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Frontiers of Structural and Civil Engineering

ISSN 2095-2430

ISSN 2095-2449(Online)

CN 10-1023/X

Postal Subscription Code 80-968

2018 Impact Factor: 1.272

Front. Struct. Civ. Eng.    2020, Vol. 14 Issue (4) : 803-838    https://doi.org/10.1007/s11709-020-0644-1
REVIEW
Design and construction of super-long span bridges in China: Review and future perspectives
Wei HUANG1, Minshan PEI2, Xiaodong LIU2, Ya WEI3()
1. Intelligent Transportation System Research Center, Southeast University, Nanjing 211189, China
2. China Communications Construction Company Ltd., Beijing 100088, China
3. Department of Civil Engineering, Tsinghua University, Beijing 100084, China
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Abstract

Super-long span bridges demand high design requirements and involve many difficulties when constructed, which is an important indicator to reflect the bridge technical level of a country. Over the past three decades, a large percentage of the new long-span bridges around the world were built in China, and thus, abundant technological innovations and experience have been accumulated during the design and construction. This paper aims to review and summarize the design and construction practices of the superstructure, the substructure, and the steel deck paving of the long-span bridges during the past decades as well as the current operation status of the existing long-span bridges in China. A future perspective was given on the developing trend of high-speed railway bridge, bridge over deep-sea, health monitoring and maintenance, intellectualization, standard system, and information technology, which is expected to guide the development direction for the construction of future super long-span bridges and promote China to become a strong bridge construction country.

