Pont Île-aux-Tourtes Bridge | Montreal, Canada

Partnership Built on Scale and Capability

CNPIAT brought EFCO onto the project for capabilities few formwork suppliers can match. The project calls for a comprehensive system of PLATE GIRDER® formwork featuring 12-foot PLATE GIRDER®, E-Z DECK® shoring towers, SUPER STUD® work platforms, E-BEAM® components, and heavy-duty support brackets. Together, these proven products let CNPIAT establish an efficient forming cycle for structures reaching 13 meters (roughly 45 feet) in height.

Minimizing Ties, Maximizing Efficiency

EFCO’s PLATE GIRDER® system addressed one of CNPIAT’s top concerns: reducing tie penetrations in architecturally finished concrete. Side-by-side 12-foot PLATE GIRDER® panels require only one row of ties down the center, while competitive panel systems need ties every 2 to 3 feet — that’s 50% fewer ties with EFCO. On the tallest pier (11.52 meters, approx. 38 ft tall) by 24’ wide, that translated to just 11 tie penetrations total. That difference adds up fast: fewer tie holes to patch, lower material costs, quicker stripping, and cleaner finishes on bridge elements the public sees every day.

The large panel sizes also reduce joints in the finished product and keep ties out of complex architectural areas with sloped bulkheads and unique “sail support” details — steel rod elements that resemble sailboat sails. EFCO pre-drilled all holes in the PLATE GIRDER® face sheets at precise angles and spacing so CNPIAT crews could bolt sloping forms into place without field layout work. And because the system uses positive bolted connections throughout, reassembly requires fewer joints and moves faster than competitive systems that rely on wedges or pins.

Engineered for Water-Based Construction

Working over the St. Lawrence River ruled out conventional ground-based shoring and introduced extreme wind loads that called for innovative engineering. EFCO designed SUPER STUD® work decks that served double duty: safe access platforms for crews and integrated wind-bracing systems that redirected lateral loads down through the formwork into the footings below.

Getting there required close coordination months before pier forming even started. CNPIAT had to cast specific anchors into the footings during the initial pours so SUPER STUD® hubs could bolt securely to the concrete and prevent formwork from tipping in high winds. This integrated bracing approach kept everything stable without external support structures, which would have been nearly impossible to install in open water.

The engineering work extended to detailed assembly drawings that broke complex assemblies into manageable gangs crews could pre-build on the ground. That level of planning was especially critical for sections over water, where access and working space were tight.

Pre-Assembly: The Biggest Efficiency Gain

EFCO engineered more than 95 percent of the formwork so CNPIAT could build complete form gangs flat — on land or barges — then lift entire assemblies into position in single crane picks. SUPER STUD® stiffbacks mounted on the exterior of the PLATE GIRDER® provided the rigidity needed to hoist tall form sections from horizontal to vertical in one pick. The forms were preassembled in back-to-back “U” shapes, so the entire form system could be set in place with just two picks per pier.

After concrete placement and stripping, crews barged complete form gangs back to shore, reconfigured them for the next pour, and returned them to position — all without extensive assembly work over water. That approach cut out dangerous over-water construction activities, substantially reduced crane time, and sped up the overall forming cycle. Fewer picks to strip, fewer joints to reassemble, and faster cycling thanks to positive bolted connections and no superfluous pieces.