The Port Mann Bridge: Geotechnical and Post-Tensioning Systems for North America’s second largest Stay Cable Bridge
Port Mann Bridge is part of Canadian Highway 1, connecting Vancouver with Surrey over the Fraser River. The new, 10-lane stay cable bridge replaces the original 5-lane bridge that was built in the early 1960s and doubles its capacity. The Port Mann Bridge is the second largest stay cable bridge in North America. At a width of 65m, it is the world’s widest long-span bridge according to the Guinness World Records, overtaking the world-famous 49m wide Sydney Harbour Bridge, which held the record since 1932.
The 2km long bridge consists of a 850m long stay cable bridge, a 360m long southern and an 820m long northern approach structure that were built using 1,158 precast concrete segments. The bridge crosses Fraser River, providing a clearance of 42m.
For this large infrastructure project, DSI Canada supplied both high quality geotechnical products and DYWIDAG Post-Tensioning Systems. For geotechnical applications, DSI supplied double corrosion protected (DCP) bar anchors for the retaining walls located along the entire length of the project. In total, 900 Ø 25mm DYWIDAG Bar Anchors, 800 Ø 29mm DYWIDAG Bar Anchors and 180 Ø 32mm DYWIDAG Bar Anchors in lengths of 18.3m each were installed in the retaining walls. In addition, DSI supplied the stressing equipment and supported the contractor during the performance and proof tests of all ground anchors.
For the superstructure of Port Mann Bridge, DSI Canada produced and supplied the necessary post-tensioning systems. In total, 272 Type 12-0.6" DYWIDAG Strand Tendons, 1,245 Type 19-0.6" DYWIDAG Strand Tendons, 1,915 Type 27-0.6" DYWIDAG Strand Tendons and 48 Type 37-0.6" DYWIDAG Strand Tendons were installed in the superstructure. In addition, 10,100 Type 4-0.6" DYWIDAG Strand Tendons with Flat Anchorages were used as transverse deck tendons.
DYWIDAG THREADBAR Post-Tensioning Systems were needed for the temporary tensioning of the precast segments and the permanent tensioning of the bridge structure. For this purpose, DSI Canada supplied 182.9m each of Ø 26 and 32mm DYWIDAG THREADBAR , 2,179m of Ø 36mm of DYWIDAG THREADBAR , 4,542m of Ø 46mm DYWIDAG THREADBAR and 884m of Ø 66mm DYWIDAG THREADBAR .
In addition, DSI Canada rented the stressing equipment and provided technical support during material inspection and site troubleshooting.
The major challenge for DSI Canada’s team was the fact that design information was only provided a short time before the material was needed. Thanks to the excellent co-operation between DSI and the jobsite, all products were supplied within the required schedules.
The great flexibility and the depth of training of all DSI technicians, engineers and sales personnel ensured that work was always completed when needed.