Eaglehead Drive | Frederick, Maryland

Building Bridges: Hands-on Training for Innovative Non-Traditional Forming Solutions

Frederick, Maryland

The Eaglehead Drive Bridge Project: A Comprehensive Overview

The Eaglehead Drive Bridge project in the Linganore Creek Community of Frederick County, Maryland, aims to replace an existing twin culvert crossing with a new twin-span bottomless arch structure. Each arch will have a diameter of approximately 51’-10” (15.8 m), while the roadway above the arch will measure 24’-1” (7.3 m) wide. Canyon Contracting is overseeing the construction, including installing concrete headwalls and wing walls to ensure the structure’s stability and durability. The bridge will accommodate increased traffic and enhance Linganore Creek’s environmental management upon completion.

Innovating with Non-Traditional Forming Solutions

Canyon Contracting chose EFCO to provide the formwork for this unique project, which includes designing a forming solution for the soffit of the headwall—a premanufactured radiused metal ribbed structure. EFCO recommended mounting the E-BEAM & SUPER STUD formwork system inside the arch, using ground supports on the exterior for stability. The formwork needed to be configured to allow access to the inside of the arch. The nontraditional aspect of this setup involves the SUPER STUD extending to the ground on the outer face and being anchored to the arch on the inner face.

Adaptability for Headwalls and Wingwalls

The adaptability of the E-BEAM & SUPER STUD system meant the formwork designed for the headwall could also be reconfigured to form the wing walls. This was especially cost-effective given the remote location of the project. This adaptability also allowed the formwork to efficiently shape different heights for the wing walls – up to 25’ (7.6 m) on one side and down to 4’-6” (1375 mm) on the other. EFCO also demonstrated that the E-BEAM & SUPER STUD formwork could be ganged in large 16’ by 32’ (4.9 m by 9.8 m) gangs and easily lifted for the next pour. The ties, on average, were 4′ (1200 mm) apart from left to right and 6′ (1800 mm) between ties going up the wall. Ties can be placed anywhere along a SUPER STUD to accommodate the curved geometry of the headwall.

Adaptability for Headwalls and Wingwalls

EFCO’s E-BEAM & SUPER STUD system allowed for a simplistic ease to use on our Eagle Head Bridge project. The system was easy to learn for those with limited knowledge of the application, and EFCO sent out representatives to the site to ensure all crew members had a firm grasp of the system. Canyon all around loved the product and will absolutely use the system on future projects.

-Nelson Garcia, Field Superintendent