Bridge and deck construction
Our portfolio of methods
1/ In situ construction
- Incremental launching
- Cast-in-place cantilever
- Construction on scaffolding
2/ Precast segmental erection
- Balanced cantilever erection with launching gantry / lifting frames / cranes
- Span by span erection with launching gantry / on falsework
- Precast girder erection
- Full span precast method
3/ Heavy lifting and handling of structures
- Heavy lifting: strand lifting, precision jacking
- Sliding techniques: autoripage, autofonçage, airpad sliding, lateral sliding
- Rotation systems
- Special formwork
- 1946First development and use by Freyssinet of industrialized methods for bridge erection, for the Luzancy bridge
- 320+Number of cable-stayed bridges where Freyssinet has been involved
- 70+Number of bridges built in situ by Freyssinet
- 50+Number of precast bridge decks erected by Freyssinet
Why choose Freyssinet
Hundreds of bridge and deck construction projects around the world for over 70 years, small to large-scale.
Applicable to:
- In situ construction
- Precast segmental erection
- Lifting and handling of structures
Including:
- Choice of construction method
- Optimization of superstructure design and construction method
- Design & supply of equipment and temporary structures
- Erection of the superstructure, equipment operation, concrete casting, prestressing
- Finishing work, including installation of structural fittings
- Maintenance and repair services
Proven ability to propose and implement alternative designs and methods to achieve the best possible value at the lowest life cycle cost.
Under the leadership of our Major Project Department for the largest and most complex projects, our specialist supervising teams are able to manage safely the construction project within budget and on time, taking into account all technical and environmental factors.
Bridge and deck construction
A global approach to bridge construction
Selection of construction method
- Structural design of substructure and superstructure
- Material quantities and specifications
- Review of options for the construction methodology
- Assessment of temporary works and special equipment requirements
- Phasing of works
- Cost estimates for budgeting
- First approaches to project, quality and safety management
Optimization of construction method & equipment
- Construction engineering
- Assistance to designers in reviewing all details that will facilitate construction
- Development of temporary works and special equipment
- Detailed methods of construction
- Integrated shop drawings for the fabrication of the superstructure
- Integration of post-tensioning with all associated drawings and details
- Design of temporary works associated with precast yards and molds
Execution
As a main contractor, subcontractor or through innovative partnership agreements, our teams are able to execute construction project efficiently, in compliance with specifications, costs, deadlines and quality:
- Mobilisation of an experienced project team
- Supply and operation of the temporary works for the precast yard and the superstructure construction
- Project and risk management and effective coordination with the various stakeholders
Monitoring and maintenance
Our teams can assist in monitoring the structure, advise on maintenance activities and help anticipate repair interventions and costs:
- Define the most suitable monitoring scheme, assess its cost
- Supply monitoring hardware and software
- Provide training and handover
- Inspect the structure and issue recommendations
- Propose and implement repair or strengthening plans if required
Our references
Build
Turkey
Ihsaniye viaduct incremental launching
Important savings in raw material and optimized execution planning were some of the many advantages of the alternative solution proposed by Freyssinet to build the Ihsaniye viaduct.
Build
Hong Kong
TMCLK Link in Hong-Kong: balanced cantilever erection
As part of the design-build project for a set of precast segmental bridges, choice of the erection method was key to its achievement. Opting for the balanced cantilever erection with launching gantry made the difference.
Build
Turkey
Çayırköy viaduct incremental launching
While incremental launching was the most appropriate method to construct the viaduct, it required complete rethinking to adapt to the project’s unusual configuration.
Build
Australia
Adelaïde Superway erected with a launching gantry
Connecting north and south Adelaïde, the South Road Superway includes a 2.8-km elevated roadway. Freyssinet proposed the balanced cantilever erection with launching gantry as the most beneficial construction method.
New build
Hong Kong
Yuen Long Station LTR footbridge erection
The project involves the construction of two 50m-long bridges above the light rail tracks, in non-traffic hours only, making the use of conventional erection method impossible.
Build
UK
Immingham bridge: underpass autofonçage
Meticulous contingency planning and an innovative underpass bridge sliding technique were the keys that enabled a crucial railway line to reopen on time despite the British weather.
Build
Hong Kong
Lian Tang interchange highway erection
Cantilever erection by lifting frame was the preferred construction method to build the four precast segmental viaducts of the Lian Tang interchange highway located next to Kiu Tau, Fanling.
