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


  • 8x productivity (compared to conventional removable form construction)
  • Eliminate stripping forms

SAFETY


  • Reduced exposure, less risk to labor
  • Less disruption to travelers, safer for public

SUSTAINABILITY


  • 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.

Inspection

Element level inspection of the deck is required by bridge owners according to the FAST ACT, per NBIS and AASHTO Specifications, to evaluate defects like cracking, spalling, delamination, and efflorescence.

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

ClearCast Forms FAQs

Q: Can removable wood forms be directly replaced by ClearCast Forms? Toggle Accordion

Yes, ClearCast Forms are a 1:1 direct substitution for wood forms, allowing for the same deck thickness and reinforcement properties.

Q: What range of beam spacing can ClearCast Forms accommodate? Toggle Accordion
Q: What do the forms weigh? Toggle Accordion

ClearCast Forms plus girder attachments typically weigh 3 to 5 psf in total, adding minimal dead load to the bridge girders.

Q: What area of the deck can be seen through the form? Toggle Accordion

ClearCast Forms provide for ~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.

Q: Do ClearCast Forms contribute to the structural capacity of the deck? Toggle Accordion

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. 

Q: What are the advantages of installing ClearCast Forms? Toggle Accordion

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.

Q: What is the savings compared to conventional plywood forms? Toggle Accordion

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.

Q: How much do ClearCast Forms cost? Toggle Accordion

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.

Q: How do the forms connect to the bridge? How are variable haunch heights accounted for? Toggle Accordion

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.

Q: Will the plastic fog over time? Toggle Accordion

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.

Q: Does welding burn off the galvanizing? Toggle Accordion

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.

Q: Will the galvanized steel rust? Toggle Accordion

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.

Q: Could the form be removed if necessary to make repairs to the deck? Toggle Accordion

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.

Q: Is plastic durable enough for my job site? Toggle Accordion

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.

Q: Temperature Effects Toggle Accordion

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.

Q: Chemical Attack Toggle Accordion

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.

Q: What is included with the ClearCast Form System? Toggle Accordion

TrueTech Bridge 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.

Q: Does the form retain moisture? Chlorides? Toggle Accordion

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.

Q: What amount of tolerance is provided for girder spacing and slight variations in bay width? Toggle Accordion

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.

Q: What maintenance is required over time? Toggle Accordion

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.).

Q: What if a form gets damaged before or during installation? Toggle Accordion

Replacement parts and simple repair procedures are available if needed due to accidental damage.

ADDITIONAL RESOURCES

PERRY CREEK INSTALLATION

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CLEARCAST STRESS TEST

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CLEARCAST DIFFERENCE

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SAMPLE DRAWINGS, SQUARED ENDS

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SAMPLE DRAWINGS, SKEWED ENDS

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SAMPLE SPECS

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INSTALLATION GUIDE

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CLEARCAST FAQS

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RESEARCH: MICHIGAN DOT / FHWA

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RESEARCH: OHIO DOT / FHWA

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RESEARCH: TEMPERATURE CYCLING / DURABILITY OF CLEARCAST FORMS

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RESEARCH: 40-YEAR SUMMARY OF DECK PERFORMANCE, CHLORIDE / MOISTURE RETENTION

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TECHNICAL INFORMATION REQUEST

WHAT BRIDGE OWNERS ARE SAYING...

I am pleased with the performance of the panels and time it saves in forming the deck and the stripping of the deck. There could be a real benefit for the contractor in using these panels when stripping is either difficult or dangerous. I would recommend that these panels be approved for use on Iowa DOT projects at the contractor's option.

— Darwin Bishop, Iowa DOT