MAKING A LOW COST BRIDGE DESIGN THROUGH PROTOTYPE USING

POPSICLE STICKS, NAILS, AND WOOD GLUE

A Research Project

Presented to the Faculty of the High School

Philippine School (Bahrain)

Kingdom of Bahrain

In Partial Fulfillment of the Requirements

in Practical Research 12

by

JOSE MISAEL C PASCUAL

12 - MAPAGPALAYA

APRIL 2017

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 INTRODUCTION

What are the branches of engineering? Do you know at least 1 of them? Well there are
6 major branches of engineering that are offered in the universities as of today, according to
Wikipedia.com and typesofengineeringdegrees.org. But my research will fall only on one of
those 6 branches, which is Civil engineering. Civil engineering has 6 sub-branches namely,
Environmental engineering, Geotechnical engineering, Structural engineering, Mining
engineering, transport engineering, and lastly Water resources engineering. My research topic
will fall on the Structural, Geotechnical, and Transport engineering “only”

Since grade 4 my dream was to be a Civil engineer, due to the fact that both of my
parents are Civil Engineers, and even my aunties and uncles are mostly Civil Engineers and
Mechanical Engineers. Basically I’m in a family of engineers.

Chapter one will scrabble about the history of bridge designs that were used by “Civil
Engineers” throughout the centuries. This research paper will also show the statement of the
problems that will be put in this research paper as well as the scope and delimitation. And
lastly to conclude the chapter one of this research paper, it will show you the significance of
this research today and on the future.

The Chapter 2 of this research paper will show the literature that were related to my
research and was used to strengthen the reliability and the dependability of my research.

The Chapter 3 of this research paper will let the readers know the tools and materials
that will be used, the methodology of the research, and lastly the step by step procedure that
will be done.

The Chapter 4 of this research paper will show the presentation, analysis, and
interpretation of data gathered on the experiment.

And lastly chapter 5 of this research paper will present the summary of the data,
conclusion about the experiment, and recommendation for others in the future. So without
further ado let us proceed on the chapter one of my research paper.

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 CHAPTER 1

RESEARCH PARADIGM

Input Process Output

- Make a research - Draw a design - The sustained

from the said weight of the
topic.
- Input it on
prototype bridge
software/(West
design.
- Getting some Point Bridge
information from Designer) -
the past studies
about the said
- Conduct the
experiment
topic.
- Make a
- Document the
experiment
hypothesis.
- Gather the data.

FIGURE. 1

CONCEPTUAL FRAMEWORK

BACKGROUND OF THE STUDY

I will be making my own bridge design prototype, mainly using Popsicle sticks and
wood glues. Basically I will adapt the concept and strategies that were used on building a real
bridge design prototype, but I will be modifying it by making a hybrid design that can bear
more weight.I called it a hybrid design because it is a combination of two bridge design,
Through Truss Pratt and Through Truss Warren design. I will be testing as well the rigidness
and the sturdiness of the prototype bridge design that I will be making. This prototype hybrid
design will “only” fall under the category of Truss bridge designs.

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 This project will “only” last for 2 months and shall be presented on the final defense
of this research paper. The estimated time of a bridge design to be built is, two weeks. I will
be using 250 to 500+ of Popsicle sticks and lots of wood Glue. I will be following the
samerules that were used by “Building and Construction Sciences of Mohawk College” on its
2014 annual Popsicle bridge competition.

The rules will be discussed further on the scope and delimitation section, of the
chapter one of this research paper.

So without keeping you waiting any longer let us carry on to the next section of the
chapter one of this research paper which is the Statement of the Problem.

STATEMENT OF THE PROBLEM

When I was still a young boy, I always ask my father questions like this;why do we
need a bridge? Is it safe? How much does it cost to build a bridge? Now that I’m grown up I
want to answer these questions on my own.

These questions are the main reason why I took up STEM and not ABM, and also it is
the main reason why I want to conduct this research. Because of these childish questions it
helps me formulate these questions. These questions will serve as my statement of the
problem.

My statements of the problem are the following:

1. What is/are the effect of bridge length on its capacity to bear weight?

2. What is the maximum weight that can be supported by the prototype hybrid bridge design?

3. What are the factors that can affect that rigidness, and sturdiness of the bridge?

4. What are the materials that will be used in making this experiment successful?

5. How do material properties affect the strength of the bridge?

6. How to lessen the cost of building a bridge?

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SCOPE AND DELIMITATION.