Bridge and deck construction methods and solutions
In situ deck construction
Incremental launching
The principle is to progressively build the bridge deck behind one of the abutments.
Segments of comparable length are concreted in a formwork or assembled in an assembly area. Then, each segment is match-cast against the previous one and prestressed to the section of the deck already built. As segments are added and slided over special bearings, the increasing length of bridge deck is repeatedly pushed / pulled out of the formwork or assembly area, over the abutment onto the piers, to reach its final position. Provision of a launching nose stressed against the first deck segment will reduce the big bending moments in the deck during launching.
Segments of comparable length are concreted in a formwork or assembled in an assembly area. Then, each segment is match-cast against the previous one and prestressed to the section of the deck already built. As segments are added and slided over special bearings, the increasing length of bridge deck is repeatedly pushed / pulled out of the formwork or assembly area, over the abutment onto the piers, to reach its final position. Provision of a launching nose stressed against the first deck segment will reduce the big bending moments in the deck during launching.
- Erection rate
one segment every 7 or 8 days - Quality of segment fabrication
with a sheltered casting yard - Limited investment in special equipment
(launching nose, jacking system,
launch bearings, side guides)
Incremental launching
The principle is to progressively build the bridge deck behind one of the abutments.
Segments of comparable length are concreted in a formwork or assembled in an assembly area. Then, each segment is match-cast against the previous one and prestressed to the section of the deck already built. As segments are added and slided over special bearings, the increasing length of bridge deck is repeatedly pushed / pulled out of the formwork or assembly area, over the abutment onto the piers, to reach its final position. Provision of a launching nose stressed against the first deck segment will reduce the big bending moments in the deck during launching.
Segments of comparable length are concreted in a formwork or assembled in an assembly area. Then, each segment is match-cast against the previous one and prestressed to the section of the deck already built. As segments are added and slided over special bearings, the increasing length of bridge deck is repeatedly pushed / pulled out of the formwork or assembly area, over the abutment onto the piers, to reach its final position. Provision of a launching nose stressed against the first deck segment will reduce the big bending moments in the deck during launching.
- Erection rate
one segment every 7 or 8 days - Quality of segment fabrication
with a sheltered casting yard - Limited investment in special equipment
(launching nose, jacking system,
launch bearings, side guides)
Incremental launching specifications
Incremental launching sketch
Cast-in-place cantilever with form travellers
The method consists in building the deck by successive segments, in symmetry on both sides of the pier, by making the built part support the weight of the next segment and of the mobile casting equipment. The deck construction does not have to be linear; it can be sequenced to follow pier construction.
This method is ideally suited: to cross high gaps and avoid ground constraints for bridges whose length does not require prefabrication, or with different cross sections or casting lengths
This method is ideally suited: to cross high gaps and avoid ground constraints for bridges whose length does not require prefabrication, or with different cross sections or casting lengths
- High erection rate
one pair of segments every 3 to 7 days - Long-span bridges
with access constraints - Limited investment
Cast-in-place cantilever with form travellers
The method consists in building the deck by successive segments, in symmetry on both sides of the pier, by making the built part support the weight of the next segment and of the mobile casting equipment. The deck construction does not have to be linear; it can be sequenced to follow pier construction.
This method is ideally suited: to cross high gaps and avoid ground constraints for bridges whose length does not require prefabrication, or with different cross sections or casting lengths
This method is ideally suited: to cross high gaps and avoid ground constraints for bridges whose length does not require prefabrication, or with different cross sections or casting lengths
- High erection rate
one pair of segments every 3 to 7 days - Long-span bridges
with access constraints - Limited investment
Our references in deck construction
Build
Turkey
Ihsaniye viaduct incremental launching
Important savings in raw material and optimized execution planning were some of the many advantages of the alternative solution proposed by Freyssinet to build the Ihsaniye viaduct.
Build
Turkey
Çayırköy viaduct incremental launching
While incremental launching was the most appropriate method to construct the viaduct, it required complete rethinking to adapt to the project’s unusual configuration.
