Weirton Wastewater Treatment Plant | Weirton, West Virginia

Lightweight Solutions for Heavy Demands | RAPID CAST

Weirton, West Virginia

Weirton Wastewater Treatment Plant Expansion

The Weirton Wastewater Treatment Plant expansion is a $40 million project aimed to increase the capacity of the facility from 4 million gallons (15.1 million liters) of water processed daily to 8 million gallons (30.2 million liters) processed per day. This facility is designed to efficiently separate, treat, and safely release or recycle water while handling the byproducts in an eco-friendly manner. Triton Construction was selected as the contractor for the project and elected to use EFCO’s new RAPID CAST® system due to its lightweight design and innovative functionality.

Triton Construction’s Choice of the RAPID CAST System

EFCO’s RAPID CAST system provided Triton with an advantage due to its lightweight and durable design. With a ganged weight of approximately 8 pounds per square foot (39 kg per square meter), RAPID CAST is considerably lighter than competitor systems, which often average around 13 pounds per square foot (63.5 kg per square meter). This weight reduction allowed Triton to work more efficiently, minimizing the crane capacity required for assembly and reducing labor costs. While RAPID CAST panels are designed in 9-foot (2700 mm) Imperial dimensions, many alternative systems are not always available in Imperial sizes, making RAPID CAST’s compatibility and ease of use a standout feature for the 22-foot (6.7 meter) tall walls of the plant. The seven-panel-wide gangs allowed easy stacking, fewer parts, and simpler installation.

Enhanced Efficiency with EFCO’s RAPID CAST System

RAPID CAST’s composite design, which includes EFCO’s plastic E-BOARD face sheets, aluminum rails, and sturdy steel ribs, offered exceptional durability. This meant the panels could withstand the wear and tear of a large-scale project with minimal reconditioning, significantly lowering maintenance and repair costs. Additionally, the steel ribs made the panels climbable, providing safe, direct access for crew members without the need for additional scaffolding or ladders.

EFCO’s taper tie system and simplified component alignment enabled Triton to achieve precise, secure panel connections with minimal adjustments, which translated to a smoother, more uniform wall surface. This precise finish not only reduced labor demands but also enhanced the visual and structural quality of the plant’s tall concrete walls.

The bolted corner design further reduced or even eliminated the need for walers by naturally aligning and straightening the panels.

Why Triton Chose EFCO

Triton Construction selected EFCO’s RAPID CAST system for the Weirton Wastewater Treatment Plant expansion due to its alignment with EFCO’s core values of Quality, Innovation, Integrity, and Super Service. The system’s lightweight, durable design reduced crane requirements and labor costs, enabling Triton to achieve the Lowest In-Place Concrete Cost (LIPCC) while maintaining high standards of safety and efficiency. RAPID CAST’s climbable steel ribs and secure panel alignment simplified installation, and its precision finish provided a smooth, uniform wall surface with minimal rework. With EFCO’s commitment to excellence, Triton met project demands efficiently and cost-effectively.

Triton Construction, a diversified company enhancing infrastructure across multiple states, has consistently relied on EFCO for the design of water, wastewater, bridge, and highway projects. With a longstanding partnership, EFCO’s Territory Manager Mark Dulacy introduced Triton to the new RAPID CAST Clamp Forming System. As first-time users, Triton received field service support for the initial form ganging setup and pour rate, and they were impressed by the system’s performance. The lighter weight reduced crane costs, the form-facing material minimized cosmetic work, and the fast clamp system lowered labor needs. Triton completed the Headworks Structure 68’ L x 40’ W x 22’ H (20.7 m L x 12.2 m W x 6.7 m H) in four pours and finished the project in six weeks from offloading to return at the Weirton WWTP. Triton is now re-using the same system for the Clearwell/Filters Structure at the Weirton WTP.

-Greg Ferri, Project Manager | Operations