Construction Method of Float-Bridge for Various Field

Conditions

Helmy Alvianie
Politeknik Negeri Bandung, Bandung, Indonesia

*[email protected]

Abstract. Cilacap floating bridge is a pilot project by PUSJATAN that would be applied to
various regions in Indonesia. There is four work items at Cilacap floating bridge, that is
fabrication, lifting, towing, and assembly. When the construction process, the bridge has a
structural failure. So it is necessary to review the construction method to determine the reason
of structural failure. The analysis is done by did some simulation with load displacement for
each stage of works to find the reliable method of implementing a floating bridge. The first
stage is fabrication, the quality and dimension of steel material must be accordance with shop
drawing and also the material should have through the testing required. Second stage is lifting
by analyzing hook crane to determine the bridge structural. The analysis is simulating with
load displacement 1000mm and 1800mm direction x,y,z. Result from analysis is known that
lifting bridge is not allowed to move 1000mm for x,y,z direction and the ultimate move for
1800mm. Then on the towing stage have to use reinforcement to pontoon bridge with modular
pontoon system. Simulation of movement by input load displacement 1000mm with 6
different towing condition. Result for the analysis known that structure can hold displacement
until 1000mm to condition-1 and condition-2 with maximum value of load structure
20,15MPa, condition-3 29,59MPa and condition-6 20,52MPa. While condition-4 is limit to
800mm with value 19,89MPa. The last stage is the assembly. Things who necessary in this
stage is the sequence every work item. That is because every sequence can take effect to the
bridge structure.

1. Introduction
1.1 Background
Infrastructure plays an essential role in economic growth regardless of the development level:
developed or less developed. The urgency is especially for transportation infrastructures like
highways, rivers, seas, air, railways, and bridges. Bridge is one kind of the infrastructure that is
expected to intensify development in Indonesia. Given Indonesia's geographical conditions which are
often separated by a river or sea flow, bridges may connect critical area in the community. The
alternatives may vary. In this study, the floating bridge was observed, taking Cilacap floating bridge
as the object.

The Cilacap floating bridge is the first floating bridge in Indonesia and is a pilot project for leveling
the country's development in accordance with Presidential Regulation No. 2 of 2015 concerning the
2015-2019 National Medium-Term Development Plan (RPJMN). The Cilacap floating bridge was
built to connect the Lempong Pucung area of Ujung Alang Village with Nusakambangan Island which
is separated by a 50 meter wide river. Floating bridges are considered to be the most effective media
in this area due to socio-geographical form. Firstly, there has been a discovery of sediments at the site,
wherein the bridge will be built in a depth of 30 meters.Furthermore, transportation is limited to the
area.

The floating bridge was designed by utilizing separate pontoons so as not to disturb the traffic of
fishing boats which often pass through this area. The construction method of the Cilacap floating
bridge was carried out in a different place with the location of the bridge itself so that it requires 4
(four) stages of bridge construction, namely the assembly stage, lifting, withdrawal and bridge
installation stage.

1.2 Problem
Considering the urgency of this bridge to be built, there must be a way for engineer to construct well-
designed bridge. It is questioned how engineer may improve the reliability of floating bridge
construction methods if one is to implement them in various conditions.

1.3 Objective
The aim of this study was to design a steel frame floating bridge construction method by PUSJATAN, in order
to make it more reliable. The study considered its basis for implementation in a variety of conditions, hence the
formulation is expected to overcome problems during assembly, withdrawal, and installation. The reliability
parameters are determined in terms of the quality of the bridges built according to the quality of the plan.

2. Methodology
A methodology is a breakdown of the steps taken to solve a problem. The method adopted in
completing this thesis is as follows.
Conduct a literature review that supports the writing of the argument.
Collection of project data obtained from Dru PUSJATAN and technical data through direct
observation in the site.
Review assembly work in the form of standard procedures for steel frame assembly and pontoons.
Analyzing the task of lifting the steel frame floating bridge by making a hook configuration and
analyzing the strength of the structure at the time of lifting;
Examining the work of steel frame floating bridges by predicting conditions and simulations to
determine the limits of structural strength at the time of withdrawal and conducting simulation
experiments by making a 1:50 scale steel frame floating bridge model.
Analyze the work of installing a steel frame floating bridge by making the right installation steps, to
maintain the stability of the structure to be applied.

