MATCHSTICK WARREN TRUSS BRIDGE

PREPARED FOR

Gregg L. Fiegel, PhD, PE, GE

PREPARED BY

DESIGN TEAM YELLOW 10

Alyssa Wade:

Lindsey Wong:

Jolene Xu:

22 NOVEMBER 2024
 Method of Approach
Several methods of approach were utilized to be able to methodically build a well structured,
lightweight bridge in a timely manner. The first step was research. We researched lightweight truss
bridges that would best suit our standards. We chose the Warren truss design for our matchstick bridge
due to its triangular framework, which efficiently distributes weight. The top sections handle compression
by pushing down under the load, while the bottom sections manage tension by pulling against the forces.
This balanced design ensures strength and stability, allowing the bridge to support significant weight with
minimal materials.
The next step was to prepare a detailed design layout, including the bridge's dimensions and each
structural component’s placement. We then drafted four views: longitudinal elevation, transverse
elevation, deck plan, and isometric view, to ensure clarity in construction and a strong visual reference.
Each view helped us visualize the final structure, allowing for careful planning in terms of where
matchsticks would be placed for maximum support while keeping the bridge lightweight.
Building the matchstick bridge involved a careful and creative process, starting with the preparation of the
matchsticks. We first cut off the heads to ensure uniformity and reduce any potential fire hazards during
construction. This also helped reduce bulkiness of the matches, allowing us to more easily construct.
Once the matchsticks were ready, we focused on creating the bridge structure by employing a three-piece
design component. This consisted of laying three matchsticks in an alternating pattern similar to laying
brick. Two pieces are connected at the bottom and one piece is centered on top, creating more support.
Even though all the matchsticks were the same length, this design added additional support and helped
create a more intricate truss pattern.
We began the construction of the matchstick bridge by focusing on the deck, which serves as the
main surface for the bridge. To create a solid foundation, we laid out the matchsticks side by side,
carefully aligning them to ensure a flat and level surface. This initial step was crucial, as it would support
the load of the bridge itself and loads placed on the bridge. We used glue to attach the matchsticks
together. As we built the deck, we made sure to leave enough space between the matchsticks for
flexibility, allowing the structure to absorb some movement without compromising its integrity. Once the
deck was complete, it provided a strong base upon which we could build the trusses and support system,
setting the stage for the rest of the bridge’s construction.
After completing the deck, we moved on to constructing the trusses, which form the primary
structural framework of the bridge. The trusses were built in sections, with each triangle carefully
assembled and connected to adjacent sections. This process required precise measurements to ensure that
each triangle was uniform in size, maintaining the symmetry and structural integrity of the bridge.
We used a combination of glue and small clamps to secure the matchsticks in place as they dried,
ensuring a strong bond between components. Each triangular segment was tested for strength before
moving on to the next, minimizing the risk of weak points in the overall structure. This step demanded
patience and attention to detail, as even slight misalignments could compromise the bridge's performance.

Once both trusses were completed, we attached them to the deck, carefully aligning them to
maintain balance and stability. This stage involved reinforcing the connection points between the trusses
and the deck with additional matchsticks placed at strategic angles to distribute the load evenly. These
reinforcements acted as cross-braces, enhancing the overall rigidity of the bridge and preventing lateral
movement.

With the trusses securely in place, we added lateral bracing between them to further stabilize the
structure. This bracing was critical in preventing the bridge from twisting under weight, ensuring that it
remained strong and steady during testing. The lateral bracing was constructed using shorter matchstick
segments arranged diagonally between the trusses, forming additional triangles within the framework for
maximum strength.

Finally, we conducted a thorough inspection of the entire bridge, checking for any weak or
uneven connections. Any areas of concern were reinforced with additional glue and matchsticks. After
ensuring the bridge was structurally sound, we allowed the glue to cure fully before proceeding to the
testing phase.

Critique of Finished Product

The completed matchstick bridge meets the design expectations, showcasing a visually stable and
symmetrical structure that reflects the strengths of the Warren truss design. The triangular framework and
careful placement of reinforcements give confidence in its ability to distribute weight effectively,
minimizing stress points. The lightweight construction demonstrates efficient use of materials while
adhering to the intended dimensions and aesthetic goals. However, without physical testing, the true
performance of the bridge under load remains theoretical.

One concern that arose during construction was the precision of alignment. While great care was
taken to ensure uniformity, small discrepancies in matchstick placement could lead to uneven stress
distribution. These minor imperfections may affect the bridge’s overall ability to handle significant loads,
an uncertainty that can only be resolved through testing. Additionally, while the glue joints seem strong
and secure, their long-term reliability under sustained pressure is uncertain. Ensuring consistent adhesive
application without excess material was a challenge, and future projects could benefit from refining this
technique.

Although the project has not been physically tested, these observations highlight areas for
improvement that can be addressed in future builds. Prototyping smaller components or conducting
preliminary stress simulations could provide valuable insights into weak points and overall structural
behavior. Despite these potential concerns, the bridge reflects a strong understanding of design principles
and construction techniques, leaving us optimistic about its performance in upcoming tests.

Teamwork Assessment

The success of this project relied heavily on collaboration and effective communication among
team members. Each person brought unique strengths to the process, contributing to the research, design,
and construction phases. Early in the project, we delegated tasks based on individual skills and interests,
ensuring that responsibilities were distributed fairly and efficiently. For example, some team members
focused on drafting detailed design layouts and measurements, while others concentrated on preparing the
materials and assembling the bridge. This division of labor allowed us to stay on track and complete the
project in a timely manner.

Our teamwork was especially strong in problem-solving and decision-making. When challenges
arose—such as how to reinforce certain sections or address alignment issues—team members openly
shared ideas and discussed potential solutions. These collaborative discussions often led to creative and
practical strategies, which strengthened both the bridge and the group dynamic. Furthermore, we
maintained clear and consistent communication throughout the process, checking in regularly to ensure
everyone was aligned on goals and expectations. This proactive approach minimized misunderstandings
and kept the project running smoothly.

However, there were areas where our teamwork could improve. At times, differences in opinions
slowed down decision-making, as we struggled to reach consensus on specific design details. While this
was ultimately resolved through compromise, it highlighted the need for more efficient conflict resolution
methods. Additionally, a few moments of miscommunication led to minor delays during construction,
such as when a team member misunderstood a measurement and needed to redo a section. These
experiences underscore the importance of clarifying instructions and double-checking work as a team.