This research will “only” focus on 3 sub branches of Civil Engineering, which are the
following; Structural, Geotechnical, and Transport engineering.My prototype hybrid design
will “only” fall under the category of Truss bridge designs.

Also this research will “only” be focusing on the strength, rigidness, and sturdiness
of the prototype hybrid design that I will be making. The software’s that I will be using will
“only” be; Bridge Designer 2016, and AutoCAD. The prototype hybrid design must “only”
be made of Popsicle sticks and Wood Glue. The dimension of this prototype bridge design
must not exceed to 10 by 110 mm, and for the span it should not exceed 500 mm, and lastly
the weight should not exceed to 1000 grams or 1 KG.

SIGNIFICANCE OF THE STUDY

I believe that this study is important because it will give the Civil Engineers a wide
variety of bridge designs that works best, and can be used on a certain type of land. This
research may also be used as a basis of making a hybrid prototype design of a bridge that is
more sturdy, rigid, and strong.

This research can also serve as a basis or source for the future students who will make
the same research topic that I am making.

I want to make a bridge design that is cheaper than most of the bridges that are being
constructed today.

Lastly I want to give others an idea on how the bridges were being designed, and what
types affect its strength.

I chose this research mainly because it is in the field of civil engineering, which is my
3rd choice in college course. Also I’m fond of making prototypes, and other hand crafts things
especially body armors, and weapons.

I have experience as well on using AUTOCAD, and other 3D making/editing

software’s like Sketch-up, and Blender. I also have my father and other civil engineers,

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specifically Transport engineer, Geotechnical engineer and Structural engineer to give me
advice, and help me on making this project.

Because of this I am confident enough that my research experiment will not fail.

I will know conclude the chapter one of my research by a quote “Don’t give up what
you want most, for what you want now”

HYPOTHESIS

A. The geometric shape/design has something to do with the stability and

sturdiness of the bridge.

Ha: The geometric shape/design of the bridge has no effect at the stability and
sturdiness of the bridge
Ho: The geometric shape/design of the bridge can affect the stability and
sturdiness of the bridge

CHAPTER 2

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REVIEW OF RELATED LITERATURES

In this chapter you will see all of the related literatures, studies and related readings. I
as the researcher have gone through intensive readings of materials, such as articles online
and files that are downloaded through internet which has a great significance to problem
during the course of thesis writing.

We can see bridges everywhere we go. When we go to our work we use this
infrastructure, and as well when we travel on vacation. Why? Because it is the most efficient
way to transport anything from one place to another. “Bridge are as old as nature itself” by
Erik Scow (2014) because bridges can be anything. It can be a big log or a stone, which
connects the other side of the land to another. In this chapter we will see some related studies
and reading that will help my research to be reliable, and realistic.

jhsBridges conducted a study about the the physics of bridge design and 3 most
common bridge design. He gives structural analysis for every bridge design and also gives
the tension, compression of the bridge. The aim of this research is to compare the 3 most
common bridge design on its capacity to bear weight.
This study becomes related to my study for this also focuses on the effects of bridge
design on weight bearing capacity.

Bruce S. Criddlebaugh (1999-2008) conducted a study about the most common fixed
bridge types. In his study he discusses the four main factors that are used in describing a
bridge and this are the ff. Span, material, placement, and form. He also gives examples and
trivia’s about the types of bridges.
This study becomes related to my study in the sense that it is concerned about the
effects of bridge design in weight bearing capacity. The only difference is that this study is
only concerned on the types of bridges, and how span, material, placement, and form affect
the bridge.

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 Erik Scow (2014) conducted a study about the strength of a bridge design by making
a model of the 3 most used design of a bridge and tests its capacity on bearing weight.
This study becomes related to my study in the sense that this study also focuses on the
effect of bridge design on weight bearing capacity.