3. Result And Discussion

3.1 Bridge Technical Data
The floating bridge structure has the following construction classifications and material data.
Usability : Pedestrian
Structure : Steel Frame
Load Class : Class C Bridge
Total Span : 70,772 Meters
Span Main Frame : 46,772 Meters
Close Span : 12,000 Meters
Road Bridge Width : 2,000 Meters
Bridge Height : 7.323 Meters
Total Ponton : 2 Pieces

3.2 Bridge Preparation

Before the implementation of the bridge work, preparatory work is carried out in advance. The
purpose of this preparatory work is to arrange equipment, building aids, and other supporting facilities
in such a way that the implementation of work can run efficiently, smoothly, safely and accordingly.
3.2.1 Understanding of Shop Drawing
Shop drawings are field technical drawings that are used as a reference for conducting work. Shop
drawing is composed by a contractor, who has submitted an approval to the MK / Supervising
Consultant / Owner prior to work. Shop drawing images must be made in detail, hence may close
room of image interpretation that might occur in the field.

3.2.2 Tools Preparation

The selection of heavy equipment plays a significant role. Equipment is considered to have high
capacity if it produces high or reliable production at low cost. In the floating bridge case, the
operation uses a mobile crane. Mobile crane is one variety of alternative crane tower in heavy
equipment which covers height with mobility.

3.2.3 Materials Preperatio

The material used in the work must be in accordance with the shop drawing that has received approval
from the MK / Supervisory Consultant / Owner, both material quality or type of material used.

3.3 Bridge Assembly

3.3.1 Bridge Frame Assembly
Before performing the assembly stage, there are several things to be ascertained in advance,
including:
a. The quality and dimensions of steel frame materials used must be in accordance with shop
drawings.
b. The neutral line of each rod that meets must intersect through one point so that the right shape of the gusset
plate needs to be planned.

3.3.2 Pontoon Assembly

Pontoon assembly begins with the preparation of foam modules, reinforcement and formwork on the
pontoon, concrete casting and curing as shown in the following flow diagram.

No

Yes

Figure 1. Pontoon Fabrication Flow Chart

3.3.3 Abutment Making and Drafting

The construction of abutments begins with the bridge measurement and abutment operation.
Furthermore, the installation of floating bridges in rivers generally has the same stages as on land but
the difference is in the initial stages. Where if the land prepared for erection is usually in the plate for
the base of the tool, but above the water is prepared the foundation for the tools which can use wood
as support even with a pontoon anchored or fixed depending on the needs and loads of the tool itself.

3.4 Bridges Lifting

3.4.1 Lifting Behavior Analysis
Prior to lifting work, it is crucial to analyze whether the lifting affects the structure or not. This
checking is helpful as it may lead to check whether the preceding method option is feasible.
Furthermore, it may make ease to measure how much impact is given toward structure at the time of
lifting hence it is indisputable and able to maintain structural stability.
This structural analysis was carried out using MIDAS Civil Version 2011 software by modeling the
bridge's main frame span. Analysis is conducted using material properties from material specifications
in the field. The analysis will use a dead load of its weight according to material properties, while for
structural geometry refers to the shop drawing image used in the field.

After identifying the maximum stress that occurs due to the weight itself then observing the behavior
of the structure, namely by providing horizontal (x and y) and vertical (z) load displacement on one of
the supports. The aim is to determine the difference in crane movement that is permitted. The changes
in structural behavior occur as follows:

 1000 mm Displacement Load on –X direction hangers

Figure 2. Maximum Stress Result Due to 1000 mm Displacement to X-Direction

The maximum stress result due to 1000 mm x-direction displacement load on the crane hook point is
70.71 MPa while the permissible stress value is 231 MPa, meaning that the structure is strong enough
to withstand the stress that occurs.

 1800 mm Displacement Load on direction -x hanger (Ultimate Displacement)

Figure 3. Maximum Stress Result Due to Displacement Load 1800 mm to X-direction

The maximum stress results due to the 1800 mm x-direction displacement load on the crane hook
point of 108.32 MPa while the permissible stress value is 231 MPa, meaning that the structure is
strong enough to withstand the stresses that occur.

