Bridges

Precast segmental construction of bridges is becoming more prevalent in Australia. The use of match cast dry joints avoids the need to apply and cure epoxy across segment joints enabling reduced span erection times which is advantageous in the brownfields construction of linear infrastructure. This paper explores the recent work undertaken on the Caulfield to Dandenong Level Crossing Removal Project and West Gate Tunnel Project in Melbourne, Australia where several precast segmental box girder bridges with match cast dry joints and external post-tensioned tendons were erected span-by-span.

Australian Standards provide limited guidance for the analysis of match cast dry joints, and this paper outlines the design methodology adopted for the precast segmental bridges on these projects. The provisions for match cast dry joint shear capacity have recently been revised in the Australian Bridge Design Standard which now align with other international standards and recognised technical publications and provide a more practical and economical solution for the design of new and the assessment of existing infrastructure.

This paper also shares the lessons learnt during the construction of these projects with an emphasis on match cast dry joint defects and repair strategies. This required a comprehensive review of local authority construction specifications, which are general specifications for bridgeworks and do not explicitly address the particular requirements of precast segmental construction and match casting.