According to TeachEngineering.org after an engineer determines the highest or most critical

load combination, s/he determines the size of the members. A bridge member is any
individual main piece of the bridge structure, such as columns (piers) or beams (girders).
Column and beam sizes are calculated independently. To solve for the size of a column,
engineers perform calculations using strengths of materials that have been pre-determined
through testing. The Figure 1 sketch shows load acting on a column. This force represents the
highest or most critical load combination from above. This load acts on the cross-sectional
area of the column.
The stress due to this load is σ = Force ÷ Area. In Figure 1, the area is unknown and hence
the stress is unknown. Therefore, the use of the tensile and compressive strength of the
material is used to size the member and the equation becomes Force = Fy x Area, where force
is the highest or most critical load combination. Fy can be the tensile strength or compressive
strength of the material. For common building steel, this value is typically 50,000 lb/in2. For
concrete, this value is typically in the range of 3,500 lb/in2 to 5,000 lb/in2 for compression.
Typically, engineers assume that the tensile strength of concrete is zero. Therefore, solving
for the Area, Area = Force ÷ Fy. Keeping the units consistent is important: Force is measured
in pounds (lbs) and Fy in pounds per square inches (lb/in2). The area is easily solved for and
is measured in square inches (in2).
To solve for the size of a beam, engineers perform more calculations. The sketch in
Figure 2 shows a beam with load acting on it. This load is the highest or most critical load
combination acting on the top of the beam at mid-span. Compressive forces usually act on the
top of the beam and tensile forces act on the bottom of the beam due to this particular
loading. For this example, the equation for calculating the area becomes a bit more
complicated than for the size of a column. With a single load acting at the mid-span of a
beam, the equation is Force x Length ÷ 4 = Fy x Zx. As before, force equals the highest or
most critical load combination pounds (lbs). Length is the total length of the beam that is
usually known. Usually, units of length are given in feet (ft) and often converted to inches.
Fy is the tensile strength or compressive strength of the material as described above. Zx is a
coefficient that involves the dimensions of the cross-sectional area of the member. Therefore,
Zx = (Force x Length) ÷ (Fy x 4), where Zx has units of cubed inches (in3).

In aboutcivil.org, it gives the formulas and equations that are being used to calculate
the bending moment of the bridge. It also stated that a simply supported beam is the simplest
arrangement of the structure. The beam is supported at each end, and the load is distributed

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along its length. A simply supported beam cannot have any translational displacements at its
support points, but no restriction is placed on rotations at the supports.

According to J.B Calvert (2000) The Pratt truss proved thoroughly reliable, never
providing any surprises and capable of confident design. It is, however, not the most
economical solution. Most of its dead load is in the middle of the span, and as the span
increases it becomes increasingly more expensive to support. The depth of the truss increases
with the span, which makes the members longer and more subject to buckling. There are
modifications of the Pratt truss for longer spans that involve more bracing and other
measures. It was usually more economical to break the bridge up into multiple spans
supported on piers. The bridge is observed to be 'thinnest' at the piers, and 'thickest' between
them. A more economical truss is designed like a continuous beam, which removes the joint
at the pier, and allows the truss to bend over the pier. Now the bridge is thickest over the pier,
with less material in mid-span. The ultimate is something like the Forth Bridge, with giant
cantilevers over the piers, connected by light spans between the ends of the cantilevers. A
continuous beam is not statically determinate, and the stresses depend on how much the
members stretch. Nevertheless, the longest bridges are all of this type, since it is very
advantageous.

The number of my review of related literatures will grow as I go further with my

research and experiments.

Chapter 3
RESEARCH METHODOLOGY

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 This chapter discusses the research design and framework, the data gathering methods

and experiments, sampling procedures, and the treatment and analysis of the data gathered.

Materials

In order to make the prototype bridge design, the researcher used the following

materials:

1. Graphing paper- for drawing bridge schematics.

2. Popsicle Sticks- for the structure of the bridge.

3. Wood Glue- for sticking the Popsicle Sticks.

4. Ruler- for measuring the length and width of the prototype bridge.

5. Cotton Swabs- for applying the wood glue.

Equipment

In order to gather data and design the bridge, the researcher used the following

material(s)/equipment(s).

1. Weights- for testing the strength of the bridge.

 Sack of Rice (10kg/sack)

 Brick(s) (3kg/brick)

 Hollow Block(s)

 Human

2. Bathroom Scale- for weighing how much weight it takes to break the bridge.

3. Camera- for before and after photos, and/or videos.

4. Computer or tablet- for making a digital bridge design.

Tools

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In order to build the prototype bridge design, the research used the following tools.

