Akron’s State Route 8 Bridge Replacement | Akron, Ohio 

EFCO’s Solution: Comprehensive Formwork System

Ruhlin-Great Lakes State Rt. 8 Joint Venture selected EFCO for the project based on a proven track record with large-scale infrastructure. The solution included High-Strength PLATE GIRDER® and SUPER PLATE GIRDER® systems for pier caps handling structural loads, the GRS Jump System for pier stem construction, REDI-RADIUS® panels for curved bulkheads, SUPER STUD®s for structural support, and custom steel void forms for distinctive architectural features.

GRS System: Safe, Simple Single Picks for Each Lift

The Guided Rail Jump System (GRS) supported the outside Plate Girder formwork, while a SUPER STUD® Flipper Lock Platform supported the interior forms allowing for vertical cycling without the need to remove equipment. This innovative system enabled crews to pour concrete on Friday, let it cure for seven days, and then move the system up the following Friday—significantly reducing crane usage compared to traditional stacking methods.

In addition to improving efficiency, the GRS and SS Fipper Lock platform systems enhanced safety by providing a protected workspace, ensuring safe rebar placement and work conditions, even during harsh winter weather. Field crews appreciated the ability to “pull back and work inside” this secure formwork environment, which boosted both productivity and worker safety.

The GRS system also simplified the vertical cycling process, allowing for safe and efficient single picks. Each side of the column was lifted as a single unit, speeding up the cycle between lifts.

PLATE GIRDER Minimizes Costs and Provides an Architectural Finish

EFCO’s PLATE GIRDER® solution eliminated the need for excessive ties, reducing labor. Additionally, the system eliminated the need for guy wires, as the PLATE GIRDER® stiffbacks provided necessary wind bracing and ensured the forms remained plumb throughout the process. One of the key advantages of the PLATE GIRDER® system was the ability to cycle the forms quickly with minimal setup, requiring only the unbolting of 4 vertical joints to lift and reposition them. This simplified process reduced the number of steps involved in setting up each pour, cutting down on time and labor.

PLATE GIRDER® also provided a superior architectural finish, significantly reducing the need for concrete cleaning after pours. The smooth, precise finish created by the PLATE GIRDER® facesheet minimized the imperfections typically found when using wooden formwork, offering a cleaner, more consistent surface finish.

Preassembled Form Stacks: Simplifying the Process

A major operational advantage came from the ability of the contractor to preassemble form stacks before lifting them into position. These 8-foot-tall form stacks were assembled on the ground and then lifted as a single unit. This preassembly method allowed for faster placement and fewer crane lifts. By lifting large, preassembled form stacks into position, Ruhlin-Great Lakes JV was able to save time, increase productivity, and reduce labor costs.

Forming V-Notches with EFCO Custom Steel Forms Instead of Wood

One of the project’s more challenging architectural features was the custom V-shaped notches required in each pier. Traditionally, contractors would have used wooden formwork to create these features, requiring them to custom-cut new wood forms for each individual pier, a process that had to be repeated throughout the project. Traditionally, contractors would have used wooden formwork to create these features, requiring them to custom-cut and rebuild new wood forms for each individual pier. This innovative solution eliminated the repetitive cutting and rebuilding of wooden forms, providing the same level of precision while significantly reducing material costs and labor time across multiple pours.

REDI-RADIUS for Soffit Forms

To address the curved bulkheads and soffits, EFCO used REDI-RADIUS® panels, which offered an efficient and versatile solution for creating the curves of the bridge’s architectural pattern. The REDI-RADIUS® panels were supported by SUPER STUD®s, providing added structural integrity for the radial soffits. The REDI-RADIUS® system’s ability to form these curves while maintaining the project’s high-quality standards was key in achieving the desired architectural aesthetics.