Flyover ES-26 | S19
Babica–Jawornik Expressway
Babica, Poland
Engineering at altitude
With ten piers reaching heights of up to 66 metres and spans of up to 188 metres, the ES-26 Flyover is one of Poland’s most impressive infrastructure projects.
The bridge is being constructed in southeastern Poland as part of the new S19 expressway and forms a key section of the Via Carpatia, a major European north-south transport corridor linking the Baltic region with Southeast Europe.
Exceptional construction heights, challenging terrain, and the balanced cantilever construction of the bridge deck place high demands on both planning and execution. Doka supports the project with engineering expertise and on-site technical assistance. The solution combines Automatic climbing formwork, Heavy-duty support solutions, Cantilever forming travellers, and model-based 3D planning to ensure safe, efficient, and reliable project delivery.
Building type
Piers, Hammerhead, Balanced Cantilever Construciton
Challenge
Steep slopes and restricted assembly areas around Poland’s highest bridge, reaching a height of 80 m, posed significant challenges for the construction of the bridge piers.
Constructing the hammerhead segments more than 60 m above ground required an alternative to conventional ground-supported shoring.
With spans of up to 188 m, the bridge required a construction method that combined precision, efficiency, and high productivity to meet the ambitious project schedule.
Solution
Three units of the SKE100 Automatic Climbing Formwork, equipped with integrated working platforms, stair towers and ladders, ensured safe and efficient operations at heights exceeding 60 m.
UniKit 400 kN wall brackets, combined with UniKit beams and lowering heads, provided a robust heavy-duty support solution for the starter segments of the balanced cantilever construction.
Five pairs of Cantilever Formwork Travellers enabled segment-by-segment construction of the superstructure while supporting parallel operations on multiple piers.
Safe at height. Efficient in execution.
For the construction of the bridge piers, three units of Doka’s SKE100 Automatic climbing formwork were deployed. The fully enclosed system, featuring integrated working platforms, stair towers, and ladders, provided safe access and protected working areas throughout the construction process, even at significant heights.
Safe load transfer at 60 m height.
Following completion of the bridge piers, construction focused on the hammerhead segments, which formed the starting point for the balanced cantilever construction of the bridge deck. At heights exceeding 60 m, conventional ground-supported shoring was no longer a feasible option.
Instead, 400 kN UniKit wall brackets were suspended directly from the piers, enabling the safe transfer of loads into the permanent structure. Combined with UniKit beams, UniKit lowering heads and Supporing construction frames on the outside, the system provided a robust yet economical heavy-duty solution for the construction of the 13 m wide starter segment.
Long Spans. Built Segment by Segment.
Starting from the hammerhead segments, the bridge spans are now being constructed using five pairs of Cantilever forming travellers in a balanced cantilever sequence. Each concreting cycle creates a new segment measuring approximately 3.25 to 5.0 m in length. Once the concrete has reached the required strength, the segment is post-tensioned to the previously completed structure. This process maintains the necessary compressive forces within the cross-section and allows the form travellers to be safely advanced to the next casting position.
A total of ten form travellers are operating simultaneously on multiple piers, enabling the construction of bridge spans of up to 188 m. In 18 casting cycles per direction, the bridge deck gradually extends outward from the piers into the free spans until the cantilever arms meet at mid-span, completing the structural connection.
From Concept to Completion.
With model-based 3D planning, digital construction sequence simulations, and on-site technical support, Doka accompanies the project throughout every stage of construction, from the first pier lift to the final balanced cantilever segment, ensuring safe, efficient, and well-coordinated project execution.
Jan Wędzicha | Bridge Works Manager | Intercor construction company
"The high load capacity of the UniKit brackets and the well-thought-out assembly method enabled smooth, fast and safe installation even at heights of 66 m. The option to use hydraulic jacks to lower the heads further accelerates the work and increases safety.”
Once completed, the S19 expressway will significantly improve traffic on this crucial transportation route, connecting northern and southern Europe through Poland.
Project data
Year of completion
2027
Project duration
2024-2027
Country
Poland
City
Babica
Contractor
Intercor Sp. z o.o.
Building data
Construction method
Flyover
Pier height
up to 66m
Construction Type / Segmentation
Pier, Hanmmerhead, Balanced Cantilevered
Total length
1.150m
Max. span length
188m