Launch Slideshow

Bexar Concrete Works – Dallas, Texas

Precast/prestressed producer Bexar Concrete Works is producing girders for the six-lane Sylvan Avenue Bridge, which will connect downtown and west Dallas when it opens in early 2014. Bexar is casting 150-foot standard prestressed girders for the project, as well as special spliced precast/prestressed girders.

Bexar Concrete Works – Dallas, Texas

Precast/prestressed producer Bexar Concrete Works is producing girders for the six-lane Sylvan Avenue Bridge, which will connect downtown and west Dallas when it opens in early 2014. Bexar is casting 150-foot standard prestressed girders for the project, as well as special spliced precast/prestressed girders.

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    Mark Greenberg

    Armador Corpus works on a section or rebar on pre-cast line at Bexar Concrete Works in San Antonio, Texas.
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    Mark Greenberg

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    Mark Greenberg

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    Jorge Hinojosa/Bexar Concrete Works

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    Jorge Hinojosa/Bexar Concrete Works

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    Mark Greenberg

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    Mark Greenberg

Launch Slideshow

Speed Fab-Crete – Fort Worth, Texas

Speed Fab-Crete is producing 170,000 square feet of precast sound walls for the $2.5 billion North Tarrant Express (NTE) 183 extension project. The precaster is using battery forms, designed by Hamilton Form Co., that can be adjusted to accommodate the different sizes of panels needed for the job.

Speed Fab-Crete – Fort Worth, Texas

Speed Fab-Crete is producing 170,000 square feet of precast sound walls for the $2.5 billion North Tarrant Express (NTE) 183 extension project. The precaster is using battery forms, designed by Hamilton Form Co., that can be adjusted to accommodate the different sizes of panels needed for the job.

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    Carl Hall/Speed Fab-Crete

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    Marianne Methven/Hamilton Form Co.

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    Marianne Methven/Hamilton Form Co.

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Launch Slideshow

Texas Concrete Partners – Victoria, Texas

Texas Concrete Partners produced precast haunch girders and Type 6 modified beams for the 550-foot Clearfork Main Street Bridge in Fort Worth. The bridge is constructed with a system of precast concrete beam segments that are spliced together using post-tensioned steel strands to form a streamlined structure.

Texas Concrete Partners – Victoria, Texas

Texas Concrete Partners produced precast haunch girders and Type 6 modified beams for the 550-foot Clearfork Main Street Bridge in Fort Worth. The bridge is constructed with a system of precast concrete beam segments that are spliced together using post-tensioned steel strands to form a streamlined structure.

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    Marianne Methven/Hamilton Form Co.

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    Marianne Methven/Hamilton Form Co.

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    Marianne Methven/Hamilton Form Co.

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    Marianne Methven/Hamilton Form Co.

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    Marianne Methven/Hamilton Form Co.

Many state DOTs are collaborating with industry associations and experts to develop bridge beams that are more efficient for both bridge designers and precast producers. The widespread adoption of these new designs has given precast producers a competitive edge.

The Florida Department of Transportation (FDOT) worked in collaboration with the Florida Prestressed Concrete Association and Dr. Maher Tadros of the University of Nebraska to develop the Florida I-Beam (FIB). First produced by Standard Concrete Products in Tampa, in 2009, the beams feature a constant top and bottom flange with a variable web to facilitate the use of fillers in casting various beam sizes.

The FIB shape accommodates more strand than the old Florida Bulb-T beam design. The increased strand allows for longer beams, which means bridges can be designed with fewer beams and spans.

New FIBs have a wider bottom flange and lower center of gravity than the AASHTO beams, making them more stable in shipping, handling, and placement. The FIBs also have a fully predesigned reinforcement option that significantly reduces fabrication time.

In 2009, the Texas DOT (TxDOT) also replaced AASHTO Type 4 I-beams a new Texas I-Girder. The new beam features a thinner vertical section, thinner flange, and more bulbous bottom than the AASHTO design. Although it uses less material, the I-Girder is stronger so it can be designed in longer lengths, and bridges can be built with fewer beams.

The Precast Concrete Manufacturers’ Association of Texas (PCMA) consulted on the I-Girder design, with suggestions to make it easier for precasters to pour. Although its adoption meant precasters had to purchase new forms, the PCMA reports they have ultimately received more orders with the I-Girder — even with fewer beams being used per bridge.