Assessment, refurbishment, and replacement

Bearings Maintenance

As a moving link, bearings ensure proper functioning of the entire structure by transferring vertical and horizontal forces, horizontal movements, and rotations.

When bearings malfunction, the repair costs can be significantly higher than the expenses associated with regular maintenance and timely replacements.

Freyssinet specializes in maintaining bridge structural components. We assist in inspecting and assessing damaged bearings and facilitate their replacement, ensuring restored traffic safety for both road operators and users.

 

Bearings and expansion joints maintenance

Bridge Maintenance Considerations

Thermal movement of the bridge that exceeds the range of slide bearings or the rotational capacity of a rocker bearing could require the bearings to be reset.

If corrosion or deterioration has compromised a bridge bearing to the extent that it can no longer perform its intended function or adequately support structural loads, a full replacement may be required to maintain safety and integrity.

While the most effective preventive maintenance for bridge bearings is preserving watertight deck joint seals, maintaining their integrity remains an ongoing challenge.

Since joint failure is inevitable over time, routine cleaning, along with protective painting or sealing of bridge bearings, is essential to prevent deterioration and extend their lifespan.

Bridge bearing maintenance often includes refurbishing the support plates. This process differs based on the type of plate—lower plates are typically formed through mortar casting, while upper plates are restored using matting or injection techniques.

Freyssinet provides tailored solutions for the demolition and reconstruction of bearing plates, ensuring durability and structural integrity.

 

Adjusting load distribution or support reactions can alter a structure’s loading conditions—whether by shifting support points or redistributing forces at existing ones.

The primary goal of this process is to control lifting forces while monitoring potential movement and deformation, ensuring structural stability and performance.

 

 

Resetting or replacing bridge bearings typically requires unloading both dead and live loads to safely carry out repairs. Therefore, this process may involve temporary bridge closures, traffic restrictions near support areas, or shoring affected bridge members.

To prevent overstressing adjacent structural elements, it may be necessary to uniformly jack all bearings at a common substructure. A structural engineer should always be consulted before any repair work involving jacking operations to ensure safety and stability.

In some cases, the need for additional bearings or their removal may arise 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 evaluation of these factors is essential to determine the appropriate course of action for maintaining structural integrity and performance.

Bearings maintenance

Our Complete Range of Services

Condition Assessment

Freyssinet offers a wide range of specialized inspection methods to assess the condition and performance of bridge bearings, 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 help ensure the long-term safety and functionality of bridge infrastructure.

Routine Maintenance Tasks

Ongoing monitoring allows for early detection of developing issues, enabling timely minor maintenance to prevent further deterioration. These 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

Following a thorough assessment, three potential refurbishment strategies can be considered for each 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

Selecting the appropriate bearing type—whether spherical, pot, laminated elastomeric, or oscillating guided/free sliding—requires a detailed analysis of the structure’s vertical load capacity and allowable rotation.

Our engineers also assess key factors to determine the most effective jacking solution, including existing jacking points, propping requirements, corbels, pier clamps, hanger beams, and restraint systems. By considering these elements, Freyssinet ensures a tailored approach that optimizes structural stability and longevity.

Jacking Preparation

Bearing maintenance is a complex process that involves modifying the structure’s support conditions. To safely carry out these operations, the structure must be jacked up to relieve pressure on the bearings.

This process requires applying a controlled vertical—and sometimes horizontal—force at designated jacking points to lift the superstructure, such as the bridge deck or slab, by a precise amount. Proper planning and execution ensure stability and minimize structural stress during the procedure.

Why Choose Freyssinet for Your Project

01. Certified in-house bearings

Freyssinet bearings are exclusively designed and engineered by our in-house technical team, ensuring they meet project-specific requirements and comply with all applicable standards. Our bearings are EC-marked and certified for use in various countries, adhering to industry-leading regulations such as AASHTO LRFD 2012 (U.S.), BS 5400 (U.K.), and AS 5100 (Australia), among others. This commitment to quality guarantees reliability, safety, and long-term performance.

02. Industry-leading expertise in jacking operations

We provide a comprehensive range of specialized lifting and handling equipment, including cylinders, hydraulic power units, and hoists, all designed for precision and real-time control to meet the most demanding force and movement requirements at jacking points. Our experienced teams execute jacking operations with strict adherence to site-specific constraints, whether on highways, railways, or waterways, ensuring safe and efficient structural support adjustments.

03. Knowledge that adds value

Freyssinet enhances project efficiency and precision with advanced techniques, including: Jacking/de-jacking under traffic, temporary guided bearings, temporary stainless steel fixings, pre-setting of bearings, and computerized 3D modeling. These innovations allow for safer, more accurate, and efficient bearing maintenance and replacement solutions.

04. Sustainable maintenance approach

We prioritize extending the lifespan of bearings whenever possible, rather than decommissioning them prematurely. We collaborate closely with our clients to develop practical, cost-effective solutions that maximize durability, such as cleaning, touch-up painting, resealing, and applying protective systems. By taking this proactive approach, we help clients delay full replacements, allowing time for proper planning and budgeting while maintaining structural integrity and performance.

