Doka: The Longest Cable-Stay Bridge in the US Rises

US, June 8, 2020.-   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.

Project Facts:

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.

Products used: Hydraulic climbing formwork SKE50 plus, Hydraulic climbing formwork SKE100 plus, Large-area formwork Top 50