The Interchange Bridges Darmstadt A5/A67 project involved the replacement of three steel composite bridges, all constructed simultaneously in order to minimise disruption to traffic at one of the region’s busiest motorway interchanges.
BrandSafway provided a comprehensive range of formwork and scaffolding solutions for the construction of foundations, abutments and piers, supporting an efficient and carefully phased construction process while maintaining traffic flow beneath the structures.
The primary challenge of the project was to carry out extensive bridge replacement works above live traffic while keeping lane closures and disruptions to a minimum. This required effective protection of the traffic lanes below, combined with safe and efficient working platforms for construction crews.
In addition, the simultaneous construction of three bridges demanded high load-bearing shoring systems, rapid assembly and disassembly, and formwork solutions that could be reused efficiently across multiple structures and construction phases.
BrandSafway delivered an integrated solution combining formwork, scaffolding and shoring systems tailored to the complex site conditions. MANTO® large-frame formwork was used for piers and abutments, supported by H20 timber formwork, while pre-assembled ES 24 large-area formwork elements were employed to accelerate construction of the foundations.
To ensure uninterrupted traffic flow, the new bridge structures were shielded by pre-assembled protective roofs measuring 5 m (16 ft) in height, installed above the motorway lanes. For the shoring requirements, 16 m (52 ft) long units with a 12 m (39 ft) span, each weighing approximately 11 tonnes of scaffolding material, were provided to support the construction loads.
In a subsequent construction phase, the protective roof system was expanded to achieve an even larger 18 m (59 ft) span. Throughout the project, the scaffolding systems served a dual purpose, functioning both as protective roofs for the traffic below and as working platforms for site personnel, ensuring safety, efficiency and continuity of traffic operations.
