Views: 221 Author: Site Editor Publish Time: 2026-02-28 Origin: Site
Content Menu
● Defining Hanging Basket Technology: The "Moving Factory" Concept
>> Key Advantages for Steel Temporary Bridges
● The Anatomy of a High-Performance Hanging Basket System
>> The Main Truss System (The Backbone)
>> The Walking and Anchoring System (The Legs)
>> The Suspension and Lifting System (The Arms)
>> The Template and Work Platform (The Floor)
● The Operational Cycle: A Step-by-Step Engineering Symphony
>> Stage 1: The "Zero-Segment" Construction
>> Stage 2: Basket Assembly and Pre-loading
>> Stage 3: Positioning and Anchoring
>> Stage 4: Segment Lifting and Precise Alignment
>> Stage 5: Joining and Structural Integration
>> Stage 6: The "Walk" Forward
● Innovative Breakthroughs: The EVERCROSS Perspective on "Smart" Baskets
>> Innovation 1: IoT and Real-Time Structural Monitoring
>> Innovation 2: BIM (Building Information Modeling) Integration
>> Innovation 3: Lightweight, High-Performance Alloys
● Strategic Synergy: Collaboration with Central Enterprises
● Safety Protocols and the "Zero-Failure" Philosophy
>> Mandatory Pre-Pressing Tests
>> The "Twin-Anchor" Redundancy
● Comparison: Why Hanging Baskets Win in Modern Engineering
● Shaping the Future of Connectivity
● Frequently Asked and Questions regarding Hanging Basket Technology
>> Q2: How does EVERCROSS BRIDGE ensure the safety of the basket during the "walking" phase?
>> Q3: What are the weather limitations for operating a hanging basket on-site?
>> Q5: How long does a typical construction cycle take for one bridge segment?
>> Q6: Why is the "Pre-loading Test" considered the most critical step before starting construction?
In the modern landscape of global infrastructure, the efficiency, safety, and speed of bridge assembly are no longer just goals—they are absolute requirements. For large-span projects where traditional ground-supported scaffolding is physically impossible or economically unfeasible, hanging basket technology (frequently referred to in international engineering as Form Traveler technology) has emerged as the definitive gold standard.
As a premier, top-three Chinese manufacturer with an annual output exceeding 10,000 tons of high-grade steel bridges, EVERCROSS BRIDGE has been at the forefront of this evolution. Our extensive collaboration with China’s central state-owned giants—including CCCC (China Communications Construction), CREC (China Railway Group), POWERCHINA, and Gezhouba Group—on high-stakes railway, highway, and international procurement projects has allowed us to refine hanging basket technology into a precise, high-performance science.
Hanging basket technology is a specialized cantilever construction method designed to build bridge segments sequentially without relying on ground-based support. Think of it as a "mobile factory" that creates the bridge as it moves across the void. In this system, the bridge itself provides the support for the equipment that builds the next section.
Traditional bridge construction often requires "falsework"—massive forests of steel scaffolding built from the ground up to support the bridge deck during construction. However, when crossing a 200-meter deep canyon, a busy eight-lane highway, or a navigable shipping channel, building from the ground up is impossible. The hanging basket solves this by "hanging" from the completed portion of the bridge and extending outward into space.
While originally developed for reinforced concrete box girders, modern steel temporary bridges have revolutionized this technology.
●Environmental Preservation: Because no ground support is needed, the local ecosystem (wetlands, forests, or riverbeds) remains untouched.
●Continuous Traffic Flow: Construction can occur high above active transit lines without requiring road closures.
●Precision: Hydraulic adjustment systems within the basket allow for millimetric precision in segment alignment, which is critical for steel structures where bolting and welding tolerances are extremely tight.
A hanging basket is not merely a steel frame; it is a sophisticated mechanical assembly designed to withstand massive gravitational and environmental loads. At EVERCROSS BRIDGE, we categorize the system into four primary sub-assemblies:
The main truss is the primary load-bearing structure. It is typically designed in a rhombic or triangular configuration using high-strength structural steel such as Q345B or Q355B.
●Structural Rigidity: The truss must be rigid enough to resist deflection under the weight of the steel segments, but light enough to not overstress the bridge's permanent piers.
●Modular Design: Our trusses are often modular, allowing them to be reconfigured for different bridge widths and curvatures, maximizing the return on investment for contractors.
This system is what allows the "moving factory" to advance.
