and lifted,
making effective use of the work area.
②. PIER TABLE WORKS
(2). COUNTERMEASURES AGAINST MASS CONCRETE FOR CROSS BEAM OF PIER TABLE

Each Lift Height(mm)

Backing Concrete

(Main Girder) (Pier)

As shown in the figure, the column head cross girder is mass concrete with a width of 22.29 m, a girder height of 6.4
m, and a thickness of 4.0 m.

Therefore, temperature stress analysis was carried out based on the strength development characteristics of the
actual mixture, the risk of cracking was understood, and necessary countermeasures were examined.

As shown in the figure, the column head was divided into 3 lifts.
②. PIER TABLE WORKS
(2). COUNTERMEASURES AGAINST MASS CONCRETE FOR CROSS BEAM OF PIER TABLE

No Cooling No Cooling
Temperature Distribution Crack Index
Distribution

Pipe Cooling Pipe Cooling

Temperature Distribution Crack Index
Distribution

As a result of temperature stress analysis, in the initial casting plan without cooling, the temperature inside the
horizontal girder rose up to 98.9℃ at maximum, and the crack index fell below 1.0 in a wide range. Therefore, a
water-cooling system was adopted.
In addition, it has become possible to reduce the temperature inside the cross beam by nearly 20 to 30 degrees
Celsius through cooling.
On the other hand, although the crack index improved, the crack index fell below 1.0 in a wide range even after
cooling. Therefore, additional reinforcing bars were investigated for the purpose of crack width control.
③. FORM TRAVELLER

Form Traveller Details and Capacity

・ Machinery Weight : 270 ton per one side
・ Capacity : 22,500 kN・m
(Maximum Concrete Volume : 200m3)
(Maximum Block Length : 8m)
・ Hydraulic Jack Unit : Main Jack : 400ton x 2, Rear Jack : 200ton x 2
: Launching Jack : 15 ton x2, Stroke : 1,250mm
・ Lifting facilities : Electric Chain Hoist (10ton Capacity) x 6 nos
: Electric Chain Hoist ( 6ton Capacity) x 2 nos
③. FORM TRAVELLER
Main Jack
Main Jack
Main Jack : Capacity 400ton
Form Traveller Details and Capacity
・ Machinery Weight
・ Capacity
・ Hydraulic Jack Unit
・ Lifting facilities
Launching Jack
Rear Jack
Launching Jack : 15ton Stroke:1,250mm Rear Jack : Capacity 200ton
: 270 ton per one side
: 22,500 kN・m
(Maximum Concrete Volume : 200m3)
(Maximum Block Length : 8m)
: Main Jack : 400ton x 2, Rear Jack : 200ton x 2
: Launching Jack : 15 ton x2, Stroke : 1,250mm
: Electric Chain Hoist (10ton Capacity) x 6 nos
: Electric Chain Hoist ( 6ton Capacity) x 2 nos
③. FORM TRAVELLER
(1). REACTION FORCE CALCULATION OF MAIN JACK AND REAR ANCHOR

Main Jack : Capacity 400ton

③. FORM TRAVELLER
(2). ELECTRICAL LIFTING FACILITIES FOR CSPW/STRUT INSTALLATION WORKS

Electric Chain Hoist

Electric Chain Hoist : Capacity 10ton CSPW Erection by Electric Chain Hoist

During the Cantilever Construction, a lot of lifting work was required at the top of the slab, such as installing
corrugated steel plates web and inner/outer struts fabricated at the site yard in the Cantilever Block.

On the other hand, the tower crane (maximum capacity: R = 70.0 m x 3.0 t) installed near the piers could not
handle the work after the sixth block of the overhang due to the limited working radius.

Therefore, a total of eight electric hoists (6 units with a capacity of 10 tons and 2 units with a capacity of 3
tons) were installed on the Form Traveller to secure the heavy lifting equipment at the top of the overhang.
③. FORM TRAVELLER
(3). EDUCATIONAL VIDEO FOR STUDYING CANTILEVER WORKS WITH FORM TRAVELLER

Video Image of Cantilever Construction

In Myanmar, few bridges have been constructed using the overhang erection method, and
many of the construction workers were handling the mobile work vehicles for the first time.
Thank you for listening!!