Keywords long-span bridges      steel box girder      design technology      construction technology      review and future perspectives     
Corresponding Author(s): Ya WEI   
Online First Date: 21 July 2020    Issue Date: 27 August 2020
 Cite this article:   
Wei HUANG,Minshan PEI,Xiaodong LIU, et al. Design and construction of super-long span bridges in China: Review and future perspectives[J]. Front. Struct. Civ. Eng., 2020, 14(4): 803-838.
 URL:  
https://academic.hep.com.cn/fsce/EN/10.1007/s11709-020-0644-1
https://academic.hep.com.cn/fsce/EN/Y2020/V14/I4/803
world ranking bridge name main span (m) completed year award won
2 Hutong Yangtze River Bridge 1092 under construction First Prize of the 2017 National BIM Application Competition
3 Angchuanzhou Bridge 1018 2009
4 Edong Yangtze River Bridge ?926 2010
7 Jiujiang Bridge ?818 2013
8 Jingyue Yangtze River Bridge ?816 2010
9 Wuhu Yangtze River No. 2 Bridge ?806 2017 2018 George Richardson Award
10 Yachihe Bridge ?800 2016 2018 Gustav Lindenthal Award
Tab.1  Cable-stayed bridges of China ranking Top 10 in the world
world ranking bridge name main span (m) completed year award won
2 Nansha Bridge 1688 2019
3 Xihoumen Bridge 1650 2009 2010 Gustav Lindsall Award of International Bridge Conference, 2014–2015 China Construction Engineering Luban Award
7 Runyang Yangtze River Bridge 1490 2005
8 Dongting Lake Bridge 1480 2018
9 The Fourth Nanjing Yangtze River Bridge 1418 2012
Tab.2  Suspension bridges of China ranking Top 10 in the world
world ranking bridge name main span (m) completed year award won
1 Chaotianmen Yangtze River Bridge 552 2009
2 Lupu Bridge 550 2003 2008 International Bridge and Structural Engineering Association “Outstanding Structure Award”
3 Hejiang First Bridge 530 2013
7 Wushan Yangtze River Bridge 492 2005
8 Guantang Bridge 457 2018
9 Mingzhou Bridge 450 2011
9 Xijiang Bridge 450 2014
10 The First Beipan River Bridge (Qinglong Railway Bridge) 445 2016
Tab.3  Arch bridges of China ranking Top 10 in the world
world ranking bridge name total length (km) completed year award won
1 Hong Kong-Zhuhai-Macao Bridge 50?? 2018
2 Hangzhou Bay Bridge 36?? 2008
3 Jiaozhou Bay Bridge 35.4 2011 2013 George Richardson Award
4 East Sea Bridge 32.5 2005
6 Zhoushan Peninsula Project 25?? 2009
Tab.4  See-crossing bridges of China ranking Top 10 in the world.
Fig.1  (a) Sutong Yangtze River Bridge; (b) Hutong Yangtze River Bridge; (c) Edong Yangtze River Bridge.
Fig.2  (a) Jiangyin Yangtze River Bridge; (b) Xihoumen Bridge; (c) Haicang Bridge; (d) Taizhou Yangtze River Bridge.
Fig.3  (a) Lupu Bridge; (b) Chaotianmen Yangtze River Bridge; (c) Nanjing Dashengguan Yangtze River Bridge; (d) Shanghai-Kunming High-speed Railway Beipanjiang Bridge.
Fig.4  Design of the steel box girder cross-section: (a) single-box girder and (b) double-box girder.
bridge name (completed year) bridge type main span
(m)
design parameters of stiffened steel box girder
height
(m)
width (m) deck thickness (mm) longitudinal stiffener type transverse diaphragm spacing (m)
Humen Bridge (1997) suspension bridge ?888 3.0 33.0 12 U 4.00
Jiangyin Yangtze River Bridge (1999) suspension bridge 1385 3.0 36.9 12 U 3.20
Haicang Bridge (1999) suspension bridge ?648 3.0 36.6 12 U 3.00
The Second Nanjing Yangtze River Bridge (2001) cable-stayed bridge ?628 3.5 38.2 14 U 3.75
Junshan Yangtze River Bridge (2001) cable-stayed bridge ?460 3.0 38.8 12, 14, 16 U 3.00
South Branch Main Bridge of Runyang Bridge (2004) suspension bridge 1490 3.0 38.7 14 U 3.22
Runyang Bridge (2005) cable-stayed bridge ?406 3.0 37.4 14 U 3.75
The Third Nanjing Yangtze River Bridge (2005) cable-stayed bridge ?648 3.2 37.5 14, 16 U 3.75
Yangluo Bridge (2007) suspension bridge 1280 3.0 38.5 14 U 3.20
Hangzhou Bay Bridge (2008) cable-stayed bridge ?448 3.5 37.1 14, 16, 20 U 3.75
Xihoumen Bridge (2009) suspension bridge 1650 3.5 36.0 14, 16 U 3.60
Sutong Yangtze River Bridge (2008) cable-stayed bridge 1088 4.0 35.4 14-24 U 4.00
The Fourth Nanjing Yangtze River Bridge (2012) suspension bridge 1418 3.5 38.8 14, 16 U 3.12
Yunnan Long Jiang Bridge (2016) suspension bridge 1196 3.0 33.5 16 U 3.10
