Night mission went according to plan

In the night from 09 to 10 November the new railway overpass in Heppenheim (Bergstraße) was successfully lifted in. Completely manufactured and coated each of the components was transported by truck to the construction site where it was assembled in a tandem lift. The transport length was approx. 18.6 m with a unit weight of up to 100 tons.

Donges SteelTec has been contracted with the manufacturing, delivery and assembly of the steel construction for the railway overpass in Heppenheim, Germany. The railway bridge will span the railway line 3601 Frankfurt – Heidelberg via the federal road B 460 “Lorscher Straße”.

The overpass consists of two separate superstructures. Each superstructure is designed as a trough bridge with thick sheet metal. On one side of each of the two superstructures a walkway will be added.The span width of the bridge is approx. 15.40 m, the construction height 0.8 m. This results in a slenderness of L/H = 19.25. Each of the superstructures is 4.70 m wide. The pavements have widths of up to 1.45 m.


The superstructure of the Viaduct Heidingsfeld has reached the other side of the valley

With the sixth and last movement of the 2nd construction phase, the superstructure reached the other side of the valley as planned.

In the coming days preparations will be made for stacking the bridge, which will bring it into its final position. Subsequently, our erectors will carry out the remaining work on the steel structure,

so that by the end of next year the 2nd construction phase will also be completed and opened to traffic.

Second construction phase of the new bridge over the motorway A1 was successfully completed.

Last September weekend, 10 steel girders of the new bridge over the A1 near Köln-Niehl were assembled in two night operations.

The A1 section was completely closed for the entire weekend.

As in the first construction phase, the components manufactured in our workshop in Darmstadt were transported to the construction site by heavy goods vehicles, lifted by a 500 tons crane and placed on prepared support benches.

Fifth movement took place as planned

See the video for details on the move operation.

BR Media Library Video

A45 – New bridges of the B54 arrived at their location

Darmstadt/Haiger, 22.07.2019.
3000 tons of steel construction roll on 384 wheels on the motorway A45 near Haiger.

The two new truss bridges of the B54 near Haiger, each weighing around 3000 tonnes, were successfully driven over the existing A45 motorway during a 50-hour closure on the weekend of Friday, 19 July to Sunday, 21 July and lowered in their final position.

The 96 m and 120 m long steel structures with a weight of 800 tons and 1200 tons, which were manufactured as large components at the Donges SteelTec GmbH plant in Darmstadt, were completely pre-assembled next to the motorway for months, welded and subsequently fitted with a concrete roadway slab.

The superstructures were then stacked up to 9.00 meters and brought to their respective end positions by self-propelled platform module transporters (SPMT).

The manufacturing process and the running-in process are regarded as a unique project in Germany, especially due to the almost complete completion in lateral position.


The first bridge section was achieved

Darmstadt/Linz 24.06.2019.
On Friday, 21.06.2019 the middle section of the bypass bridges in Linz was successfully erected. The 950 t heavy and over 90 m long bridge section was moved into position by ship and pulled into end position by steel cables. Thus, the first bridge section of approx. 3500 t across the Danube was achieved. Next week a further bridge section will be erected in Urfahr in the bank area and the preparatory work for the second bypass bridge has also begun with the first deliveries to the pre-assembly site.

Bridge spectacle on the Danube bank

Darmstadt/Linz, 28.05.2019.
An extraordinary spectacle was to be observed at the Danube bank in Linz at the motorway bridge A7.

At the end of May, numerous onlookers were able to watch the first of three pre-assembled steel bridge sections of the new bypass bridges swim from the pre-assembly site to the Linz side of the river bank under the expert guidance of the Donges assembly team, turn it there, stack it up and then move it to its final position on the river piers. The component has a total length of 74 m and a tonnage of over 1,000 t. Two pontoons, a push boat and a special climbing system are used to float in.

Work on the other two pre-assembled steel components is currently being continued at the pre-assembly site in order to move them into the final position in the same manner in the coming weeks.

First movement has taken place as planned.

The first movement of the 2nd construction phase was successfully completed.
The shots 1 – 5 with a total length of 130 m were moved into the valley.

Immediately after the movement, the foundations were rebuilt, since in the following week the shots 6 – 10 will already be delivered and laid down.

Steel construction work on the north bridge structure completed

After completion of the steel structure, the construction was stacked up by a specialist company and set down on temporary abutments.
In this state, the bridge now waits for the roadway slab to be concreted before it is moved into its end position with the aid of SPMTs.

On February 8th, 2019 the bidding consortium Züblin/Donges/Strabag was awarded the contract for the replacement construction of the Grumbachtal bridge by the State Office for Road Construction, Neunkirchen. The total order volume amounts to around € 71 million. Donges SteelTec has been commissioned with the manufacture, delivery and assembly of the 4,800 t steel structure and the corrosion protection work and will thus take over almost 30 % of the order volume.

The construction will be carried out in 2 phases of 2,400 t each, with the first phase to be completed in 2020 and the second phase in 2022. This will ensure good capacity utilisation of the Donges bridge production facilities beyond 2019.

The existing structure is a composite bridge, built in 1961. As it is not possible to repair or reinforce the structure, it will be replaced by a new structure.

The new construction is planned as a composite bridge with two separate superstructures. In order to maintain the four-lane traffic during the entire construction project, the superstructure of the 2nd partial structure will initially be constructed in a provisional lateral position on temporary substructures. After demolition of the existing structure and erection of all final substructures, as well as after construction of the superstructure of the 1st partial structure, the superstructure of the 2nd partial structure will be moved to its final position. The temporary structures are then to be demolished.

The spans were optimised in terms of structural design. In order to avoid a collision between the foundation of the existing building and the foundation of the new building and the associated complications during the construction of the structures and the bored piles, the spans were increased in comparison to the existing building.


Technical Information

Type: Composite bridge with two separate superstructures
Length: 380 m
Largest span: 86 m
Building width: 16.5 m per superstructure
Tonnage: 4,800 t
Client: State Office for Road Construction Neunkirchen