A1 Aurachbridge
Regau, Austria
Doka quality for the next hundred years
Doka, an experienced partner in cantilever construction, plays a crucial role in the construction of the new Aurach Bridge, the tallest bridge on the West Autobahn in Austria, standing at 50 meters in height.
Being heavily trafficked with peak times of approximately 50,000 vehicles daily, the steel composite bridge required a complete renovation after 60 years of service. Despite the ongoing construction, it was necessary to maintain a high-capacity crossing of the Aurach Valley for traffic. Therefore, a new structure was initially built parallel to the existing bridge to provide a temporary diversion for the traffic.
To ensure that, once completed, the new Aurach Bridge can function as a functional and reliable transport link across the Aurach Valley for at least the next hundred years, the executing consortium HABAU/PORR is relying on Doka's know-how.
After all, the engineers' many years of experience and the tailor-made solutions in the field of cantilevering are indispensable in the implementation of this major project.
Customer Requirements
- weekly cycle to meet the tight construction schedule
- high requirements with regard to documentation - detailed recording of the measured values in all concreting sections
Challenge
- short length of the hammer heads makes it difficult to place the cantilever traveller
- post-tensioning of the bridge tension cables, therefore reliable strength knowledge is required to carry out the post-tensioning safely
Solution
- Interlocking cantilever forming travellers ( fork solution) allow space-saving assembly and quick cantilevering without a lot of conversion work
- Concremote sensors (2 slab sensors per casting) and web portal
- by using the mobile app the site crew was able to follow concrete strength right after casting the concrete, and also at any time
- documentation made easy with the new documentation feature “report”
New piers for significantly higher load
For the five piers of the bridge in a horizontal position, 30 drilled piles with depths of over 30 meters were required, for which the largest rotary drilling rig in Austria with a weight of 180 tons was used in 2022. In the autumn, the five foundations were then concreted, upon which the heavy piers were subsequently erected. For the construction of these piers, which can reach heights of up to 40 meters, the Framed formwork Framax Xlife the Climbing formwork MF240 were used, each of which was set up using cranes.
Concrete casting using the cantilever method
After the completion of the piers, the so-called hammerheads, which serve as starting points for the cantilever construction method, were concreted on top of them. In this construction method, Doka cantilever forming travellers are used, combining planning and cost certainty with an optimal construction process. The perfect coordination between support structures and formwork, the high safety standards, and the optimized ergonomics ensured swift and secure progress in construction. This allows the subsequent construction sections to be added in parallel to the freely protruding ends of the hammerheads.
Stastny Markus | Technical Manager at Doka Austria
"The limited length of the hammerheads present a challenge, as a result of which the two cantilever forming travellers could not be placed one after another or side by side," explains Markus Stastny, Technical Manager at Doka Austria. His team had the so-called "fork solution" ready as a response. "This made it possible to place the traveller interlaced inside each other at the same time and very few conversion work of the Cantilever forming traveller planned via DokaCAD for Revit was required," says Stastny. Starting in March 2023, the bridge structure was constructed horizontally, starting from the hammerheads, in symmetrical 5-meter sections.
Safe tensioning of bridge cables thanks to Concremote
Due to the tight construction schedule and the client's high demands regarding detailed documentation, our client decided to use #Concremote for monitoring early compressive strength. Significant time savings in the required documentation as well as increased safety when tensioning the bridge cables thanks to the real-time data in the web portal and app are particularly appreciated by our customer.
Significant time savings in the required documentation, thanks to a specially developed reporting function.
Safe post-tensioning of the bridge cables through verification of compressive strength by Concremote.
Project data
Year of site completion
2025
Country
Austria
City
Regau
Construction company
ARGE Aurachbrücke (HABAU / PORR)
Building owner
Asfinag
Building data
Construction Method
Free-cantilever method
Construction Type / Segmentation
Foundation, Piers, Superstructure
Total length
420m
Section width
14.89m
Section height
3.8m
Section length
5.0m
Cycle time
weekly
Period of Concremote use
11/2022 - 2024
Used Concremote hardware
8 pcs. slab sensors 2.0, 2 pcs. calibration boxes 2.0
Concrete mixes in use
4
Number of measurements
200