 1000 mm Displacement Load on y-direction hangers

Figure 4. Maximum Stress Result due to 1000 mm Displacement Load to Y-direction

Hasil Tegangan maksimum akibat load the 1000 mm y-direction displacement on the hook crane
point is 38.57 MPa while the permissible stress value is 231 MPa, meaning that the structure is strong
enough to withstand the stresses that occur.

 1800 mm Displacement Load on y-direction hanging (Ultimate Displacement)

Figure 5. Maximum Stress Result due to Displacement Load 1800 mm to Y-direction

The maximum stress results due to the 1800 mm y-direction displacement load on the crane hook
point of 38.64 MPa while the permissible stress value is 231 MPa, meaning that the structure is strong
enough to withstand the stresses that occur.
 1000 mm Displacement Load on the Z-direction hanger

Figure 6. Maximum Stress Result Due to 1000 mm Displacement Load to Z-Direction

The maximum stress result due to 1000 mm displacement load on the crane hook point is 57.24
MPa while the permissible stress value is 231 MPa, meaning that the structure is strong enough to
withstand the stress that occurs.

 1800 mm Displacement Load on the -Z direction (Ultimate Displacement)

Figure 7. Maximum Stress Result due to Displacement Load 1800 mm to Z-Direction

The maximum stress results due to 1800 mm displacement load on the crane hook point of 59.82
MPa while the permissible stress value is 231 MPa, meaning that the structure is strong enough to
withstand the stresses that occur.
The results of structure behavior on load displacement showed that the difference of bridge
structure movement is feasible. Lifting the bridge is allowed to move horizontally (x and y) and
vertically (direction Z) as far as 1 meter and ultimate movement as far as 1.8 meters. The structure is
strong enough for lifting. However, in the implementation of the bridge frame lifting, it is
recommended that the crane is controlled to move simultaneously.

3.4.2 Floating Bridge Lifting

After the analysis of lifting the floating bridge, frame is completed, the next step is the
implementation of lifting the bridge frame onto the pontoon. The stages of the work are as follows:
a. Monitor and be convinced that the appointment plan uses procedures accordingly as approved by
the relevant supervisor.
b. Monitor and be convinced that the area around mobile crane has strong soil and flat (do
compaction and stockpiling if necessary), and the mobile crane can access the assembly location.
c. Position 2 (two) mobile cranes with symmetrical floating bridges on the bridge as shown below.

Figure 8. Crane Position and Floating Bridge Before Lifting

d. Prepare a mobile crane to lift the bridge steel frame.

e. Prepare the bridge by tying the bridge according to the planned hook point, namely the hook
point for lifting and the hook point for bridge control.
f. Install the safety line in the crane and lifting movement area so that no one is in the lifting area
other than the relevant officer.
g. Appointment is adjusted to procedures approved by the relevant officer.
h. After the pontoon is at sea, the pontoon is placed according to the specified distance. So that the
pontoon's position does not change position by the current, the pontoon is tied to the land.
i. The transfer of the bridge circuit from land to the pontoon uses 2 (two) cranes that can lift a load
of 30 tons.
j. Control the movement of the bridge frame, the two ends of the bridge are tied and controlled by
the officer.

3.5 Bridge Pulling

3.5.1 Bridge Pulling Analysis

Before the bridge pulling of Cilacap floating bridge, an analysis is conveyed in advance to determine
the stresses that occur during pulling. Throughout construction, environmental loads are the main
burden that happens on floating bridges. However, due to water waves and winds that are perverse to
estimate, the loading is simulated in the form of displacement loads. The environmental load can
rotate the bridge or move the bridge randomly; therefore displacement simulations are carried out as
shown in Exhibit 9.62.

Figure 9. Loading Simulation during Pulling Out

Bridge modeling with Midas Civil 2013 software was performed by modeling the geometry and
material properties of the existing Cilacap floating bridge, as shown below.

Figure 10. Position of Load and Placement

As for the 6 (six) simulations carried out, the extreme conditions are known as 6-conditions. The
following are the results of his observations.

In condition 6, modeling the stability of stability on the bridge during withdrawal, by providing
displacement in the direction of z, as shown below.

Figure 11. Displacement values given for stability

 Maximum Stress results due to displacement with the value given in Exhibit 9.61. with condition 6
at the fulcrum / reaction bridge position, which is 493.55 MPa while the value of the permit Stress is
350 MPa. Not safe.