Jacking Solutions

With years of experience in jacking and structural handling, Freyssinet’s specialized teams are equipped to manage projects of any complexity. From simple operations, such as bearing replacements or sheave repairs, to highly technical procedures, like the synchronized movement of entire structures, we deliver precision, efficiency, and reliability in every project.

Jacking a structure is a highly delicate process that requires thorough planning to ensure 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

With a large inventory of modern equipment, 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), Freyssinet is fully equipped to execute high-quality jacking operations.

We continuously develop cutting-edge tools, including our proprietary jacking controllers (CAL system). This advanced technology ensures 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

For structures with pre-designed jacking recesses or sufficient clearance between the superstructure and its bearings, lifting jacks can be positioned directly on the bearings for efficient load transfer. In cases where clearance is limited, flat jacks are the preferred solution, ensuring a safe and controlled lifting process while accommodating space constraints.
  • Easy to use
  • Safety bedding integrated in the hydraulic jacks

Jacking on Brackets

When direct jacking on the bearings is not feasible, temporary support brackets can be installed as an alternative. These brackets, made of metal or reinforced concrete, are securely attached to the bearing structure using pre-stressed or sealing bars. Once in place, these brackets serve as stable support points for the lifting jacks, ensuring a controlled and safe jacking operation.
  • Compact size
  • No underpinning

Jacking on Pilings

In situations where high vertical loads must be managed and existing bearings cannot transfer jacking forces, temporary pilings provide a reliable solution. These modular metal structures can be assembled into columns or lattice towers, offering strong, adaptable support. Depending on project requirements, the pilings can be anchored to existing foundations or newly constructed foundations designed specifically for the operation.
  • High vertical loads
  • Modular system
  • Easy to mount and dismantle

Synchronized and Precise Lifting System

When lifting a structure at multiple points using hydraulic jacks, it is essential to monitor and control stress distribution in real time to prevent structural imbalances. Freyssinet’s CAL® system ensures precise synchronization of all jacks by continuously analyzing key lifting parameters, including jack pressure, stroke, and structural movement. This advanced technology enables automated coordination of jacks with accuracy down to a few tenths of a millimeter, guaranteeing 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 simple yet innovative solution designed to extend the lifespan of bridge bearings by shielding them from harmful environmental factors, such as rainwater and road salts, which are primary causes of corrosion. This added layer of protection helps prevent premature bearing failure, reducing maintenance costs, minimizing structural downtime, and avoiding the environmental impact associated with full replacements. By proactively safeguarding bearings, asset owners can ensure long-term durability and operational efficiency.
  • Extended bearing life
  • Effective protection
  • Cost-effective solution

Jacking on Bearings

For structures with pre-designed jacking recesses or sufficient clearance between the superstructure and its bearings, lifting jacks can be positioned directly on the bearings for efficient load transfer. In cases where clearance is limited, flat jacks are the preferred solution, ensuring a safe and controlled lifting process while accommodating space constraints.
  • Easy to use
  • Safety bedding integrated in the hydraulic jacks

Jacking on Brackets

When direct jacking on the bearings is not feasible, temporary support brackets can be installed as an alternative. These brackets, made of metal or reinforced concrete, are securely attached to the bearing structure using pre-stressed or sealing bars. Once in place, these brackets serve as stable support points for the lifting jacks, ensuring a controlled and safe jacking operation.
  • Compact size
  • No underpinning

Jacking on Pilings

In situations where high vertical loads must be managed and existing bearings cannot transfer jacking forces, temporary pilings provide a reliable solution. These modular metal structures can be assembled into columns or lattice towers, offering strong, adaptable support. Depending on project requirements, the pilings can be anchored to existing foundations or newly constructed foundations designed specifically for the operation.
  • High vertical loads
  • Modular system
  • Easy to mount and dismantle

Synchronized and Precise Lifting System

When lifting a structure at multiple points using hydraulic jacks, it is essential to monitor and control stress distribution in real time to prevent structural imbalances. Freyssinet’s CAL® system ensures precise synchronization of all jacks by continuously analyzing key lifting parameters, including jack pressure, stroke, and structural movement. This advanced technology enables automated coordination of jacks with accuracy down to a few tenths of a millimeter, guaranteeing 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 simple yet innovative solution designed to extend the lifespan of bridge bearings by shielding them from harmful environmental factors, such as rainwater and road salts, which are primary causes of corrosion. This added layer of protection helps prevent premature bearing failure, reducing maintenance costs, minimizing structural downtime, and avoiding the environmental impact associated with full replacements. By proactively safeguarding bearings, asset owners can ensure 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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Discover Freyssinet's Solutions

Repairs

Structural Integrity Management
Repair

Seismic Retrofitting
Repair

Concrete Restoration
Repairs

Structural Integrity Management
Repair

Seismic Retrofitting
Repair

Concrete Restoration

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