Assessment, refurbishment, and replacement

Replacement of Bridge Bearings

Replacement services for bridge bearings restore the structural performance of aging or damaged infrastructure by addressing the bearing systems responsible for transferring vertical loads, horizontal forces, and rotational movements. When bearings malfunction, the resulting repair costs can far exceed the expenses associated with regular maintenance and timely bearing replacements. Freyssinet, a specialized civil engineering company, provides comprehensive bearing inspection, assessment, and replacement services to maintain traffic safety for both road operators and users.

 

Bearings and expansion joints maintenance

Bridge Maintenance Considerations

Bridge bearing replacement becomes necessary when thermal expansion exceeds the capacity of slide bearings or when a rocker bearing loses its rotational range, requiring a full reset of the affected components. Corrosion, material deterioration, and long-term structural fatigue can compromise a bearing’s load transfer capacity to the point where it no longer supports the structure safely. In these conditions, prompt bearing replacement restores the performance and long-term structural integrity of the bridge.

Bridge bearing maintenance begins with preserving watertight deck joint seals, the most effective preventive measure for protecting the steel and rubber parts of the bearing assembly. Since joint failure is inevitable over time, routine cleaning, protective painting, and resealing of bearing components are critical steps to preventing deterioration and extending operational lifespan.

Bearing support refurbishment targets the concrete plates that seat each bearing assembly during a replacement project. Lower plates are rebuilt through mortar casting, and upper plates are restored using matting or injection construction techniques. Freyssinet’s crews handle the selective demolition and full reconstruction of bearing plates to deliver long-term structural durability.

 

Bridge bearing load evaluation determines how shifting support points or redistributing forces affects a structure’s loading conditions. Engineers control lifting operations to adjust load distribution, monitoring movement and deformation at each stage to maintain structural stability and verify that the bearing design meets performance requirements.

 

Resetting or replacing bridge bearings requires unloading both dead and live loads from the deck before crews can safely carry out repairs. This process may involve temporary bridge closures, traffic restrictions near support areas, or shoring of affected bridge members. Heavy jacking operations must uniformly lift all bearings at a common substructure to prevent overstressing adjacent structural elements. A structural engineer should be consulted before any bearing replacement involving jacking, particularly when installing new elastomeric bearing pads.

Additional bearings or the removal of existing ones may be required due to installation defects, design errors, changes in load conditions, or shifts in the bridge deck’s structural behavior from isostatic to hyperstatic. A thorough engineering evaluation of these factors determines the appropriate course of action for preserving the structure’s long-term integrity and load-bearing performance.

Bridges in seismic zones may need specialized bearing systems and structural reinforcement. Discover our seismic retrofitting solutions.

Bearings maintenance

Our Complete Range of Services

Condition Assessment

Freyssinet’s inspection teams access each bearing location to assess condition and structural performance using specific diagnostic methods, including:

  • Evaluating movement capacity in relation to temperature variations and the structure’s age
  • Identifying defects such as cracks, misalignment, or unexpected movements
  • Assessing the condition of pads and fixings for signs of cracks or corrosion
  • Verifying the effectiveness of corrosion protection measures
  • Detecting visible structural defects in areas around the bearings

These inspections support the long-term safety and functionality of bridge infrastructure

Routine Maintenance Tasks

Bridge bearing monitoring programs detect developing issues before they compromise structural performance, enabling timely corrective maintenance that prevents further deterioration. Routine tasks include:

  • Cleaning and removing debris or obstructions that may restrict bearing movement
  • Clearing dirt and buildup around bearings and pads
  • Maintaining gutters and drainage systems to prevent water accumulation
  • Reapplying protective coatings to extend the lifespan of structural components

 

Bearings Refurbishment Strategy

A detailed condition assessment determines which of three refurbishment strategies best meets the requirements of each bridge bearing:

  • Adjustment of Existing Bearings – Retaining and resetting the current bearings without replacement if they remain functional.
  • Replacement with Identical Components – Installing new bearings identical to the originals to address aging, installation defects, or non-compliance with current standards.
  • Upgrading Bearing Type or Design – Modifying the bearing system, such as resizing or replacing small pot bearings with sliding rubber bearings, to better suit the structure’s needs.

Customized Solutions

Each bridge bearing replacement project requires selecting the right bearing type, whether spherical, pot, laminated elastomeric, or oscillating guided/free sliding, based on a detailed analysis of vertical load capacity and allowable rotation. Our engineers evaluate the full scope of jacking requirements, including existing jacking points, propping needs, corbels, pier clamps, hanger beams, and restraint systems. This comprehensive evaluation allows Freyssinet to deliver a project-specific solution that maximizes structural stability and service life.

