Chapter 18

The Runcorn bridge crosses the Manchester Ship Canal and the Mersey in one span of 1000 ft., and four approach spans of 55½ ft. on one side and one span on the other. The low-level approach roadways are 35 ft. wide with footpaths 6 ft. wide on each side. The supporting structure is a cable suspension bridge with stiffening girders. A car is suspended from the bridge, carried by a trolley running on the underside of the stiffening girders, the car being [v.04 p.0545] propelled electrically from one side to the other. The underside of the stiffening girder is 82 ft. above the river. The car is 55 ft. long by 24½ ft. wide. The electric motors are under the control of the driver in a cabin on the car. The trolley is an articulated frame 77 ft. long in five sections coupled together with pins. To this are fixed the bearings of the running wheels, fourteen on each side. There are two steel-clad series-wound motors of 36 B.H.P. For a test load of 120 tons the tractive force is 70 lb per ton, which is sufficient for acceleration, and maintaining speed against wind pressure. The brakes are magnetic, with auxiliary handbrakes. Electricity is obtained by two gas engines (one spare) each of 75 B.H.P.

On the opening day passengers were taken across at the rate of more than 2000 per hour in addition to a number of vehicles. The time of crossing is 3 or 4 minutes. The total cost of the structure was £133,000.

14. In the United States few railway companies design or build their own bridges. General specifications as to span, loading, &c., are furnished to bridge-building companies, which make the design under the direction of engineers who are experts in this kind of work. The design, with strain sheets and detail drawings, is submitted to the railway engineer with estimates. The result is that American bridges are generally of well-settled types and their members of uniform design, carefully considered with reference to convenient and accurate manufacture. Standard patterns of details are largely adopted, and more system is introduced in the workshop than is possible where the designs are more varied. Riveted plate girders are used up to 50 ft. span, riveted braced girders for spans of 50 ft. to 75 ft., and pin-connected girders for longer spans. Since the erection of the Forth bridge, cantilever bridges have been extensively used, and some remarkable steel arch and suspension bridges have also been constructed. Overhead railways are virtually continuous bridge constructions, and much attention has been given to a study of the special conditions appertaining to that case.

_Substructure._

15. The substructure of a bridge comprises the piers, abutments and foundations. These portions usually consist of masonry in some form, including under that general head stone masonry, brickwork and concrete. Occasionally metal work or woodwork is used for intermediate piers.

When girders form the superstructure, the resultant pressure on the piers or abutments is vertical, and the dimensions of these are simply regulated by the sufficiency to bear this vertical load.

When arches form the superstructure, the abutment must be so designed as to transmit the resultant thrust to the foundation in a safe direction, and so distributed that no part may be unduly compressed. The intermediate piers should also have considerable stability, so as to counterbalance the thrust arising when one arch is loaded while the other is free from load.

For suspension bridges the abutment forming the anchorage must be so designed as to be thoroughly stable under the greatest pull which the chains can exert. The piers require to be carried above the platform, and their design must be modified according to the type of suspension bridge adopted. When the resultant pressure is not vertical on the piers these must be constructed to meet the inclined pressure. In any stiffened suspension bridge the action of the pier will be analogous to that of a pier between two arches.

_Concrete in a shell_ is a name which might be applied to all the methods of founding a pier which depend on the very valuable property which strong hydraulic concrete possesses of setting into a solid mass under water. The required space is enclosed by a wooden or iron shell; the soil inside the shell is removed by dredging, or some form of mechanical excavator, until the formation is reached which is to support the pier; the concrete is then shot into the enclosed space from a height of about 10 ft., and rammed down in layers about 1 ft. thick; it soon consolidates into a permanent artificial stone.

_Piles_ are used as foundations in compressible or loose soil. The heads of the piles are sawn off, and a platform of timber or concrete rests on them. Cast iron and concrete reinforced piles are now used. _Screw piles_ are cast iron piles which are screwed into the soil instead of being driven in. At their end is fixed a blade of cast iron from two to eight times the diameter of the shaft of the pile; the pitch of the screw varies from one-half to one-fourth of the external diameter of the blade.

