Valley Prestressed Products, Inc.

Copano Bay Bridge

Hydraulic Round Piling Form

Hydraulic Round Piling Form

The Copano Bay Bridge in Rockport, Texas is a three and a half mile project with a two mile bridge that included a 150-foot center span. The prestressed bridge is built with 54-inch beams, flat slabs and called for 460, 54-inch cylindrical piles. The piles have a 42-inch voided center and vary in length from 83 to 168 feet. Hamilton Form worked in close collaboration with Valley Prestressed to develop the formwork.

The forms were made in multiple segments to allow the bed to be set-up and broken down in stages. The two-piece outer base form has a bolt on, removable top. Both sections have threaded coil rods bolted to the exterior of the form to act as void hold-ups and hold-downs. Headers are split horizontally. The collapsible inner void is hydraulically actuated.

The overall bed is 520 feet long. Outer forms were built in 50 foot sections with inner forms at varying lengths to be assembled as needed for different product lengths.

To strip product, the core and headers are pulled out of the form longitudinally, then the core is collapsed and removed on a roller assembly.

Hydraulic Round Piling Form

The 2-piece outer form was made in 50-foot lengths.

Hydraulic Round Piling Form

The void is pulled from the form onto a roller system.

Hydraulic Round Piling Form

Longest pile is 183 feet.