Figure 12. Condition of 6 Stress Due to Displacement

The results showed that the maximum stress which exceeds the permit Stress tends to occur at the
displacement condition with both moving pedestals, i.e. condition 1, condition 2, condition 4 and
condition 6. The following is a summary of the results of the draw analysis on the Cilacap floating
bridge.

Table 1. Summary of Analysis Results

Tegangan Maksimum < Tegangan Izin
Kondisi Displacement (mm)
10 25 50 100 500 1000
1 Aman Aman Aman Tidak Aman Tidak Aman Tidak Aman
2 Aman Aman Aman Tidak Aman Tidak Aman Tidak Aman
3 Aman Aman Aman Aman Aman Aman
4 Aman Aman Aman Aman Tidak Aman Tidak Aman
5 Aman Aman Aman Aman Aman Aman
6 Aman Aman Tidak Aman Tidak Aman Tidak Aman Tidak Aman

3.5.2 Strengthening with Modular Pontoon

Based on research conducted by Ali Halim Saleh, floating bridges must basically be rigid so that they
can withstand forces due to water and wind currents. As the matter of fact, reinforcement of steel
frame floating bridges is carried out by making floating bridge pontoons with a modular tomporary
system as shown in Exhibit13 because during the construction period the bridge will receive loads that
are not intended.

Figure 13. Floating Bridge with Continuous Ponton

With continuous ponton configurations temporarily the frame can stand like on the ground and not
accept the load that occurs during the construction pulling period. Before reinforcement is given, an
analysis of the steel frame conveyed because the load will be distributed to the frame. However, after
being given a reinforcement in the form of a modular pontoon, the power will focus on the pontoon.

Afterward, pontoon analysis by modeling the entire structure, the bridge and pontoon frame, is shown
in Figure 14. The analysis was conducted using the SAP2000 program with the AASHTO concrete
standard according to the material properties used, namely fc 30. The following are the stages of study
carried out:
 Figure 14. Modeling of Cilacap and Modular Ponton Floating Bridges

After the analysis, it was found that almost all conditions experienced increased stiffness, the
following are the results of the analysis of Condition-1.

Figure 15. Pontoon Maximum Stress - Condition 1 (1000 mm)

Figure 16 Pontoon Minimum Stress - Condition 1 (1000 mm)

Table 2. Resume of Ponton Stress - Condition 1 (1000 mm)

TABLE: Element Forces - Area Shells
OutputCase CaseType FMax FMin
Text Text N/mm N/mm
Max 20.15 3.92
COMB-1
Min -5.01 -16.80

The maximum Stress results due to 1000 mm load displacement in the direction of X at the pontoon
point of 20.15 MPa while the permissible Stress value is 30 MPa, meaning that the strong structure
withstand the stresses that occur. The summary is as follows:

Table 3. Summary of analysis results

KONDISI AMAN MAKSIMAL 1000mm
TANPA DENGAN DENGAN PERKUATAN
NO KONDISI PERKUATAN PERKUATAN PERKUATAN PONTON
(mm) 1 (mm) 2 (mm) (mm)
1 KONDISI 1 50 50 50 1000
2 KONDISI 2 50 50 50 1000
3 KONDISI 3 1000 1000 1000 1000
4 KONDISI 4 100 100 100 800
5 KONDISI 5 1000 1000 1000 600
6 KONDISI 6 25 25 25 1000
3.5.3 Pontoon Pulling Experiment
This experiment was conducted to prove the method used in the study in order to produce the right
method to maintain the quality in accordance with the plan. It is imperative to test whether the
configuration is feasible to apply to floating bridges. The following is an experiment conducted on a
floating bridge with a scale of 1:50 for the withdrawal of floating bridges with the aim of matching
bridge movements and the stability of the additional configuration.

i. Objective
Proving that the method used in the study is appropriate in maintaining the quality in accordance
with the plan and to improve the conditions of transportation in the field that was conducted
beforehand.

ii. Equipment and Materials

a. Glasswool strap
b. PVC pipe
c. Stereofoam
d. Scissors
e. Cutter
f. Glue
g. Measuring Instrument
h. Miniature model of steel frame with a scale of 1.4m in length.
i. Miniature scale boat model 0.18m x 0.02m x 0.014m.
j. Modular Pontoon with acrylic measuring 0.12m x 0.05m x 0.025m.

iii. Steps
a. Cut styrofoam measuring 0.16m x 0.08m x 0.025m as a pontoon.
b. Cut the PVC pipe along 0.025m as a pontoon plate (hook point of withdrawal).
c. Assemble tools and materials that have been prepared following the Cilacap floating bridge.
The bridge frame is placed on styrofoam pontoons, and the pontoon is affixed with a PVC
pipe to simulate the plate. Afterwards, the modules of modular pontoons are arranged
according to plan like Figure 17.

