Wasena Bridge Project | Roanoke, Virginia

Transforming Roanoke’s Landscape with EFCO Formwork

Roanoke, Virginia

The Wasena Bridge Project

The Wasena Bridge project in Roanoke, Virginia, serves as an important component of the city’s 75-year beautification plan. This infrastructure upgrade transforms a standard bridge into an architectural landmark in a residential park area, providing a visually appealing gateway to the highway. The unique Y-pier design not only serves as functional support but also creates an aesthetic enhancement that will be enjoyed for generations to come. Archer Western was selected as the contractor of choice for this project.

Archer Western Chooses EFCO for Architectural Excellence

Archer Western selected EFCO formwork based on their history of successful collaborations and their ability to meet the project’s specific requirements. The city’s strict architectural finish demanded formwork that produced minimal joints and consistent concrete surfaces.

EFCO’s SUPER PLATE GIRDER® and high-strength PLATE GIRDER® systems were installed for all column and footing pours. The formwork was engineered to withstand the hydrostatic pressure of 2,747 psf (131.5 kPa), providing full liquid head capability when using Self-Consolidating Concrete (SCC) while maintaining the demanding finish requirements.

Custom steel rustication strips and custom V-soffit forms were designed and manufactured by EFCO to create continuous architectural elements from the columns through the caps, delivering the distinctive Y-pier design.

Formwork Design Meeting Complex Requirements

The bridge project consists of five bridge piers, each containing three Y-pier bends, creating a total of 15 piers with a distinctive hollow center design. The piers are 17 feet (5.2 m) to 18 feet-3⅛ inches (5.6 m) tall x 43 feet-6 inches (13.3 m) long x 5 feet (1.5 m) wide. EFCO’s engineering team developed an innovative solution that accommodated this unique configuration. The system allowed workers to set the L form, tie the rebar within this structure, and then fly in the top soffit form to complete the Y-shape. This enabled construction crews to maintain the Integrity of the design while efficiently advancing through the building process.

Responsive Manufacturing and Superior Service

When the weather threatened the project timeline, EFCO’s manufacturing team responded by producing a complete second set of custom Y-pier forms. This responsiveness allowed Archer Western to recover lost time and stay on track. Additionally, EFCO Field Service’s on-site support helped proactively identify potential issues that might have caused costly delays.

Performance Benefits and Concrete Quality

EFCO Manufacturing fabricated the custom rustication and form blockouts, creating distinctive architectural features across the structure. Despite the challenging full liquid head pours, the SUPER PLATE GIRDER® system required just 18 ties per assembly. This efficiency in design significantly reduced labor costs while achieving superior results without the need for extensive remedial work after stripping—demonstrating how the right formwork solution directly impacts the bottom line.

Why Archer Western Chose EFCO

Impressed by EFCO’s proven commitment to Quality, Integrity, Innovation, and Super Service, Archer Western selected EFCO for this project based on their ability to meet demanding architectural finish requirements with minimal joints, while adapting to a specialized concrete mix and complex design elements. EFCO’s formwork systems enabled the achievement of Lowest in-Place Concrete Costs (LIPCC), reinforcing how the right formwork partner delivers end-to-end solutions that drive construction excellence from design through execution—resulting in a landmark structure that reflects both companies’ dedication to exceptional results.

EFCO EQUIPMENT

PLATE GIRDER®

SUPER PLATE GIRDER®

Support Bracket

Custom steel rustication strips

Custom V-soffit forms