After the emergency repairs were completed to the damaged North East main span end link on the Forth Road Bridge in December 2015, it was decided that the long term solution would be to completely replace the existing end link with a new style. This end link that would be supported from a supporting bracket connected to the bridge tower.
Millar Callaghan were given the contract to fabricate and install the new end link and also to fabricate and install temporary steelwork to support the bridge sections while the existing end link was removed. Once the design had been confirmed and the construction drawings had been approved, our fabrication department went into full production on the new end link, supporting brackets and temporary supports. All fabrication was carried out by our skilled tradesmen to execution class 4.
While the fabrication was taking place in our Irvine workshop, our specialised site team were carrying out extensive additional strengthening works both inside and outside the North Tower. This additional strengthening was required to reinforce the areas of the tower that would support the new shelf bracket and bearing. With the fabrication, testing and painting complete for the new end link section and bracket, they were transported by barge to the base of the north tower. Extensive lifting and rigging equipment had been strategically positioned on the bridge to remove and install the end link sections.
With all the temporary supporting steelwork in place, the existing end link section was cut out during a bridge closure and lowered down to the base of the north tower. The new end link sections were lifted up and suspended in position and the supporting bracket and bearing were assembled at ground level and raised into position as one unit. The support bracket was then bolted to the tower using high tensile rods. The end link was aligned with the bearing and fully welded to the existing bridge sections. When all site welds were NDT and ultrasonically tested the temporary supporting steelwork was removed and the new end link and bearing were left to take the full load of the bridge section. To assist with future maintenance, a full access platform and stair were constructed to allow access to the link span and bearing.
