Bridge construction has advanced rapidly over recent decades, driven by the need for faster, safer, and more cost-efficient infrastructure. Among the most important innovations transforming this field are launching gantries, specialized machines that lift and position large bridge segments with exceptional precision.

These systems have become essential in the construction of long-span and precast segmental bridges, where accuracy and speed are crucial. Launching gantries allow builders to assemble entire bridge decks in the air, eliminating the need for cranes or temporary scaffolding on the ground.

What Are Launching Gantries?

A launching gantry (also called a bridge launching girder) is a large truss system used to lift, transport, and position precast concrete bridge segments. Unlike cranes that depend on ground-level support, launching gantries move along the bridge alignment and place each segment directly above the piers.

They are usually made of high-strength steel and equipped with hydraulic jacks, winches, and trolleys that enable controlled vertical and horizontal movement. Depending on site conditions, launching gantries can be configured to operate above the bridge deck (overhead) or below it (underslung).

Their self-launching capability allows the equipment to shift from one span to the next without disassembly. This feature saves time, reduces setup effort, and increases productivity, especially in large-scale viaducts and elevated highway or railway projects.

Key Advantages of Launching Gantries

1. High Precision and Alignment

Launching gantries achieve millimeter-level accuracy when placing precast segments. This ensures perfect alignment of each piece, contributing to the strength, performance, and durability of the entire bridge.

2. Faster Construction with Reduced Downtime

By automating lifting and placement, launching gantries speed up the assembly process and reduce downtime between spans. Projects that previously took months using traditional methods can progress faster and more continuously, meeting demanding construction schedules.

3. Improved Safety

Because launching gantries operate directly above the piers, they reduce the need for workers to operate at height or near suspended loads. This greatly decreases accident risks and creates a safer working environment for construction teams.

4. Adaptability to Complex Bridge Designs

Modern launching gantries can handle curved alignments, variable slopes, and wide decks. Advanced articulations and hinge points make it possible to adapt to different geometries without compromising precision or load distribution.

5. Reduced Environmental Impact

Since launching gantries operate above the bridge structure, they require no temporary supports on the ground. This minimizes ecological disruption in rivers, valleys, or urban areas and helps maintain environmental integrity.

6. Cost and Labor Efficiency

A single gantry can perform the work of several cranes. This reduces labor requirements, simplifies logistics, and lowers overall construction costs. It also eliminates the need for heavy ground-based lifting equipment, which is often difficult to transport or operate in remote areas.

Applications of Launching Gantries

Launching gantries are used in a wide variety of bridge construction projects, including:

• Precast segmental bridges
• Metro and railway viaducts
• Elevated highways and flyovers
• River and valley crossings

They are especially efficient for projects with repetitive spans and high precision requirements, where ground access is limited or unsuitable for cranes.

Strukturas: A Global Authority in Launching Gantry Systems

Strukturas, a Norway-based company with more than 30 years of experience, is one of the world’s leading providers of bridge construction technology. Their launching gantries have been used in major projects throughout Europe, the Middle East, and Asia, recognized for their performance, safety, and long-term reliability.

Strukturas designs both overhead and underslung launching gantries, each customized to meet specific project needs such as span length, bridge curvature, and load capacity. All systems comply with Eurocode 3 and EN-1090 standards and are built from high-quality structural steel grades such as Q235 and Q345 for superior strength and fatigue resistance.

In addition to manufacturing, Strukturas offers complete project services, including design, assembly, testing, training, and on-site supervision. Their deep expertise ensures seamless integration of equipment into each construction process, even under challenging site conditions.

Innovations and Technical Excellence

Strukturas’ launching gantries feature advanced hydraulic systems that provide smooth segment handling, accurate load balancing, and precise positioning. Many of their models are modular, allowing them to be reused for different projects and adapted to changing structural requirements.

Systems such as the JP50/40 model are capable of handling spans of up to 40 meters while maintaining high stability and operational efficiency. These innovations reflect Strukturas’ commitment to combining engineering precision with practical on-site usability.

