Chacao Bridge | Canal de Chacao, Chile

Building Bridges: Inside EFCO’s Role in South America’s Longest Suspension Bridge

Canal de Chacao, Chile

Chacao Bridge Project Overview: A Milestone for Connectivity

The Chacao Bridge project in Chile marks a transformative step in connecting mainland Chile to the island of Chiloé. As South America’s longest suspension bridge, spanning 9,022 feet (2,750 meters), it will enhance transportation, foster economic growth, and improve accessibility for residents and businesses. Upon completion, the bridge will serve as a vital link in the region’s infrastructure, opening new opportunities in this rapidly developing area.

Efficiency & Savings for Chacao Bridge: Hyundai Engineering & Construction

Led by Hyundai Engineering & Construction, the Chacao Bridge project includes an approach bridge with a structure consisting of an abutment, two 82-foot (25-meter) tall piers, and a 755-ton cross beam tying the main pylon. Each pier features two circular columns, 5 feet (1.5 meters) in diameter, and a 218-ton cap beam. These demanding specifications required advanced formwork and shoring solutions to ensure structural stability and safety, making EFCO a trusted provider for this ambitious undertaking.

EFCO’s E-Z DECK® shoring solutions played a critical role in supporting high-load structures like the lower cross beam of the southern pylon and the bridge caps for the approach bridge. A key advantage of E-Z DECK is its lightweight yet high-capacity components, making it ideal for complex and large-scale projects.

The region’s challenging climate, including 79 inches (2,000 mm) of annual rainfall and winds reaching 75 mph (120 km/h), necessitated resilient construction solutions. EFCO’s PLATE GIRDER® system, with its Quick Bolt connections, ensured safe lifting and secure installation under these conditions. Integrated working platforms further enhanced safety during assembly.

To address these environmental challenges, EFCO provided a comprehensive suite of systems, including Round Column®, SUPER STUD®, E-Z DECK®, and PLATE GIRDER®. These solutions enabled Hyundai to streamline construction schedules, optimize costs, and maintain the highest safety standards, EFCO’s significant contribution to the project’s success.

EFCO’s Product Solutions: Strength, Efficiency, and Cost-Effectiveness

EFCO’s Round Column® formwork allowed the Chacao Bridge team to construct 20 foot (6-meter) columns in a single pour, significantly reducing climbing stages and accelerating progress. The E-Z DECK® system provided stability and safety for header beams and crossbeams at heights up to 82 feet (25 meters), ensuring efficient work even under challenging conditions.

EFCO’s advanced planning and readily available inventory of the PLATE GIRDER® system optimized material usage and facilitated on-time delivery despite logistical complexities. SUPER STUD® provided versatile support for various structural applications, reinforcing the bridge’s design to withstand extreme loads. Together, these solutions highlight EFCO’s commitment to quality and efficiency while supporting Hyundai’s Lowest In-Place Concrete Cost (LIPCC) objectives.

Commitment to Exceptional Service

EFCO’s customer-focused approach was key to the project’s success. From pre-construction technical training to ongoing on-site support, EFCO ensured Hyundai’s team was equipped to use its systems effectively and safely. Throughout the project, EFCO remained accessible, addressing challenges and adapting to evolving requirements for seamless execution.

Why Hyundai Chose EFCO

Hyundai’s decision to collaborate with EFCO stemmed from EFCO’s reputation for delivering reliable, high-performance solutions tailored to demanding projects. EFCO’s systems were pivotal in optimizing the bridge’s construction timeline while adhering to strict safety and quality standards.

Additionally, EFCO’s dedication to customer service—through on-site training, technical support, and proactive problem-solving—ensured Hyundai’s team had the resources to maximize productivity and address challenges swiftly. By combining Innovation, Quality, and Super Service, EFCO played a vital role in the success of the Chacao Bridge project, establishing itself as a reliable provider for world-class infrastructure initiatives.