Material-efficient forms for very long-span bridges: Buildability and

construction processes

Keywords: Long-span, buildability, construction, process, gravity, self-weight, material,

layout optimisation, structural optimisation, bridges

Aims and objective:

This project focuses on understanding how to build a proposed long-span bridge layout
(Figure 1a) by examining the construction process in detail. The goal is to explore practical
aspects like construction sequencing, ensuring stability during each phase, and managing
the time it takes to bring the design to life. By concentrating on how the structure can
actually be built, the project aims to address challenges that often arise between a great
design on paper and its real-world implementation. Ultimately, it seeks to make long-span
bridge designs not just material-efficient but also realistic and achievable in construction.

Background:
This research tackles the challenges of constructing the material efficient form of long-span
bridge by focusing on how practical and feasible it is to build an optimized bridge design.
While modern optimization tools create innovative layouts that save materials and reduce
carbon emissions, they often neglect the realities of construction, like how the bridge will be
assembled, whether it stays stable during the building process, and how much time and
resources the process will need. These overlooked factors can make even the best designs
impractical to build, highlighting the critical need to explore these gaps.

The purpose of this study is to bridge the gap between innovative designs and real-world
construction. It focuses on understanding the construction process of a proposed long-span
bridge layout, looking closely at issues like how to sequence the building stages, ensure the
bridge remains stable at every step, and make the process as efficient and cost-effective as
possible.

Literature review:
Over the past 20 years, nine out of the ten longest bridge spans in history have been
constructed. This highlights a growing demand for long-span bridges, and suggests that
bridge spans will continue to grow throughout the 21st century. Suspension and cable-
stayed bridges are the most common forms used for long-span bridges. These bridges
consist of vertical pylons and networks of cables that support the bridge deck. The
discussions about these bridges have mostly focused on practical aspects rather than their
theoretical efficiency. Consequently, there has been little debate about whether these forms
are the most efficient solutions from a theoretical standpoint for long-span bridges. While
these designs are practical and relatively easy to build, they often use more materials than
necessary, leading to higher costs and more resource consumption.

K.H. Ostenfeld (1996) pointed out that one limiting factor for long-span bridges is the limits
for known materials in carrying their own weight. This issue becomes more significant as the
span length increases. Lewis W.J. (2012) highlighted that steel, commonly used in bridge
 Figure 1. (a) Reference design. (b) Optimised triple split-pylon design. (c) Optimised double split-pylon design. (d) Optimised
cable-stayed design. (e) Optimised suspension bridge design. (All with variable cross section-cables). Reference: Fairclough
(2018) Figure 4

construction, has a practical span limit of less than 5 km for suspension bridges. This means
that to achieve longer spans, materials with a higher strength-to-weight ratio is required.
However, since developing new materials with these properties is unlikely in the short term, it
is crucial to identify structural forms that require less material to extend the overall span
length effectively.

Fairclough (2018) identifies theoretically optimal forms for long-span bridges under pure
gravity loading, using a numerical layout optimization procedure. The optimized layouts use
ununiform cross-section cables as elements of equal strength, The resulting layout
resembles a combination of suspension and cable-stayed bridges. The findings show that
the optimized suspension and cable-stayed forms use 78% and 38% more material,
respectively, than the reference form for a 5 km span (Figure 1c, d). Even a simplified
version of the optimized form uses significantly less material than modern long-span bridge
forms.

While the study successfully addresses material efficiency under pure gravity loading, it
acknowledges the need for further research to address other important factors. It is
important to consider factors such as wind and dynamic effects, which can significantly
impact the performance and stability of long-span bridges. Additionally, practical
considerations related to the buildability and construction processes of the optimized design
were not covered. Addressing these factors is essential for the real-world application and
implementation of these optimized designs to ensure that the theoretically optimal designs
can be translated into practical, efficient, and sustainable bridge structures in the future.
Research questions:
1. What construction strategies, including sequencing, stability measures, and
temporary structures, are needed to safely and efficiently build the chosen bridge
layout, and how does its buildability compare to traditional long-span bridges?
2. What are the time and cost of constructing this specific layout compared to traditional
designs?
3. How would site-specific factors like terrain, weather, and environmental constraints
influence the construction process?
4. Can the construction process be adapted to minimize its environmental impact?

