How to Make a Strong Truss Bridge with Popsicle Sticks

Building a bridge out of popsicle sticks is a fun craft project or an educational school assignment. You might even be thinking of entering a bridge-building competition. Unsure where to start? With popsicle sticks, a creative mind, and a few other household items, you can build a glorious bridge on your kitchen table. This article details how to assemble a simple Warren Truss bridge, but feel free to follow the steps while crafting an original design.

Part 1

Part 1 of 5:

Planning Your Bridge

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1
Decide what kind of bridge to make. There are several different kinds of bridge you can decide between, including suspension bridges, draw bridges, and truss bridges. ^{[1]
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Go to source} Since a truss bridge uses triangles in its frame to support and strengthen its structural integrity, it’s an ideal design for a popsicle stick bridge.
- For the purposes of providing a guided example, the following model bridge will be built following the classic Warren truss bridge structure. ^{[2]
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Familiarize yourself with the parts of a truss bridge. Truss bridges have varying degrees of complexity. Popular truss bridges include the Pratt truss, the Warren truss, and the Howe truss. ^{[3]
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Research source} Investigate a few designs on your own before choosing or inventing one. Generally, a truss bridge has: ^{[4]
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- Two long top and bottom chords
- Diagonal beams between the chords, usually in triangular arrangements
- Optional vertical beams between the chords for additional support
- Optional abutments at the ends
- Optional piers underneath
- Optional additional support beams
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Now that you have a general idea of the structure you're trying to build, as well as the tried and true essential parts of a truss bridge, you're ready to use your imagination. Take some time to sketch out your design. Don't worry too much about being true to life; your blueprint is a plan, not a perfect representation.
4
Determine the length of your bridge to know how many sticks you need. Consider how long you want to make your bridge before you go shopping for supplies. There are multiple different sizes of popsicle sticks available at your local grocery or craft store, or online. This tutorial uses about 90 popsicle sticks for the trusses and more for the deck. To get a good estimate of how many popsicle sticks you’ll need for your deck:
- Lay out a yardstick on your workspace.
- Note the approximate length of your bridge.
- Take the length of your bridge and divide it by the width of the average popsicle stick, since they’ll be laid lengthwise to create the deck.
  - The average popsicle stick is ³ ⁄ ₈ inch (0.95 cm) wide.
  - If your bridge will be about three popsicle sticks long (13.5 inches (34 cm) using standard sticks), your deck needs 36 sticks. 36 + 90 = 126 sticks total.
- The average bridge requires between 100 and 200 popsicle sticks. ^{[5]
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Place a piece of cardboard or construction paper on a table or any other type of smooth, flat, level surface. Make sure that the size of your workspace is large enough to accommodate the bridge you will be constructing. Measure out its rough dimensions against the area available on your workspace. If it’s insufficient, try to find a place to work on the floor or outside.

Part 2

Part 2 of 5:

Constructing the Truss Walls

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1
Lay out three rows of three popsicle sticks for each chord. The chords of a truss are the four long, horizontal beams that run along the top and bottom of your bridge. There are two on each side. To make a standard-sized popsicle stick bridge chord, follow these steps:
- Lay out three horizontal rows of popsicle sticks, with each row being three sticks wide. For the top and bottom row, place three sticks end-to-end. For the middle row, place two sticks end-to-end and two half-sticks along their ends.
  - Each row should be equal in length.
  - Discard bent or misshapen popsicle sticks. The sticks that form your bridge must be uniform and flat.
- Repeat this layout until you have four rows of three, which are the components of your four chords.
2
Glue your truss chords together. Take the popsicle sticks of each of your four rows and, keeping the popsicle sticks even, hot glue your truss chords together. Start by gluing the middle row with the half-sticks on top of the top row. Next, glue the bottom row on top of that. Repeat four times to create your four, three-stick-thick truss beams.
- For best results, clamp your popsicle sticks together with binder clips as soon as the glue has been applied.
- If you don’t have clips, press the popsicle sticks together and apply firm pressure so your trusses are securely glued.
3
Lay out your chords and let the glue dry for 10 minutes. If you are using a hot glue gun , this won't take long. By allowing the glue to fully dry, you prevent yourself (or others) from knocking loose a popsicle stick from your truss. Other kinds of glue, like wood glue or general-purpose glue, should be allowed to rest for 15 minutes.
- If, when you touch your glued truss, the bond feels weak, tacky, or loose, allow the glue to dry for another 15 minutes.
4
Measure the spacing of your truss’s diagonal beams. Use your pencil and a yardstick or ruler to measure out regular intervals along the chords where the ends of your cross-bracing popsicle sticks will go. For the purposes of this model (a Warren truss), you use two sticks side by side in alternating diagonals, forming a W pattern. ^{[6]
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- Start by measuring near the end of the top chord. Measure three equally spaced intervals away from that end and mark them. Once done, two markings are at the ends of the top chord, and two are in the middle.
- Place two popsicle sticks over each marking, angling them to form one-and-a-half “W” shapes that connect the top and bottom chords.
- Repeat this for all four of your chords .
5
Glue your diagonals to the chords in a W pattern. With the W pattern planned out, determine how many popsicle sticks you will need (8 for each “W”, 4 for half a “W”). Count out the appropriate number to have at the ready, then assemble as follows:
- Position your popsicle sticks along the truss beams before gluing to verify the final structure of the beams. Make sure each triangle in the “W” is equilateral, meaning each of its three sides are equal in length and all the interior angles measure 60 degrees.
  - Check the angles of your triangles with a protractor.
- Use hot glue or another suitable glue to adhere the popsicle stick diagonal beams to the truss chords.
- Wait 10-15 minutes for the glue to dry.
- Repeat this for your right-side top and bottom chords and your left-side top and bottom chords. At the end, you have your bridge’s two trusses!