_Disk piles_ have been used in sand. These piles have a flat flange at the bottom, and water is pumped in at the top of the pile, which is weighted to prevent it from rising. Sand is thus blown or pumped from below the piles, which are thus easily lowered in ground which baffles all attempts to drive in piles by blows. In ground which is of the nature of quicksand, piles will often slowly rise to their original position after each blow.

_Wells._--In some soils foundations may be obtained by the device of building a masonry casing like that of a well and excavating the soil inside; the casing gradually sinks and the masonry is continued at the surface. This method is applicable in running sands. The interior of the well is generally filled up with concrete or brick when the required depth has been reached.

_Piers and Abutments._--Piers and abutments are of masonry, brickwork, or cast or wrought iron. In the last case they consist of any number of hollow cylindrical pillars, vertical or raking, turned and planed at the ends and united by a projection or socket and by flanges and bolts. The pillars are strengthened against lateral yielding by horizontal and diagonal bracing. In some cases the piers are cast iron cylinders 10 ft. or more in diameter filled with concrete.

_Cylinder Foundations._--Formerly when bridge piers had to be placed where a firm bearing stratum could only be reached at a considerable depth, a timber cofferdam was used in which piles were driven down to the firm stratum. On the piles the masonry piers were built. Many bridges so constructed have stood for centuries. A great change of method arose when iron cylinders and in some cases brick cylinders or wells were adopted for foundations. These can be sunk to almost any depth or brought up to any height, and are filled with Portland cement concrete. They are sometimes excavated by grabs. Sometimes they are closed in and kept free of water by compressed air so that excavation work can be carried on inside them (fig. 35). Sometimes in silty river beds they are sunk 100 ft. or more, for [v.04 p.0546] security against deep scouring of the river-bed in floods. In the case of the Empress bridge over the Sutlej each pier consisted of three brick wells, 19 ft. in diameter, sunk 110 ft. The piers of the Benares bridge were single iron caissons, 65 ft. by 28 ft., sunk about 100 ft., lined with brick and filled with concrete. At the Forth bridge iron caissons 70 ft. in diameter were sunk about 40 ft. into the bed of the Forth. In this case the compressed air process was used.

16. _Erection._--Consideration of the local conditions affecting the erection of bridges is always important, and sometimes becomes a controlling factor in the determination of the design. The methods of erection may be classed as--(1) erection on staging or falsework; (2) floating to the site and raising; (3) rolling out from one abutment; (4) building out member by member, the completed part forming the stage from which additions are handled.

(1) In erection on staging, the materials available determine the character of the staging; stacks of timber, earth banks, or built-up staging of piles and trestles have all been employed, also iron staging, which can be rapidly erected and moved from site to site. The most ordinary type of staging consists of timber piles at nearly equal distances of 20 ft. to 30 ft., carrying a timber platform, on which the bridge is erected. Sometimes a wide space is left for navigation, and the platform at this part is carried by a timber and iron truss. When the headway is great or the river deep, timber-braced piers or clusters of piles at distances of 50 ft. to 100 ft. may be used. These carry temporary trusses of timber or steel. The Kuilenburg bridge in Holland, which has a span of 492 ft., was erected on a timber staging of this kind, containing 81,000 cub. ft. of timber and 5 tons of bolts. The bridge superstructure weighed 2150 tons, so that 38 cub. ft. of timber were used per ton of superstructure.

(2) The Britannia and Conway bridges were built on staging on shore, lifted by pontoons, floated out to their position between the piers, and lastly lifted into place by hydraulic presses. The Moerdyk bridge in Holland, with 14 spans of 328 ft., was erected in a similar way. The convenience of erecting girders on shore is very great, but there is some risk in the floating operations and a good deal of hauling plant is required.

