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Design-Build Highway Project

Project data

Location: Dallas, United States

Connect 4 is part of the larger DFW Connector project, which will double the size of the existing highway system around the North entrance of Dallas Fort Worth Airport. The project started in November 2018 with a duration of 18 months. It consists of highway bridges, connectors and overpasses for the I-635/SH 121 Interchange. The contractor, Northgate Constructors, a joint venture between two of the most respected organizations in the highway construction industry – Fort Worth-based Kiewit Texas Construction L.P. and San Antonio-based Zachry Construction Corporation hired PERI to manufacture tailor-made steel column forms for the construction of the concrete piers. 


Over 400 different individual rectangular columns of various heights and cross sections ranging from 3' x 4' to 6' x 8' required a highly adaptable and labor efficient system. The contractor was able to build nearly all of them using just one set of custom PERI steel forms. PERI’s custom steel forms for this project were designed to minimize the need for ties, thus saving significant labor time and cost during installation and minimizes any patchwork later on.

Resetting the forms is straight-forward – the pre-assembled L-shaped halves are staged on the ground and then lifted into place around the rebar. The innovative single handed bullet bolt which connects the halves, takes the shear and tension loads and eliminates the need for conventional fit-up bolts, thus further increasing labor productivity.  The unique integrated waler design allows for quick attachment of handrails, plumbing braces, and hold down braces.

The largest column was 68' tall with a pour pressure requirement of 2000 PSF.


Northgate Constructors, AJV

Customer's benefit

Thanks to the single handed bolt solution the contractor reported vast labor savings on the cycling operations.


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PERI solution

PERI supplied one set of formwork that could be used on several different column sizes.

PERI systems in use