Construction Update: Malé–Thilafushi Balanced Cantilever Bridges Progress

Continuing our series on smarter segmental bridge design, we turn our attention to the Malé–Thilafushi Link (MTL) Project in the Maldives—a landmark marine crossing where Spannovation, as a sub-consultant to AECOM India, provided detailed design services for the Module 17 bridge and transverse analysis for other navigational spans (Modules 3, 4 & 12). With multiple cantilevers now visibly advancing across the lagoon at similar lengths, construction is entering a critical phase. Once complete, these segmental bridges will form a vital connection between Malé and Thilafushi, transforming accessibility in the region.

Balanced cantilevers progressing simultaneously across navigation spans of the Malé–Thilafushi Link under segmental construction.

The four navigational span modules of the MTL crossing are long-span balanced cantilever bridges. Module 17 provides a 70 m x 12 m navigation channel opening within its main span. To enable construction in deep marine waters without temporary falsework and reduce the number of in-water foundations, the team adopted a 148 m main span—close to the upper practical limit for segmental construction. While longer spans might have been possible using cable-stayed technology, airport height restrictions ruled out the use of extradosed pylons, making segmental girder the optimal solution. This approach achieved the best balance of cost, constructability, and environmental sensitivity for this location.

Foundation Flexibility and Structural Behavior

Module 17 features a span configuration of 96 m – 148 m – 93 m, supported on large-diameter bored piles socketed into coral rock. These piles remain unsupported for approximately 35 m, creating effectively tall and flexible piers. This inherent flexibility reduces the build-up of restraining forces from creep, shrinkage, and thermal effects—forces that often require mitigation methods such as the Pre-Compensation Force Method (PFM). Here, pier flexibility itself manages these effects naturally. However, this also posed challenges during maximum cantilevering stages, particularly under wind loading prior to closure, requiring careful temporary condition analysis.

Elevation of Module 17 showing span arrangement and deep marine pile foundations.

Key Segmental Design Strategies in Play

Although PFM was unnecessary here due to foundation flexibility, the MTL bridges showcase several segmental design strategies central to our ongoing series:

• Span Layout Optimization: The 96–148–93 m configuration minimizes in-water piers, reducing both environmental impact and marine construction risk.

  
  

• Balanced Cantilevering: Allows long-span construction without marine falsework.

  
  

• Integral Pier Connections: Eliminate bearings and expansion joints, improving durability in aggressive saltwater conditions.

  
  

These principles—successfully implemented in urban transit bridges such as the Mithi River and Yamuna Bridges—are also applicable a larger marine scale, underscoring their adaptability across diverse project environments.

Balanced Cantilevering Stage 7: Construction in Action

The MTL bridges are being erected using balanced cantilever construction, perfectly suited for deep lagoons where falsework is impractical. Segments are precast using the long-line method, transported via barges, and lifted into place using lifters. Each segment weighs up to 215 metric tonnes, reflecting the scale of these marine spans.

 Balanced cantilevering in Stage 7 with six lifted segments per cantilever. - Plan on left and construction on right

Current works are at Stage 7 of cantilevering, with lifters advancing segments symmetrically to maintain equilibrium. The pier table starter segments are cast-in-place, while the closure (key) segments will also be cast-in-place to achieve final continuity.

Spannovation’s Role

Spannovation’s detailed design expertise and construction-phase support on the MTL project draw directly from our experience with transit-oriented segmental bridges. By applying proven segmental principles to this challenging marine crossing, we’re helping deliver a project that blends technical innovation, durability, and constructability in an environmentally sensitive setting.

Read more about Spannovation’s role on the MTL Project here:👉 Malé–Thilafushi Bridge Project – Spannovation