Dec. 02, 2024
A form traveller is a type of travelling formwork system, which is ususally used in bridge construction, and it plays an indispensable role in bridge construction.It enables repeated construction of structural elements and is commonly used in the free-cantilever construction of post-tensioned box girders and cable-stayed concrete bridges.
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Bridge form traveller, also known as a launching gantry, it is a temporary structure used in bridge construction to support the construction of the bridge deck. It is typically a large steel or concrete frame that spans the gap between two piers or abutments and is used to lift and place precast concrete segments or steel girders into position.
The bridge traveller is designed to move along the length of the bridge as bridge construction procedure, allowing workers to build the bridge deck from one end to the other. As each section of the bridge deck is completed, the traveller bridge is moved forward to support the next section.
The advantage of using a traveller formwork is that it allows for faster construction times and reduces the need for temporary supports or scaffolding. It also provides a safer working environment for construction workers, as they can work from a stable platform rather than having to work from heights.
However, the design and construction of form traveller bridge can be complex and require significant planning and engineering expertise. The structure must be able to support the weight of the precast segments or steel girders, as well as the weight of workers and equipment. It must also be able to withstand wind and weather conditions during construction.
What are the Parts of A Form Traveller?
HY Bridge Formwork main components mainly consist of bearing bottom supporting sysytem, formworl and support syste,. walling and anchor system, suspension lifting system.
How does a Cantilever Form Traveller Work?
A Cantilever Form Traveller is a specialized construction equipment used in the construction of bridges and viaducts. It is designed to support the construction of bridge segments or deck sections in a balanced and incremental manner.
The Cantilever Form Traveller consists of a large steel framework that is supported by a set of temporary supports or towers. It is typically positioned at one end of the bridge or viaduct and gradually extends outwards as the construction progresses.
Here's How it Works:
1. Initial Positioning: The Cantilever Form Traveller is initially positioned at the starting point of the bridge or viaduct, often on one of the piers or abutments.
2. Segment Placement: The first segment of the bridge or deck section is placed on the Cantilever Form Traveller. This segment is typically precast or cast in situ.
3. Balanced Construction: The Cantilever Form Traveller uses its temporary supports or towers to balance the weight of the segment being placed. This ensures that the structure remains stable during construction.
4. Incremental Extension: Once the first segment is in place, the Cantilever Form Traveller gradually extends outward by pushing or pulling itself along the completed segments. This allows for the placement of subsequent segments.
5. Repetition: The process of segment placement, balanced construction, and incremental extension is repeated until the entire bridge or viaduct is constructed.
The Cantilever Form Traveller offers several advantages in bridge construction, such as increased efficiency, reduced labor requirements, and improved safety. It allows for the construction of long-span bridges and viaducts without the need for temporary supports in the water or deep foundations.
It's important to note that different variations of Cantilever Form Traveller exist, and their specific mechanisms may vary. However, the general principle remains the same &#; supporting balanced construction and incremental extension during bridge or viaduct construction.
What are the Advantages of Using a Cantilever Form Traveller?
A cantilever form traveller is a type of constructed travel form equipment used in the construction of bridge decks and other large concrete structures. It is a self-contained system that can be used to construct large sections of concrete in a controlled and efficient manner. There are several advantages to using a cantilever form traveller.
First, bridge traveller allows for the construction of large sections of concrete in a single pour. This means that there are fewer joints in the finished structure, which can improve its overall strength and durability.
Second, a cantilever form traveller is a highly efficient construction method. It allows for the rapid construction of large sections of concrete, which can save time and money compared to traditional construction methods.
Third, form traveller system bridge construction is a safe construction method. The equipment is designed to be self-supporting, which means that workers do not need to be exposed to the hazards of working at heights or on unstable scaffolding.
Overall, a cantilever form traveller is a highly effective construction method that can be used to build large form traveller bridge construction quickly, safely, and efficiently.
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Content
1. General
Strukturas as engineering team is committed to quality and safety in every aspect of the working environment, because quality builds trust - trust builds business.
