Alcove Apartments | Omaha, Nebraska

Zigzagging Foundation Walls No Match for EFCO’s RAPID CAST System

Omaha, Nebraska

TR Construction Tackles Complex Foundation Design

The Alcove Apartments project in Omaha features a new residential complex with underground parking, bringing much-needed housing options to the area. The foundation walls for this structure presented numerous challenges due to complex geometry and multiple corner conditions. TR Construction, a concrete subcontractor, needed a formwork solution that could adapt to the varying wall configurations while meeting tight schedules and working without a crane on-site.

Complex Geometry Challenges Met with Innovative Formwork Solution

TR Construction partnered with EFCO to tackle the zigzagging foundation walls, which included an underground parking level and storm shelter. The project featured very few straight runs, with most pours containing 10-12 corner combinations. EFCO’s RAPID CAST system was selected specifically for its modularity and adaptability to these varying wall dimensions. Being one of the first large-scale projects completed with RAPID CAST, the EFCO engineering team worked with Innovation and Super Service to deliver solutions for the complex corner challenges.

Lightweight Formwork Design Enables Off-Site Pre-Assembly

The RAPID CAST® system—weighing only 5.5 pounds per square foot (26.9 kg per square meter)—allowed TR Construction to pre-build 9’ x 13’ (2.7 m x 4.0 m) gangs at their yard before transporting them to the jobsite. This off-site assembly significantly increased productivity by preparing forms ahead of time and enabling quick installation once delivered. Without requiring a crane, the lightweight gangs could be set with a material handler, saving substantial equipment costs while maintaining quick cycling times. The 13-foot (13 m) wall height was easily achieved by combining 9-foot (2700 mm) and 4-foot (1200 mm) panels, demonstrating the quality and versatility of the system.

Like all EFCO systems, the RAPID CAST System features integrated ribs designed for convenient parts storage, placement, and staging. This thoughtful design enables accessories to be moved and cycled with the forms, significantly reducing cycle times. Beyond the immediate time savings, this integrated approach minimizes lost equipment and unreturned equipment (URE), saving customers money at the project’s conclusion and helping ensure the Lowest In-Place Concrete Cost (LIPCC).

Pre-Assembly Strategy Overcomes Weather Challenges

When unexpected rain prevented delivery trucks from accessing the site, having pre-built gangs ready to transport with their own equipment minimized delays. This approach streamlined logistics and kept the project progressing despite adverse conditions, demonstrating EFCO’s Integrity in delivering reliable solutions regardless of circumstances. The pre-assembly strategy proved especially valuable given the project’s tight timeline and challenging site conditions.

Innovative Corner Solutions Simplify Complex Configurations

The engineering team developed special applications for the RAPID CAST system to handle the project’s challenging corner configurations. Using quick bolts at the corners instead of traditional compensation walers eliminated extra components and simplified the assembly process. This Innovation proved particularly valuable where corners were positioned close together. The system’s EFCO E-BOARD face enhanced performance with its extreme durability, repairability, and strength to hold blockouts securely in place. Being lighter than plywood and resistant to moisture damage, the E-BOARD contributed to an extended service life. The bolt connections also allowed panels to maintain the same plane when stacked, making storage and transportation more efficient than competitive systems that use protruding clamps.

Why TR Construction Chose EFCO

TR Construction selected EFCO’s RAPID CAST system because it provided the Innovative solution needed for their complex foundation walls while delivering outstanding service from initial design through implementation. The engineering team’s dedication to solving unique corner configurations demonstrated EFCO’s commitment to creating custom solutions for challenging projects. By eliminating the need for a crane and allowing for efficient pre-assembly, the RAPID CAST system helped TR Construction achieve the Lowest In-Place Concrete Cost (LIPCC) while maintaining Quality and meeting schedule demands.