Jacking Preparation

Bridge bearing maintenance requires modifying the structure’s support conditions by jacking up the superstructure to relieve pressure on the existing bearings. This lifting process involves applying a controlled vertical, and sometimes horizontal, force at designated jacking points to raise the bridge deck or slab by a precise amount. Proper planning and staged execution maintain structural stability and minimize stress on adjacent elements throughout the procedure.

Why Choose Freyssinet for Your Project

01. Certified in-house bearings

Freyssinet designs and engineers all bridge bearings in-house, delivering components that meet project-specific requirements and comply with applicable industry standards. Our bearings carry EC certification for use in multiple countries and adhere to regulations such as AASHTO LRFD 2012 (U.S.), BS 5400 (U.K.), and AS 5100 (Australia), among others. This commitment to quality control guarantees reliability, safety, and long-term performance across every bearing replacement project.

02. Industry-leading expertise in jacking operations

Our specialized lifting and handling equipment includes hydraulic cylinders, power units, jacks, and hoists, all engineered for precision and real-time control to meet the most demanding force and movement requirements at jacking points. Experienced field teams execute bridge bearing replacement operations with strict adherence to site-specific constraints, whether on highways, railways, or waterways, delivering safe and efficient structural support adjustments on every project.

03. Knowledge that adds value

Freyssinet enhances project efficiency and precision with state-of-the-art techniques used across bridge bearing replacement operations: Jacking/de-jacking under traffic, temporary guided bearings, temporary stainless steel fixings, pre-setting of bearings, and computerized 3D modeling. These methods deliver safer, more accurate, and efficient bearing maintenance and replacement solutions.

04. Sustainable maintenance approach

Freyssinet prioritizes extending the service life of bridge bearings for as many years as possible, rather than decommissioning components prematurely. We collaborate with asset owners to develop practical, cost-effective solutions that maximize durability: cleaning, touch-up painting, resealing, and applying protective systems. This proactive approach helps clients delay full bearing replacements, allowing time for proper planning and budgeting while maintaining structural integrity.

Jacking Solutions

Our specialized teams bring years of experience in jacking and structural handling to bridge bearing replacement projects of any complexity. Whether the work involves simple bearing replacements and sheave repairs or highly technical procedures like the synchronized movement of entire structures, we deliver precision, efficiency, and reliability at every stage.

Jacking a structure is a delicate process that demands thorough planning for safety and precision. Key considerations include:

  • Identifying any structural links between the deck and piers (e.g., concrete connections, uplift equipment, utility pipes).
  • Assessing expansion joint connections for free movement and checking for supply lines (electricity, gas, water, etc.).
  • Determining jack positioning based on available space at piers and the deck, ensuring compatibility with lifting equipment.
  • Calculating applied loads to confirm jack capacity and structural impact.
  • Evaluating acceptable lifting tolerances for controlled elevation.
  • Assessing traffic ability during jacking operations.

Advanced Equipment & Innovation

Freyssinet maintains a large inventory of modern equipment for bridge bearing jacking operations, including hydraulic jacks ranging from 25 to 500 tons, synchronized 24-point jacking units, pumps, and precision accessories such as jacking brackets and steel or PVC shims of varying thicknesses.

We continuously develop advanced proprietary tools, including our jacking controllers (CAL system). This technology delivers precise coordination of jacks, real-time analysis of lifting parameters, and optimal structural safety, making even the most complex jacking operations both efficient and secure.

Jacking on Bearings

On structures where pre-designed jacking recesses or sufficient clearance exists between the superstructure and its bearings, lifting jacks are positioned directly on the bearing support plates for efficient structural load transfer. When clearance is limited, flat jacks deliver a safe and controlled lifting process while accommodating tight space constraints on the bridge deck.
  • Easy to use
  • Safety bedding integrated in the hydraulic jacks

Jacking on Brackets

When direct jacking on the bearings is not feasible, the construction of temporary support brackets provides a reliable alternative. Built from metal or reinforced concrete, these brackets are anchored to the bearing structure with pre-stressed or sealing bars. Once secured, they function as stable load transfer points for the lifting jacks, delivering controlled and safe bearing replacement operations where needed.
  • Compact size
  • No underpinning

Jacking on Pilings

When heavy vertical loads exceed the capacity of existing bearings to transfer jacking forces, temporary pilings provide a reliable solution for bridge bearing replacement projects. These modular metal structures are assembled into columns or lattice towers, delivering strong, adaptable support under the most demanding site conditions. Pilings can be anchored to existing foundations or newly constructed foundations designed specifically for each operation.
  • High vertical loads
  • Modular system
  • Easy to mount and dismantle

