The Veterans' Glass City Skyway used six sets of formwork to create the 197 piers.
Doka The Veterans' Glass City Skyway used six sets of formwork to create the 197 piers.
The highly complex transition to a gothic cross from an octagonal shape in the cross section of the Maumee River Crossing, now known as the Veterans' Glass City Skyways, was the largest and most expensive project ever undertaken by the Ohio DOT. The construction of the 127-meter-high main pylon in Toledo, Ohio, was undertaken by Doka Formwork Technology, which produced concepts and drawings, supplied the formwork, and provided an advisory presence onsite. Fru-Con Construction, a division of Bilfinger Berger, built the bridge.

Consisting of a 373-meter main section over the Maumee River, the cable-stayed bridge features a precast segmental concrete deck. The roadway is 39.6 meters above water level and carries six lanes of I-280 highway traffic.

Both U.S. and European technologies were used in Doka's systems for this project. “It was an enormous amount of formwork to design and build in such a short period, but we did it,” says account manager Dave Monnot.

Fru-Con's Warren Hallam welcomed being able to use a single supplier to handle all aspects of the work. “This was a strong engineering solution that delivered speedy results at an economical price,” he says.

A combination of systems built the pylon due to its complex cross section. In addition to having a unique shape, the pylon had to support a 6-ton cradle system, which keeps each cable separate in a protective tube as it passes through the pylon. This makes the project one of the first bridges in the world to have this type of stainless steel stay cable cradle system.

Formed with Doka's Steel Girder self-spanning steel form system, the first two lifts were made for the pylon's octagonal lower section. Adding to the complexity of the project, the Doka Top 50 system was integrated into the standard steel girder for the next three lifts, which featured compounded curved corners and a vertical and horizontal radii of 42.98 meters and 4.8 meters, respectively.

In order to provide a safe platform, the Steel Girder and Top 50 formwork components were fitted to Doka's MF 240 crane-handled climbing system; an arrangement that continued to the eighth pour. At this point, the pylon included cantilevered diaphragm deck units formed with the Steel Girder and marked a transition from the octagonal form to the upper cross-shaped section.

Multiple climbers could achieve the cross shape of the pylon's upper section by using the SKE 100 self-climbing system . In addition, it provided a safe working environment while enabling climbing to continue regardless of inclement weather.

In the end, six sets of formwork created 197 piers and adapted to the wide range of pier heights in the project. The platform-based system enabled seamless movement of materials without constant access to a crane.

A glass curtain wall has been incorporated in each of the four faces featuring an advanced array of LED lights shinning in unlimited color combinations.