(3) If a bridge consists of girders continuous over two or more spans, it may be put together on the embankment at one end and rolled over the piers. In some cases hauling tackle is used, in others power is applied by levers and ratchets to the rollers on which the girders travel. In such rolling operations the girder is subjected to straining actions different from those which it is intended to resist, and parts intended for tension may be in compression; hence it may need to be stiffened by timber during rolling. The bending action on the bottom boom in passing over the rollers is also severe. Modifications of the system have been adopted for bridges with discontinuous spans. In narrow ravines a bridge of one span may be rolled out, if the projecting end is supported on a temporary suspension cable anchored on each side. The free end is slung to a block running on the cable. If the bridge is erected when the river is nearly dry a travelling stage may be constructed to carry the projecting end of the girder while it is hauled across, the other end resting on one abutment. Sometimes a girder is rolled out about one-third of its length, and then supported on a floating pontoon.

(4) Some types of bridge can be built out from the abutments, the completed part forming an erecting stage on which lifting appliances are fixed. Generally, in addition, wire cables are stretched across the span, from which lifting tackle is suspended. In bridges so erected the straining action during erection must be studied, and material must be added to resist erecting stresses. In the case of the St Louis bridge, half arches were built out on either side of each pier, so that the load balanced. Skeleton towers on the piers supported chains attached to the arched ribs at suitable points. In spite of careful provision, much difficulty was experienced in making the connexion at the crown, from the expansion due to temperature changes. The Douro bridge was similarly erected. The girders of the side spans were rolled out so as to overhang the great span by 105 ft., and formed a platform from which parts of the arch could be suspended. Dwarf towers, built on the arch ring at the fifth panel from either side, helped to support the girder above, in erecting the centre part of the arch (Seyrig, _Proc. Inst. C.E._ lxiii. p. 177). The great cantilever bridges have been erected in the same way, and they are specially adapted for erection by building out.

_Straining Actions and Working Stresses._

17. In metal bridges wrought iron has been replaced by mild steel--a stronger, tougher and better material. Ingot metal or mild steel was sometimes treacherous when first introduced, and accidents occurred, the causes of which were obscure. In fact, small differences of composition or variations in thermal treatment during manufacture involve relatively large differences of quality. Now it is understood that care must be taken in specifying the exact quality and in testing the material supplied. Structural wrought iron has a tenacity of 20 to 22½ tons per sq. in. in the direction of rolling, and an ultimate elongation of 8 or 10% in 8 in. Across the direction of rolling the tenacity is about 18 tons per sq. in., and the elongation 3% in 8 in. Steel has only a small difference of quality in different directions. There is still controversy as to what degree of hardness, or (which is nearly the same thing) what percentage of carbon, can be permitted with safety in steel for structures.

The qualities of steel used may be classified as follows:--(a) Soft steel, having a tenacity of 22½ to 26 tons per sq. in., and an elongation of 32 to 24% in 8 in. (b) Medium steel, having a tenacity of 26 to 34 tons per sq. in., and 28 to 25% elongation. (c) Moderately hard steel, having a tenacity of 34 to 37 tons per sq. in., and 17% elongation, (d) Hard steel, having a tenacity of 37 to 40 tons per sq. in., and 10% elongation. Soft steel is used for rivets always, and sometimes for the whole superstructure of a bridge, but medium steel more generally for the plates, angle bars, &c., the weight of the bridge being then reduced by about 7% for a given factor of safety. Moderately hard steel has been used for the larger members of long-span bridges. Hard steel, if used at all, is used only for compression members, in which there is less risk of flaws extending than in tension members. With medium or moderately hard steel all rivet holes should be drilled, or punched 1/8 in. less in diameter than the rivet and reamed out, so as to remove the ring of material strained by the punch.

