Modular Bridge, North Rhine-Westphalia

The steel structure serves as a key component of the internal infrastructure, ensuring the safe and efficient transport of materials and products between production halls. The first step involved a thorough on-site survey to capture the exact dimensions and specific conditions of the construction site. Based on this data, a detailed 3D model of the bridge was created, incorporating all necessary structural requirements. Simultaneously, a static calculation was performed to guarantee the bridge's load-bearing capacity and safety under various conditions. The production process included the fabrication of bridge components in a specialized steel workshop, with high precision to ensure proper fit during assembly. Workshop and assembly plans were meticulously prepared to facilitate smooth and timely construction and installation.

Challenges

One of the biggest challenges in this project was the precise planning and adaptation of the modular bridge to the existing infrastructure of the industrial plant. Limited space and the need to avoid disruptions to ongoing production during assembly required detailed coordination and complex logistics. Additionally, the static requirements and special load conditions of the industrial facility placed high demands on the design and manufacturing.

01.03.2020 - 01.09.2020

Weight	112	tons
Planning hours	1340	hours
Total area	368	m²
Length	46	m
Width	8	m
Height	8.5	m

Adress:

North Rhine-Westphalia, Germany

Project phases

Requirement Analysis

During the requirement analysis phase, the client's needs and expectations regarding the modular bridge were thoroughly assessed. Key considerations included load-bearing capacity, functionality, safety standards, and integration into the existing plant infrastructure. This phase helped establish a clear understanding of project requirements and objectives to guide subsequent planning and implementation processes.

Surveying with 3D Laser Scanning

To obtain an accurate representation of the current structural conditions and terrain, the existing industrial site was surveyed using 3D laser scanning. This method provided highly precise data of the area and existing structures, forming the basis for further planning phases. The digital model enabled precise planning of the modular bridge within its surrounding environment.

As-Built Modeling

Based on the laser scan data, a detailed 3D model of the existing structures and all relevant components was created. This modeling included critical interfaces and adjacent infrastructure relevant to the modular bridge, ensuring that all essential details were considered and made available for later planning stages.

Design Phase (LPH 3) and Concept

In this phase, the design was developed according to the German Fee Scale for Architects and Engineers (HOAI) performance stage (LPH 3). The bridge concept was established, including layout, dimensioning, and load-bearing systems. A customized design was created to meet both functional and aesthetic project requirements. The concepts were reviewed and refined with the client before proceeding to the approval planning phase.

Approval Planning (LPH 4)

In the approval planning phase (LPH 4), all essential plans were finalized, and static calculations were verified to obtain legally binding construction approval. This phase included preparing all necessary documents for permitting procedures and ensuring compliance with applicable regulations and standards.

Execution Planning (LPH 5)

In the execution planning phase (LPH 5), detailed workshop and assembly plans for the modular bridge were prepared. These plans ensured that all components were manufactured accurately and could be assembled on-site. Additionally, all assembly processes were meticulously planned to enable a swift and safe installation on the plant premises. The execution plans formed the basis for the bridge's realization.