Figure 17. Modular Ponton Model and Floating Bridge

d. Tie the plate with the glaswool strap to the boat with 2 hook points on the pontoon, 2
binding points on the rear rope and the system adjusts Y tow at the front point of the draw
according to the plan as shown below.

.
Figure 18. (a) 2 Hook Points on the Pontoon (b) Adjust Y Tow System on the Front Point of
Pulling
e. Utilizing the configuration, make a pulling and check the ease of maneuvering on a flat
plane whether it is suitable or feasible to be applied to the floating bridge. The floating
bridge maneuvering procedures such as container trucks are the first front boat and the rear
boat as support and the draft follows the motion of the front boat and petrified the bridge
turns with the addition of boat speed on the outer side of the turn and reduction on the rear
side.

Figure 19. Maneuver of Bridge with Boat-1

Figure 20. Maneuver of Bridge with Boat-2

Figure 21. Maneuver of Bridge with Boat-3

f. From checking on a flat plane, it is concluded that the maneuver is following the plan. After
being tested on a flat plane, the test is then carried out on water.
g. From checking the maneuver then check on the water with the corresponding configuration
that is performed on land. However, when checking on water, there are obstacles, namely
the rope for Y tow configuration is not biased with a rope because when it is wet, the rope is
jammed and cannot move. Consequently, a solution is needed in the form of a ring or ring as
a connector as previously explained.

Figure 22. Maneuvering of Bridge over the water

iv. Conclusion
After conducting a floating bridge draw experiment it can be concluded that:
a. Overall the rope and boat configuration moves accordingly as planned.
b. The use of temporary modular pontoons makes the steel frame intact and stable at the time
of withdrawal.
c. The rope tie is needed by the ring or ring on the y tow position and the boat so that the rope
configuration can move when the rope is wet.

3.6 Bridge Installation

In the installation of bridges there are several elements that need to be considered, namely measuring
the width of the river and the elevation of the river to find out the effective length of the bridge and
knowing the land that must be cut or filled, making abutments and approaching bridge rails, bridge
maneuvers during installation, erection and installation approach range.

Following are some of the steps to floating bridge anchoring:

a. After the location to lower the anchor is determined, measure the depth of the location and check
the space availability.
b. Slowly drop the anchor from the top of the pontoon to land and underwater as shown in Exhibit
IV.126.
c. Tie the anchor strap to the connection point between the pontoon and the outer steel frame
structure on both the left and right sides of the bridge.
d. Check anchorage using reference points.
e. After successful installation, remove the temporary (pontoon modular) reinforcement.

Figure 23. Mooring System Under Water

4. Conclusion
The conclusions can be drawn as follow:
a. The quality and dimensions of steel frame material must be in accordance with shop drawings. In
addition, the material must go through the required testing.
b. The analysis of the behavior of the structure due to load displacement on the crane hook point
showed that the difference in movement of the bridge structure is feasible to use. Lifting the
bridge is allowed to move horizontally (x and y) and vertically (direction Z) as far as 1 meter and
ultimate movement as far as 1.8 meters. The structure is sturdy enough for lifting. However, in
the implementation of the bridge frame lifting, it is recommended that the crane is controlled to
pass simultaneously.
c. The structure can withstand displacements up to 1000mm in condition-1 and condition-2 with the
maximum structural stress of 20.15MPa, condition-3 of 29.59MPa and condition-6 of 20.52MPa;
whereas the 4th condition is limited to 800mm with a Stress of 28.70MPa and 5-conditions
limited to 600mm with a Stress of 19.89MPa.
d. As for installation, it is essential to highlight the sequence of each work since every step may
affect construction structure.

References
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[4] 1998., Persyaratan Teknis Aksesibilitas Pada Bangunan Umum Dan Lingkungan., Indonesia:
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[5] Iswanto, 2016., Pekerjaan Pengangkatan Struktur Baja Jembatan Apung., Indonesia: Politeknik
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