Synchronized and Precise Lifting System

Bridge bearing replacement operations that involve lifting a structure at multiple points demand that engineers monitor and control stress distribution in real time to prevent structural imbalances. Freyssinet's CAL® system delivers precise synchronization of all jacks by continuously analyzing key lifting parameters: jack pressure, stroke, and structural movement. This technology automates the coordination of jacks with accuracy down to a few tenths of a millimeter, producing a safe, stable, and precisely controlled lifting operation.
  • Quick and easy to set up
  • Recording of jacking operation data
  • Accuracy of one tenth of a millimeter

Bodygarde

Freyssicare Bodygarde™ is a protective solution engineered to extend the service life of bridge bearings for years by shielding bearing components from harmful environmental factors such as rainwater and road salts, both primary drivers of corrosion. This system helps prevent premature bearing failure, reducing maintenance costs, minimizing structural downtime, and eliminating the environmental impact of full bearing replacements. By safeguarding bearings proactively, asset owners maintain long-term durability and operational efficiency.
  • Extended bearing life
  • Effective protection
  • Cost-effective solution

Jacking on Bearings

On structures where pre-designed jacking recesses or sufficient clearance exists between the superstructure and its bearings, lifting jacks are positioned directly on the bearing support plates for efficient structural load transfer. When clearance is limited, flat jacks deliver a safe and controlled lifting process while accommodating tight space constraints on the bridge deck.
  • Easy to use
  • Safety bedding integrated in the hydraulic jacks

Jacking on Brackets

When direct jacking on the bearings is not feasible, the construction of temporary support brackets provides a reliable alternative. Built from metal or reinforced concrete, these brackets are anchored to the bearing structure with pre-stressed or sealing bars. Once secured, they function as stable load transfer points for the lifting jacks, delivering controlled and safe bearing replacement operations where needed.
  • Compact size
  • No underpinning

Jacking on Pilings

When heavy vertical loads exceed the capacity of existing bearings to transfer jacking forces, temporary pilings provide a reliable solution for bridge bearing replacement projects. These modular metal structures are assembled into columns or lattice towers, delivering strong, adaptable support under the most demanding site conditions. Pilings can be anchored to existing foundations or newly constructed foundations designed specifically for each operation.
  • High vertical loads
  • Modular system
  • Easy to mount and dismantle

Synchronized and Precise Lifting System

Bridge bearing replacement operations that involve lifting a structure at multiple points demand that engineers monitor and control stress distribution in real time to prevent structural imbalances. Freyssinet's CAL® system delivers precise synchronization of all jacks by continuously analyzing key lifting parameters: jack pressure, stroke, and structural movement. This technology automates the coordination of jacks with accuracy down to a few tenths of a millimeter, producing a safe, stable, and precisely controlled lifting operation.
  • Quick and easy to set up
  • Recording of jacking operation data
  • Accuracy of one tenth of a millimeter

Bodygarde

Freyssicare Bodygarde™ is a protective solution engineered to extend the service life of bridge bearings for years by shielding bearing components from harmful environmental factors such as rainwater and road salts, both primary drivers of corrosion. This system helps prevent premature bearing failure, reducing maintenance costs, minimizing structural downtime, and eliminating the environmental impact of full bearing replacements. By safeguarding bearings proactively, asset owners maintain long-term durability and operational efficiency.
  • Extended bearing life
  • Effective protection
  • Cost-effective solution
Repairs
Maryland, United States

Howard St. Arch Bridge

As the General Contractor, we replaced the two roller nest expansion bearings on this historic bridge by utilizing custom-designed welded jacking brackets.
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Repairs
Washington DC, United States

Washington Aqueduct (3rd High Main)

We were responsible for the extensive restoration of damaged bearings, pedestals, corbels, and the replacement of deteriorated pipe saddles that support the aging bridge's water main.
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New Structures
South Carolina, United States

Wando Bridge

Emergency tendon replacement and concrete repairs on box girder bridges spanning the Wando River in Charleston, South Carolina.
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Repairs
Philippines

Ayala Bridge Seismic Protection Upgrading

Freyssinet's innovative rehabilitation approach delivered substantial savings in both time and budget, presenting a smart alternative to replacing this historic city-center bridge in Manila. By prioritizing seismic protection upgrading, the project ensures enhanced durability and resilience for the future.
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Repairs
Romania

Bucharest City Hall Seismic Protection

Bearings and dampers were designed for the seismic protection of this historic structure in Bucharest, providing resilience against earthquakes.
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Repairs

Structural Integrity Management
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Seismic Retrofitting
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Concrete Repair
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Structural Integrity Management
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Seismic Retrofitting
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Concrete Repair

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