Why Choose Strukturas for Launching Gantries

• Tailored Engineering: Custom-built systems for specific bridge geometries and site conditions.
• Certified Quality: Designed and produced under Eurocode 3 and EN-1090 standards.
• Comprehensive Service: From design and fabrication to operation and dismantling.
• Proven Experience: Equipment successfully deployed in projects worldwide.
• Sustainability Focus: Modular systems designed for reuse and reduced environmental impact.

Launching gantries are among the most efficient tools available for modern bridge construction. Their ability to lift, move, and position heavy bridge segments with precision makes them essential for fast, safe, and sustainable infrastructure projects.

Strukturas continues to lead this field with state-of-the-art launching gantries that combine durability, safety, and performance. For contractors and engineers seeking reliable equipment and technical excellence, Strukturas remains a trusted partner for bridge construction worldwide.

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Introduction

Eurocode 3 (EN 1993) serves as the European standard for steel structure design, while EN-1090 governs manufacturing compliance, together forming the foundation of safe, reliable bridge construction across Europe. These standards are critical for ensuring structural integrity and safety in modern bridge projects, particularly when working with specialized bridge construction equipment like Movable Scaffolding Systems and Form Travellers.

Specialized bridge construction equipment such as Movable Scaffolding Systems (MSS) and Form Travellers represents the backbone of efficient, safe bridge assembly. These systems must handle heavy loads while maintaining structural integrity throughout complex construction phases, making compliance with the strictest design and manufacturing standards absolutely essential.

What This Guide Covers

This guide covers Eurocode 3 design principles for structural steel applications, EN-1090 manufacturing requirements for steel components, compliance essentials for specialized bridge equipment, and practical implementation strategies for construction projects.

Who This Is For

This guide is designed for bridge engineers, construction managers, steel fabricators, and project managers involved in European bridge construction projects. Whether you are designing suspension bridges or managing the fabrication of structural components, you will find actionable insights for ensuring compliance and project success.

Why This Matters

Understanding these standards directly impacts structural safety, regulatory compliance, and successful project delivery. Non-compliance can result in structural failures, legal issues, and significant financial losses, making mastery of these standards essential for professional success in the construction industry.

Understanding Eurocode 3 (EN 1993): The Foundation of Structural Steel Bridge Design

Eurocode 3 (EN 1993) is the European standard for the design of steel structures, encompassing bridges, building structures, and industrial applications using structural steel as the primary material. It ensures consistent design practices across Europe by providing engineers with reliable methods for calculating load-bearing capacity and ensuring structural integrity.

It includes design principles for various steel grades such as Q235 and Q345, describing their chemical composition, yield strength, tensile strength, and elongation properties. These steel grades are essential in balancing cost, weldability, and mechanical performance for modern infrastructure.

Eurocode 3 uses ultimate limit state and serviceability limit state principles to ensure structures remain safe under maximum and long-term loading conditions. It also includes fatigue assessment, vibration control, and corrosion resistance criteria.

Steel Properties and Characteristics in Modern Bridge Construction

Selecting the right structural steel is critical for bridge performance. The most common steels, Q235 and Q345, are chosen based on their mechanical and chemical properties.

Q235 Steel: Known for cost-effectiveness and weldability, with a tensile strength of 370–500 MPa and elongation around 26%. It is comparable to ASTM A36 (US) and S235JR (Europe).

Q345 Steel: Offers higher yield strength (around 345 MPa) and tensile strength (470–660 MPa). It contains low carbon (below 0.2%) and alloying elements like manganese and silicon, enhancing toughness and corrosion resistance. Q345 steel performs well in cold climates and under dynamic loads, making it ideal for arch bridges, suspension bridges, and heavy-duty structures.

Both steels can be galvanized or powder-coated to improve durability and reduce corrosion.

EN-1090: Manufacturing and Fabrication Standards for Steel Components

EN-1090 complements Eurocode 3 by defining manufacturing, fabrication, and welding standards for steel components. It ensures design intent translates into field reliability through strict control of materials, welding, heat treatment, and testing.

