Bridge Erecting Machine
Key Features
✔ Hydraulic Lifting System – Handles heavy loads (up to 1,000+ tons).
✔ Adjustable Supports – Adapts to different bridge heights and curves.
✔ Automated Control – Ensures millimeter-level precision.
✔ Self-Propelled Mechanism – Reduces need for external cranes.
Specification
Environmental Conditions
Operating Temperature: -20°C to +50°C
Wind Resistance: Stable up to 15–20 m/s (depending on configuration)
Weather Protection: Can operate in light rain/snow (with precautions)
Dimensions & Weight
Machine Length: Adjustable (e.g., 60–120 m, depending on span)
Width: ~6–10 m (fits within bridge deck)
Self-Weight: ~200–400 tons (depends on configuration)
Compliance & Standards
Design Codes: EN 1991, AASHTO, BS, or other relevant bridge construction standards
Certifications: CE, ISO 9001, or project-specific approvals
Pictures & Components
A bridge erecting machine (BEM) consists of multiple specialized components that work together to lift, transport, and precisely position bridge segments or girders. Below is a detailed breakdown of its key components:
1. Main Gantry / Truss Structure
The primary load-bearing frame that spans the construction area.
Made of high-strength steel to support heavy loads.
Can be adjustable in length to accommodate different bridge spans.
2. Lifting System
Hydraulic Jacks / Winches – Lift and lower precast segments or girders.
Spreaders & Lifting Beams – Distribute load evenly to prevent damage.
Trolley & Hoist Mechanism – Moves segments horizontally along the gantry.
3. Support System (Temporary & Self-Launching)
Front & Rear Supports (Legs or Towers) – Provide stability during segment placement.
Temporary Bearings / Piers – Hold segments before permanent installation.
Self-Launching Mechanism – Allows the machine to "walk" forward autonomously.
4. Propulsion System
Crawler Tracks / Wheels – Moves the machine along the bridge alignment.
Hydraulic Push-Pull System – Used in incremental launching.
Rail-Based Movement – Some machines run on temporary rails.
5. Alignment & Positioning System
Hydraulic Adjusters – Fine-tune segment positioning (mm-level accuracy).
Laser / GPS Guidance – Ensures precise placement.
Computerized Control System – Automates operations for efficiency.
6. Auxiliary Components
Work Platforms – Provide access for workers.
Safety Railings & Fall Protection – Ensures worker safety at heights.
Power Unit (Generator / Electric Drive) – Powers hydraulic and control systems.
7. Segment Handling & Connection System
Temporary Post-Tensioning Jacks – Secures segments before final tensioning.
Bolting / Welding Equipment – For steel girder bridges.
Grouting System – Fills gaps in precast concrete segments.
Sketch
Advantages
Bridge erecting machines offer significant benefits over traditional construction methods, making them indispensable in modern infrastructure projects. Here are the key advantages:
1. High Construction Speed
Can install 2-3 bridge spans per week, drastically reducing project timelines.
Automated processes minimize manual labor, speeding up assembly.
2. Enhanced Safety
Reduces the need for workers at dangerous heights.
Stable, controlled lifting minimizes accidents compared to cranes.
3. Precision & Quality Control
Laser/GPS-guided alignment ensures millimeter-level accuracy.
Uniform segment installation improves structural integrity.
4. Cost-Effectiveness
Lower labor costs due to automation.
Reduced material waste from precise placement.
Minimal traffic disruption (critical in urban areas).
5. Adaptability to Challenging Environments
Works efficiently in:
Mountainous terrain
Rivers & valleys
Urban areas with limited space
6. Reduced Environmental Impact
Less noise and vibration than traditional methods.
Smaller construction footprint minimizes ecosystem disruption.
Application
Bridge erecting machines are used in various large-scale infrastructure projects, including:
1. Highway & Expressway Bridges
Viaducts & flyovers (e.g., China's elevated highways).
Long-span bridges where traditional cranes are impractical.
