Hydraulic Cylinders in Bridge Construction
Special cylinders for movable bridges and complex infrastructure projects
What do the Golden Horn Bridge in Istanbul, the Friesen Bridge in Lower Saxony, and the Botlek Bridge in Rotterdam have in common? They are among the most impressive movable bridges in Europe – and they use hydraulic cylinders from HYDAC as their main drive technology.
Whether it’s a swing bridge, a lifting bridge, or the precise positioning of bridge segments: hydraulic systems enable motion sequences that would be virtually impossible to achieve in this form using other drive technologies. Enormous forces are at play here, which must be precisely controlled and reliably managed – in challenging environmental conditions and with the highest demands on safety and availability.
How hydraulic cylinders move modern bridges
Our video demonstrates how hydraulic cylinders are used in various types of bridges. Depending on the design, different types of special cylinders are used, such as lifting cylinders, locking cylinders, or clamping cylinders.
Whether it’s a swing bridge, a lifting bridge, or a combined lift-and-swing design, hydraulic drive systems enable precise, controlled movements even with the heaviest loads and the most complex requirements.
Hydraulic cylinders in bridge construction – a weighty challengeExtreme loads, precise motion sequences and challenging environmental conditions place the highest demands on the design and engineering of our special cylinders
Extreme forces & weights
Moving and positioning bridge structures weighing several thousand tonnes requires hydraulic cylinders with high load capacities and ample safety margins.
Precision & synchronisation
Several cylinders must operate in perfect synchronisation to prevent deformation and stress. Millimetre-precise motion sequences are crucial for operational reliability.
Corrosion resistance
The use of materials, coatings, and sealing systems in maritime and exposed environments presents significant challenges, particularly in the presence of moisture, saltwater and temperature fluctuations.
Safety & reliability
As a critical component of infrastructure, hydraulic systems must function reliably at all times. Redundant designs and secure locking mechanisms ensure smooth operation.
Standards & regulations
Hydraulic cylinders used in bridge construction must meet project-specific standards and directives – such as those for hydraulic steel structures – and comply with the highest quality and safety requirements.
System integration
Hydraulic cylinders are a part of complex overall systems. Close coordination with the hydraulics, control technology, and other components is essential for overall functionality.
Our hydraulic cylinder solutions for use in bridge constructionLifting cylinders, special cylinders and thrust cylinders for movable bridges
At HYDAC, hydraulic cylinders for bridge construction are consistently designed to meet customer requirements and are precisely tailored to the specific conditions of each project.
Whether it’s a swing bridge, a lifting bridge, a combined swing and lifting bridge, or a bridge shifting unit, our solutions are used in a wide range of applications. Development and manufacturing are handled by a single source, ensuring a transparent and traceable process. At the same time, HYDAC hydraulic cylinders comply with the highest quality standards so that they can meet the special requirements for safety and durability in bridge construction.
From clamping cylinders to lifting cylinders: a selection of our special cylinders for bridge construction
Lifting cylinders
Hydraulic lifting cylinders enable the safe and precise lifting and positioning of heavy loads, even in extreme conditions. Performance, durability, and reliability are at the heart of every application.
Clamping cylinders
Hydraulic clamping cylinders are used in bridge construction to apply controlled tension to cables and tension components. The cables are fed through the cylinders, clamped, and hydraulically tensioned. This enables the precise application of extreme tensile forces, which can then be utilised for lifting and securing operations.
Thrust cylinders
Hydraulic thrust cylinders are used in bridge construction to enable the controlled movement of entire bridges or bridge structures. They transmit high-pressure forces in a synchronously controlled system. They ensure precise, safe, and repeatable movements.
Bolting cylinders (earthquake protection)
Special cylinders designed for the secure bolting and support of swing bridges. They ensure a reliable connection between bridge segments and prevent the structure from swinging or shifting, even in the event of an earthquake. They play a crucial role in ensuring the stability, safety, and functionality of the structure.
Locking cylinders
Hydraulic locking cylinders ensure maximum holding force and the highest operational reliability when bridge structures are at a standstill. They are designed for maximum availability and durability.
Rotary cylinders
Hydraulic rotary cylinders are used in swing bridges to enable large bridge segments to be pivoted in a controlled and precise manner. They transmit high torque in the tightest of installation spaces and enable reliable motion sequences even in challenging environmental conditions. Its robust design ensures maximum operational reliability and availability.
Bridge construction projects implemented with HYDAC cylindersSwing bridges, lifting bridges and bridge shifts: our successful projects
The versatility and power of hydraulic cylinders in bridge construction is particularly evident in the successful completion of large-scale projects. Whether it’s a bascule bridge, a lifting bridge, a swing bridge, or a combination bridge design, each application has specific requirements in terms of technology, design, and system integration.
The Golden Horn Metro Bridge in Istanbul, the Friesen Bridge in Lower Saxony, and the Botlek Bridge in Rotterdam exemplify the diverse range of applications and technical challenges involved. All projects were completed in close collaboration with our partner companies, HYCOM and Kraeft Systemtechnik. These partnerships enabled us to achieve optimal coordination between the hydraulic systems and the hydraulic steel structures.
Friesen BridgeRailway lifting and swinge bridge in Weener (Lower Saxony)
The Friesen Bridge in Lower Saxony is currently the largest lifting and swinge bridge in Europe. The railway bridge is part of what is known as the "Wunderline" between Bremen and Groningen, which connects Germany with the Netherlands. The Friesen Bridge spans the Ems river at Weener, providing a safe crossing point for pedestrians and cyclists alike.
