I-285/I-20 East Interchange | Atlanta, Georgia

Building Smarter and Faster with EFCO Formwork on the I-285/I-20 Flyover Ramps

Atlanta, Georgia

East Interchange Builders Easing Congestion with High-Speed Flyover Ramps

I-285/I-20 East Interchange Project

The I-285/I-20 East Interchange in Atlanta has long been a major traffic bottleneck, primarily due to high truck volume and outdated cloverleaf-style off-ramps. To address these challenges, East Interchange Builders (EIB)—a joint venture between Archer Western and ER Snell—was awarded the design-build contract. The project introduces two high-speed flyover ramps to ease congestion, improve safety, and enhance traffic flow, providing lasting benefits for both commuters and commercial transportation.

Located just ten minutes from EFCO’s Atlanta district warehouse, the project benefited from rapid deliveries and immediate access to expertise whenever challenges arose. This proximity enabled EFCO’s team to actively engage on-site, developing an intimate understanding of Archer Western’s needs and delivering tailored solutions that directly supported their success.

Reliable & Adaptable Formwork for Efficient Construction

EIB selected EFCO’s formwork solutions for their proven reliability and adaptability in handling complex structures. The hammerhead and straddle caps supporting the flyover ramps required formwork capable of supporting heavy concrete loads while maintaining construction efficiency.

EFCO’s PLATE GIRDER® and SUPER PLATE GIRDER® (SPG) systems delivered the necessary strength and reusability, keeping the project on schedule and reducing material costs. Meanwhile, the EFCO LITE® system, known for its ease of use and durable steel facesheet, was chosen for the retaining walls along the new collector-distributor lanes. EFCO’s E-BEAM® system, featuring a modular template that can be easily adjusted in the field, ensured precise rebar placement while accommodating the varying elevations required across the bridge structure, eliminating costly rework and keeping the project on schedule. EFCO LITE® and EFCO E-BEAM® worked in conjunction with the SPG system to enhance efficiency and performance throughout the project.

Optimizing Efficiency with Reusable Formwork Solutions

EFCO’s formwork solutions allowed EIB to construct multiple hammerhead caps using the same side formwork efficiently, reducing material waste and labor while streamlining workflow. Each hammerhead cap measured 56 feet in length and up to 11 feet in height.

For the 80-foot-span straddle cap, EFCO’s Self-Spanning SUPER PLATE GIRDER® system eliminated the need for extensive shoring, enabling a staged installation that improved safety. The lower half of the cap was placed first (Figure A) so that rebar and post-tension duct could be installed easily and accurately. Once the cage was complete, the upper formwork was installed to form the sides of the cap and provide additional spanning strength (Figure B). Self-spanning formwork eliminates shoring, reducing labor while keeping the jobsite open and accessible. With a clear span of 60 feet between columns, this efficient approach optimized site logistics by allowing unrestricted movement of personnel, materials, and equipment beneath the structure.

Precision, Integration, and Support: EFCO’s Custom Solutions in Action

Beyond high-performance formwork, EFCO engineered a custom adjustable rebar fixture that adapted to elevation changes and curvature. This fixture ensured precise rebar placement while minimizing labor-intensive adjustments.

EFCO’s E-BEAM® system seamlessly integrated with the contractor’s bridge overhang brackets, enhancing structural integrity and efficiency while eliminating the need for traditional lumber. This engineered solution provided superior performance and sustainability compared to conventional wood alternatives. EFCO’s field service team provided hands-on support throughout construction, offering real-time guidance and quickly addressing challenges to ensure smooth execution at every stage.

EFCO has been a longtime partner on many of our design-build projects. At the EIC project, EFCO and the EIB team collaborated on the design and forming options for the many post-tensioned hammerhead piers required at the high-speed flyover bridges. A two-piece cap form system and a ground-based jig were developed to allow pre-tied rebar cages with the PT duct preinstalled to minimize work at height. A similar concept was utilized on an 80’ long post-tensioned straddle bent, in which we could set a pre-tied cage and eliminate intermediate shoring requirements. The EFCO team brings best-in-class experience, engineering, innovation, and customer service from concept to completion.

-Tim Williams P.E. & Trey Swick PM Archer Western

Why EIB Chose EFCO

EIB selected EFCO for its reliable, efficient, and cost-effective solutions. With extensive experience in complex bridge projects, EFCO provided adaptable and reusable formwork, giving the project a clear advantage. The option to lease PLATE GIRDER® and SUPER PLATE GIRDER® helped reduce upfront costs while still ensuring the durability needed for repeated use. EFCO’s in-depth understanding of project requirements, combined with proactive on-site support, gave the construction team confidence at every stage. By introducing practical innovations and working closely with the construction team, EFCO played a key role in successfully delivering this critical infrastructure upgrade while helping our customer achieve the Lowest in-Place Concrete Cost (LIPCC).

EFCO EQUIPMENT

PLATE GIRDER®

SUPER PLATE GIRDER®

EFCO LITE®

E-BEAM®