Expanding Transportation in Dallas Forth Worth
The Dallas Fort Worth Connector project doubles the size of the existing highway system around the North entrance of the Dallas Forth Worth Airport. The project features new main lanes, frontage road lanes, and TEXpress lanes. One portion of the larger project, Connect 4, consisted of highway bridges, connectors, and overpasses for the I-635 and SH 121 Interchange.
As a joint venture between Fort Worth-based Kiewit Texas Construction L.P. and San Antonio-based Zachary Construction Corporation, Northgate Constructors served as the contractor. The team turned to PERI USA’s expertise to manufacture tailor-made steel column forms for the construction of the concrete piers.
Custom Engineered Support
Over 400 individual rectangular columns of different heights and cross sections ranging from 3-feet-by 4-feet to 6-feet-by 8-feet required a highly adaptable and labor efficient system. PERI USA engineered a custom steel formwork solution to meet project requirements, including meeting the challenge of the largest column at 68-feet tall with a pour pressure of 2000 psf.
PERI custom heavy-duty steel formwork is most used in civil construction for bridge columns and caps. Engineers work with the project team to evaluate schedule, cycling speed, site labor productivity, as well as technical requirements to find the most cost-effective solutions. The steel form face provides a uniform and clean concrete finish, and with optional tieless solutions, there is the option to further enhance the visual appeal while reducing labor costs.
Northgate Contractors was able to build nearly all columns using just one set of custom PERI steel forms design to minimize the need for ties. This engineered solution saved labor time and installation cost and minimized the potential for patchwork at later points.
The pre-assembled L-shaped halves of the custom steel forms were staged on the ground and lifted into place around the rebar. The innovative single-handed bullet bolt connecting the halves takes the shear and tension loads and eliminates the need for conventional fit-up bolts, further increasing labor productivity. This unique integrated waler design allowed for the quick attachment of handrails, plumbing braces, and hold down braces.
The project reached substantial completion in August 2021, six months ahead of schedule.