Kirikkale high-speedrailway line, Turkey / Cast-in-place cantilever
Liakhvi viaduct, Georgia / Incremental launching
Oum Rbia, Morocco / Cast-in-place cantilever
Canakkale Viaduct, Turkey / Incremental launching
Canakkale Viaduct06, Turkey / Incremental lauching
Canakkale Viaduct06, Turkey / Incremental lauching
Kaoshing viaduct, Taiwan / Cast-in-place cantilever
Kuzey Marmara viaduct, Turkey / Incremental launching
Kuzey Marmara viaduct, Turkey / Incremental Launching / Prestressing operations
Majura road, Australia / Incremental launching
Ratathibet viaduct, India / Cast-in-place cantilever
Iron Cove bridge, Australia / Incremental launching
Sehzadeler viaduct, Turkey / Cast-in-place cantilever
Sehzadeler viaduct, Turkey / Cast-in-place cantilever
Ihsaniye viaduct, Turkey / Incremental launching
Sheahan bridge, Australia / Cast in place cantilever
Akh project, Ethiopia / Incremental Launching
Assouan Bridge, Egypt / Cast-in-place cantilever
Bai Chai bridge, Vietnam / Cast-in-place cantilever
Chevire bridge, France / Cast-in-place cantilever
Chiapas steel bridge, Mexico / Incremental launching
Fern street bridge, Australia / Incremental launching
Hwaebuck / Cast-in-place cantilever
Istanbul's third ring road, Turkey / Incremental launching
Precast segmental deck erection
Balanced cantilever erection
with launching gantry
The prefabricated segments are transported by truck or barge to the erection site.
They are then installed symmetrically on either side of the supports using gantry cranes or floating cranes, mobile handling equipment fixed to the deck and launching girders.
This construction method is adapted to long structures (deck span from 30m to 60m) with multiple spans; it combines the advantages of cantilever construction together with segment prefabrication.
- High erection rate
1 or 2 pairs of segments per shift - Minimal disruption to existing
roads, traffic and services - Clear access to several work fronts
Balanced cantilever erection
with lifting frame
Following installation and commissioning, our lifting frames can operate independently, providing both lifting and self-launching mechanisms.
While the gantry crane is used for medium and large projects, this method is suitable for smaller, long span structures (30m to 170m).
It is particularly versatile and applies both to precast segmental decks and cable-stayed decks (either precast, composite, or steel) regardless of span range and segment weight. The equipment can be reused for other projects.
- High erection rate
up to 2 pairs of segments per shift - Craneless method applicable
both to precast segmental decks
and cable-stayed decks - System adapted to large segments
Balanced cantilever erection
with launching gantry
The prefabricated segments are transported by truck or barge to the erection site.
They are then installed symmetrically on either side of the supports using gantry cranes or floating cranes, mobile handling equipment fixed to the deck and launching girders.
This construction method is adapted to long structures (deck span from 30m to 60m) with multiple spans; it combines the advantages of cantilever construction together with segment prefabrication.
- High erection rate
1 or 2 pairs of segments per shift - Minimal disruption to existing
roads, traffic and services - Clear access to several work fronts
Balanced cantilever erection
with lifting frame
Following installation and commissioning, our lifting frames can operate independently, providing both lifting and self-launching mechanisms.
While the gantry crane is used for medium and large projects, this method is suitable for smaller, long span structures (30m to 170m).
It is particularly versatile and applies both to precast segmental decks and cable-stayed decks (either precast, composite, or steel) regardless of span range and segment weight. The equipment can be reused for other projects.
- High erection rate
up to 2 pairs of segments per shift - Craneless method applicable
both to precast segmental decks
and cable-stayed decks - System adapted to large segments
Span by span erection with launching gantry
This method consists of assembling a complete span as it moves forward. The span is made of segments that are hung on a launching gantry and are assembled by pre-stressing while the span is placed on the piers.
The technique is applicable to prestressed concrete bridges, continuous spans, multiple spans not exceeding 50m, and spans with steeply curved alignment, regardless of the longitudinal and plane profiles of the structure.
The technique is applicable to prestressed concrete bridges, continuous spans, multiple spans not exceeding 50m, and spans with steeply curved alignment, regardless of the longitudinal and plane profiles of the structure.
- Most economic and fastest method
for multi-span viaducts
High erection rates
2 to 4 spans per shift - Strict geometry controls
of segments on precast area - Smaller crew size required
compared to balanced cantilever construction
Precast girder erection
The method is based on the use of launching beams, beam launchers or lifting frames capable of receiving prefabricated beams (I-, U- or T-beams) behind, below or parallel to the erection system. Strand and winch lifting systems are used, ensuring precise placement of the precast elements, with several degrees of alignment possible and at an efficient rate.