1. Scissors- for cutting the Popsicle Sticks.

2. Binder Clips- for clamping joints.

3. 1m ruler- for measuring.

4. Bondo Scrapper- for making the surface of the bridge smooth.

5. Nails- For making the bridge sturdier.

Methods

In making the prototype bridge design, the researcher followed the following steps:

Research design/Framework

For the purpose of describing the data gathered in this research more efficiently,

the researcher made a conceptual research design which focuses on identifying and

analyzing the input, process, and the output of the experiments and observation.

Data Gathering Instruments

The data gathering instrument(s) that will be used on this experiment are the

following; Bathroom scale, Software Design, and lastly the weight(s) that will be used

on the experiment.

Data Gathering Procedures

In doing this study the researcher will follow this steps:

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 After the validation of the research instrument that has been presented, the

researcher start building the prototype bridge design using the materials, equipment,

and tool that are listed on first paragraph of the Research Methodology section of this

research paper. The experimentation and observation will last only for 3 days. The

researcher will measure the weight capacity of the prototype bridge design by putting

weight(s) until it broke. If the prototype bridge design doesn’t break, then the

researcher will try to hang on the bridge design to test if it will be able to carry a

person’s weight; after that, the researcher may now start gathering the data.

A. The researcher makes an elevated platform for the bridge.

B. After the making of the platform, the researcher may now proceed on putting

weights on the top of the prototype bridge.

C. The researcher may now observe and if possible chat down all the data(s) that

can be gathered.

D. In the end of the experimentation, all of the data that have been gathered will

be calculated.

CHAPTER 4

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 PRESENTATION, ANALYSIS AND INTERPRATATION OF DATA

This chapter shows the presentation, analysis and interpretation of the data of this

research study. The corresponding tables or graphs will discuss and explain on what it tells. It

also answered specific problems given in the statement of the problem in the previous

chapter.

OVERVIEW

The researcher made a 10 by 110mm in diameter and 50 cm in length, bridge design

using wood glue, Popsicle sticks, and nails. The researcher used about 400 Popsicle sticks,

68 nails, and 325 grams of wood glue, out of 700 Popsicle sticks and 500 grams of wood

glue.

The researcher gathers all the weights that will be used on the experiment. First the

researcher used hollow blocks to test the strength, rigidness, and sturdiness of the prototype

hybrid bridge, the design carried 5 hollow blocks weighing 109 kilograms in total before

showing some bends. In the second trial the researcher used bricks weighing 3 kilos/brick. He

then loaded 4 bricks on the first trial, and then 4 bricks again on the 2nd trial, another 4 bricks

on the 3rd trial, another 4 bricks again on the 4th trial and finally another 4 bricks again on the

5th trial. The Prototype Hybrid Bridge Design carried a total of 20 bricks weighing 60

kilograms in total. Thus the Prototype Hybrid Bridge Design carried a total of 169 kilograms

of weight which is equal to 1.65732385 Kn.

CONDITIONS

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There researcher used certain types of conditions such as the following:

1. The researcher must not use broken Popsicle sticks

2. The researcher must not use bent Popsicle sticks.

3. The researcher must not use uneven size of Popsicle sticks.

4. The researcher must follow the said diameter and length of the bridge.

5. The researcher must not put any supports that can make the data unreliable.

6. The researcher must use only the said materials, tools and equipment’s.

STRENGTH TO WEIGHT RATIO CALCULATION

After conducting the experiment, the researcher calculates the strength to weight ratio

of the Prototype Hybrid Bridge Design. To get the strength to weight ratio the researcher

needs the following; the weight of the Prototype Hybrid Bridge Design, which is 600 grams,

and the weight of the total sustained weight of the Prototype Hybrid Bridge Design, which is

169 kilograms. After gathering this data(s) the researcher may now proceed on calculating the

strength to weight ratio by dividing the total weight of the bridge to the total weight it

sustained after it breaks.

