Viaduct renovation

The steel truss structures of the historic Wipkinger viaduct in Zurich are currently undergoing extensive renovation. With the new mageba bridge bearings and expansion joints, the bridges will have the necessary "freedom of movement" to cope with future traffic.

The Wipkinger Viaduct was opened in 1894 to carry railway traffic from the north of Zurich to the main train station in the city centre, and for 130 years it has been one of the city’s most prominent transportation structures. As part of a wider structural renovation project, the four steel truss structures that carry the railway line over a busy road and the Limmat River were dismantled in March 2024 for extensive refurbishment in a factory – and mageba was contracted to supply the new bearings and expansion joints required.

Apart from designing and manufacturing these key structural components, mageba’s local team also participated closely in developing the appropriate assembly sequences. From lowering and aligning the bridge to the special requirements resulting from the very limited space available, mageba was involved in the project in a planning and advisory capacity from an early stage.

Following their refurbishment, the truss structures have now been reinstalled, with modern RESTON®SPHERICAL bearings replacing the old-fashioned roller bearings that previously supported them at each end. As well as designing the new bearings to meet the viaduct’s movement and rotation requirements, mageba’s local team also took great care to ensure that the new bearings would fit precisely into place with perfect load transmission – even participating in the fitting of the required connection plates in the factory where the trusses were being renovated, pouring a special quick-hardening material to compensate for any unevenness in the old steelwork.

Our team then went on to install the newly supplied TENSA®RAIL RSU expansion joints to accommodate the superstructure movements at the surface. These were fabricated from stainless steel for maximum durability, extending the length of service life before replacement becomes necessary – who knows, perhaps 130 years from now?

Client’s engineer: AFRY
Owner: SBB
Contractor: Marti AG

This photograph from the year 1898 shows the Wipkinger Viaduct just a few years after its opening in 1894

Most of the viaduct’s 834m-length was constructed of masonry, but the main crossings of roads, railway tracks and a river contain steelwork structures

View from below of the steelwork truss structures that carry the railway line over a busy road

Each of the four steel truss structures was supported by a pair of roller bearings at each abutment

The steelwork trusses were dismantled and transported to a factory for extensive renovation

Following design and manufacture of RESTON®SPHERICAL bearings to replace the old rocker bearings, mageba visited the truss renovation factory to help prepare for installation on site

In the factory, mageba mounted new steel connection plates at each bearing location to ensure proper load distribution to the changed bearing type (no longer linear)

For perfect load transmission, a special quick-hardening material was poured onto the new steel connection plates before bolting these to the bottom of the old steelwork

Ready for bolting of a new bearing’s steel connection plate to the bottom of a steelwork truss

A fully mounted bearing connection plate, ready to distribute the load from the steelwork superstructure to the new bearing that will support it on site

The steel trusses were supported on hydraulic jacks before lowering them gently onto the new bridge bearings – an operation carried out by mageba for each truss

Thanks to the efforts of mageba’s local team, the new RESTON®SPHERICAL bearings fit perfectly into place and the assembly process was well planned for maximum efficiency and quality

Lifting a new TENSA®RAIL RSU expansion joint into place on the Wipking Viaduct to accommodate the steel truss bridge’s movements

The new TENSA®RAIL RSU expansion joints were fabricated from stainless steel to maximise their durability

Thanks to their optimised design, their high quality and the stainless steel used in their manufacture, the new TENSA®RAIL RSU expansion joints will not need to be replaced for many years