Tab.5  Design parameters of steel box girders of the representative bridges in China [1724]
Fig.5  Shapes of the (a) open ribs and (b) closed ribs.
bridge name year opened main span (m) bridge type deck stiffener form
(upper opening width × lower opening width × height × thickness) (mm)
Jiangyin Yangtze River Bridge 1999 ??1386.0 suspension U-shape rib (300 × 170 × 280 × 6)
Haicang Bridge 1999 ???648.0 suspension U-shape rib (300 × 170 × 280 × 6)
The Second Nanjing Yangtze River Bridge 2001 ???628.0 cable-stayed U-shape rib (320 × unknown × 280 × 8)
Anqing Yangtze River Bridge 2004 ?510 cable-stayed U-shape rib (300 × 170 × 280 × 8)
Yangluo Bridge 2007 1290 suspension U-shape rib (300 × unknown × 280 × 6)
Sutong Yangtze River Highway Bridge 2008 1088 cable-stayed U-shape rib (300 × 180 × 300 × 8)
The Fourth Nanjing Yangtze River Bridge 2012 1418 suspension U-shape rib (300 × 170 × 280 × 8)
Hong Kong-Zhuhai-Macao Bridge 2018 1150 cable-stayed U-shape rib (300 × 180 × 300 × 8)
Nansha Bridge 2019 1688 suspension U-shape rib (300 × 170 × 280 × 8)
Tab.6  Information about stiffening rib of long-span steel bridges in China.
item AASHTO (US) Eurocode 3 (Europe) Japan road specifications
cross-section
Tab.7  Diagrammatic sketch of different openings in U-shape rib from different codes (mm).
Fig.6  (a) Xinghai Bay Bridge with portal shaped concrete tower; (b) Sutong Yangtze River Bridge with the “A” shaped concrete tower; (c) Hutong Yangtze River Bridge with inverted “Y” shaped steel pylon; (d) Taizhou Yangtze River Bridge.
Fig.7  (a) Rectangular anchorage foundation of Runyang Yangtze River Bridge; (b) “∞” shaped anchorage foundation of the Forth Nanjing Yangtze River Bridge; (c) pile group foundation of Sutong Yangtze River Bridge; (d) caisson foundation of Taizhou Yangtze River Bridge.
bridge name year opened steel deck thickness (mm) pavement layer thickness (mm) current status
Jiangyin Yangtze River Bridge 1999 12 55 in 2010, the cast asphalt was replaced with double-layer EA, and it has been used until now
The Second Nanjing Yangtze River Bridge 2001 12 50 maintain good performance without overhaul
Runyang Yangtze River Bridge 2005 14 50 no overhaul, local maintenance
The Third Nanjing Yangtze River Bridge 2005 14 50 no overhaul, local maintenance
Yangluo Yangtze River Bridge 2007 14 60 no overhaul, still using the original pavement
Sutong Yangtze River Bridge 2008 14–22 55 no overhaul, local maintenance, still using the original pavement
Tianxingzhou Yangtze River Bridge 2009 14 60 massive repairs in 2015
Minpu Bridge 2009 16 55 no overhaul, local maintenance
Tab.8  Parameters of EA pavement of the representative bridges in China [4854]
Fig.8  Wearing surface of steel deck of some long-span bridges in China. (a) Double-layer EA; (b) GA+ SMA; (c) EA+ SMA; (d) GA+ EA.
bridge name year opened main span (m) initial wearing surface system maintenance record
Jiangyin Yangtze River Bridge 1999 1385 47 mm GA re-paved in 2003 according to the original plan;
in 2010, replaced with 55 mm double-layer EA
Haicang Bridge 1999 648 30 mm SMA13(upper layer)
35 mm SMA10 (lower layer)
In 2002, 2005, and 2013, the original paving plan was used for overhaul
Junshan Yangtze River Bridge 2001 460 35 mm SMA (upper layer)
40 mm SMA (lower layer)
re-paved in 2010:
40 mm SMA (upper layer) + 30 mm SMA (lower layer)
re-paved in 2018:
30 mm asphalt (upper layer) + 50 mm UHPC (lower layer)
The Second Nanjing Yangtze River Bridge 2001 628 50 mm double-layer EA the first and second lanes are not overhauled; for the pre-conservation considerations, the pavement is replaced by using the original pavement plan in the heavy traffic lane (the third lane) in 2018 [49]
South Branch Main Bridge of Runyang Bridge 2005 1490 50 mm double-layer EA local maintenance and repair, no overhaul
Yangluo Yangtze River Bridge 2007 1280 30 mm EA
(upper layer)
30 mm EA
(lower layer)
no major repair record, still using original pavement
Sutong Yangze River Highway Bridge 2008 1088 30 mm EA
(upper layer)
25 mm EA
(lower layer)
paving without overhaul
South Branch Bridge of Tianxingzhou Yangze River Bridge 2009 504 25 mm EA
(upper layer)
35 mm EA
(lower layer)
paving without overhaul