In the specification for bridge material, drawn up by the British Engineering Standards Committee, it is provided that the steel shall be acid or basic open-hearth steel, containing not more than 0.06% of sulphur or phosphorus. Plates, angles and bars, other than rivet bars, must have a tensile strength of 28 to 32 tons per sq. in., with an elevation of 20% in 8 in. Rivet bars tested on a gauge length eight times the diameter must have a tensile strength of 26 to 30 tons per sq. in. and an elongation of 25%.

18. _Straining Actions._--The external forces acting on a bridge may be classified as follows:--

(1) The _live_ or _temporary load_, for road bridges the weight of a dense crowd uniformly distributed, or the weight of a heavy wagon or traction engine; for railway bridges the weight of the heaviest train likely to come on the bridge. (2) An allowance is sometimes made for _impact_, that is the dynamical action of the live load due to want of vertical balance in the moving parts of locomotives, to irregularities of the permanent way, or to yielding of the structure. (3) The _dead load_ comprises the weight of the main girders, flooring and wind bracing, or the total weight of the superstructure exclusive of any part directly carried by the piers. This is usually treated as uniformly distributed over the span. (4) The _horizontal pressure_ due to a wind blowing transversely to the span, which becomes of importance in long and high bridges. (5) The _longitudinal drag_ due to the friction of a train when braked, about one-seventh of the weight of the train. (6) On a curved bridge the _centrifugal load_ due to the radical acceleration of the train. If w is the weight of a locomotive in tons, r the radius of curvature of the track, v the velocity in feet per sec.; then the horizontal force exerted on the bridge is wv^2/gr tons. (7) In some cases, especially in arch and suspension bridges, changes of temperature set up stresses equivalent to those produced by an external load. In Europe a variation of temperature of 70° C. or 126° F. is commonly assumed. For this the expansion is about 1 in. in 100 ft. Generally a structure should be anchored at one point and free to move if possible in other directions. Roughly, if expansion is prevented, a stress of one ton per sq. in. is set up in steel structures for each 12° change of temperature.

i. _Live Load on Road Bridges._--A dense crowd of people may be taken as a uniform load of 80 to 120 lb per sq. ft. But in recent times the weight of traction engines and wagons which pass over bridges has increased, and this kind of load generally produces greater straining action than a crowd of people. In manufacturing districts and near large towns loads of 30 tons may come on road bridges, and county and borough authorities insist on provision being made for such loads. In Switzerland roads are divided into three classes according to their importance, and the following loads are prescribed, the designer having to provide sufficient strength either for a uniformly distributed crowd, or for a heavy wagon anywhere on the roadway:-- [v.04 p.0547]

| Crowd, | Wagon, | lb per sq. ft. | tons per axle. | | Main Roads ....... | 92 | 10 with 13 ft. wheel base Secondary Roads .. | 72 | 6 " 10 " " Other Roads ...... | 51 | 3 " 8 " "

In England still larger loads are now provided for. J.C. Inglis (_Proc. Inst. C.E._ cxli. p. 35) has considered two cases--(a) a traction engine and boiler trolley, and (b) a traction engine and trucks loaded with granite. He has calculated the equivalent load per foot of span which would produce the same maximum bending moments. The following are some of the results:--

Span Ft. |10. |20. |30. |40. |50. | | | | | | | Equivalent load in tons per ft. run, | | | | | | Case a ............................. |1.75|0.95|0.70|0.73|0.72| Do. Case b ......................... |3.25|1.7 |1.3 |1.2 |1.15|

Large as these loads are on short spans, they are not more than must often be provided for.

