TEUPE scaffolding technology for the concrete refurbishment of the Flehe Bridge

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The Flehe Bridge between Düsseldorf and Neuss carries the BAB A46 over the Rhine and connects the region on the left bank of the Rhine with the south of Düsseldorf. The motorway bridge (construction period 1976-1979), with three lanes in each direction, a hard shoulder and a cycle path and footpath parallel to the carriageways, has to withstand an average daily traffic load of around 76,000 vehicles. In the foreland area it is designed as a prestressed concrete structure and over the Rhine as a cable-stayed bridge. Its total length is 1165 m. With a span of 368 m over the river, it has the largest span of all cable-stayed bridges in Germany. Its bridge pylon is 145 m above ground, the highest in Germany, and can be seen from a long distance.

Meanwhile, the more than 40-year-old highway bridge is getting on in years and has corrosion problems as well as concrete damage and cracks on the pylon. Therefore, it has been undergoing extensive renovation for some time.

The ARGE Pylon Fleher Brücke Massenberg GmbH / Teupe & Söhne Gerüstbau GmbH was awarded the contract by the construction authority in 2016 for all services of the concrete rehabilitation, including all construction aids and steel construction as well as locksmith work. Massenberg's share of the contract comprises the complete concrete repair including the application of a surface protection system on the entire pylon. TEUPE's share of the contract includes the complete scaffolding and enclosure of the bridge pylon, including all steel construction work, as well as site equipment, erection of a roadway protection roof and provision of elevators for passenger and load transport, as well as metal construction and locksmith work.

The bridge refurbishment is a high undertaking. To carry out the work, a scaffold structure had to be designed from the foundation to the pylon head at a height of 145 meters. The two pylon legs were scaffolded in sections by TEUPE and completely enclosed with patented scaffold cladding. The material and personnel transports for the scaffold erection were carried out by means of transport platforms and freight elevators, which, due to the inclined 80 m high lower scaffold at the pylon legs, were object-specific and with inclined mast construction.

In May 2017, the scaffolding and enclosure was completed up to a height of 145 m.

Already in May 2016, TEUPE installed a 1,400 m² steel construction protective roof over the entire carriageway width of the Flehe Bridge. To avoid traffic disruptions, the protective roof was installed during two 28-hour weekend closure breaks. The protective roof was supported on the center cap on steel construction support yokes and on the right and left on the pylon projections on a specially designed steel construction bracket substructure. In total, more than 180 t of steel and 60 t of timber planks were used.

TEUPE is certified for load-bearing components and kits for steel structures up to EXC3 in accordance with EN 1090-2, so all work from project planning and verification of steel structure fabrication to the foundation on and in the bridge deck could be carried out in-house. In addition, all necessary locksmith and structural steel work on the pylon, including the dismantling and reassembly of approximately 2,200 m² of trapezoidal sheet metal cladding, was carried out by TEUPE.

The special requirements and the complexity of this structure require optimal execution planning and detailed work preparation as well as verifiably prepared static calculations. With individual concepts and well thought-out scaffolding solutions, TEUPE guarantees time and cost advantages for all parties involved in the construction project, taking into account the high demands on work and schedule safety.

The special requirements and complexity of this structure demand optimal execution planning and detailed work preparation, as well as verifiable structural calculations.

The execution of the refurbishment measures on the pylon continued until the end of 2017.

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