Execution Classes

EN-1090 defines four Execution Classes (EXC1–EXC4), which correspond to increasing levels of complexity and safety:

• EXC1: Simple structures
• EXC2: Standard buildings and bridges
• EXC3: Major structures
• EXC4: Critical infrastructure such as suspension or arch bridges

Each level adds stricter requirements for documentation, testing, and welder qualification.

Welding Standards and Quality Control

The standard ensures all welding and jointing processes maintain the mechanical properties defined in Eurocode 3. High-level projects (EXC3 and EXC4) require extensive non-destructive testing (NDT) and traceability documentation.

Specialized Bridge Construction Equipment: Movable Scaffolding Systems and Form Travellers

These temporary structures must meet the same quality standards as permanent ones because they support heavy loads and changing configurations during construction. Compliance with Eurocode 3 and EN-1090 ensures stability, safety, and durability.

Movable Scaffolding Systems (MSS)

MSS must meet design and manufacturing standards addressing variable load paths and stability during movement. EN-1090 compliance guarantees structural reliability through proper material selection, welding quality, and fatigue performance. Q345 steel, with high strength and toughness, is often used for MSS frames and joints.

Form Travellers

Form travellers are designed according to Eurocode 3 principles for cantilever loading and asymmetric conditions. They require tight fabrication tolerances, reliable welds, and heat treatment of steel elements to ensure safe load transfer during concrete casting.

Standard Components vs. Specialized Equipment

Feature	Standard Bridge Components	Specialized Equipment
Design Life	100+ years	20–30 years
Load Factors	Standard traffic and dead loads	Variable construction loads
Execution Class	Typically EXC3	Always EXC4
Testing Requirements	Standard NDT	Enhanced load verification

Strategic Advantages of Eurocode 3 and EN-1090 Compliance

Risk Mitigation and Safety Assurance

Compliance ensures steel components meet strict yield, tensile, and fatigue performance standards, reducing the risk of failure. It guarantees safety for both workers and future bridge users.

International Market Access and Project Qualification

Compliance with EN-1090 enables CE marking, granting market access across the European Union and globally recognized regions. It simplifies cross-border project collaboration and supplier integration.

Quality Assurance and Project Success

Adherence to standards ensures consistent material quality, reduces rework, and improves durability. Properly manufactured components result in lower maintenance costs and extended bridge life.

Strukturas: Specialist in Compliant Bridge Construction Equipment

Strukturas designs and manufactures Movable Scaffolding Systems and Form Travellers that fully comply with Eurocode 3 and EN-1090. Their expertise spans design, testing, and precision manufacturing to ensure every component meets structural and safety requirements.

Strukturas’s integrated engineering and production approach guarantees compliance while optimizing strength, durability, and efficiency. Their systems are used across Europe for high-standard infrastructure projects.

Frequently Asked Questions

What is the difference between Eurocode 3 and EN-1090?

Eurocode 3 covers the design of steel structures, while EN-1090 governs manufacturing, welding, and fabrication processes.

Why is compliance mandatory for bridge equipment?

It ensures that temporary and permanent structures can safely handle heavy loads while protecting workers and the public.

How do Execution Classes affect cost?

Higher classes require more documentation, testing, and quality control, increasing upfront cost but preventing expensive future failures.

What documentation is needed for EN-1090?

Material certificates, welding qualifications, inspection reports, and traceability documentation for all structural components.

Can non-European manufacturers be certified?

Yes. Certification is possible through approved notified bodies that verify factory control systems and quality processes.

Conclusion

Eurocode 3 and EN-1090 form the foundation of safe, modern bridge construction. They ensure structural components and equipment meet strict performance and quality standards, preventing failures and ensuring long-term reliability.

Whether constructing a permanent bridge or using specialized systems such as MSS and Form Travellers, compliance ensures durability, safety, and project success.

To begin:

1. Evaluate your current design and fabrication compliance.
2. Work with qualified engineers familiar with Eurocode 3.
3. Partner with certified EN-1090 manufacturers.