BRIDGE DESIGNER LOAD TEST RESULT

Material Cross Size Length Compression Compression Tension Tension

Slenderness
type section (mm) (m) Force Strength Force Strength
1 CS Bar 180 4.00 76.98 1012.12 5336.92 0.00 7695.00
2 CS Bar 180 4.00 76.98 0.00 5336.92 0.00 7695.00
3 CS Bar 180 4.00 76.98 0.00 5336.92 868.10 7695.00
4 CS Bar 180 4.00 76.98 0.00 5336.92 868.10 7695.00

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5 CS Bar 180 4.00 76.98 0.00 5336.92 561.18 7695.00
6 CS Bar 180 4.00 76.98 0.00 5336.92 561.18 7695.00
7 CS Bar 180 4.00 76.98 379.97 5336.92 0.00 7695.00
8 CS Bar 180 4.00 76.98 0.00 5336.92 288.89 7695.00
9 CS Bar 180 4.00 76.98 227.34 5336.92 0.00 7695.00
10 CS Bar 180 4.00 76.98 94.76 5336.92 10.56 7695.00
11 CS Bar 180 4.00 76.98 0.00 5336.92 174.84 7695.00
12 CS Bar 180 4.00 76.98 320.63 5336.92 0.00 7695.00
13 CS Bar 180 4.00 76.98 7.96 5336.92 164.11 7695.00
14 CS Bar 180 4.00 76.98 0.00 5336.92 636.94 7695.00
15 CS Bar 180 4.00 76.98 25.17 5336.92 126.68 7695.00
16 CS Bar 180 4.00 76.98 0.00 5336.92 636.94 7695.00
17 CS Bar 180 3.20 61.61 471.77 5969.85 0.00 7695.00
18 CS Bar 180 3.20 61.61 0.00 5969.85 449.34 7695.00
19 CS Bar 180 3.20 61.61 0.00 5969.85 0.00 7695.00
20 CS Bar 180 3.20 61.61 36.72 5969.85 331.46 7695.00
21 CS Bar 180 3.20 61.61 161.89 5969.85 130.84 7695.00
22 CS Bar 180 3.20 61.61 36.72 5969.85 5.67 7695.00
23 CS Bar 180 3.20 61.61 0.00 5969.85 203.17 7695.00
24 CS Bar 180 3.20 61.61 234.23 5969.85 0.00 7695.00
25 CS Bar 180 3.20 61.61 0.00 5969.85 440.01 7695.00
26 CS Bar 180 3.20 61.61 462.44 5969.85 0.00 7695.00
27 CS Bar 180 5.66 108.87 0.00 3907.09 870.22 7695.00
28 CS Bar 180 5.66 108.87 442.25 3907.09 0.00 7695.00
29 CS Bar 180 5.66 108.87 27.17 3907.09 243.87 7695.00
30 CS Bar 180 5.66 108.87 0.00 3907.09 504.68 7695.00
31 CS Bar 180 5.66 108.87 793.63 3907.09 0.00 7695.00
32 CS Bar 180 4.00 76.98 575.42 5336.92 0.00 7695.00
33 CS Bar 180 4.00 76.98 937.29 5336.92 0.00 7695.00
34 CS Bar 180 4.00 76.98 825.98 5336.92 0.00 7695.00
35 CS Bar 180 4.00 76.98 563.76 5336.92 0.00 7695.00

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Table.1 shows the load test result on the computerized design in bridge designer 2016. The
material that I used on this bridge design is (CS) carbon steel that has a bar cross section, and
180x180 mm in diameter. The computerized bridge span is 20m and has an elevation of 12m
high. The computerized bridge is a two way bridge that can sustain an average of 5313.49kN
compression strength and an average of 7665.00kN tension strength. The truck that passed
through the bridge has a weight of 22Kn or22943.61 Kg, the average compression force that
the truck exerted is 275N/m^2 which is lower than the compression strength limit of
5313.49kN, on the other hand the average tensions force that the truck exerted is 230N/m^2,
which is also lower than the average tension strength limit of 7695.00kN.

Table.2

Table.2 shows the strength vs length of the Prototype Hybrid Bridge Design. The blue line
represents the tension strength of the bridge which is 7695kN and the red line represents the
member length in meters. The green line represents the length per member of the bridge and
the blue and red rectangles below represent the tension force that has been exerted by a
moving truck.

Table.3

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Table.3 show the unit cost of the bridge which is $1093.66/meter. The total cost of the
Prototype Hybrid Bridge design is $459,981.32 including all the materials. This only mean
the bridge that I’ve built is low cost, because even a pedestrian bridge can cost $250,000.