- Length of the swing bridge: 145 metres (total length: 335 metres)
- 6 HYDAC lifting cylinders with a 2.2m stroke and a weight of 16 tonnes each
- Integrated triple-redundant linear position measurement
- Hydraulic cylinders for lifting and locking
Botlek BridgeLifting bridge in the port of Rotterdam
The Botlek Bridge in the Netherlands is one of the largest lifting bridges in the world. The 1,200-metre-long and 49-metre-wide structure enables cars, trains, pedestrians, and cyclists to cross the Oude Maas river.
- Length: 1200 metres (lifting bridge: 92 metre span)
- Cylinders for lifting and securing truss structures
- A total of 8 hydraulic cylinder types with piston diameters ranging from 80 to 520 millimetres and load capacities from 5 to 350 tonnes
Bridge over the Rotes SielBascule bridge over the Ems-Jade Canal in Emden
The bascule bridge on the Rotes Siel connects two districts of Emden, crossing the Ems-Jade canal in the process. It is operated by two hydraulic cylinders that run in sync. The cylinders, in combination counterweights weighing several tonnes, ensures that the two-lane bridge structure moves safely, smoothly and in a controlled manner.
- Length: 17 metres
- Special cylinders for raising and lowering the bridge deck
- Cylinder with a piston diameter of 220 millimetres, a stroke of 2.2 metres and a retraction force of 70 tonnes
Golden Horn Metro BridgeRailway swing bridge over the Bosphorus in Istanbul
The Golden Horn Bridge spans the Bosphorus, connecting Asia and Europe in Istanbul. The Istanbul Metro's M2 line runs across it. Thanks to its rotating mechanism, it can be opened for shipping traffic when needed, allowing even larger vessels to pass through.
- Length: 120 metres
- Cylinders for lifting, rotating, anchoring & earthquake protection
- A total of six hydraulic cylinder types, ranging in diameter from 80 to 1,600 millimetres
- Load capacity from 8 to 3,500 tonnes
Rinsdorf viaductA45 motorway bridge (North Rhine-Westphalia)
As part of the replacement project, the northern section of the steel composite bridge was initially built adjacent to the existing old bridge. After the blasting, the new bridge, along with its piers, was moved to its final position with millimetre precision.
Video of the bridge shift
- Length: 485 metres
- Height: 72 metres
- Weight: 40,000 tonnes
- Horizontal shift achieved by 24 HYDAC thrust cylinders
- Duration of the shift: approx. 30 hours
Stefan Haben, Sales Manager at HYDROSAAR
We don't just see ourselves as a component supplier. We're a development partner who works with you on equal terms. With our many years of experience and in close cooperation with our partners HYCOM and Kraeft, we develop solutions that are precisely tailored to the specific requirements in bridge construction.
FAQ – Frequently asked questions on hydraulic cylinders in bridge construction
The role of hydraulic cylinders in bridge construction
What tasks do hydraulic cylinders perform in bridge construction?
Hydraulic cylinders enable bridge structures to be moved, positioned and secured. They are used to lift, rotate, or move bridge components, ensuring controlled and precise movement even under the heaviest loads.
What types of bridges use hydraulic cylinders?
Hydraulic cylinders are primarily used in movable bridges, such as swing bridges, lifting bridges, bascule bridges, and combined lifting and swing bridges. They are also used to transport entire bridge structures during the construction phase.
Requirements placed on bridge cylinders
What special requirements apply to hydraulic cylinders in bridge construction?
Hydraulic cylinders used in bridge construction must transmit high forces precisely, reliably, and safely. They are used, among other things, to lift, move, or lower heavy bridge sections, enabling precise positioning even with loads of several hundreds or thousands of tonnes. In this case, synchronised movement of multiple cylinders is crucial to prevent tension in the structure and ensure a safe construction process.
As bridges are designed to last for several decades – often even over 100 years – and their renovation or closure involves high costs and significant traffic disruptions, the hydraulic cylinders used must also meet the highest reliability and durability standards. Robust designs, high-quality materials, long-lasting sealing systems, and integrated safety and monitoring features ensure that the systems operate reliably over the long term, even in challenging environmental conditions. As every bridge project has unique requirements in terms of force, stroke, installation space, and control, special cylinders for bridge construction are typically designed and manufactured as custom solutions.
What standards and regulations must be complied with?
In bridge construction, strict project-specific standards and directives apply, especially in the hydraulic steel structures sector. These include, among other things, the safety, design, materials, and quality assurance of the component used.
Hydraulic cylinders for bridge construction are designed and manufactured in compliance with relevant national and project-specific regulations. In Germany, the requirements for design, materials, corrosion protection, testing, and quality assurance are primarily based on standards such as DIN 19704, ZTV-W and ZTV-ING. In projects within the Dutch market, the requirements of both ROK and NBD 6000 are also taken into account. The design is always developed in accordance with the project-specific requirements of the respective client and operator.
HYDAC as a development partner in bridge construction
What are the benefits of a development partnership with HYDAC?
A development partnership with HYDAC enables custom solutions that are precisely tailored to the specific requirements of bridge construction. From the design phase to implementation, customers benefit from years of experience, in-depth engineering expertise, and a comprehensive understanding of systems. Through close collaboration with partner companies Kraeft Systemtechnik, HYDROSAAR, and HYCOM, hydraulics, control systems, and engineering technology are seamlessly integrated to ensure maximum safety, reliability, and operational efficiency.
