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

Increment 1 successfully pre-assembled

The initial steel components of the second construction phase were completely pre-assembled in the form station. Sections 1 to 5 have been placed on the completed staging frame.

In the next step, the interior diagonal sections were installed. Since then, the welding work on the entire superstructure has been in full swing.

By the end of the year, the lateral cantilevers will be assembled before the entire first increment cycle is moved in February.


North bridge structure shortly before completion

Steel construction is nearing completion on the north bridge structure.

The deck coating has already been applied on more than half the bridge.
The welding work of the second half is almost complete and the corrosion protection work is in full swing.

After completion of the steel construction, the later roadway slab still needs a layer of concrete before it can be moved via SPMTs into its final position in spring.

Completion of the steel structure assembly on the A45 motorway

In another night operation, the last steel components were assembled on the A45 Dorlar viaduct.

The 650t crawler crane was once again deployed. It successfully lifted the end cross girder in axis 12 and the four corresponding longitudinal girders.