●The Walking System: Utilizes heavy-duty hydraulic jacks and precision-engineered rails. Modern "trackless" designs use the bridge deck itself as the guide, reducing dead weight and assembly time.
●The Anchoring System: This is the most critical safety component. While the basket is cantilevered out, the "back" of the truss is anchored deep into the previously completed bridge segment. This counteracts the "overturning moment"—the physical force trying to tip the basket into the abyss.
The suspension system consists of high-tensile steel rods (often nested in protective sheaths) that hang the workspace from the main truss.
●Vertical Adjustment: Using hydraulic winches or electric hoists, the elevation of the steel segment can be adjusted in real-time.
●Lateral Alignment: Specialized "side-shift" mechanisms allow the segment to be nudged left or right to align perfectly with the bridge's centerline.
This provides the safe environment for engineers to perform welding, high-strength bolting, and inspection. For steel bridges, this often includes specialized weather-shielding to ensure that wind and rain do not compromise the integrity of the welds.
Component |
Technical Function |
Material/Standard Specification |
Main Truss |
Primary load-bearing |
High-strength Q355B Steel |
Hydraulic Jacks |
Movement and leveling |
100t - 500t synchronized capacity |
Anchor Rods |
Anti-overturning safety |
Grade 8.8 or 10.9 high-tensile steel |
Control System |
Automated operation |
PLC-integrated digital control |
The construction of a bridge using hanging basket technology is a repetitive, cyclical process that demands extreme discipline.
Before a hanging basket can be used, a "base" must be established. This is called Segment 0. It is built directly on top of the bridge pier using temporary steel supports. Once Segment 0 is cured (if concrete) or bolted (if steel), it serves as the platform for the assembly of the two hanging baskets—one facing forward and one facing backward to maintain balance.
The baskets are assembled on Segment 0. Crucially, they undergo a pre-loading test. Engineers place weights on the basket equal to 1.2 times the expected load. This "settles" the structure and allows engineers to measure any elastic deformation, ensuring there are no surprises during actual segment installation.
The basket is moved to the edge of the current segment. The rear anchors are engaged and tensioned. The front of the basket now hangs over open space, ready to receive the next piece of the bridge.
For steel temporary bridges, the next truss or deck segment is typically barged or trucked to the site and lifted into the basket. Using laser-guided leveling tools and 3D modeling data, the segment is positioned.
The new segment is welded or bolted to the existing bridge. In composite structures, prestressing tendons are threaded through the segments and tensioned to thousands of pounds of pressure, literally "squeezing" the bridge pieces together into a single, incredibly strong beam.
Once the new segment is structurally sound, the basket’s anchors are released. The hydraulic system pushes the entire assembly forward onto the segment just completed. The cycle then repeats.
As an industry leader, EVERCROSS BRIDGE has moved beyond static steel frames into the realm of Smart Hanging Basket Technology. The following are three key areas where we have added unique value to the industry.
Modern bridge sites are often in extreme environments. We have integrated Internet of Things (IoT) sensors into our hanging baskets.
●Strain Gauges: Measure the real-time stress on every truss member.
●Anemometers: Monitor wind speeds. If wind exceeds safe limits (typically Level 6 or 13m/s), an automated alarm notifies the crew to lock the system down.
●Inclinometers: Ensure the basket remains level within a fraction of a degree. This data is streamed to a cloud dashboard accessible by project managers anywhere in the world.
We utilize BIM to "build the bridge before we build the bridge." By creating a digital twin of the hanging basket and the bridge segments, we can simulate the entire construction sequence. This identifies potential "clashes" where the basket might hit a bridge component before it ever happens on-site, saving weeks of potential delays.
By utilizing advanced metallurgical techniques, we have reduced the dead weight of our hanging baskets by approximately 15% without sacrificing load capacity. This reduction in weight means the bridge structure itself is under less stress during construction, allowing for longer spans and more ambitious architectural designs.
Our role as a top-three manufacturer isn't just about building steel; it's about navigating the complex standards of global giants like CCCC and CREC.
●Customized Engineering: No two bridges are the same. Whether it’s a variable-width bridge deck or a high-altitude railway bridge with extreme temperature fluctuations, our engineering team provides bespoke hanging basket solutions.
●Global Standard Compliance: Because we work on international government procurement projects, our technology is designed to meet not just Chinese national standards (GB), but also AASHTO (American) and Eurocode standards. This makes EVERCROSS BRIDGE a preferred partner for Belt and Road Initiative projects and other international infrastructure tenders.
