Corpus Christi Harbor Bridge

The Texas Department of Transportation project to build a bridge featuring the longest concrete segmental cable-stayed main span in North America is quietly taking shape in Corpus Christi, Texas. It features improved safety for the traveling public, facilitates economic activity and provides for a lowermaintenance, more corrosion-resistant structure.

The $803 million design-build project includes the replacement of the existing Harbor Bridge as well as the reconstruction of the IH-37, US 181, SH 286 interchange.

The signature feature of the concrete, segmental cable-stayed bridge is the 1,661-foot-long main span, which - when complete - will be the longest bridge of its type in North America. The main span will arc gracefully across the entrance to the Port of Corpus Christi, providing 205 feet of navigational clearance. The two main support towers will soar to a height of 538 feet, making them the tallest structures south of San Antonio.

The Texas Department of Transportation awarded the development contract to Flatiron/Dragados, LLC. in April 2015.

The concrete bridge segments are precast elements being manufactured by Flatiron/Dragados, LLC. at a site in Robstown, just west of Corpus Christi. This precast yard is a 70-acre facility boasting seven casting beds that can produce a bridge segment every day. The segments are 10 feet in length and stretch the entire width of the roadway section. Ranging in weight from 50 to 180 tons each, the project will demand about 2,600 of these precast segments to build the approach and main span structures.

Due to the large number of precast segments needed, adjustable metal forms are being utilized to allow for different section and geometry control. Using a “match-cast” system with concrete, which has been designed to provide a service life of more than 100 years, ensures segments will be a perfect match with each other when they are connected to the permanent support structure

The first segments, which make up the approach structure, were trucked to the north end of the project site from the precast yard the first week of September 2018, marking a milestone for the project. Currently, the first of these segments are being lifted and placed on support columns. Over the next few weeks the launching gantry will be installed which will allow for the construction of a complete span. The typical approach span is 180-feet-long and comprised of 18 segments.

Timeline: TxDOT issued the Notice to Proceed in early 2016, and construction began later that year. The project is expected to be complete by late 2021, which includes demolition of the existing Harbor Bridge.

Project Details

Owner:

Texas Department of Transportation
 

Design Build Team:

Flatiron/Dragados, LLC