Extradosed Bridge –Technical aspects

Understanding the Technical challenges in the project implementation and methodology to

handle those challenges in Extradosed cable stayed bridge.

Introduction
Extradosed bridges provide an economical means of crossing spans of 100 to 250 m with new
aesthetic opportunities relative to cantilever constructed girder bridges and cable-stayed bridge.
Extradosed bridge consists of a girder supported by inclined stay cables from a pylon. The
extradosed bridge may be defined as a continuous girder bridge with external prestressing.

Challenges
For successful completion of construction of extradosed bridges we shall understand the
Various components of extradosed bridge, sequence of construction, forces application and
releasing at each stage, profile correction, stay cable force adjustment and finally joining adjacent
spans with stitch segments. All these shall be followed as mentioned in detail design drawings. If
there is any deviation in construction sequence during execution, then re- engineering shall be done
with actual site conditions.
Below explained what the components are and how construction is done at stages. In addition
protection and acceptance criteria of components also mentioned
A.Components
The main components of bridge are
i)Substructure ii)superstructure iii)Pylon iv)Internal prestress cables v) Stay cables vi)Saddles and
Anchorages
B.Design phase

During the design process of any bridge, the construction method is chosen based on the available
construction equipment, economy requirements and the selected bridge type. Extradosed bridges
are usually erected by the cantilever method. Cantilevering method is found to be preferred for the
construction of extradosed bridges. Spans may be supported on bearings or by monolithic with piers.
Segment casting methods like precast or cast in situ to be considered during design stage.

C.Fabrication of segments

The concrete precast segments are fabricated normally with the “match-cast” technique
which means that every segment is cast against the preceding segment creating a matching
which permits the re-establishment of the casting geometry configuration at the erection
time.
D.Stage Construction

The erection of an extradosed bridge is a very complex task due to its structural complexity and
change in load conditions during the erection stage. Below mentioned operation of various activities
performed in each construction stage.

i)Erection of segments

The following erection methods are followed for the erection of segments.

- Erection of precast segments on Scaffolding.

The scaffolding should be provided by hydraulic and mechanical jack systems to allow the
trolley along with the precast segment to move.
- Erection by the balanced cantilever method.
The precast segments may be also erected by the “balanced cantilever method” using Form
Traveller.
- Span by span erection method.
The precast segments may be also erected by the “span by span erection method”.
- Incremental launching method.
In this erection method, the concrete deck is cast in segments behind the abutment
subsequently prestressed and pushed forward along with the previously cast segments.

ii) Stressing internal cables

Post tensioning of internal cables is performed as mentioned in drawings and in respective

construction stage.

iii) Stressing stay cables

External stay cables are prestressed/released to a required force as mentioned in design

drawings in each stage and anchored at both ends.

iv) Camber Correction/Cable tuning

Precamber adjustment is done in next segment at each stage as per precamber analysis
performed at design phase. If any deviation happens during construction sequence, revised
camber analysis will be performed considering all time dependent effects.
 v) Cable tuning or cable adjustment

External stay cable stand no’s and prestress forces shall be adjusted at each stage to avoid
any compression in already stressed cables. Final adjustment of stay cable forces will be
done before applying Live load.

vi) Key segment

Once balance cantilever portion on either side of pier completed at each span,
adjacent cantilever spans or with abutment span connected with a key segment to
convert into a continuous span structure.

E) Acceptance
Acceptance of manufactured items like strands, cable anchorages, pylon saddle, bearing
plates are done by testing the items as per international codes/standards in specified
laboratories.

F)Protection
Extradosed bridges in service are subjected to various forces due to continuous wind, traffic
loads and corrosion which will reduce its durability. Hence protection systems like internal
dampers or external viscous dampers to stay cables are provided. Shock transmission units
are provided if horizontal forces are more at any one pier so that total load distributed to
other piers. Corrosion prevent measures like application of grease and PVC /HDPE pipes to
external cables provided.

Remedial measures
During casting of segments casting geometry shall match with construction at site including
prestressing duct locations, stay cable coordinates and other dimensions. If any error found
during erection, rectifying or replacing of segment shall be done at the stage itself.

Camber correction shall be done at each stage to meet the required profile after erection.
Pylon erection and placing saddle shall be done as per approved geometry and tolerances.

During stressing of stay cables if observed pylon deflection is more than permissible, work
shall be stopped and design to be revised.

During erection if any cable strand is broken, then it shall be replaced immediately and re-
stressed to required force.

Bridge design shall be checked such that during service if any one cable is broken
completely, it shall not affect bridge performance.

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