Flatiron and Dragados joint venture near completion of $1.3 billion U.S. 181 Harbor Bridge project in Corpus Christi by spring 2025. New cable-stayed bridge with safety enhancements includes 18 non-CSB bridges and ramps, LED lighting, and a belvedere. Challenges like weather and extreme temperatures overcome by dedicated crews. Significance of milestone celebrated by workers and community.
Photo courtesy of Harbor Bridge Project
The two ends of the new Harbor Bridge are close to meeting.
With work now in its final phase, the countdown is on for completing one of Corpus Christi's most anticipated construction projects. After years of research, public input and collaboration, the new U.S. 181 Harbor Bridge is poised to debut in spring 2025.
"Our team is eager to showcase the new cable-stayed bridge [CSB] structure with enhanced safety and aesthetic features," said Lynn Allison, a Harbor Bridge Project public information manager. "Our roadworks team is making tremendous progress toward completing the new south interchange, which includes many of the 18 non-CSB new bridges and ramps."
Photo courtesy of Harbor Bridge Project
The Texas Department of Transportation (TxDOT) is overseeing the $1.3 billion project, which includes replacement of the existing Harbor Bridge and reconstruction of portions of U.S. 181, Interstate 37 and the Crosstown Expressway. The effort includes the development, design, construction and maintenance of 6.44 mi. of bridge and connecting roadway.
Constructed by a joint venture between Flatiron and Dragados, the new bridge will include six US 181 main lanes, three lanes in each direction with a median barrier, shoulders and a bicycle and pedestrian shared-use path. Construction calls for the reconstruction of approximately 1.6 mi. of I-37, reconstruction of approximately 1 mi. of the Crosstown Expressway and, by 2026, demolition of the existing Harbor Bridge.
According to TxDOT, dramatic change was necessary to maintain a safe and efficient transportation corridor. Issues have included a lack of shoulders, steep grade, a reverse curve and an accident rate higher than the statewide average.
The Harbor Bridge also is costly to maintain and provides no acceptable access for those on foot or on bicycles. Its 138 ft. of navigational clearance makes it difficult for the Port of Corpus Christi to compete with other Gulf Coast deepwater ports because of today's larger ships.
The new structure will be the longest concrete segmental cable-stayed bridge in North America, with a main span length of 1,661 ft. and clearance equal to 205 ft. above water. Once complete, it also will be the tallest structure in South Texas.
The new bridge will include LED lighting features and a belvedere. The main tower height is 538 ft., and the base of each tower is approximately the size of two basketball courts.
One recent challenge for workers on the project has been the weather, which has impacted this summer. In early July, North Pylon crews lifted and placed eight main span segments in two workforce shifts as Hurricane Beryl closed in on the Gulf Coast. Delta frame lifting resumed after a brief pause to monitor the storm.
Extreme temperatures also have been an issue.
"We take extra precautions to mitigate heat exhaustion and fatigue for our crews, including taking frequent breaks, providing electrolyte popsicles and ample cooling station placements around the project," Allison said.
"Our CSB crews work in shifts at night and on weekends to maintain the schedule, and to make up for rain or weather days."
As part of the plans, workers were tasked with placing specialized concrete traffic barriers at the medians and outside lanes.
"The bridge surface is constructed of precast concrete box girders that make up the CSB spans from the shared-use path to six traffic lanes and four shoulders," Allison explained. "The riding surface over the prestressed concrete segments, fabricated to last up to 170 years, will be incredibly smooth for commuters.
"Cast-in-place median slabs where cables connect to the delta frames down the center of the spans were designed to create unobstructed views for commuters crossing the bridge over the Corpus Christi Ship Channel."
Photo courtesy of Harbor Bridge Project
According to Allison, milestones continue to be reached.
"This September, we connected Cycle 13 on each tower to the back span piers, which offer additional support to the overall bridge structure during ongoing construction activities and high-wind events once the CSB opens to traffic. Cycle 13 marks two-thirds of the way to completion in placing cables and segments."
This winter, the final spans will come together over the Corpus Christi Ship Channel. Allison said the project-wide efforts to achieve this goal deserve recognition.
"A drone operator will be onsite to capture the monumental moments of placing the last segments. Employees are already signing the final segment(s) and will join in group photos to commemorate the ‘meeting in the middle.'"
Allison noted that Flatiron/Dragados crews have invested long hours to make certain the new bridge is a success.
"We have trained almost 7,000 crew members, subcontractors and administrative personnel from across the globe to build all features on the Harbor Bridge Project safely," Allison said. "Many in the Coastal Bend will celebrate the milestone opening, but none more so than those who built the phenomenal piece of history." CEG
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