_Live Load on Railway Bridges._--The live load is the weight of the heaviest train which can come on the bridge. In the earlier girder bridges the live load was taken to be equivalent to a uniform load of 1 ton per foot run for each line of way. At that time locomotives on railways of 4 ft. 8½ in. gauge weighed at most 35 to 45 tons, and their length between buffers was such that the average load did not exceed 1 ton per foot run. Trains of wagons did not weigh more than three-quarters of a ton per foot run when most heavily loaded. The weights of engines and wagons are now greater, and in addition it is recognized that the concentration of the loading at the axles gives rise to greater straining action, especially in short bridges, than the same load uniformly distributed along the span. Hence many of the earlier bridges have had to be strengthened to carry modern traffic. The following examples of some of the heaviest locomotives on English railways is given by W.B. Farr (_Proc. Inst. C.E._ cxli. p. 12):--

_Passenger Engines._

Total weights, tons ......... 84.35 | 98.90 | 91.90 | 85.48 Tons per ft. over all ....... 1.58 | 1.71 | 1.62 | 1.61 Tons per ft. of wheel base .. 1.92 | 2.04 | 1.97 | 1.95 Maximum axle load, tons ..... 19.00 | 16.00 | 18.70 | 18.50

_Goods Engines._

Total weight, tons .......... 77.90 | 78.80 | 76.46 | 75.65 Tons per ft. over all ....... 1.54 | 1.50 | 1.54 | 1.51 Tons per ft. of wheel base .. 2.02 | 2.02 | 2.03 | 2.00 Maximum axle load, tons ..... 15.90 | 16.00 | 13.65 | 15.50

_Tank Engines._

Total weight, tons .......... 53.80 | 58.61 | 60.80 | 47.00 Tons per ft. over all ....... 1.60 | 1.68 | 1.70 | 1.55 Tons per ft. of wheel base .. 2.45 | 2.52 | 2.23 | 3.03 Maximum axle load, tons ..... 17.54 | 15.29 | 17.10 | 15.77

Farr has drawn diagrams of bending moment for forty different very heavy locomotives on different spans, and has determined for each case a uniform load which at every point would produce as great a bending moment as the actual wheel loads. The following short abstract gives the equivalent uniform load which produces bending moments as great as those of any of the engines calculated:--

Span in Ft. | Load per ft. run equivalent | to actual Wheel Loads in Tons, | for each Track. | 5.0 | 7.6 10.0 | 4.85 20.0 | 3.20 30.0 | 2.63 50.0 | 2.24 100.0 | 1.97

Fig. 36 gives the loads per axle and the distribution of loads in some exceptionally heavy modern British locomotives.

[v.04 p.0548] In Austria the official regulations require that railway bridges shall be designed for at least the following live loads per foot run and per track:--

| Span. | Live Load in Tons. | | - - - - - - - -|- - - - - - - - - - - - - - - -| |Metres. | Ft. | Per metre run. | Per ft. run. | | | | | | | 1 | 3.3 | 20 | 6.1 | | 2 | 6.6 | 15 | 4.6 | | 5 | 16.4 | 10 | 3.1 | | 20 | 65.6 | 5 | 1.5 | | 30 | 98.4 | 4 | 1.2 |

It would be simpler and more convenient in designing short bridges if, instead of assuming an equivalent uniform rolling load, agreement could be come to as to a typical heavy locomotive which would produce stresses as great as any existing locomotive on each class of railway. Bridges would then be designed for these selected loads, and the process would be safer in dealing with flooring girders and shearing forces than the assumption of a uniform load.

Some American locomotives are very heavy. Thus a consolidation engine may weigh 126 tons with a length over buffers of 57 ft., corresponding to an average load of 2.55 tons per ft. run. Also long ore wagons are used which weigh loaded two tons per ft. run. J.A.L. Waddell (_De Pontibus_, New York, 1898) proposes to arrange railways in seven classes, according to the live loads which may be expected from the character of their traffic, and to construct bridges in accordance with this classification. For the lightest class, he takes a locomotive and tender of 93.5 tons, 52 ft. between buffers (average load 1.8 tons per ft. run), and for the heaviest a locomotive and tender weighing 144.5 tons, 52 ft. between buffers (average load 2.77 tons per ft. run). Wagons he assumes to weigh for the lightest class 1.3 tons per ft. run and for the heaviest 1.9 tons. He takes as the live load for a bridge two such engines, followed by a train of wagons covering the span. Waddell's tons are short tons of 2000 lb.