Suspension Bridge - Construction Sequence (wire Strand Cable Type)

Construction Sequence (wire Strand Cable Type)

Typical suspension bridges are constructed using a sequence generally described as follows. Depending on length and size, construction may take anywhere between a year and a half (construction on the original Tacoma Narrows Bridge took only 19 months) to as many as a decade (the Akashi-Kaikyō Bridge's construction began in May 1986 and was opened in May, 1998 – a total of twelve years).

1. Where the towers are founded on underwater piers, caissons are sunk and any soft bottom is excavated for a foundation. If the bedrock is too deep to be exposed by excavation or the sinking of a caisson, pilings are driven to the bedrock or into overlying hard soil, or a large concrete pad to distribute the weight over less resistant soil may be constructed, first preparing the surface with a bed of compacted gravel. (Such a pad footing can also accommodate the movements of an active fault, and this has been implemented on the foundations of the cable-stayed Rio-Antirio bridge. The piers are then extended above water level, where they are capped with pedestal bases for the towers.
2. Where the towers are founded on dry land, deep foundation excavation or pilings are used.
3. From the tower foundation, towers of single or multiple columns are erected using high-strength reinforced concrete, stonework, or steel. Concrete is used most frequently in modern suspension bridge construction due to the high cost of steel.
4. Large devices called saddles, which will carry the main suspension cables, are positioned atop the towers. Typically of cast steel, they can also be manufactured using riveted forms, and are equipped with rollers to allow the main cables to shift under construction and normal loads.
5. Anchorages are constructed, usually in tandem with the towers, to resist the tension of the cables and form as the main anchor system for the entire structure. These are usually anchored in good quality rock, but may consist of massive reinforced concrete deadweights within an excavation. The anchorage structure will have multiple protruding open eyebolts enclosed within a secure space.
6. Temporary suspended walkways, called catwalks, are then erected using a set of guide wires hoisted into place via winches positioned atop the towers. These catwalks follow the curve set by bridge designers for the main cables, in a path mathematically described as a catenary arc. Typical catwalks are usually between eight and ten feet wide, and are constructed using wire grate and wood slats.
7. Gantries are placed upon the catwalks, which will support the main cable spinning reels. Then, cables attached to winches are installed, and in turn, the main cable spinning devices are installed.
8. High strength wire (typically 4 or 6 gauge galvanized steel wire), is pulled in a loop by pulleys on the traveler, with one end affixed at an anchorage. When the traveler reaches the opposite anchorage the loop is placed over an open anchor eyebar. Along the catwalk, workers also pull the cable wires to their desired tension. This continues until a bundle, called a "cable strand" is completed, and temporarily bundled using stainless steel wire. This process is repeated until the final cable strand is completed. Workers then remove the individual wraps on the cable strands (during the spinning process, the shape of the main cable closely resembles a hexagon), and then the entire cable is then compressed by a traveling hydraulic press into a closely packed cylinder and tightly wrapped with additional wire to form the final circular cross section. The wire used in suspension bridge construction is a galvanized steel wire that has been coated with corrosion inhibitors.
9. At specific points along the main cable (each being the exact distance horizontally in relation to the next) devices called "cable bands" are installed to carry steel wire ropes called Suspender cables. Each suspender cable is engineered and cut to precise lengths, and are looped over the cable bands. In some bridges, where the towers are close to or on the shore, the suspender cables may be applied only to the central span. Early suspender cables were fitted with zinc jewels and a set of steel washers, which formed the support for the deck. Modern suspender cables carry a shackle-type fitting.
10. Special lifting hoists attached to the suspenders or from the main cables are used to lift prefabricated sections of bridge deck to the proper level, provided that the local conditions allow the sections to be carried below the bridge by barge or other means. Otherwise, a traveling cantilever derrick may be used to extend the deck one section at a time starting from the towers and working outward. If the addition of the deck structure extends from the towers the finished portions of the deck will pitch upward rather sharply, as there is no downward force in the center of the span. Upon completion of the deck the added load will pull the main cables into an arc mathematically described as a parabola, while the arc of the deck will be as the designer intended – usually a gentle upward arc for added clearance if over a shipping channel, or flat in other cases such as a span over a canyon. Arched suspension spans also give the structure more rigidity and strength.
11. With completion of the primary structure various details such as lighting, handrails, finish painting and paving are installed or completed.