Form Traveler System for Cantilever Bridge Construction Using Power Team’s Hydraulic Cylinders

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Home Case Stories Infrastructure Form Traveler System for Cantilever Bridge Construction Using Power Team’s Hydraulic Cylinders
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Project Details
Industry: Infrastructure
Brand: Power Team

Overview

A form traveler system used in free cantilever concrete bridge construction required precise lifting, alignment, and locking during concrete placement. Hydraulic cylinders were used to lift and secure the formwork traveler, then safely lower it for forward launching after concreting. 

The Challenge

During the construction of a concrete bridge using a free cantilever method, a formwork traveler needed to be lifted, precisely aligned, and locked in position to support concrete placement. After concreting was complete, the traveler needed to be safely lowered to allow forward launching for the next construction segment.
 
Form traveler systems must support heavy loads while maintaining precise alignment during concrete placement. The process also requires secure locking during curing and controlled lowering afterward. Any loss of control could impact construction accuracy, safety, or schedule.

Solution Presented

A Power Team PE400 hydraulic power unit supplied hydraulic power to the system. The R2806L locking collar cylinder served as the primary structural support, providing secure load holding during concrete placement. RH10010 cylinders were used for bar stressing, while custom hydraulic cylinders were applied to pull down and lower the form traveler after concreting.This type of form traveler application is solved using hydraulic cylinders that provide controlled lifting, secure mechanical load holding, and precise lowering for repeatable bridge construction cycles.

Results

The hydraulic cylinder system enabled the form traveler to be lifted, aligned, locked, and lowered safely and efficiently. The controlled process supported accurate concrete placement and reliable forward launching, helping maintain construction quality and project continuity.
 
Using hydraulic locking collar cylinders and controlled stressing typically reduces manual alignment corrections and repositioning during form traveler operations by approximately 15–25%. Mechanical locking of the R2806L cylinders minimizes reliance on continuous hydraulic pressure, improving safety during concrete placement. Controlled lowering and pull down also help reduce launch preparation time and improve repeatability between construction stages, supporting more predictable bridge construction schedules.

Other Applications

• Free cantilever bridge construction
• Form traveler lifting and positioning
• Concrete bridge segment casting
• Infrastructure construction and expansion

Key Metrics

System Impact & Engineering Advancements

Performance Metrics & Key Achievements

25% *

Fewer Corrections

Secure Load Holding

Reduced Launch Prep Time

Improved Repeatability.

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*Estimated versus conventional alignment methods without locking-collar cylinders on comparable projects; not measured here.
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