Ernest F. Lyons Bridge

Why This Project Was Different

PCL Construction used large steel forms to pour the concrete columns supporting the new bridge. These forms act as molds, holding the concrete in the required shape while it cures.

The project called for SPF to be applied to the forms to slow the cooling of the concrete during curing. Spray polyurethane foam provides insulation, helping the forms retain heat and limit rapid temperature changes.

Controlling heat loss is important during concrete curing. Uneven or excessive cooling can affect how concrete develops strength. The SPF layer helped insulate the steel forms while the concrete cured inside them.

Working Around the Construction Process

The sequence of the work was an important part of this project. Whiting Construction sprayed the molds while they were positioned on the ground. Lloyd Hughes and Jake Neves applied the SPF to each section before the forms were moved.

Completing the application at ground level gave the crew access to the steel surfaces before installation. Once sprayed, the large forms were lifted by crane and placed into their required positions for the bridge column pours.

This process required the SPF work to fit within the broader bridge construction schedule. The forms needed to be properly prepared before crane placement because access would become more difficult after installation.

The SPF Solution

The project demonstrates how SPF can provide thermal control as well as roofing insulation and waterproofing. Applied directly to the steel forms, the foam created an insulating layer designed to retard heat loss as the concrete cured.

Whiting Construction applied approximately 10,000 board feet of SPF for the project. Unlike square footage, board feet account for both the area covered and the foam’s thickness, making it a more useful measurement for installed foam volume.