Mayan Train Project |  Boca del Cerro, Tabasco, Mexico

Transforming Railway Infrastructure: EFCO’s Cutting-Edge Solutions Propel the Mayan Train Project Forward

Boca del Cerro, Tabasco, Mexico

Railway Construction Supported by EFCO

The Mayan Train (also known as Tren Maya) project is a 1,554 km (966 mile) railway in Mexico that spans five states in southern Mexico. This ambitious project aims to connect tourist destinations in the Caribbean with sites further inland, including historic Mayan sites. Mota Engil Mexico was selected as the project contractor and sought a formwork solution capable of overcoming the project’s unique challenges. Tasked with constructing bridge components with complex engineering requirements, Mota Engil turned to EFCO for their engineering expertise and quality formwork systems.

E-Z DECK Stands Out for Load Capacity

A major challenge faced during the construction of the Mayan Train included the need to offer high load resistance for the bridge slab. Allowing up to 125 kN (28 kip) per post, EFCO’s E-Z DECK® system vastly outperforms the standard market offering of 45 kN (10 kip) and was selected as the system for the project. The key advantage of this enhanced post capacity lies in the minimized number of required posts, leading to reduced labor during installation thanks to the decreased quantity needed. The system needed to be strong but adaptable; being close to the river meant ground levels constantly shifted. Time was also a factor as the rainy season approached, and the potential for flooding increased.

The flexibility of PLATE GIRDER and SUPER STUD

The project used PLATE GIRDER® and SUPER STUD® systems to create the abutment walls and the super structure’s cantilevered section. The system supported the E-Z DECK on uneven ground while a bridge slab up to 2,050 mm (6′-8-1/2″) thick was poured on top. As with the E-Z DECK system selection, PLATE GIRDER and SUPER STUD were selected due to their ability to handle substantial concrete loads and flexibility to serve multiple roles.

EFCO Engineering’s Flawless Execution

EFCO’s Engineering and Field Service teams demonstrated EFCO’s core value of Super Service by being adaptable to the ever-changing conditions of the project. EFCO supplied over 50 sets of custom drawings to the contractor, and the Field Service team was on-site to coach in implementing them. The support of these teams and EFCO’s warehousing team mitigated the project’s logistical challenge. Being over 1,150 km (715 miles) from an EFCO warehouse wasn’t a problem when all product shipments were accurate—down to the last bolt.

Why Mota Engil Chose EFCO

EFCO’s commitment to its core values of Quality, Innovation, Integrity, and Super Service shone throughout the project. The innovative approach to formwork design, EFCO’s support in optimizing equipment use, and diligence in supplying the needed materials meant the project was completed quickly and efficiently. Quality products and superb service were the hallmarks of the project, with EFCO’s team members providing constant onsite support, helping Mota Engil realize the lowest in-place concrete costs.