Renovation of the Galecopper Bridge

The Need for Renovation

After years of heavy use, it was found that the anchor points of the bridge’s cable stays, which are critical for stability, had been affected by rust. These cables are essential to the bridge’s structure, and their integrity is vital for safety. In addition, other key components of the bridge required strengthening and replacement to ensure safety and functionality. The challenge? All of this had to be completed while keeping the bridge open for both traffic and maritime shipping. Rijnstaal applied innovative techniques and smart solutions to carry out this essential renovation of the Galecopper Bridge with minimal disruption.

Crucial Strengthening Work

In addition to replacing the anchor points of the cable stays, Rijnstaal carried out several other vital tasks:

1. Strengthening the Pylons: The pylons, the vertical towers to which the cables are attached, were reinforced at both the upper and lower ends. This was done to install new saddles—components that support and secure the cables. This reinforcement was essential to ensure the stability of both the cables and the entire bridge.
2. Replacing Pylon Bearings: The bearings, which support the pylons and provide a stable connection to the rest of the structure, were also replaced. This ensured the pylons remained reliable and capable of withstanding the forces exerted by the cables.
3. Adding Accessibility Features: To carry out work in hard-to-reach areas, various features were added, including:
   • Manholes. Rijnstaal installed openings in the structure to allow access to difficult-to-reach parts of the bridge. This enabled inspections and maintenance to be carried out more easily.
   • Work Platforms. Special work platforms were added to ensure safe working conditions at great heights when working on the pylons and other parts of the bridge.
   • Pylon Scaffolding Support. We reinforced the scaffolding around the pylons to ensure that work at height was safe and efficient.

Logistical Challenges and Smart Solutions

A significant portion of the work and renovation was carried out beneath the Galecopper Bridge, where new anchor blocks weighing over 8000 kilograms were installed. These anchor blocks, fabricated entirely in our workshop, were transported via a barge to the bridge and then lifted into place. This was a precise process, requiring eight technicians—including climbing experts—to work in difficult-to-reach locations.

We also accounted for the bridge’s clearance height. Because certain tasks would interfere with the shipping traffic underneath, we designed an innovative scaffolding structure. This work platform could be lifted when not in use, allowing ships to pass through unimpeded. As a result, only a few instances per week required navigational guidance, significantly reducing the impact on shipping traffic.

Specialized Techniques

The Galecopper Bridge renovation demanded the use of advanced techniques. For example, welding was carried out according to the strict EXC 3/4 standards, which are required for high-risk structures. Additionally, we preheated the steel to reduce the risk of cracking during welding, due to its high carbon content. We also used 6000 pre-tension bolts (M20, M24, and M30) to secure components tightly and under tension, contributing to the bridge’s stability and durability, ensuring it will serve for decades to come.