Pipestem Dam | Jamestown, North Dakota

Pipestem Dam: How EFCO Strengthened Flood Protection & Cut Costs

Jamestown, North Dakota

Strengthening Infrastructure for Long-Term Flood Protection

The Pipestem Dam project in Jamestown, ND, is a critical flood control structure designed to withstand a 100-year flood event. As part of the region’s water management system, it plays a vital role in protecting surrounding communities. While expected to remain dry for decades, extreme weather conditions this year tested its resilience. Barnard Construction turned to EFCO for cost-effective, high-quality formwork solutions to meet the project’s evolving needs.

Adaptive Formwork Solutions to Overcome Challenges

EFCO’s E-BEAM® & SUPER STUD® wall forming system provided the flexibility to be reconfigured and reused across multiple project elements, including:

Labyrinth Weirs
Chute Walls
Roller-Compacted Concrete (RCC) Walls
Sealing Basin
Approach Walls

Engineering Solutions for Complex Structural Demands

One of the project’s biggest challenges was creating rounded concrete formations on top of the Weir Walls specifically designed to minimize water resistance. EFCO developed custom curved panels that improved hydraulic performance by allowing water to flow more smoothly over the rounded surface.

Another critical challenge was maintaining a consistent top elevation on a sloped slab for the labyrinth weir walls. Using an E-BEAM & SUPER STUD skeleton, sheeting was precisely cut to ensure proper alignment throughout the structure.

Additionally, EFCO collaborated with Barnard Construction to create custom radial bullnose and corner forms, which were bolted to the tops of the walls. A specialized screed tool further refined the radius, ensuring a high-quality finish.

Flexible Formwork to Meet Unexpected Demands

The 2024 concrete season brought unforeseen challenges that impacted the project schedule. Due to these disruptions, Barnard Construction was limited to working on only half of the terminal structure, restricting RCC placement. A one-sided RCC formwork system, known as the centerline formwork, was implemented to adapt. EFCO leveraged on-site formwork, eliminating the need for additional deliveries, which streamlined operations and reduced costs.

RCC formwork is complex and requires continuous adjustments throughout the project. EFCO’s expertise in formwork design and rapid adaptability ensured the project stayed on track despite changing conditions.

Maximizing Efficiency and Cost Savings

EFCO’s approach prioritized efficiency and cost savings without compromising quality or safety. By integrating E-BEAM & SUPER STUD gangs with Phenolic Plywood, Barnard Construction reduced material expenses while achieving a high number of panel reuses. This improved cost-effectiveness and ensured a smooth, high-quality concrete surface, minimizing additional finishing work.

EFCO’s formwork system enabled concrete placement rates of up to 50 cubic yards per hour, accelerating construction timelines. Additionally, streamlined setup and stripping processes reduced labor hours, contributing to overall project efficiency. EFCO’s on-site field service support and real-time adjustments further optimized the project’s execution.

Why Barnard Construction Chose EFCO

From initial planning to overcoming unexpected site challenges, EFCO demonstrated a steadfast commitment to quality, innovation, and service. Barnard Construction selected EFCO for its ability to engineer practical solutions that addressed critical project challenges efficiently. With industry-leading formwork systems and responsive support, EFCO helped keep the Pipestem Dam project on track while maintaining cost efficiency.

Through expertise, adaptability, and a focus on the Lowest In-Place Concrete Cost (LIPCC), EFCO once again proved why it is a trusted partner for complex concrete construction projects.