I-270 crossing | Granite City, IL

How EFCO Boosted Productivity for the I-270 Bridge Project

Granite City, IL

Transforming Connectivity on the I-270 Mississippi River Crossing

The I-270 crossing near Granite City, Illinois, represents a significant infrastructure achievement spanning the Mississippi River to Missouri. This joint venture between the Illinois Department of Transportation (IDOT) and the Missouri Department of Transportation (MoDOT) involves constructing a new bridge beside the existing bridge, demolishing the existing bridge, and then expanding the new bridge into a twin bridge to support eastbound and westbound traffic. The bridge’s completion will enhance regional connectivity, facilitate smoother transit, and bolster economic growth.

Meeting High Demands with EFCO’s Expertise and Products

The project is led by Walsh Construction, known for managing complex infrastructure projects. EFCO was selected as the primary formwork provider for its proven expertise in delivering innovative and efficient solutions. EFCO’s products, including the PLATE GIRDER®, hinged soffit pier cap system, custom bullnose forms, and REDI-RADIUS® for non-standard piers, were key to meeting the project’s demands. The choice of EFCO was driven by its ability to provide formwork systems that ensured fast cycle times and high productivity, contributing to achieving the Lowest In-Place Concrete Cost (LIPCC).

Four-Man Crew Surpassing Goals with EFCO Formwork

EFCO’s PLATE GIRDER® hinged soffit pier cap system played an important role in the project’s success. With wind beams positioned at the bottom, the system allowed unobstructed installation of pre-tied rebar cages. Unlike traditional dance floor systems, EFCO’s PLATE GIRDER side forms are the load-bearing members, carrying the entire weight of the cap and reducing the need for additional beams below the pier cap. In rapidly changing water conditions such as the Mississippi, this reduces the number of down days due to high water. After a pour is made, EFCO’s entire soffit panel can be hinged open, releasing the concrete dead-load from the support brackets and allowing the fully assembled cap to be cycled over the top of the new cap. Walsh used the hinged soffit system on both the transfer beams and pier caps to pour up to a 9′-8″ (2.9 m) wide x 12′-0″ (3.6m) tall cap. Most caps measured 64 feet (19.5 m) in length, with a few reaching 68 feet (20.7 m). This design enabled a four-man crew to handle multiple pours simultaneously, surpassing production estimates and showcasing EFCO’s ability to deliver highly efficient formwork solutions.

Optimizing Productivity with EFCO’s Robust Solutions

The pier cap can be cycled in as little as two picks, showcasing EFCO’s engineering innovation and dependable solutions for complex conditions. First, the pier cap formwork is stripped as one large gang and set on the ground, where it is cleaned and oiled using EFCO ‘s Form Release agent to ensure better results and keep projects running smoothly. Next, the soffit is re-bolted in the closed position, preparing the assembly for reuse. Finally, the entire setup is lifted with a single four-point pick using 40,000 lbs (178 kN) heavy-duty lifting eyes, preserving structural integrity and simplifying the placement process before being installed on the next set of pier caps.

Maintaining Project Momentum Through Unpredictable River Conditions

One of the project’s biggest challenges was adapting to fluctuating river conditions, including both flooding and low water levels. These environmental factors required rapid on-site adjustments. EFCO’s field service and engineering team responded swiftly, devising solutions that kept the project on schedule despite the river’s unpredictability. When low water levels restricted barge access to Pier 3, EFCO adapted their design quickly, enabling the team to continue using existing formwork and avoid delays. The robustness of EFCO’s formwork systems ensured that even when debris and strong river currents posed threats, the structures withstood these forces, demonstrating the resilience and quality of EFCO products.

Why Walsh Construction Chose EFCO

EFCO’s solutions helped Walsh meet and exceed their productivity goals while maintaining the precision and integrity required for a high-profile infrastructure project. What truly sets EFCO apart is its ability to provide both custom and standard products from the same manufacturing plant located in Des Moines, Iowa. This combination is rare in the formwork industry. EFCO’s custom products are uniquely designed to integrate seamlessly with our standard products, offering a level of versatility our competitors can’t match. Combined with our service team’s proactive and adaptable approach, these capabilities enabled Walsh to achieve outstanding results while keeping costs optimized. This success reflects EFCO’s commitment to delivering the Lowest In-Place Concrete Cost and empowering contractors like Walsh Construction to complete their projects with efficiency and reliability.

EFCO has been great to work with from the design phase to implementing these forms out in the field. Their support staff were always available for prompt responses and in-field personnel who would monitor our progress and provide insight as work progressed. The hinge-form cycle times greatly improved production while providing a safer work environment due to minimizing exposure to risk.

– Chris Johnson, Project Manager