Multiple Cantilever form travellers in action

The S19 Babica–Jawornik section forms part of Via Carpathia, the transnational route linking the Baltic region with south-eastern Europe. The hilly terrain requires several major engineering structures, including Flyover ES-26 – an eight-span viaduct characterized by tall piers, long spans and limited space for assembly. As part of this strategic north–south connection, the new section is expected to improve regional accessibility once completed. Steep slopes, exposed working conditions and tight scheduling parameters add to the complexity of construction.

Tailored solutions for tall piers and long spans
Doka’s contribution covers both the construction of the tall piers and the balanced cantilever erection of the superstructure. Three sets of the Automatic Climbing Formwork SKE100 are used to execute the pier cycles safely and efficiently. A Heavy-duty support solution with UniKit and Supporting Construction Frames enables the construction of the hammerhead segments at heights where ground-supported shoring is no longer practical. Large-area formwork Top 50, Staxo load-bearing towers and Framed formwork Framax Xlife complement the solution across the different structural elements.

Advancing span by span
Starting from the hammerhead segments, five pairs of Doka Cantilever form travellers support the balanced cantilever construction of the superstructure. With spans reaching up to 188 m, ten travellers operate simultaneously on multiple piers, enabling efficient segment-by-segment construction. The cantilever arms gradually advance towards the adjacent spans until they meet at mid-span, completing the bridge deck.

To address the complex geometry and the height of the works – with assembly platforms more than 60 m above ground – Doka combined DokaCAD and Revit for detailed 3D modelling. The construction sequences were visualized as animations, supporting team coordination and contributing to safe execution in exposed conditions. Pre-assembled components and onsite formwork instruction helped streamline the process and maintain quality under tight scheduling constraints.

Engineering precision from planning to execution
The contractor consortium benefits from the early involvement of Doka’s engineering team and the heavy-duty solution developed for the starting segments. The combination of precise digital planning, tailored climbing and traveller concepts, and onsite technical support helps coordinate interfaces and maintain progress in challenging terrain and geometry.

According to contractor Intercor, the project ranks among the most demanding bridge construction projects currently underway in Poland: “Constructing the viaducts along the S19 Babica–Jawornik expressway is an engineering challenge that requires innovative construction technologies. During peak construction, we are utilizing multiple cantilever form travellers simultaneously on the largest viaducts, enabling efficient progress on spans of up to 188 m,” says Sebastian Dobrzański, Contract Director at Intercor.

In response to the project's demanding geometry and construction conditions, Doka Polska implemented model-based 3D planning and visualized construction sequences from an early stage. These digital planning tools supported the coordination of climbing and balanced cantilever operations, helping to ensure safe and efficient execution despite the structure's height and limited assembly space.

The Babica–Jawornik section of the S19 is scheduled for completion in 2027.