INFRASTRUCTURE OWNERS / ENGINEERS
Built on proven methods of deck form construction and materials, our stay-in-place system improves durability and enables inspection of the bridge deck during construction and over the life of the bridge deck.
THE ClearCast Forms DIFFERENCE
Our transparent stay-in-place deck forming system is the result of years of research and development, yielding an innovative method of bridge deck construction that improves productivity and safety while complying with bridge owner inspection criteria.
SPEED
- Prefabricated forms save time on-site
- 5x productivity (compared to conventional removable form construction)
- Eliminate stripping forms
SAFETY
- Reduced exposure, less risk to labor
- See defects and repair deck to avoid structural failures
- Less disruption to travelers, safer for public
SUSTAINABILITY
- Inspect concrete during placement to confirm quality
- Comply with inspection requirements
- Extend service life with proper assessment and maintenance
KEY FEATURES
Durability
ClearCast Forms improve on the weaknesses of current stay-in-place forms.
- Flat surface eliminates corrugations where moisture can pond.
- Corrosion resistant acrylic plastic eliminates the corrosion on the concrete side of the form surface.
- Galvanized connections are heavier than what has been used in the past to prevent appreciable section loss over time.
- Allows for full depth, monolithic concrete deck for improved service life of the deck and superstructure.
Inspection
Construction Inspection
- Inspect concrete during the deck pour to confirm concrete is consolidated properly.
- Defects can be identified and corrected before concrete cures.
Routine Inspection
- Collect element level data for the deck as required by the Specifications for the National Bridge Inventory and AASHTO Specifications. Evaluate defects like cracking, spalling, delamination, and efflorescence over time such that preservation actions can be taken at the right time to extend the life of the deck.
Condition Assessment
The severity and density of the defects found after the inspection are used to categorize the condition state of the deck. Depending on the condition, a structural review may be needed to determine the strength or serviceability of the deck.
Bridge Preservation
Feasible actions to take based on the condition assessment and structural review include protecting, repairing, or replacing the deck.
HOW ClearCast Forms COMPARE
STATE DOT STAY-IN-PLACE FORM PREFERENCES
LATEST PROJECT VIDEOS
View on-site video from our most recent U.S. projects.
ClearCast Forms FAQs
Yes, ClearCast forms are a 1:1 direct substitution for wood forms, allowing for the same deck thickness and reinforcement properties.
Bay widths up to 8 feet can be accommodated with the typical ClearCast form. Bay width is defined as the distance between the face of top girder flanges. For wider bay widths, contact us for options.
ClearCast forms plus girder attachments typically weigh 3 to 5 psf in total, adding minimal dead load to the bridge girders.
ClearCast forms provide for 70-80% transparency to the concrete deck, easily allowing for inspection during the pour for concrete consolidation, and post-pour for evaluation of any cracks, spalling, or efflorescence.
No. Our stay-in-place forms are designed to carry the wet concrete and construction loads as a stay-in-place bridge deck forming system only.
ClearCast forms have all the proven advantages of stay-in-place forms: reduced labor cost and construction duration and improved safety, but with the added benefit of transparent form technology allowing for inspection during construction and over the life of the bridge deck.
Contractors who have installed ClearCast say the total installed cost of the deck is similar to removable forms, but the time difference allows for significant savings related to lane closures, flaggers, detours, user costs, construction engineering, and even jobsite office rentals.
Pricing for engineered plans and calculations, girder supports, ClearCast Forms, installation materials, and freight varies for each project. Contact us to review your project today.
ClearCast forms are supported on the girders similar to conventional corrugated metal stay-in-place deck forms. Variable haunch heights are set by the contractor by adjusting the height of the steel angle prior to welding the supports. Details are available for precast and steel bridge connection methods.
The ClearCast transparent surface is an acrylic plastic material which has proven to maintain transparency and durability in heavy highway applications like soundwalls where aesthetics and functionality are critical.
Yes, the welding process used to connect the form support to the bridge results in burning the galvanized coating. These areas are typically touched-up per the State DOT specification prior to pouring the deck concrete.
The steel members are protected by the acrylic sheet on the concrete deck side, preventing any moisture or chlorides from penetrating the surface of the structural steel. Where the underside of the form is exposed to the environment, the galvanized coating protects the steel from corrosion.
Yes, the entire form or small areas of the form can be separated and removed to make repairs. Drilling through the acrylic is easy and allows for convenient epoxy injection repairs.
Acrylic sheet plastic is used across numerous industries due to its high clarity and strength. Our own internal testing revealed durability in the face of common worksite conditions. Of course, as with any on site asset, care should be taken not to put unnecessary stress on the panels.
Structural properties, durability and clarity are not influenced by extreme weather. Temperatures from -30 degrees F to 130 degrees F are accommodated. Thermal expansion and contraction is accounted for in the connections.
Acrylic is resistant to fresh and hardened concrete as well as most chemicals. Certain chemicals should be avoided and these are listed in the product documentation. A protective film is provided on each form and should remain attached until just before reinforcing steel is placed.
Contech Engineered Solutions will design and supply the ClearCast form system including signed and sealed shop drawings, prefabricated ClearCast forms customized to the project, the form support system (galvanized steel support angles with weld anchors in precast beams or steel strips for steel beams), and all screws and attachment hardware needed for installation.
Significant research has shown that decks constructed with stay-in-place forms perform as well as decks constructed with conventional plywood forms. Review FHWA funded, DOT reports in the Additional Resources section of this page, concluding that neither moisture retention nor chloride retention is a concern for the service life of the deck.
For most projects, a tolerance of 1 inch in lateral space is provided to ensure the ClearCast form fits between the girders. Details are available for cases with varying site conditions where more tolerance is needed.
No additional maintenance is expected beyond what is typically done to keep the bridge deck and surrounding members functioning properly (i.e. power washing, cleaning, etc.).
Replacement parts and simple repair procedures are available if needed due to accidental damage.
ADDITIONAL RESOURCES
