Semi-Precast Segmental Bridge Construction Method: construction of a prototype and shear tests on cross-frames

The Institute for Structural Engineering of TU Wien is investigating the use of thin‐walled pre‐ fabricated elements, for the construction of box girder bridges. Thin‐walled pre‐fabricated elements, such as double walls and semi‐pre‐fabricated slab elements have been used successfully in building construction for years. The aim of the research project is to create a fast, economic and resource saving construction method for the erection of lightweight bridge girders from segments, utilizing thin‐walled pre‐fabricated elements and post‐tensioning.

The newly developed construction method consists of the following steps:

• Highly automated production of thin‐walled concrete elements in a pre‐fabrication plant

• On site assembly of box‐girder segments using the thin‐walled elements and standard steel screws

• Connection of the segments with post‐tensioning tendons to form a bridge girder

• Movement of the lightweight semi‐pre‐fabricated girder to its final position using any chosen construction method as for example incremental launching or the balanced lift method.

• Completion of the cross‐section by pumping in‐situ concrete onto the girder in its final position

In the paper, the construction method will be described. Based on this, the planning and construction of a prototype‐segment made from thin‐walled prefabricated elements will be shown. Furthermore, shear tests on double wall elements and thin‐walled plates with steel girders, which are essential parts for the newly developed construction method, will be presented and compared to manual calculations based on the Eurocode 3 for two of the tested specimens.

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