COPANO BAY BRIDGE

Valley Prestress Products was recently awarded a contract for the prestress products for the Copano Bay Bridge in Rockport, Texas. The project includes four hundred and sixty 54-inch cylindrical piles with a 42-inch voided center, ranging in lengths from 83 to 168 feet.

The round piles were a new product for Valley Prestress. A new bed, forms and an efficient production process needed to be developed to produce the new product.

Valley Prestress installed a 520-foot bed, staging and curing areas to produce the piles. Hamilton Form fabricated the cylindrical pile forms with a hydraulically actuated interior void and two piece headers. The two part outer form was designed with integral hold ups and hold downs to keep the void in place during the pour. Production is running smooth.

UNISTRESS WAFFLE SLAB FORM

When Unistress Corporation of Pittsfield, MA needed formwork for some unusual floor slabs, they called on Hamilton Form. Each slab has a series of holes for ventilation pipes and wire chases. The slabs form the floor of the clean room for a stateof-the-art semiconductor foundry being built in upstate New York. The 22’ long by 8’ wide slabs have an overall perimeter depth of 4’ and weigh as much as 24 tons each.

The formwork had to be extremely efficient for set-up and stripping, while maintaining strict tolerances. Steel alignment plates are used to precisely place the voids that form the cylindrical holes. To simplify stripping, the upper disc assembly is positively pulled out of the product and void by turning its mounting bolt. Sideforms pivot back for stripping.

The self-contained precast forms allowed for ease of set-up. A few innovative features simplified what could have been a complex set-up and stripping process. The “fabricator friendly” formwork performed perfectly, to help keep the project on time and within budget.

SELF-STRESSING JUMBO TEE

Precast, prestressed concrete is a highly engineered, complex product that requires a precision-fabricated, high-quality, durable formwork.

That’s why, when The Shockey Precast Group needed to cast a unique double tee product, they called on Hamilton Form Company.

The “Jumbo Tee” has sixty inch stems with a highly stressed bulb configuration at the stem bottoms. Hamilton Form built the self-stressing formwork in sections for both shipping and stripping considerations. The stems have minimal draft requiring the sideforms to be pull back for stripping. The 118-foot long, twelve foot wide product is casting efficiently and strips easily, keeping productivity high and delivery on time.

INDIAN STREET BRIDGE

The new Indian Street Bridge will cross the south fork of the St. Lucie River to connect Palm City with the city of Stuart in southeastern Florida. The bridge has a haunch girder center section and the newly introduced FIB78 (Florida I-Beams) on the approach spans.

CDS Manufacturing in Florida recently added several new beam lines to produce the new Florida beams including a dedicated line to produce the high volume FIB78 for the Indian River project. This project however, also calls for haunch girders.

Hamilton Form quickly went to work to design and build formwork to cast the haunch girders. The girders are 114-feet long, 11-feet tall at the center, and slope to 6-foot, 6-inches at the ends. A recess in the sideform creates the haunch at the centerline. Forms were completed with a hinged catwalk, railing, and Vibrotrack.TM

Hamilton Form also supplied CDS with galvanized embed and beveled plates for the project.

TAPERED LIGHT POLES IN HAITI

Concrete light poles are more durable and have a longer life span than typical wood poles, two important features – especially on a tropical island. For that reason, concrete poles are being specified more often, especially in coastal areas. A precaster who was setting up a plant to produce concrete light poles in Haiti reached out to Hamilton Form for formwork.

The first set of forms were ready to ship just as Hurricane Irma made her way into the Caribbean. With winds of 185 mph, Irma caused devastation in the eastern Caribbean, swept across Puerto Rico and then hit Florida. Irma caused over $64.8 billion in damage. As residents began assessing the damage from Irma, Hurricane Maria followed right behind. Maria made a direct hit on the Island of Hispaniola, desolating the nations of Haiti and the Dominican Republic. Maria, one of the costliest hurricanes in history, caused $94 billion in damage.

Over the last decade, weather events including tornados, floods, wildfires and hurricanes have become more intense. This new reality of superstorms calls for more durable, resilient building materials such as precast concrete. We expect the market for precast products used for infrastructure projects will continue to grow. The forms made for light pole production will help deliver more reliable lighting to the people of Haiti. Hamilton Form is proud to have contributed in a small way to make that happen.

The pictured form was built to produce prestressed tapered light poles at varying lengths, from 45 feet long to 30 feet long in 5-foot increments. A set of headers was provided for each length. Headers and jacking plates for the forms were lettered or numbered to assure each set stays together. The dual-cavity forms were built in 100-foot lengths and were designed to cast four products at a time, tip to tip. The forms are self-stressing to produce durable and resilient light poles.