Total Total Total

Number number Weight Number Number Weight weight
Length Weight
Material of of of the of of of the carried
of the of the
used popsicle popsicle bridge Brick(s) Hollow Hollow by the
bridge brick
sticks sticks design used block(s) block(s) bridge
used bought design
Popsicle
sticks,
600 3kg/per 23kg (3)
Wood 50cm 400 700 20 5 169kg
grams brick 14kg (2)
glue,
Nails

Table. 4

Table. 4 shows the data gathered on making the bridge design and the experiment. The bridge
design length is 50 cm and has a weight of 600 grams. The researcher uses 20 bricks as a
weight and 5 hollow blocks as weight combined together the total weight will be 169 kg,
x281.6 percent of the total weight of the bridge design.

TotalWeight that broke the bridge

Total Weight of the Bridge Design

Table.5

Table 5 is the equation used to calculate the strength to weight ratio of the Prototype Hybrid
Bridge Design

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 CHAPTER 5

SUMMARY OF FINDINGS, CONCLUSIONS, AND RECOMMENDATIONS

This chapter shows the summary or the research work undertaken, the conclusions drawn and

the recommendations made that will improve this study.

DOCUMENTATION:

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SUMMARY

Chapter one is about the history of bridge designs that were used by “Civil Engineers”
throughout the centuries. It alsoshows the statement of the problems that was used in the
research paper as well as the scope and delimitation.

What I found interesting is that, shape determines the rigidness, and sturdiness of the
bridge. How so? I found the answer when I am making the computerized design in bridge
designer 2016, when I used a box instead of a triangle, though you can use a box as design
but if you use it on an actual bridge it cannot carry much weight than the triangle design.
Thus this answers my hypothesis and my third statement of the problem.

Other thing that I found is the length of the bridge has something to do to its rigidness
and sturdiness, because when I try to use the 40m design and use a 180x180mm carbon steel
as a component of the bridge it didn’t pass the load test. It only means that the strength of the
bridge can be determined by checking the materials that has been used in making it and also
its length. This answers my question 1, 4 and 5 in my statement of the problem.

My Prototype Hybrid Bridge design carried 169kg of weight that is x281.6 of its total
weight which is 600 grams, this answer my question number 2 in my stamen of the problem.

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 Lastly to answer my question number 6 in my statement of the problem, the materials
that was used on the design is not that expensive because I only used 180x180mm of carbon
steel metal which is only roughly $1000 dollar per member, I also can reduce the size of the
steel, but the strength will definitely change.

The Chapter 2 of this research paper shows the literature that was related to my
research and I used it to strengthen the reliability and the dependability of my research.

The Chapter 3 of this research paper will let the readers know the tools and materials
that I used, the methodology of the research, and lastly the step by step procedure I made.

The Chapter 4 of this research paper shows the presentation, analysis, and
interpretation of data gathered on the experiment.

And lastly chapter 5 of this research paper presents the summary of the data,
conclusion about the experiment, and recommendation for others in the future.

CONCLUSION
Today we can see magnificent structures, especially here in Bahrain. Buildings,
bridges, houses, name it all, this are all part of our life until we die. As a grade 12 student and
as a STEM student I am eager to make my own design that can be used in the future.
I choose this research because it is my dream to make my own design since when I
am in grade 4. Now after how many years I am able to make a design that is low cost, and
that is sturdy, rigid enough to be called as a bridge.
As a conclusion I am sure that my research is a success because it sustained x281 of
its own weight, and made it a low cost design.
RECOMMENDATION
Doing this project is hectic, you need time to create, plan, and execute. I recommend
others to start as soon as possible because it will eat your time completely. If your deadline is
until the end of the year try to start 6 months before the deadline.
Making the Design is really confusing when you’re new about this thing, because you
will need accurate measurements in order for the design to be successful. I recommend you to
buy a meter stick or a tape measure.
Also I recommend buying Popsicle sticks online or check the Popsicle sticks first
before buying it, because I wasted 57.1% of my Popsicle sticks, because most of them are
broken, uneven, and bended.
Lastly I recommend others to ask help, or if not search for ways in the internet, you
should not use your ego on this research, because you will surely need help from a
professional. Listen to them carefully and take note the thing they are saying because it will
surely help you

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