Construction of Climbing Bridge Supports

Climbing bridge supports are constructed using specialized climbing formwork and shoring systems that allow vertical elements like pylons, towers, and piers to be built efficiently, safely, and with minimal crane use.

Foundations and Vertical Supports

Bridge supports begin with a foundation capable of handling the loads from towers, piers, or portal frames. Common foundation methods include H-piles, pipe piles, bore piles, or precast concrete piles depending on soil conditions and load requirements . The vertical elements themselves—bridge towers for cable-stayed or suspension bridges, and piers for conventional spans—are typically constructed using high-strength in-situ concrete. For tall or complex structures, mechanical climbing formwork is often employed to cast the concrete efficiently .

Climbing Formwork Systems

Climbing formwork systems are designed to move upward along the structure as construction progresses, eliminating the need for extensive scaffolding or crane operations. There are two main types:

• Self-climbing systems: These use hydraulic or mechanical mechanisms to lift the formwork along the wall or pylon surface. Platforms for workers, concrete pouring, and formwork positioning are integrated into the system .
• Rail climbing systems: These attach to the structure and allow formwork to climb along rails, often used for hollow or complex cross-sections . These systems can handle complex geometries, including tapered or curved pylons, and allow for fast cycle sequences while maintaining high load-bearing capacity and safety .

Shoring and Auxiliary Support

For large or high-headroom structures, heavy-duty shoring and scaffolding are combined with climbing formwork to support the concrete until it gains sufficient strength. Systems like VARIOKIT Engineering Construction Kit and PERI UP scaffolding provide modular solutions that can be adapted to different bridge designs . Shoring also supports auxiliary elements such as concrete placing booms or small cranes attached to the climbing system .

Safety and Efficiency

Climbing systems integrate safety features such as fall protection, wind shields, and controlled access platforms. Pre-assembly of formwork sets off-site can minimize on-site assembly time, allowing continuous operations even in challenging conditions like winter concreting . The combination of climbing formwork, shoring, and scaffolding ensures precise alignment, minimal dimensional tolerances, and efficient load transfer throughout construction.

Practical Example

A notable application is the construction of 90 m high pylons for a cable-stayed bridge over the Ohio River, where a combination of ACS self-climbing systems, RCS rail climbing systems, VARIO GT 24 wall formwork, and heavy-duty shoring enabled the construction of complex, tapered pylon legs with hollow box sections and cross beams, all within a tight schedule and with minimal crane dependency .

Summary

The construction of climbing bridge supports relies on a coordinated system of foundations, climbing formwork, shoring, and scaffolding. These systems allow for efficient vertical construction, accommodate complex geometries, ensure worker safety, and reduce reliance on cranes, making them essential for modern high-rise bridge projects .