2. Railway Bridges
High-speed rail viaducts (e.g., China's HSR network).
Metro & light rail overpasses.
3. Urban Infrastructure
Elevated roadways in congested cities.
Pedestrian bridges with prefabricated segments.
4. Mountainous & River Crossings
Deep valley bridges (e.g., Millau Viaduct, France).
River bridges with minimal scaffolding.
5. Mega Projects
Sea-crossing bridges (e.g., Hong Kong–Zhuhai–Macau Bridge).
Multi-span viaducts in large-scale transport corridors.
Production Procedure
1. Design & Engineering Phase
Requirement Analysis: Define load capacity, span length, mobility, and operational conditions.
Structural Design: CAD modeling (using software like AutoCAD, SolidWorks, or CATIA) for beams, booms, supports, and hydraulic systems.
Simulation & Validation: Finite Element Analysis (FEA) to test stress, deformation, and fatigue resistance.
Regulatory Compliance: Ensure adherence to international standards (ISO, EN, AISC, etc.).
2. Material Procurement
High-Strength Steel: ASTM A572 Grade 50 or equivalent for main girders and booms.
Hydraulic Components: Pumps, cylinders, and valves from certified suppliers.
Electrical & Control Systems: PLCs, sensors, and motors for automation.
Welding Consumables: High-grade electrodes/flux for structural integrity.
3. Fabrication Process
A. Structural Fabrication
Cutting: CNC plasma/oxy-fuel cutting of steel plates.
Bending & Forming: Roll bending for curved sections (e.g., arches).
Welding:
Submerged arc welding (SAW) for thick plates.
Shielded Metal Arc Welding (SMAW) for field joints.
Ultrasonic/X-ray testing for weld integrity.
Machining: Drilling, milling for precision parts (e.g., pivot points).
B. Hydraulic & Electrical Systems
Hydraulic Assembly: Integration of cylinders, hoses, and pumps.
Electrical Wiring: Installation of control panels, sensors, and power distribution.
4. Sub-Assembly
Boom Sections: Fabricate and pre-assemble telescopic/cantilever arms.
Support Legs: Manufacture outriggers/stabilizers for ground support.
Gantry Frames: Build modular segments for easy transport.
5. Main Assembly
Erection of Main Girder: Join sections using high-strength bolts or welding.
Integration of Hydraulics: Mount cylinders for lifting/lowering mechanisms.
Installation of Controls: Fit PLCs, HMI panels, and safety systems (limit switches, overload protection).
Painting & Coating: Apply anti-corrosion layers (e.g., epoxy primer + polyurethane topcoat).
6. Testing & Commissioning
Load Testing:
Static test at 120% of rated capacity (576 tons).
Dynamic test with simulated bridge segments.
Hydraulic Tests: Check for leaks, pressure stability, and response time.
Functional Tests: Verify movement (launching, rotation, lifting) via control system.
Safety Checks: Emergency stop, overload alarms, and stability under wind loads.
7. Disassembly & Packaging
Modular Breakdown: Dismantle into transportable sections (max. 40-ton units for road transport).
Secure Packaging: Protect sensitive components (e.g., electronics) during shipping.
8. On-Site Reassembly & Final Inspection
Foundation Preparation: Ensure ground stability for machine setup.
Reassembly: Bolt/weld major components on-site.
Calibration: Fine-tune sensors and control parameters.
Client Training: Operational and safety training for end-users.
9. Documentation & Delivery
As-Built Drawings: Updated CAD models reflecting final modifications.
Certificates: Material test reports (MTRs), weld logs, and load test certificates.
User Manuals: Detailed operation, maintenance, and troubleshooting guides.
Workshop View
The company has installed an intelligent equipment management platform, and has installed 310 sets (sets) of handling and welding robots. After the completion of the plan, there will be more than 500 sets (sets), and the equipment networking rate will reach 95%. 32 welding lines have been put into use, 50 are planned to be installed, and the automation rate of the entire product line has reached 85%.
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