D1 Motorway Flyover
Říkovice and Přerov, Czech Republic
Formwork Precision in Motion
Doka Composite forming carriages adapt seamlessly to the complex, changing geometry of the 941 m long motorway flyover
The 10.1 km section includes extremely complex structures. One of the key elements of the construction is the flyover, the implementation of which requires advanced engineering technologies. The pair of bridges with a width of 17.1 m and 14.95 m is designed as a composite structure, where the load-bearing element consists of steel beams equipped with shear connectors for later connection with the concrete slab.
Doka delivered Composite forming carriages specifically designed for the complex needs of the steel-concrete structure. These carriages ensure high precision, safety, and efficiency, even for challenging aspects such as the variable geometry of the bridge.
The completion of this section brings a significant improvement in the traffic situation in Přerov, where transit traffic continues to burden the city center. With this step, the D1 motorway becomes a fully interconnected backbone road, connecting Prague, Brno, and Ostrava.
Building type
Composite Bridge
Challenge
Formwork solution that ensures the tight project schedule and guarantees the highest safety standards above the high-traffic railway line Economically movable formwork solution for a composite steel bridge with varying cross-sections of the steel structure from an I-profile to a box section
Solution
The Composite forming carriages ensure smooth and safe operations thanks to the suspended working platforms and provide the ideal basis for all-round closure.
Thanks to an atypical solution with SL-1 profiles from the standard SL-1 system and a suspension, not only were the increased loads of the wide bridge absorbed, but the standard length of a unit was also extended from 5.0 m to 6.3 m.
Cost-effective system with rentable components, enabling faster repositioning and larger segments
The main benefit of the technology is the facilitation of the construction of the bridge slab by means of formwork traveller, which can be precisely adapted to the required changes in the geometry of the steel structure.
The cost-effective construction using rentable standard parts and the high work safety of the Composite forming carriages were decisive advantages, so Doka was commissioned to deliver a total of five travellers. Thanks to an atypical solution with vertical SL-1 profiles from the standard SL-1 system and a suspension, the increased loads due to the bridge width could be optimally transferred. Additionally, the units consisting of two cross frames could be extended from the standard size of 5 m to 6.3 m - an important factor for short cycle times and adherence to the tight project schedule. The internal formwork slides in the area of the I-profiles on the cross beams of the steel structure and in the box cross-section on specially concreted consoles, eliminating the need for lost anchor parts.
Ing. Libor Kokeš | Site Manager | Doprastav a.s.
"Doka supported us on this construction site, from project planning, through the solution of atypical situations and the supply of technology, to the deployment of special carriages for composite structures. Thanks to the these professional systems, and especially the know-how of Doka experts, the construction is moving forward rapidly."
Libor Radecký | Team Leader Engineering | Doka Czech Republic
"The chosen technology brings a significant acceleration of work and at the same time ensures high quality and accuracy of the concrete structure. The use of steel-concrete composite carriages is the ideal solution where high demands are placed on load-bearing capacity, safety and speed"
A Comprehensive Approach
Doka supported the project beyond the Composite forming carriages, supplying other systems such as Frami Xlife, Staxo 100, and Ringlock scaffolding. The company also provided technical planning, system customization, and on-site consultancy, ensuring smooth and efficient implementation.
Project data
Project duration
2024 - 2025
Contractor
Doprastav, a.s.
Country
Czech Republic
City
Přerov
Building data
Construction type
Flyover
Section length
24 m
Total length
941 m
Section width
17.10 m / 14.95 m