In the field of long-span cable-stayed bridge construction, the form traveler serves as the core equipment for cantilever casting construction, directly determining project quality, construction efficiency and safety factors. Among various types of form travelers, the cable-stayed traveler stands out as the preferred solution for cable-stayed bridge construction thanks to its unique structural design and performance advantages. Whether it is a highway cable-stayed bridge, a railway cable-stayed bridge or a combined highway-railway cable-stayed bridge, the cable-stayed traveler can adapt to complex construction environments and stringent project requirements. Starting from the core pain points of cable-stayed bridge construction, this article will deeply analyze the core advantages of the cable-stayed traveler and why it has become the unrivaled choice for cantilever casting of cable-stayed bridges.

1. Core Difficulties in Cable-Stayed Bridge Construction

The core structural characteristics of cable-stayed bridges are "long span and flexible main girder", which determine that their cantilever casting construction has to face three core difficulties: first, the main girder needs to bear huge dead weight and construction loads during pouring, which is prone to deformation and deviation; second, the complex construction environments, mostly spanning rivers, valleys and other areas, impose extremely high requirements on the stability and wind resistance of equipment; third, tight construction schedules call for high-efficiency construction equipment to ensure pouring progress and avoid increased costs caused by construction delays.

2. Four Core Advantages of Cable-Stayed Travelers, Aligning with Cable-Stayed Bridge Construction Needs

Derived from the conventional underslung form traveler, the cable-stayed traveler is upgraded with a cable-stay system and a positioning adjustment device. It balances construction loads through the tension of stay cables to achieve precise pouring of the main girder. Its core advantages are reflected in the following four aspects, perfectly meeting the stringent requirements of cable-stayed bridge construction:

(1) More Rational Load Bearing for Effective Control of Main Girder Deformation

The biggest advantage of the cable-stayed form traveler lies in "load sharing". Through the cable-stay system, construction loads such as the self-weight of the traveler and the weight of poured concrete are transferred to the main pylon and stay cables of the cable-stayed bridge, instead of being borne entirely by the main girder. This load-bearing method can significantly reduce the stress on the main girder during construction, effectively control the vertical deformation and horizontal deviation of the main girder, and ensure the linear accuracy of the girder body.

(2) Higher Stability for Adapting to Complex Construction Environments

Cable-stayed bridge construction is mostly carried out in complex environments such as high altitudes and across water areas, where equipment stability is directly related to construction safety. The stay cable form traveler adopts a triple stable structure of "stay cables + traveler main body + anchoring system". The tension of stay cables can be adjusted according to construction needs to ensure the traveler remains horizontally stable during pouring. Meanwhile, the main body of the traveler is designed with high-strength steel structure, featuring excellent wind resistance, which can guarantee construction safety even in wind conditions of force 8 or above.

(3) Higher Construction Efficiency for Shortening Construction Period and Reducing Costs

Cantilever casting construction of long-span cable-stayed bridges involves many construction segments, and the pouring cycle of each segment directly affects the total construction period. The structural design of the cable-stayed traveler facilitates standardized construction with simple and efficient processes for installation, commissioning and dismantling. Moreover, it enables a continuous construction mode of "quickly moving to the next segment upon completion of one segment's pouring".

(4) Wider Adaptability for Meeting the Needs of Different Spans and Bridge Types

The cable-stayed form traveler has a strong customizable adaptability. Targeted structural design and parameter optimization can be carried out according to the span size, main girder cross-section form and construction load requirements of cable-stayed bridges. Whether it is a small-span urban cable-stayed bridge or a long-span sea-crossing/river-crossing cable-stayed bridge, whether it is the wide main girder of a highway cable-stayed bridge or the heavy load requirements of a combined highway-railway cable-stayed bridge, the cable-stayed traveler can perfectly adapt to construction needs by adjusting parameters such as the number of stay cables, traveler size and load-bearing tonnage. Such wide adaptability makes the cable-stayed traveler a "universal core equipment" for cable-stayed bridge construction.

3. Project Case Evidence: Cable-Stayed Traveler is the Optimal Solution for Cable-Stayed Bridge Construction

Practice is the best test of equipment performance. In recent years, many major domestic cable-stayed bridge projects have adopted the cable-stayed traveler for construction and achieved excellent engineering results.Taking the Xiaojiaba cable-stayed bridge project as an example, the bridge is a single-pylon double-cable-plane concrete cable-stayed bridge with a main span of 180 meters and a pylon height of up to 117 meters. The long-span structure imposes extremely high requirements on construction accuracy and stability. During construction, it is necessary to accurately control the verticality of the pylon, the tension of stay cables and the alignment of the concrete box girder to ensure reasonable stress on the bridge during construction and avoid structural deformation or cracks.The truss main body of Boyoun's underslung form traveler adopts a structural form of two longitudinal girders plus two cross girders. All components are made of Q355 material and box-type structure, and the front cross girder is reinforced to prevent deflection for long-span construction.To meet the on-site construction needs and the customer's requirement for backward movement, the traveling system adopts a C-type hook + reverse jacking wheel structure and an intelligent control hydraulic traveling system, making the traveling smoother and the operation more convenient.The internal formwork system adopts an arch frame structure combined with an intelligent lifting hydraulic system, which makes the formwork stripping and closing on site more efficient and convenient.

Xiaojiaba Cable-Stayed Bridge

4. How to Choose a Reliable Cable-Stayed Traveler Manufacturer? 

The performance of the stay cable form traveler directly determines the quality and safety of cable-stayed bridge construction, so it is crucial to choose a reliable manufacturer. Combining years of engineering practice experience, it is recommended to inspect the manufacturer's strength from the following three core points:

Customized design capability: Cable-stayed bridge projects are highly differentiated, requiring manufacturers to have a professional design team that can accurately customize cable-stayed traveler solutions according to project drawings, construction environments and load requirements.

Manufacturing strength: Manufacturers need to have their own production bases and advanced steel structure processing equipment to ensure the welding quality and precision of the traveler's main structure, and at the same time have a complete quality inspection system.

Technical service support: The construction of cable-stayed travelers involves complex installation, commissioning and technical guidance. Manufacturers need to provide full-process technical follow-up services, including on-site installation guidance, technical support during construction and after-sales maintenance, to ensure the efficient and stable operation of the equipment.

As a professional integrated manufacturer of bridge steel formwork and cable-stayed travelers, Boyoun has 20 years of experience in customizing cable-stayed bridge equipment and a professional design team. We can customize and produce cable-stayed travelers with strong adaptability and excellent performance according to the needs of different cable-stayed bridge projects. Meanwhile, we provide one-stop services covering "design, production, installation and after-sales", and arrange professional technicians to follow up the construction in the whole process to ensure the smooth progress of the project.

Conclusion

The core demands of cable-stayed bridge construction are "precision, efficiency and safety". The cable-stayed form traveler perfectly meets these demands with its rational load-bearing structure, excellent stability, high construction efficiency and wide adaptability, thus becoming the first-choice equipment for cable-stayed bridge construction. Choosing a reliable cable-stayed traveler manufacturer with customized capabilities and comprehensive services is the key to ensuring project quality and construction period. We look forward to cooperating with you to facilitate the efficient progress of cable-stayed bridge projects!If you want to learn about the customization solutions, quotations and construction cases of underslung form travelers for cable-stayed bridges, please feel free to contact us. Our professional engineers will answer your questions and provide targeted equipment solutions at the first time!