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In Corpus Christi, a new US 181 Harbor Bridge is being constructed to replace the existing bridge that crosses the Corpus Christi Ship Channel. A new bridge is necessary to replace the current aging bridge and to permit larger ships to pass beneath, with a 205-foot clearance. When complete, the US 181 Harbor Bridge will be the tallest point in South Texas and the longest cable-stay concrete segmental bridge in the United States.
Doka was brought on the job because of our experience and unique solutions. The challenge was to come up with a way to reuse the same formwork from pour to pour with continually changing geometry. The upper and lower pylons were very different shapes requiring two unique designs. The primary pylon structures have a unique geometry that narrows and angles at the same time. A reusable system was needed that would have minimal changes between pours. Doka worked with the customer to collaborate on the formwork designs, and ensuring that the final solution was exactly what was required.
To do this, Doka used large-area formwork Top 50 as well as hydraulic climbing formwork SKE50 and SKE100 platforms. The platform system was designed with telescopic platforms that adjust to the changing pylon shape.
Doka helped the contractor with the schedule because there was minimal rebuild between pours. Doka also saved crane time due to the hydraulic lifting systems employed. The contractor is happy with the overall operation of the formwork system as well is the engineering backup received.
When completed, this new bridge will open up the port of Corpus Christi to larger ships and possibly even a Cruise ship terminal.
Location: Corpus Christi, TX
Type of project: Cable Stay Bridge Square footage: 5,580 sq. ft. of formwork for one pylon
General contractor: Flatiron Dragados JV Concrete contractor: Flatiron Dragados Overall project cost: $900 million
Construction time: Began in early 2018 and projected completion is late spring 2020.
Thank you for your interest - The Longest Cable-Stay Bridge in the US Rises with Doka.
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