Strukturas as constant engineering succession raised a few generations of engineers filled with wisdom of the seniors and supplementation of up to date digital tools.
Hundreds of successfully executed projects globally showcase Strukturas as leadership and adaptability.
The Strukturas as Form Traveller (FT) system is a competitive and reliable solution for balanced cantilever construction method. With our 50 years of experience in conception and designing bridge building equipment, we currently offer the market an economical and versatile formwork solution used to cast in situ bridge and viaduct deck segments.
Both the overhead and underslung Form Traveller (FT) systems have been designed to be used in building prestressed reinforced concrete decks built with the balanced cantilever method, whether suspended or not by stays.
Form Travelers for casting arch segments in concrete, or deck wings also in concrete, round out our Form Traveler solutions.
Overhead Form Traveller system
Underslung Form Traveller system
Wing Form Traveller system
Arch Form Traveller system
2. Overhead Form Traveller system
Overhead Form Traveller (FT)
The Overhead Form Traveller system is the solution most commonly used for casting bridge and viaduct decks built with the balanced cantilever method whose span varies from around 60 to 250 meters in length.
A standard Overhead Form Traveller is normally designed to be used in casting segments up to 5 meters in length and up to around 300 tons in weight.
For longer or heavier segments, &#;tailor-made&#; Form Travellers can always be designed to work in these special conditions.
Because of our extensive design experience, we can find the perfect solution for all different segments geometries.
Overhead Form Traveller (FT)
Main components
A typical Overhead Form Traveller (FT) consists of a main self-supporting structure and a launching system combined with a specific formwork.
Main components:
Overhead Form Traveller (FT) Longitudinal view
Overhead Form Traveller (FT) Cross section
Formwork
The typical formwork of a Strukturas as Form Traveller is comprised of a steel structure supplemented by saw wooden beams. Beams such as H20 and others can be used instead of saw wooden beams, especially in external formwork where the beams of the web formwork&#;s panels do not need to be sawn to adjust to the height, since they pass through the bottom slab platform of the Form Traveller (FT). Strukturas as Form Traveller design includes also the wooden components design.
Main advantages:
Internal formwork is easily adjustable to the varying height of the section Easily adaptable to future sections of other decks Economical solution
Internal formwork
External formwork
Internal formwork &#; vertical saw wooden beams and horizontal saw wooden beams acting as strong backs
External formwork&#; vertical saw wooden beams and horizontal steel beams acting as strong backs
External formwork of wide deck
Internal formwork
External formwork
External formwork
In many special projects, the internal and external formwork includes devices tailored to these specific situations to ensure the Form Travellers&#; high level of performance, minimizing cycles, auxiliary equipment and the amount of manpower needed for their operation.
Front view of Form Traveller on wide deck
Assembly over hammerhead The Cross-Support Concept
The hammerhead of a deck built with the balanced cantilever method must be at least 12 metres long in order to assemble the pair&#;s Form Travellers simultaneously.
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The Cross-Support Concept
The auxiliary structure, called Cross-Support (CS), helps to minimize the hammerhead&#;s length, thereby making its construction less complex and costly.
The Cross-Support Concept
Main stages:
Form Traveller ready to cast 1st segment
Rail and auxiliary bogies installed
Cross-Support central structure dismantled
Left Form Traveller main frame rear part installed
Launch left Form Traveller after its auxiliary bogie is dismantled
Right Form Traveller main frame rear part installed
Launch right Form Traveller after its auxiliary bogie is dismantled
Dismantle auxiliary rail
Assembly over hammerhead Non-symmetrical casting
In many cases, non-symmetrical casting of the first segment can be the solution as an alternative to Cross-Support.
Non-symmetrical casting
The use of this method corresponds to the initial assembly of only one Form Traveller (FT) and casting of the corresponding segment.
This Form Traveller (FT) is then moved to the end of the cast segment, and the pair&#;s second Form Traveller (FT) is assembled. The pair&#;s second segment is then cast. Subsequent segments will be cast symmetrically.