Part 3

Part 3 of 5:

Constructing the Deck

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Lay popsicle sticks side-by-side along the trusses to make the deck. Set your two trusses flat on your workspace so that each lies parallel. Then, take your popsicle sticks and lay them crosswise (side-to-side) between your trusses. These sticks form the deck, or the road, that runs the length of your bridge between the truss walls. Make your deck stretch the distance of the trusses.
- Be sure that all of your popsicle sticks are even in length. Otherwise, the deck leading over your bridge may look irregular or uneven.
2
Anchor your deck with staggered lengthwise supports. Larger-sized popsicle sticks provide more stability, but smaller popsicle sticks work fine if you don't have any larger ones on hand. Lay your sticks in a staggered formation lengthwise to join your deck into one, continuous piece. Use your hot glue gun or some other suitable glue to fasten your supports in place.
- Place about eight supports—three on the top, three on the bottom, and two along the center.
- If you are using wood glue or general-purpose glue, allow at least 15 minutes for the glue to dry before handling the deck.
3
Measure and cut floor beams to place under the deck. Using a yardstick or ruler, take the measure of your deck and the thickness of both trusses to get the necessary measurement. Cut three or four popsicle sticks to the length you just measured. Glue them together, one on top of the other, to form a floor beam three or four sticks thick. Repeat to make four.
- If your popsicle sticks are too short, make a longer one. Cut two sticks and, with glue, join each by attaching another stick to the bottom for support.

Part 4

Part 4 of 5:

Putting It All Together

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Glue the floor beams along the truss walls to connect them. Consider having a friend help you for this part of the bridge assembly. Place your floor beams along the truss bridge, with two at the ends and two along the center. Use hot glue to attach your floor beams to the lower chords of each truss.
- Make sure the two side trusses are parallel to each other and perpendicular to the ground/your work surface. Consider propping them against boxes or books ot make sure they’re parallel. ^{[7]
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You may want to leave your deck loose so you can show off every aspect of your bridge's construction. However, if you want the deck connected to the floor beams, simply apply hot glue to the floor beams and lay your deck into place.
If you have long popsicle sticks, you can simply lay these across the top of the truss walls and glue each into place. If your popsicle sticks aren't long enough, make longer ones. Space them evenly along the top of your truss walls.

Part 5

Part 5 of 5:

Testing Your Bridge

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1

Place your popsicle stick bridge between two supporting surfaces. Place two chairs, tables, or boxes across from one another, a little less than the length of your bridge. Balance the ends of the bridge over the gap. ^{[8]
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Go to source} Make sure the bridge is suspended high enough that you can hang a weight from it—about 6 feet (180 cm) should work.
2
Suspend a weight from the top center of the bridge on a rope. First, place a loading block—either a plank of wood or a brick—atop the center of the bridge. Tie a rope around it. Let the rope hang down. This only works if you can remove the deck of your bridge. Secure a small bucket of water, a barbell, or another type of weight to the other end of the rope. ^{[9]
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Research source} Film your bridge to capture it staying secure (or collapsing under the weight).
- Another option is to slowly increase the weight until the bridge breaks, helping you learn just how much it can bear.
3

Calculate the bridge’s strength-to-weight ratio. Take the mass it took to break the bridge. Divide it by the mass of the bridge. Use the same units to measure both and ensure an accurate calculation. The resulting figure is the bridge’s strength-to-weight ratio, which tells you how strong the bridge is relative to its weight. The higher the number, the stronger your bridge. ^{[10]
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Community Q&A

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Question

Does it have to be a hot glue gun, or can I use just regular wood glue?

Community Answer

You can use regular craft glue, or superglue as well; it is just that a hot glue gun speeds up the entire process, especially useful for the less patient builder!

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How many sticks does this take to make?

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Around 150-200 sticks, but you can make smaller or larger trusses depending on the material you have

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How much load can this type of bridge carry, if it has a span of 50 cm in length?

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A 50 cm long, well-constructed bridge like this could hold a few kilograms of weight, and 8 kg would probably be the limit. However, it's not the weight placed on a bridge that matters, it's at the force with which it comes into contact with the bridge. For example, if you were to drop a 4 kg ball on the bridge from two meters high, the bridge would weaken or even collapse.

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When layering sticks together, a process sometimes called "lamination," you can achieve better strength by staggering your popsicle sticks.

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For the construction of this bridge, there were two sizes of popsicle sticks used. However, you should be able to accomplish this design even with only one size of popsicle stick.

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Tips from our Readers

The advice in this section is based on the lived experiences of wikiHow readers like you. If you have a helpful tip you’d like to share on wikiHow, please submit it in the field below.

Be sure to test your bridge strength if you'll be using it for model trains. Your bridge must be able to handle the weight of the train and tracks.
Wood glue is perfect for holding your bridge together. I like Titebond II, but any solid wood glue brand will do.
For maximum strength, use clamps. Clothespins work well.

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Warnings

Always exercise caution when operating a hot glue gun. Improper handling can result in you getting burned. Be very careful and be prepared.

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Things You'll Need

Popsicle sticks
Hot glue gun (and glue)
Large piece of cardboard or construction paper
Paper (for designing)
Pencil
Scissors or shears (for cutting popsicle sticks)
Yardstick, ruler, or tape measure

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How to Make a Strong Truss Bridge with Popsicle Sticks

Steps

Planning Your Bridge

Constructing the Truss Walls

Constructing the Deck

Putting It All Together

Testing Your Bridge

Community Q&A

Video

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Tips

Tips from our Readers

Warnings

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