The Viaducto Sargento Menadier | Puente Alto, Santiago, Chile

Dance Floor System Outperforms Traditional Formwork Methods at Key Chilean Viaduct

Puente Alto, Santiago, Chile

Connecting Communities: EFCO Formwork Solutions Deliver on the Viaducto Sargento Menadier Project

The Viaducto Sargento Menadier project connects the communities of Puente Alto and La Pintana across an abandoned quarry in Santiago’s Metropolitan Region. This 400′ (120-meter) transportation link, divided into four 100′ (30-meter) spans, provides connectivity to Chile’s capital. With structures reaching 100′ (30 meters) in height, the project required Innovative formwork solutions that could deliver Quality results while meeting tight construction deadlines.

After evaluating numerous formwork suppliers, FLESAN S.A. selected EFCO for this challenging project. Their decision was based on EFCO’s comprehensive range of specialized products, including Round Column® forms, E-BEAM®, SUPER STUD®, PLATE GIRDER®, and the Innovative Dance Floor system. FLESAN’s thorough analysis concluded that EFCO’s systems would provide superior performance, which was later affirmed by the successful completion of this section of the project.

Engineering Excellence: EFCO Systems Conquer Complex Column Challenges

EFCO’s systems successfully addressed the project’s technical challenges. The SUPER STUD® Jump System allowed for the safe formation of standard-diameter round columns reaching heights of 100′ (30 meters). Each of the three piers consisted of three columns with a 98″ (2.5-meter) circumference, spaced about 26′-3″ (8 meters) apart, supporting a 78′-9″ (24-meter) by 98″ (2.5-meter) pier cap.

For the columns, the engineering team adapted a 96″ (2.4-meter) Round Column® with fillers to achieve the required 98″ (2.5-meter) diameter. This modification limited the maximum pressure rating to 1500 psf (72 kPa) for safety, even though standard 98″ (2.5-meter) columns can handle up to 2000 psf (96 kPa). The E-BEAM & SUPER STUD® combination provided the necessary strength and versatility for these complex structures, ensuring precise alignment and structural Integrity during high-elevation concrete pours.

Game-Changing Efficiency: Dance Floor System Saves 1,200 Man-Hours

EFCO’s Dance Floor system transformed the pier cap construction process. Instead of erecting conventional tower systems beneath the pier caps, the contractor installed the PLATE GIRDER® Dance Floor system directly from the columns. This approach dramatically reduced assembly time and labor requirements, saving approximately 1,200 man-hours throughout the 7-month project. The system also minimized the risks involved in erecting traditional high-rise towers while reducing the potential for theft or loss of aluminum material that’s common on open-air construction sites, thanks to its equipment design. Workers could safely place reinforcement and pour concrete for the massive caps in a single operation, eliminating multiple construction phases and accelerating the project schedule.

Proven Performance: Fast Installation, Superior Finishes

The PLATE GIRDER® Dance Floor system demonstrated exceptional performance during concrete pours. Crews completed pier cap pours in just a few hours, with the formwork providing all necessary strength and stability. Crane operators needed only 30-40 minutes to position each Dance Floor platform section. The finished concrete surfaces exhibited superior Quality, meeting all aesthetic requirements without extensive remediation.

Why FLESAN S.A. Chose EFCO

In choosing EFCO as their formwork partner, FLESAN S.A. made a decision that ultimately defined the success of the Viaducto Sargento Menadier project. Beyond the technical advantages, EFCO’s comprehensive support throughout construction, from initial design to on-site troubleshooting, ensured smooth execution under challenging conditions. This partnership exemplifies how selecting the right formwork provider transcends mere equipment supply to become a strategic advantage. As Santiago’s communities now enjoy improved connectivity across what was once an impassable quarry, the Quality and efficiency demonstrated have established a new benchmark for infrastructure development in Chile’s metropolitan region. FLESAN S.A.’s experience with EFCO has not only delivered this vital transportation link but has also formed the foundation for ongoing collaboration on future infrastructure projects.

EFCO EQUIPMENT

PLATE GIRDER®

E-BEAM & SUPER STUD®

Round Column®