Completed & in service

Q4 2022 Road axis – New Cairo

Contractors & Government Bodies

Bridges and heavy steel structures for national projects

Fabrication and supply of bridges and heavy steel structures for national projects.

Technical Documentation & Operations Gallery

4 high-resolution photos

Client Requirement & Operating Constraints

A main contractor on a national project needed box girders and steel bridge members up to 30 m long, delivered in step with the site concrete works.

Strict defined criteria:

  • Fabrication to AASHTO bridge specifications.
  • Ultrasonic testing of all main welds.
  • Phased delivery to the project schedule.

Mega Steel Scope of Work (Execution Phases)

  1. Phase 01

    Shop Drawings & Splicing

    Girders split into transportable segments with designed splice joints.

  2. Phase 02

    Box-Girder Welding

    Automatic submerged-arc welding of thick plates.

  3. Phase 03

    Trial Assembly in the Workshop

    Each span trial-assembled to check straightness and camber.

  4. Phase 04

    Transport & Erection

    Special-trailer transport and night erection to limit traffic disruption.

Engineering Materials & Alloys Used

Certified, documented engineering

  • S355J2+N bridge plates
  • HSFG splice bolts
  • Shear studs
  • Bridge protective coatings

ENGINEERING BOTTLENECKS

The Project’s Complex Engineering Challenges

  • Large Lengths and Weights

    Members up to 45 tonnes had to travel on public roads.

  • Pre-Camber

    Girders needed a precise pre-camber to offset deflection under load.

ENGINEERED RESOLUTION

Innovative Engineering Solutions Applied

  • Planned Transport

    Transport routes and permits studied ahead, with members split to suit.

  • Cambered Assembly Jigs

    Girders assembled on jigs set to the pre-camber curve.

Custom Engineering Fabrication Solutions

Do you have a project that needs pressure vessels or specialised mechanical fabrication?

Send your materials list, engineering drawings or samples for immediate review by our engineers, who will define the best technical path and schedule.