Tufts Buildable Bridge

Segmental Box Beam Bridge Construction Manual

Professor Brian Brenner, PE

Tufts University
Medford, MA 02155
Kevin Walsh
Ishmael Alleyne
Mark Pinkos
Jason Karp

History of Segmental Bridges

First pre-cast pre-stressed segmental concrete bridge
The first pre-cast pre-stressed segmental concrete bridge
constructed was the Choisy-le-Roi Bridge in France from 1962 1965.
The Choisy-le-Roi Bridge, which was designed by Jean Muller, is a road
bridge that crosses the Seine River, has a total length of 131m,
individual spans of 38m 55m 38m, and a deck width of 28.4m.
First cast-in-place segmental concrete bridge
The first cast-in-place segmental concrete bridge constructed was the

Balduinstein Bridge in 1950 in Germany using the balanced cantilever

method. The Balduinstein Bridge, which was designed by Ulrich
Finsterwalder, is a road bridge that crosses the Lahn River and has a
main span of 62 m.
First U.S. pre-cast segmental concrete bridge
In 1973, the first U.S. pre-cast segmental concrete bridge was built
and opened to traffic in Corpus Christi, Texas. In 1974, the first U.S.
cast-in-place segmental bridge was built and opened to traffic near
San Diego, California.

Where & When to use Segmental Bridges

Environmentally sensitive areas where disruption to the

ground surface must be minimized (e.g., wetlands, slopes
subject to erosion or areas with hazardous materials).
Reconstruction of large-scale urban expressways where
disruption to existing operations must be minimized or
eliminated.
Repetitive bridge projects that lend themselves to
standardization of structural components and
construction activities, such as long transit viaducts or
elevated expressways.
Long-span bridges over navigable waterways, long
crossings over water or crossings over waterways subject
to scouring or unique hydraulic features.
Bridges over areas with poor construction accessibility,
such as steep terrain or canyons.
Large-scale projects where a bridges construction
schedule needs to be compressed to fit overall project
schedule limitations.

Assembly Procedure
Balanced Cantilever Method:
Step 1:
Place Pier A-B on table
top.

Step 2:
Locate:
- 6 wooden dowels
- Segments A1, A2, A3
and B1, B2, B3

Step 3:
Place segment A1 against
A-Side of pier.
The piers wooden pegs
will insert into the holes
in segment A1.

Step 4:
Put one dowel through
the top rubber band on
pier. Stretch rubber band
outward from pier.

Step 5:
Let rubber band pull
dowel into slot on outer
edge of segment A1.

Step 6:
Repeat steps 3, 4, and 5
for each segment in the
following order:
B1, A2, B2, A3, B3.

Note: Each segment

added should use the

highest unused rubber
band on the pier.
This will keep the weight
of the segments balanced
on each side of the pier.

Progress Check:
Your bridge should now
look like this.
Notice how the bridge
sags under the weight of
the segments.

Step 7:
We will now add the final
support.
Locate:
(1) Steel threaded rod
(1) Nut and Washer
(1) Wing Nut
This will give the bridge
more bending support so
that it does not sag.

Step 8:
Remove Wing nut from
threaded rod and insert
the rod through the
bridge deck entering
from the B-Side of the
pier.

Note: Make sure the nut

and washer are in the
counter-sunk hole.

This step should be

completed by an adult.

Step 9:
Tighten wing nut on ASide of bridge. Hold nut
stable on the opposite
side while tightening.

Progress Check:
Your bridge should now
look like this.
Notice how the bridge no
longer sags under the
weight of the segments.

Step 10:
Repeat steps 1 through 9
with Pier C-D and
segments C1, C2, C3, D1,
D2, and D3.
D

Step 11:
We will now connect the
two halves using the
Keystone.
Line up the bridge halves
and place the Keystone in
the gap. The notches in
the Keystone fit around
the pegs in segments B3
and C3.

Step 12:
Now we install the final
support, a very long
rubber band.
Stretch the colored
rubber band from the CSide of the first pier to
the B-Side of the second
pier. It hooks onto the
white hook on the pier
face.

Congratulations:
Your bridge is now complete and should look like this:

Cast-in-Place Method:
Step 1:
Locate the scaffolding.

Step 2:
Place the scaffolding
beneath where the next
segment will go.

Step 3:
Place the incoming
segment on top of the
scaffolding. And secure
the segment using the
wooden pegs.

Step 4:
Fully install the segment
using the dowel and
rubber band as done in
balanced cantilever
method steps 3 through
5.

Note: Repeat this

sequence for all segments

in the bridge.

Gantry Crane Method:

This construction technique can only be used for
the segments between the two piers on this
model.
Step 1:
Place Gantry crane so that
the four legs sit on the
two piers.

Step 2:
Place any interior segment
on table top beneath the
gantry crane.
Attach segment to the
hooks under the segments
deck. (There are small
holes)

Step 3:
Lift segment using crane
wires to appropriate
height.
Then follow normal
procedure to secure the
segment against pier or
previous segment.

Step 4:
Repeat this sequence for
all segments in the bridge
until bridge is completed.