Methods:
This research will start by exploring how long-span bridges are typically built, choosing one
construction sequence that fits the proposed optimized layout (double split-pylon design)
(Figure 1c). Using computer software like Oasys GSA, we’ll simulate each stage of the
construction process to check if the structure remains stable and whether temporary
supports are needed to keep everything safe during the build. We’ll then compare these
findings with traditional long-span bridges to see how our approach stacks up in terms of
practicality and efficiency.

Next, we’ll estimate how long the construction would take and how much it would cost,
comparing these results to conventional methods. We’ll then consider site-specific factors,
like the terrain, weather, and environmental challenges, to understand how they might affect
the construction process. Finally, we’ll look at ways to reduce the environmental impact,
such as cutting emissions, minimizing waste, and protecting the surrounding ecosystem.
Planning:

Start
Task Week Duration (Weeks) End Week
Research existing construction sequences 1 2 2
Select a suitable construction sequence 3 1 3
Simulate construction phases for stability 4 3 6
Analyze need for temporary structures 7 1 8
Estimate time and cost for proposed design 8 2 10
Compare findings with traditional designs 10 1 11
Evaluate site-specific factors 11 0.5 11
Assess environmental impact minimization 11 0.5 11
Final Report 12 1 12

Table 1: Research Planning and time schedule

This timetable provides a general framework and structured approach to the project. The
planning is flexible. The required time can be adjusted depending on the complexity, specific
requirements, and available resources of the work. It is recommended to conduct a review
after every stage to make sure the project is on track and meets the planned objectives. The
review can also be used to foresee challenges that may arise during the project and adjust
approaches.

Risk assessment:

Likelihoo
Risk d impact Mitigation
Inaccurate simulation results may
Validate simulations with case
lead to incorrect conclusions about
Medium High studies, expert feedback, and
stability during construction
conservative safety margins
phases.
Source data from reliable
Incomplete or inaccurate data on
references, consult industry experts,
materials, construction methods, High High
and validate assumptions through
and site conditions.
cross-checks.

Table 2: Project Risk Assessment

Outcomes:

This research aims to make long-span bridge designs not only efficient but also practical to
build. By focusing on how to construct optimized layouts, it will provide clear strategies for
sequencing construction, maintaining stability at every stage, and reducing risks. The study
also hopes to promote sustainability by using less material and lowering carbon emissions.
With insights into advanced technologies and real-world challenges, it will offer practical
guidelines to balance ambitious designs with buildability. Ultimately, the research will help
create safer, more efficient, and environmentally friendly bridges, shaping the future of
infrastructure in challenging and sensitive environments.

Reference List:

Ostenfeld KH. 1996 Comparison between different structural solutions. The Great Belt
project. In Proc. 15th Cong. IABSE, Copenhagen, Denmark, 16–20 June, pp. 1063–
1078. Zurich, Switzerland: IABSE.

Lewis WJ. 2012 A mathematical model for assessment of material requirements for cable
supported bridges: implications for conceptual design. Eng. Struct. 42, 266–277.
(doi:10.1016/j.engstruct.2012.04.018)

Fairclough, H.E., Gilbert, M., Pichugin, A.V., Tyas, A. and Firth, I. (2018). Theoretically
optimal forms for very long-span bridges under gravity loading. Proceedings of the Royal
Society A Mathematical Physical and Engineering Sciences, [online] 474(2217),
pp.20170726–20170726. doi:https://doi.org/10.1098/rspa.2017.0726.

‌Fairclough, H.E., Gilbert, M. and Tyas, A. (2022). Layout optimization of structures with
distributed self-weight, lumped masses and frictional supports. Structural and
Multidisciplinary Optimization, [online] 65(2). doi:https://doi.org/10.1007/s00158-021-03139-
z.