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In-house competence centre develops innovative formwork solutions

Doka sets standards in European bridge construction

18.12.2023 | Press
In-house competence centre develops innovative formwork solutions
Doka has made a name for itself with formwork solutions for exceptional bridge constructions. Recent projects such as the Aurach, Jaruga and Aftetal bridge in the heart of Europe show that thanks to Doka's expertise, the infrastructure projects of tomorrow are already being built today. They are being developed in Doka's in-house competence centre at the company's headquarters in Amstetten by a team of highly qualified engineers, who are involved in the largest bridge projects with the most diverse construction methods.

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Impressions

  • Aurach Bridge
  • Jaruga Bridge
  • Aftetal Bridge
  • A16 Rotterdam
  • Västlänken
Building a bridge is a long-term project that requires professional planning if it is to be completed efficiently, quickly and economically. For this reason, Doka set up its own competence centre “Global Expertise Centre Infrastructure” in 2006, dedicated to comprehensive project management in bridge construction. The key to strategic success in the realisation of numerous megaprojects in over 60 countries is the competence centre’s highly qualified team. These experts work with regional representatives to plan the implementation of major bridge projects – from composite bridges to prestressed concrete bridges. The team is constantly looking for new ways to develop even more efficient and sustainable solutions for construction customers worldwide. These include the Doka cantilever formwork traveller and the Doka UniKit universal engineering kit for heavy loads, with which even the most challenging bridge projects can be mastered successfully.

Innovation leads to success

Modern formwork systems are adaptable, versatile and can be easily combined. For instance, they can be used initially to form retaining walls or pier foundations and then to form pier shafts. Furthermore, the extensive Doka product range offers the best formwork solution for different bridge construction methods. The Doka Cantilever Forming Traveller is particularly suitable for large-span superstructures, as it constructs bridge sections symmetrically on both sides. For a safe and fast construction of composite bridges, where the deck consists of both concrete and steel structures, Doka applies the Composite Forming Carriage. Doka’s universal engineering kit UniKit is ideal for handling high loads across any span. A clear advantage of these formwork systems is that they are made up of standardised rental components that can be reused on other construction sites.

The following international projects show how expertise and sophisticated solutions can make an impact:

1. Aurach Bridge: Exemplary bridge refurbishment

A team from Doka’s Austrian national organisation and engineers from the Doka Global Expertise Centre Infrastructure collaborated to develop a tailor-made project solution for the extensive renovation of the 50 metre high and 420 metre long Aurach Bridge in Regau. As the highest bridge on Austria's A1 motorway, it carries around 50,000 vehicles at peak times. So, despite the ongoing construction work, traffic must continue to flow across the Aurach valley. In order to ensure this, a new structure will be built parallel to the existing bridge, to divert traffic temporarily. Ultimately, the new bridge will be constructed to withstand significantly higher loads and to provide a functional and reliable traffic link across the Aurach Valley for the next hundred years. The Cantilever Forming Traveller will act as support structure and formwork during the construction of the new bridge, ensuring fast – and safe – progress.

2. Jaruga Bridge: Focus on 3D digital planning

The total length of the Dumanja Jaruga Bridge is 500 metres, with a maximum span width of 120 metres. Most of the viaduct was formed using four Cantilever Forming Travellers. The adjustments that had to be made to support the transverse inclination were a challenge for the formwork, as the highway had to be adapted to the S-shaped curve. Various components from the UniKit engineering kit were used to form the foreland zone. In addition to the Doka UniKit tower 480, both UniKit primary and secondary beams were used, as well as customised SL-1 towers. Doka added significant value through digital formwork planning in 3D design, checking for potential collisions and promoting smooth collaboration. This resulted in shorter planning times, cost savings and increased site safety.

3. Aftetal Bridge: Mastering complex bridge geometry

The Aftetal Bridge is a composite bridge between Brilon and Paderborn. Due to its height, pier geometry and massive pier heads, as well as its length and span, it is one of the more challenging structures. The complexity of the bridge geometry also increases the demands on the formwork. The German flagship structure was planned in collaboration with Doka’s German national organisation. Due to the demanding construction requirements, Doka developed individual solutions to ensure process reliability, schedule adherence and cost management. The use of Doka formwork solutions resulted in a 40% reduction in material consumption and a 30% reduction in construction time. A perfect example of minimising the ecological footprint whilst maintaining quality.

4. A16 Rotterdam: Supported by Doka UniKit

The universal UniKit engineering kit for heavy loads was used throughout the construction of the new 11 km link between the A16 and A13 motorways in Rotterdam. By applying formwork solutions consisting of UniKit secondary beams and a tailor-made reinforcement area, all of which can be reused despite the different geometries, bridge segments were cast, lifted and moved over the ongoing motorway traffic with the incremental launching method. Doka's expertise was also instrumental in creating the fair-faced concrete formwork that is now part of Rotterdam's cityscape.

5. Västlänken: Pioneering transportation

The Västlänken project in Gothenburg, Sweden, involves an underground rail network that will carry commuter and regional trains through the city and connect three new train stations. Part of the project is the construction of the Olskroken bridge. To form the composite bridge with ParaTop, Doka developed a special formwork shoe that ensured optimum load distribution on the steel structure when pouring concrete. A combination of UniKit primary and secondary beams, supported by an SL-1 construction, made it possible to form bridge sections with spans of up to 22 metres. The finished bridge consists of two parallel highways, each approximately 100 metres long and 6 metres wide.

Upcoming bridge projects: Jaun Valley Bridge and R2 Kriváň – Mýtná

Many more bridge projects are already underway, including the renovation of the Jauntal Bridge as part of the Austrian Federal Railway "Koralmbahn" initiative or the impressive prestressed concrete R2 Kriváň – Mýtná bridge in Slovakia.

About Doka:
Doka is a world leader in providing innovative formwork, solutions and services in all areas of construction. The company is also a global supplier of well-thought-out scaffolding solutions for a varied spectrum of applications. With more than 178 sales and logistics facilities in over 60 countries, Doka has a high-performing distribution network for advice, customer service and technical support on the spot and ensures that equipment is swiftly provided – no matter how big and complex the project. Doka employs 7,000 people worldwide and is a company of the Umdasch Group, which has stood for reliability, experience and trustworthiness for more than 150 years.

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