- Fast erection rate, 1 span per shift
- Simple method
which can be done by a small team - Minimised geometry control
Span by span erection with launching gantry
This method consists of assembling a complete span as it moves forward. The span is made of segments that are hung on a launching gantry and are assembled by pre-stressing while the span is placed on the piers.
The technique is applicable to prestressed concrete bridges, continuous spans, multiple spans not exceeding 50m, and spans with steeply curved alignment, regardless of the longitudinal and plane profiles of the structure.
The technique is applicable to prestressed concrete bridges, continuous spans, multiple spans not exceeding 50m, and spans with steeply curved alignment, regardless of the longitudinal and plane profiles of the structure.
- Most economic and fastest method
for multi-span viaducts
High erection rates
2 to 4 spans per shift - Strict geometry controls
of segments on precast area - Smaller crew size required
compared to balanced cantilever construction
Precast girder erection
The method is based on the use of launching beams, beam launchers or lifting frames capable of receiving prefabricated beams (I-, U- or T-beams) behind, below or parallel to the erection system. Strand and winch lifting systems are used, ensuring precise placement of the precast elements, with several degrees of alignment possible and at an efficient rate.
- Fast erection rate, 1 span per shift
- Simple method
which can be done by a small team - Minimised geometry control
Our references in deck construction
Build
Hong Kong
TMCLK Link in Hong-Kong: balanced cantilever erection
As part of the design-build project for a set of precast segmental bridges, choice of the erection method was key to its achievement. Opting for the balanced cantilever erection with launching gantry made the difference.
Build
Australia
Adelaïde Superway erected with a launching gantry
Connecting north and south Adelaïde, the South Road Superway includes a 2.8-km elevated roadway. Freyssinet proposed the balanced cantilever erection with launching gantry as the most beneficial construction method.
Build
Hong Kong
Lian Tang interchange highway erection
Cantilever erection by lifting frame was the preferred construction method to build the four precast segmental viaducts of the Lian Tang interchange highway located next to Kiu Tau, Fanling.
TMCLK, Hong Kong / Balanced cantilever erection / ©Cyrille DUPONT
TMCLK, Hong Kong / Balanced cantilever erection with lifting frame / ©Cyrille DUPONT
TMCLK, Hong Kong / Balanced cantilever erection with lifting frame / ©Cyrille DUPONT
TMCLK, Hong Kong / Span by span erection with launching gantry / ©Cyrille DUPONT
TMCLK, Hong Kong / Launching gantry / ©Cyrille DUPONT
TMCLK, Hong Kong / Balanced cantilever erection with lifting frame / ©Cyrille DUPONT
Bangkok Blue Line, Thailand / Span by span erection
Bangkok Blue Line, Thailand / Span by span erection
Damman bridge, Saudi Arabia / Span by span erection
Deep Bay Link, Hong Kong / Span by span erection with launching gantry
Deep Bay Link, Hong Kong / Span by span erection with launching gantry
Dubai LRT, UAE / Span by span erection
Thu Thiem2 bridge, Vietnam / Balanced cantilever erection with lifting frame
Thu Thiem2 bridge, Vietnam / Balanced cantilever erection with lifting frame
El Cantil bridge, Mexico / Precast beams method
Halic bridge, Turkey / Balanced cantilever erection with lifting frame (steel deck)
Halic bridge, Turkey / Balanced cantilever erection with lifting frame (steel deck)
South road superway, Australia / Balanced cantilever erection
Lian Tang 3, Hong Kong / Balanced cantilever erection by lifting frame / ©Cyrille DUPONT
Lian Tang 3, Hong Kong / Balanced cantilever erection by lifting frame / ©Cyrille DUPONT
Lian Tang 3, Hong Kong / Balanced cantilever erection by lifting frame / ©Cyrille DUPONT
Light Railway Transit, Dubai / Span by span erection with launching gantry
Light Railway Transit, Dubai / Span by span erection with launching gantry
Mezcala bridge, Mexico / Balanced cantilever erection (steel deck)
Mudeirej bridge, Lebanon / Precast beams method
Mudeirej bridge, Lebanon / Precast beams method
Seohae bridge, South Korea / Span by span erection with launching gantry
Seohae bridge, South Korea / Span by span erection with launching gantry
Baldwin bridge, USA / Balanced cantilever erection with launching gantry
Sungai prai bride, Malaysia / Span by span erection
Sungai Prai bridge, Malaysia / Balanced cantilever erection with lifting frame
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