The document summarizes a large infrastructure project to reconstruct an interchange in New Haven, Connecticut. The interchange was originally built in 1958 but is now handling 50% more traffic than its original design capacity. The $357 million contract includes reconfiguring the interchange, constructing new ramps and bridges, and widening existing bridges. Temporary formwork including custom transition forms between round columns and pier caps were used to construct the 85 columns and 34 pier caps efficiently.

1. 18 FORM MARKS FALL 2012 19
PEARL HARBOR MEMORIAL
BRIDGE REPLACEMENT
New Haven, Connecticut
Originally built in 1958, Connecticut’s
New Haven Interchange, was designed to
carry 90,000 vehicles per day. Currently
handling close to 150,000 vehicles per day,
the old design was not meeting the area’s
traffic needs. Contract E includes the
reconstruction of the I-95/I-91/Route 34
Interchange, which is the largest project by
scope to be undertaken by the Connecticut
Department of Transportation.
To efficiently build this project, O&G
Industries/Tutor-Perini, JV chose the
EFCO PLATE GIRDER®
for the forming
and support solutions to construct the
85 columns and 34 pier caps on this
demanding project. Each of the round
columns required custom chamfer and
a flared transition section between the
round column and the cap. Jointly EFCO
and O&G/TP worked up a forming plan
using standard round column forms and
specially designed custom transition
forms. The three sets of custom flare
forms were cycled with various setups of
standard equipment to efficiently form the
varying height piers for the 34 pier caps on
the project. EFCO also supplied two sets
of self-spanning PLATE GIRDER forming
solutions to form the concrete pier caps on
the three stem bents.
The project includes the reconfiguration
of the Interchange, construction of twelve
ramps, removal of twenty-one bridges,
construction of eighteen new bridges,
widening of three bridges and construction
of twenty-one retaining walls. The contract
is valued at $357 million and is estimated
to be completed by November 2016.
Mike Daley......................... Project Manager
Larry Doyon ..........General Superintendent
Bob Nardi............Structure Superintendent
Nick Carrieri.....Formwork Superintendent
Steve Kulla.....EFCO Sr. Territory Manager
Louis Szabo..............EFCO Field Supervisor
Joel Lindberg.......................EFCO Engineer
“In addition to the competitive price, we
chose EFCO based on their experience
and background and we are confident
they could handle this job.
Kevin Bernard, P.E.
Senior Structural Project Engineer
O&G Industries
“
BRIDGES & HIGHWAYS
EFCO Support Brackets are mounted on the column using EFCO’s Bolt Thru
Tube Support System.
Special flared column capitals were designed
to tightly fit-up to standard EFCO Column
forms to create this unique look.