Hong Kong-Zhuhai-Macao Bridge 2018 1150 38 mm SMA13 (upper layer)
30 mm GMA10 (lower layer)
no overhaul record
Nansha Bridge 2019 1200+ 1688 35 mm EA
(upper layer)
30 mm EA
(lower layer)
no overhaul record
Tab.9  Pavement structure on steel deck of long-span bridges in China [48]
Fig.9  Construction procedure of steel pylon of Taizhou Yangtze River Bridge: (a) the first section; (b) the bottom cable tower; (c) the joint section; (d) the lower cross beam; (e) the upper tower column; (f) the upper cross beam.
Fig.10  The use of hydraulic climbing formwork technology in concrete pylon of (a) Tongling Yangtze River Bridge and (b) Yangsigang Yangtze River Bridge.
Fig.11  (a) Automatic assembly positioning machine for U-shaped rib unit; (b) automatic assembly positioning machine for plate type stiffener.
mixtures mixing temperature asphalt binders production processes
GA 200°C–250°C PMB+ TLA+ hard asphalt The production of GA is a one-step process:
All ingredients are fed into the batch plant and the mixing of GA only took 2 min.
The GA mixtures are then dumped into the cooker for secondary mixing and transportation
MA 210°C–240°C TLA+ AH The production of MA consists of a two-step process:
The filler (at ambient temperature), bitumen and fine aggregate are mixed to produce ME.
ME is then fed into a cooker, mixed with coarse aggregates to produce the final MA
Tab.10  Different production processes in producing GA and MA [127]
inspection terms standardized requirements
Lueer fluidity, 240°C (s) ≤20
hardness, 35°C (mm) 0.5–2.0
impact toughnes, 15°C (N·mm) ≥400
dynamic stability, 60°C (time/mm) 300–800
planeness (mm) ±3
transversal slope (%) ±0.3
bonding force with waterproof layer (MPa) ≥0.9
Tab.11  Measuring items of GMA mixture for bottom layer [130]
technical performances test indicators requirements test method
high temperature stability dynamic stability, 60°C (time/mm) ≥4000 JTGE20-2011
(T 0719)
dynamic stability, 70°C (time/mm) ≥2000
low-temperature anti-cracking maximum bending strain, -10°C ≥8000 JTGE20-2011
(T 0715)
structural integrity bond strength, 25°C (MPa) ≥1.0
shear strength, 25°C (MPa) ≥1.5
water tightness water permeability coefficient (mL/min) ≤50 JTGE20-2011
(T 0730)
skid resistance texture depth (mm) ≤0.7 JTGE20-2011
(T 0731)
Tab.12  Technical requirements for GMA+ SMA composite structure [130]
crack type number of cracks in 2015 number of new cracks in 2017 ratio of new cracks (%)a) number of cracks in repaired welding ratio of cracks in repaired welding (%)b)
crack at U rib 4026 3597 89 429 11
crack at cross-diaphragm plate 1476 1393 94 ?83 ?6
crack at the welded joint between U rib and cross-diaphragm plate 1034 ?908 88 126 12
crack at U rib around the cable bracket ?988 ?432 44 556 56
crack at top plate ?218 ?205 94 ?13 ?6
crack at U rib joint ???8 ???7 88 ??1 13
other cracks ?154 ?152 99 ??2 ?1
total 7904 6694 85 1210? 15
Tab.13  Cracking survey in steel box girder of long-span bridges.
Fig.12  Robot anti-deformation ship position welding system.
Fig.13  Cracks in steel box girder of long-span bridge: (a) crack at cross-diaphragm plate around the hole; (b) crack at welded joint between top plate and U rib; (c) crack at welded joint between cross-diaphragm plate and U rib; (d) crack at welded joint between cross-diaphragm stiffened plate and top plate; (e) crack at welded joint between top plate and longitudinal-diaphragm plate; (f) rack at welded joint between cross-diaphragm plate and longitudinal-diaphragm plate.
defect type area of defect (cm2) number of defects ratio of defect area (%) ratio of defect number (%)
corrosion 315384 239 56.26 66.20
seepage 180900 101 32.27 27.98
coating scaling ??2465 ?10 ?0.44 ?2.77
oil contamination and sludge ?61800 ?11 11.03 ?3.05
total 560549 361 100????? 100????
Tab.14  Damage of wind fairing of long-span bridges.
Fig.14  Cable defects of long-span bridge: (a) corrosion of cable cap; (b) corrosion of sleeve; (c) oil leakage of damper; (d) scratch of sheath.
Fig.15  Restoration procedure of cable of long-span bridges: (a) welding by plastic welding gun; (b) grinding; (c) wrapping by polyester tape.
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