In cantilever construction, there is no room for error. A failure in a hanging basket doesn't just mean a delay—it can be catastrophic.
Every basket must undergo a rigorous pre-pressing procedure. This isn't just to test strength, but to eliminate "non-elastic deformation." By stressing the joints and bolts of the basket before use, we ensure that when the actual bridge segment is added, the basket doesn't sag or shift unexpectedly.
At EVERCROSS BRIDGE, we implement a redundant anchoring system. If the primary hydraulic lock were to fail, a mechanical "dead-man" anchor is always in place to prevent the basket from moving.
Steel temporary bridges often act like giant sails. Our baskets are designed with aerodynamic profiles to reduce wind resistance, and our operating manuals mandate strict cessation of movement during high-wind events, supported by automated braking systems.
Feature |
Hanging Basket (Form Traveler) |
Full-Span Falsework |
Incremental Launching |
Terrain Flexibility |
Excellent (Over any obstacle) |
Poor (Requires flat ground) |
Moderate |
Construction Speed |
High (Once cycle is mastered) |
Low (Slow setup) |
Moderate |
Initial Cost |
Moderate to High |
Low |
High |
Labor Requirement |
Skilled/Specialized |
High (Manual labor) |
Low (Automated) |
Environmental Impact |
Minimal |
Significant |
Minimal |
Hanging basket technology represents the pinnacle of bridge engineering efficiency. It turns the impossible task of building across deep voids into a manageable, rhythmic industrial process.
For EVERCROSS BRIDGE, our 10,000-ton annual capacity and our deep-rooted partnerships with China’s central enterprises are more than just statistics—they are a testament to our reliability and expertise. We don't just provide steel; we provide the technological "engines" that allow the world's most ambitious bridges to move forward, segment by segment.
Whether you are managing a domestic highway project or an international railway tender, understanding and implementing the right hanging basket technology is the key to unlocking safety, precision, and profitability.
The most significant advantage is environmental and operational independence. Hanging basket technology allows for construction high above deep valleys, wide rivers, or active transportation corridors (highways/railways) without the need for ground-supported structures. This eliminates the cost of extensive falsework, reduces the project's environmental footprint, and ensures that traffic or water flow beneath the bridge remains uninterrupted throughout the construction cycle.
Safety during the advancement (walking) phase is managed through triple-redundancy systems. First, we use PLC-controlled hydraulic synchronization to ensure the basket moves perfectly level. Second, we employ mechanical safety pins that act as a "dead-man" switch; if hydraulic pressure fails, these pins immediately lock the basket to the rails. Finally, every "walk" is preceded by a comprehensive inspection of the anchor points on the previously completed segment to ensure structural stability.
According to international safety standards and GB 51210-2016 regulations, hanging basket operations—especially "walking" and segment lifting—must cease if wind speeds exceed 13 m/s (Level 6 wind). Additionally, during extreme temperature fluctuations, our engineering team calibrates the hydraulic systems to account for the thermal expansion or contraction of the steel truss, ensuring that millimetric alignment precision is maintained regardless of the climate.
Yes. As a specialized manufacturer, EVERCROSS BRIDGE designs modular hanging baskets specifically for complex geometries. For curved bridges, we incorporate adjustable lateral guides and articulated truss joints. For variable-width decks, our baskets feature telescopic transverse beams that can expand or contract as the bridge width changes, a common requirement in highway interchange projects for central enterprises like CCCC and CREC.
While the cycle time depends on the segment's complexity and material (steel vs. concrete), a well-optimized operation using an EVERCROSS hanging basket typically achieves a cycle of 6 to 10 days per segment. This includes the time for basket advancement, positioning, segment lifting, welding/bolting, and quality inspection. Our lightweight high-strength steel designs are specifically engineered to shave 10-15% off the assembly time compared to traditional heavy-duty travelers.
The pre-loading test (usually at 120% of the design load) serves two vital purposes:
●Eliminating Non-Elastic Deformation: It "settles" all the bolted joints and structural connections within the basket, ensuring it doesn't shift unexpectedly when the actual bridge segment is added.
●Verification of Data: It allows engineers to measure the precise elastic deformation curve. This data is then used to "pre-camber" the basket, ensuring that after the segment is installed and the basket sags slightly under the weight, the bridge deck ends up at the exact elevation required by the design.