Non-symmetrical casting
Launch back system
The use of the singular optional launch back system allows the Form Traveller (FT) to be disassembled close to the hammerhead, after being used in casting the deck&#;s last segment. This procedure streamlines operation and minimizes cost.
External formwork during launch back
External formwork during launch back
Bottom slab platform lifting system
The lifting of the bottom slab platform from the level of the foundation where it was fully assembled, using the optional lifting system, allows the Form Traveller (FT) to be installed quickly and safely.
External formwork ready to be lifted
3D model picture
Lifting process
Front winch
Rear winch
Installation of pre assembled rebar cage
The Overhead Form Traveller (FT) system can be equipped with a web rebar cage installation device, allowing the panels of this rebar cage preassembled at ground level to be positioned in the formwork.
Lifting of pre assembled rebar cage
Installation of pre assembled rebar cage
Typical cycle
The simplicity of the Overhead Form Traveller (FT) solution, and our experience using it in a wide variety of situations, allows our solution&#;s users to achieve cycles of one week in building segments, even with complex deck sections.
Typical cycle - 1 week
3. Underslung Form Traveller system
The Underslung Form Traveller solution can be adapted to different types of bridge decks, such as arch bridges and cable stayed bridges, leaving enough room to assemble the temporary or final cable stays, and allowing easy launch back to the initial assembly position.
Underslung Form Traveller system
Main components:
Main components of UFT
When the rebar cage is preassembled, the Strukturas as Underslung Form Traveller is the perfect choice.
The external formwork of this type of Form Traveller is supported by the main structure, leaving enough room to install the preassembled rebar cage.
Underslung Form Travaller - UFT
4. Wing Form Traveller system
The Wing Form Traveller system is used to cast the deck wings in a second stage. The Wing Form Traveller&#;s length can be specifically sized to each project. Normally, sections up to 15 meters in length are cast.
Concrete box wing form traveller
Concrete box wing form traveller
Wing form travaller for Composite steel box deck
Concrete box wing form traveller
Concrete box wing form traveller during launching
5. Arch Form Traveller system
The Arch Form Traveller system is used in casting bridge arches, allowing normally symmetrical sections to be cast from the abutments.
Arch form traveller
Arch form traveller
Arch form traveller
Cross section of arch form traveller
6. Project gallery
Overhead Form Traveller &#; Rimbachtal, Germany
Overhead Form Traveller &#; Mondego, Portugal
Underslung Form Traveller &#; Indian River, USA
Underslung Form Traveller &#; Batan Kayan, Malaysia
Arch Form Traveller - Oparno
Overhead Form Traveller &#; Catumbela, Angola
Overhead Form Traveller &#; Zenica, Bosnia
Wing Form Traveller &#; Wisla, Polan
Overhead Form Traveller &#; Crete, Greece
Overhead Form Traveller &#; Corgo, Portugal
Overhead Form Traveller &#; Tua, Portugal
Overhead Form Traveller &#; Bad Liebenwerda, Germany
Overhead Form Traveller &#; Constantine, Algeri
Overhead Form Traveller &#; Salamanca, Spain
7. Safety and quality
More than 50 years of our experience in designing and supplying bridgebuilding equipment are leveraged by norms to uphold the high quality, simplicity and user safety of the resulting solutions.
From left: Founder Tore Gjølme,
A proper set of work platforms and ladders provides operators with safe access in carrying out all everyday tasks during span construction cycle.
The FT steel structure is produced in CE-certified steel workshops. High risk components such as hydraulic systems end threaded bars are manufactured by the world&#;s best and credible suppliers.
8. Services
Our integrated services that ensures full Quality Control and Quality Assurance during all project cycle:
Equipment assembling, operation and dismantling
A professional team at your service.
Strukturas as has teams specializing in planning, assembly, operation and dismantling of its MSS, allowing it to offer its clients turnkey solutions.
By using our teams we are able to reduce costs for the client, given that this minimizes the use of auxiliary support equipment, such as cranes, forklifts, platforms, trucks, support towers, etc.
Strukturas - we make it simple!
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