Lone Star Constructors, NEX

06/08/2026

The bridge cap in this picture is 58 feet long, 7 feet tall, and 4.5 feet wide. At 290,000 pounds including the bearing seats, it’s one of the largest of the 124 pre-cast caps on the I-35 NEX S1 project.

06/02/2026

In this photo, a slip-form machine is placing barrier rail along an exit ramp being reconstructed on I-35 NEX S1. The machine extrudes concrete in a continuous pour to create a smooth, consistent safety barrier that will help protect drivers.

Slip-forming is efficient on straight runs. Where geometry gets tighter, casting barrier rail in concrete forms is the go-to. For temporary barrier needs, segments are cast off-site, trucked in, and lifted into place.

05/28/2026

Barrier rail along the edge of an elevated bridge deck is a critical safety feature that protects drivers. It’s designed to absorb and redirect the force of a 22,000-pound truck striking it at highway speeds, keeping the vehicle contained without compromising the bridge edge.
In this photo, the crew is placing a concrete form around reinforcing steel anchored to the deck. Once concrete is poured, it will create a continuous barrier designed to perform under extreme impact.
In other areas of the I-35 NEX S1 project, we’re using a slip-rail machine to cast barriers built to the same specifications.

05/18/2026

The surveyors in the picture are verifying that the bridge cap form is set to the correct elevation and is aligned with the design. They’re also marking the centerlines for beam seats.
Once all measurements are confirmed, a rebar cage is placed within the form and concrete is poured. After the concrete cures, the form is removed, and the surveyors return to re-establish centerlines for accurate girder placement.

05/12/2026

Su***de prevention starts with conversations. In discussions with both our night and day shift crews, we encouraged everyone to check in on one another and share available support resources. Francis Arias from the American Foundation for Su***de Prevention provided insight on the prevalence of su***de in the construction industry and highlighted the 988 Su***de and Crisis Lifeline. We also shared information on free Employee Assistance Program resources available to all employees.

Su***de is preventable. Sometimes, simply asking someone “are you ok?” can open the door to a meaningful conversation and a chance for someone to seek help. Don’t be afraid to ask. Choose the right moment, listen with care, and respect the response.

05/05/2026

Safety is our first job every day, and a core part of the daily team meetings before the morning and night shifts.
On the first day of Construction Safety Week, the crew participated in a fall protection and rescue demonstration led by 3M. The week will also include mental health and su***de prevention discussions, safety awards recognizing crew members, and additional training opportunities.

04/29/2026

Beneath the orange curing blanket in this picture is a cap designed to extend over a roadway with only one supporting column.
To make that work, it’s engineered with post-tensioned cables running through the cap and column to compress the concrete and anchor it to a very large foundation, as shown in the inset.
It’s an elegant solution that allows us to build elevated lanes between the existing I-35 mainlanes and frontage roads.

04/28/2026

04/21/2026

With all this rain, our crews aren’t working today – but our storm drain protection is.
Straw-filled barriers, secured with bright orange sandbags, help keep construction debris out of the storm drains that flow into Salado Creek.
That way, when we host our next creek cleanup, we’re not picking up our own trash.